9W2ZSU = http://qrz.com/db/9w2zsu 9W2ZSU = http://qrz.com/db/9w2zsu MY INVERTER RESEARCH – SMPS/LINER 200,250,500,600,1000Watts Created by :Salim-M/ CallsignAmateur 9W2ZSU…[email protected].. 4.1. 2012 -Malaysian WARNING! Build SMPS inverter is VERY DANGEROUS!! Please take all precaution ..electric shock Can cause serious injured or death.. You must read below before start build this circuit. - This is switching mode inverter (same 100% circuit topology with commercial inverter) SMPS mode more efficient then traditional push pull liner transformer inverter.what we all know liner transformer is expensive,bulky ,more heat and UNSTABLE in solar hybrid system. - This circuit in modified sine wave! Has 30% harmonic .you can run mofied sine wave to ac motor but generate more heat than pure sine wave inverter ,others device like computer,TV,lighting,etc no problems run with mod sine wave. - You will need OSCILLOSCOPE or the project will be very much harder to build and test. A design such as this relies on careful measurements and great care to make certain that it will perform as expected. Attempting this without an oscilloscope is NOT recommended. - You must have 36 ohm 5w resistor for discharge 400v capacitor voltage storage - Large heatsinkfor all mosfets..heat will increase Rds(on), and that will make the heatsink hotter, and – BANG!!! - Always take CAREFULL this circuit run very high voltage! Make sure dischare all capacitor after testing circuit. - Most critical part is you must self winding torodial transformer! ..ferrite core has two type ETD and TORODIAL..i am choosen torodial because ETD type hard to find in market..commercial inverter use ETD but both work same picture below is my SMPS inverter circuit topology
Transcript
9W2ZSU = http://qrz.com/db/9w2zsu
9W2ZSU = http://qrz.com/db/9w2zsu
MY INVERTER RESEARCH – SMPS/LINER 200,250,500,600,1000Watts
Created by :Salim-M/ CallsignAmateur 9W2ZSU…[email protected].. 4.1. 2012 -Malaysian
WARNING! Build SMPS inverter is VERY DANGEROUS!! Please take all precaution ..electric shock Can
cause serious injured or death.. You must read below before start build this circuit.
- This is switching mode inverter (same 100% circuit topology with commercial inverter) SMPS
mode more efficient then traditional push pull liner transformer inverter.what we all know liner
transformer is expensive,bulky ,more heat and UNSTABLE in solar hybrid system.
- This circuit in modified sine wave! Has 30% harmonic .you can run mofied sine wave to ac motor
but generate more heat than pure sine wave inverter ,others device like
computer,TV,lighting,etc no problems run with mod sine wave.
- You will need OSCILLOSCOPE or the project will be very much harder to build and test. A design
such as this relies on careful measurements and great care to make certain that it will perform
as expected. Attempting this without an oscilloscope is NOT recommended.
- You must have 36 ohm 5w resistor for discharge 400v capacitor voltage storage
- Large heatsinkfor all mosfets..heat will increase Rds(on), and that will make the heatsink hotter,
and – BANG!!!
- Always take CAREFULL this circuit run very high voltage! Make sure dischare all capacitor after
testing circuit.
- Most critical part is you must self winding torodial transformer! ..ferrite core has two type ETD
and TORODIAL..i am choosen torodial because ETD type hard to find in market..commercial
inverter use ETD but both work same
picture below is my SMPS inverter circuit topology
9W2ZSU = http://qrz.com/db/9w2zsu
9W2ZSU = http://qrz.com/db/9w2zsu
Circuit diagram below is my full 1000W SMPS inverter circuit
Circuit diagram below is simple 600w SMPS inverter version
9W2ZSU = http://qrz.com/db/9w2zsu
9W2ZSU = http://qrz.com/db/9w2zsu
1ST STEP CONSTRUCTION.
TRANSFORMER CONSTRUCTION
- The most critical part is winding transformer..
- Has two type ferrite transformer – ETD and TORODIAL…because hard to find ETD wire wound in
market ,torodial was choosen…both torodial and ETD work same.
MANDATORY COMPONENT
- NTC resistor -for prevent inrush current surge what can cause H bridge mosfet BLOW
- Fast Recovery Diode – this SMPS need fast diode..if use normal diode will cause entire circuit
less power output then expected.
- DO NOT alter voltage limiter resistor value-(feedback dc bus voltage at pin 1) alter this resister
value can cause output ac voltage increase or decrease.
FIRST TIME START UP PROCEDURE
- Set oscilloscope probe.clamp it at TP1 and TP2 test point
- Turn on 12v main power source circuit and set 50hz frequency at 100k pot
- DO NOT touch any circuit with hand.!! electric shock!! this inverter can KILL you!
- After done set frequency, please discharge 330uf 400v capacitor with 36R 5W resistor!
- Use digital TRUE RMS multimeter for measure output ac voltage.do not use cheap china
multimeter will give you false reading voltage.
BELOW IS MODIFIED SINE WAVE when TP1 and TP2 connected
H bridge mosfets Output (AC) modified sine wave (DANGER!)
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FERRITE TRANSFORMER SELECTION.
PICTURE BELOW IS TRANSFORMER TORODIAL CORE (easy to find in market)
PIC BELOW IS TRANSFORMER ETD CORE
TRANSFORMER CALCULATION
A good starting point is using 5 turns for each primary (that is, 5 turns, centre tap and another 5 turns IN
THE SAME DIRECTION). To calculate the number of turns of the secondary winding, multiply by the turns
ratio. For example, if you want to build a +/- 400VDC bus supply from 12VDC, the turns ratio is
400V/12V=33.3 approx, so 33.3 x 5 = 166T (The 5 is primary) The secondary turn is 166T (better 176
turns, to overcome the diode losses) .
You MUST use enamelled copper wire for all the windings. Keep also in mind that when working with
high frequencies, the effective section of the wire is much smaller than the physical one, due to the
"skin" effect (the current concentrates only in the outer part of the wire). As high currents are involved
here, the section of the wire is very important, (if you don't want the enamel to fuse due to the heating
produced by the resistive losses of the wire and short all the windings). A good practice is to use several
thinner wires in parallel rather than a single thick one. This also eases winding. For example, three AWG
13 diameter wires can form a suitable primary for a 1000w DC bus supply.Three AWG13 winding in
PARALLEL The same applies to the secondary, although the current is reduced so you can use less wires
