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This is a heavy duty design of a Pulse Width Modulator DC/AC inverter usingthe chip SG3524 .
I've been using it as a backup to power up all my house when outages occur
since aprox. 6 years non stop.
If you like the work and intend to build the circuit don't forget to click on the
"follow" button so I know how many people benefit from the design, Thanks.
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250 to 5
000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)
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Notes:
1> The schematic circuit design is for a 250 watt output, while the pics are of my
1500 watts inverter that i built, to increase the power of the circuit you have to
add more of the Q7 and Q8 transistors in parallel, each pair you add will
increase your power by 250 watts, ex: to get 750 watts of power from the
inverter you need to add in parallel 2 of Q7 and 2 of Q8 to the original design.
2>If you increase the power transistors you have to enlarge the T2 transformer
to match the new needs, the circuit's transformer is rated 25 amps to handle 250watts of 220v, for every 1 additional amp you need on the 220v side you have to
increase 10 amps on the 12v side, of course there are limits to the thickness of
the winding so if you need more than 750 watts i recommend that you use a
24VDC supply instead of 12 volts:
DC voltage and Transformer " T2" winding recommendation:
Power Supply Winding
750w 12VDC P:24V "12-0-12" / S:220V
1500w 24VDC P:48V "24-0-24" / S:220V
2250w 36VDC P:72V "36-0-36" / S:220V
3000w 48VDC P:96V "48-0-48" / S:220V
3750w 60VDC P:120V "60-0-60" / S:220V
4500w 72VDC P:144V "72-0-72" / S:220V
5250w 84VDC P:168V "84-0-84" / S:220V
*The transformer should be "center tapped" at the primary side.
**You can make the secondary 110v if needed.
***The transformer in the pic is a custom made (48V center tapped / 220v ) 2000
watts, weights like 10 kilos.
3> R1 is to set the PWM duty cycle to 220v. Connect voltmeter to the output of
your inverter and vary VR1 till the voltage reads 220V.
4>R2 is to set the frequency to 50 or 60 Hz (R2 range is between 40Hz to
75Hz), so guys that do not have a frequency meter are advised to blindly put this
variable resistor mid-way which should drop you in the range of 50~60 Hz.
If you want you can substitue the variable resistor with a fixed resistor using the
following formula: F = 1.3 / (RxC)
in our case to get a 50Hz output we remove both the 100K and the variable
100K both from pin 6 and we put instead a 260K fixed resistor and we leave the
0.1uF (the 104 cap) as it is, this change should give out a fixed 50Hz as per the
formula :
1.3 / (260,000 ohm x 0.0000001 farad) = 50Hz
But in reality it will not exactly give 50Hz because the 260K resistor has a
specific error value margin so does the capacitor, that's why i recommend a
variable resistor so that accurate calibration can be achieved.
5>Use either tantalum or polyester film "as in pic" for the 104 caps, ceramic disc
caps change value once hot and this in turn changes the frequency of the
inverter so they are not recommended.
6> Pin 10 of the SG3524 can be used to auto shut down the inverter, once
a positive voltage is given instead of negative to pin10, the SG3524 will stop
oscillating. This is useful for persons wanting to add some cosmetic makeup to
their inverters like overload cutoff, low battery cutoff or overheating cutoff.
7>Wiring connections on the power stage side should be thick enough to
handle the huge amps drain from the batteries. I marked them with dark black
on the schema also I included a pic so you see how thick those wires must be.
8> The design does not include a battery charger since each person will be
building a custom version of the inverter with specific power needs. If you are
ordering a custom made transformer you can ask them to take out for you an
additional output wire on the primary side to give 14v (between point 0 and this
new wire) and use it to charge a 12v battery, of course this needs a seperate
circuit to control charging auto cut-off. But anyway this is not advisable because
250 to 5000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)
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it will shorten the life of the transformer itself since using it as a charger will toast
the enamel coating layer of the copper wires over time. Anyway .. YES can be
done to reduce cost.
9>A cooling fan will be needed to reduce heat off the heat sinks and
transformer, i recommend getting a 220v fan and connecting it to the output T2
transformer, when you power up the circuit the fan will start this will always give
you a simple way to know that 220v is present and everything is OK.. You can
use a computer's old power supply fan if you like.
Note that the fan must suck air out from the inverter case and NOT blow inside,
so install it the correct way or it will be useless.Also note how I fixed both the heat sinks and where the fan is, in a way that the
fan sucks hot air from like a channel between the 2 heatsinks.
10>2 circuit breakers are recommended instead of fuses, one on the DC side
and one on the AC side, depending on your design
Ex: for a 24vDC ( 1500 watts design ) put a 60Amp breaker on the DC side and
a 6Amp on the AC side.
For every 1amp of 220vAC you will be draining like 8 to 10 Amps from the 12v
battery, make your calculations !
11>The 2 Heat sinks should be big enough to cool the transistors, they are
separate and should NOT touch each other. "see the pics"
12>Important: If you're building a big design that uses more than 24VDC as
power source, make sure not to supply the driver circuit with more than 24v
maximum. (EX: If you have 4 batteries 4x12 = 48v , connect the v+ supply of the
driver circuit to the second battery's (+) terminal with a thin 1 mm wire which is
more than enough. this supplies the driver circuit with +24v while supplies the
power transformer with +48v) "see the batteries pic example"
13>"Optional" : Deep Cycle batteries are your best choice, consider them for
best results .. read more (http://en.wikipedia.org/wiki/Deep_cycle_battery)
14>Be cautious when building this circuit it involves high voltage which is lethal,
any part you touch when the circuit is ON could give you a nasty painful jolt,
specially the heat-sinks, never touch them when the circuit is on to see if the
transistors are hot !! I ate it several times :)
15>The optional "Low voltage warning" is already embedded in the PCB layout,
you can disregard it and not install it's components if you do not needed. It does
not affect the functionality of the main circuit.
16> The Motorola 2N6277 is a durable heavy duty power transistor, it is used in
many US tanks for it's reliability but unfortunately it is a very hard to find
part, instead you can substitute each 2N6277 with 2 x 2N3773 or any
equivalent.
17>I've included an optional "Battery level indicator" circuit diagram that has 4
LEDs, you can see it installed on the front panel of my inverter pic, it is
functioning great and shows precisely how much juice the batteries still have. I
have included a small relay that is powered by the last LED to auto shutoff the
inverter once last LED is off.
18>Also included an optional "Overload circuit", it is very easy to build and can
be calibrated to the desired overload current threshold cutoff point through the
potentiometer VR1.
R1 is rated 5watts for inverters upto 1000 watts. For bigger versions of the
inverter like 1000 to 3000 watts inverters, replace R1 (1 ohm, 5watts) with (1
ohm, 17watts) which should handle loads upto 10 VA.Make sure you install a proper relay to handle big current drains.
19> Please guys t ake your time to read and understand my notes, browse
and read the posts and questions asked by others because there are many
useful information listed in replies. The main reason for me not
answering your question is because it has already been asked before and
250 to 5000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)
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Make Comment
(/member/safeermaher/)
2 days ago Reply (CMJ4381HS18HR50)
(/member/nickk/)
yesterday Reply (CCEOD1RHS3GV7UU)
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yesterday Reply (CEQ14OVHS5OUFT6)
answered upon.
20> It would be nice and inspiring for others if you take some photos and
show us how you built your version, any additions to the circuit are mostly
welcomed to be listed here, we can all benefit fr om them.
safeermaher (/member/safeermaher/)
Hi, it is Micheal
I saw your design in here and i thought about trying it and fortunately i found your
circuit already made in the market so i bought it ;)but after connecting it with transformer (50 Amps) and d313 and tip35 transistors i
got low voltage "around 160v" and the low voltage alarm was already built in that
circuit and it always keeps toning for no reason!!!
can you please help me.. i tried to set the voltage to the higher and the frequency
as well but the voltage didnt exceed 170v i added few capacitors at the output so i
get 200v but it drops down to 170 when loaded with 100w lamp
i've uploaded a pic.. please check it
please any advise.. thank you very much
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nickk (/member/nickk/)(author) safeermaher
d313 and tip35??
where do you see those in my
schematic?
safeermaher (/member/safeermaher/) nickk
hi..
thank you for your note about the
transistors..
i replaced them with tip122 and
2n3773 transistors
but i still have low voltage...
can i change the windings of my TS to
9-0-9 ? do you think that this can solve
the problem?
and one more question please.. what
can i do regarding the voltage
decrease while connecting the load?
250 to 5000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)
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nickk (/member/nickk/)(author) safeermaher
1- does your 12v battery drop below
12v when the inverter is on ?
2- did you set the frequency 50Hz?
3- did you regulate with R1 to get the
voltage to 220v ?
4- if you checked all the above and
still your 220v drops, try to set the
frequency to 60Hz
5- send us feedback
safeermaher (/member/safeermaher/) nickk
Dear nick..
thank you for your quick replies.. :)
about your questions:
1- i tried two batteries.. one of then
doesn't drop below 12 while the
other drops to 11.7v but both of the
battery are doing great with
commercial normal inverter 1000w
2- the frequency was already set to
50hz when i bought it.. but it didnt
work well
3- i regulated the R1 to maximum
that what caused in that time about
10v raise.
4- i also set the R2 to maximum i
got a naughty sound from the
transformer in this case, but any
way the voltage still low..
i even tried an other TS made byother manufacturer and i still have
the same problem..
kindly awaiting for your replay :)
safeermaher (/member/safeermaher/) nickk
about the old d313 and tip35 they was
advised by the one who made the
circuit ;-)
chukzy3700 (/member/chukzy3700/)
Hello Mr. Nickk. Please I want to know the voltage of the Electrolytic Capacitors
used: 220uf, 1uf, 10uf, 4700uf and 47uf. Please what is there voltage.. I hope to
hear from you soon. Thanks..
250 to 5000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)
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nickk (/member/nickk/)(author) chukzy3700
50v should be ok
ssr ivastava11 (/member/ssrivastava11/)
hey Nick nice work
I need some of your advice..!!
I am planning to make 2kVA inverter for my solar panels.I have 250 watt 4 solar panel.
The Voltage rating of each panel at full load is 37.15 volts
The Current rating of each panel is 6.73 amps.
On the AC side I have a load of a water pump (0.5~1 hp) + 200 watt load.
My teachers told me to go for series connection for the solar panel since high
voltage is easy to handle than high current.
I don't have any battery system in my Inverter setup just the dc supply is given by
solar panels.
I would like your opinion and suggestions about it.
Jawaaz (/member/Jawaaz/)
Hello Nick,
I have made the design you have posted and I was successful in getting a
oscillating output from emitter A and emitter B from SG3524.I build a test power
stage using a single pair of IRFZ44N mosfets for negative and positive half cycles
respectively and used a 12-0-12 .5A small transformer for it.I have the following
problem:
WHen I connect the transformer to the supply,The primary reads 24VAC across as
it should be but the secondary reads only 145VAC..I also checked the transformer
at 220VAC output and it gave me exactly 24VAC on primary,so I am puzzled why I
am getting 145VAC when primary is 24VAC,Is there any problem in flux generation
for square wave signal???I am scratching my head..
nickk (/member/nickk/)(author) Jawaaz
Hello Jawaaz,
Please upload a photo of your setup.
Jawaaz (/member/Jawaaz/) nickk
HEllo Mr. Nick,
Well I have rectified my problem now,actually I was only getting 32hz of
frequency and at that frequency ,the induction process fails and cannot
transfer all of the potential to the secondary coil,so I increased the
frequency to about 60hz and the voltage on secondary coil got increased to
optimum level...I guess in a transformer,the voltage on output side is
directly proportional to the frequency of the potential on primary side...SO
FOR ALL THE PEOPLE WHO ARE GETTING LESS OUTPUT VOLTAGE
ON SECONDARY SIDE,TRY TO INCREASE THE FREQUENCY FROM
50HZ TO 60HZ AND RECHECK YOUR SECONDARY VOLTAGE AFTER
THAT...
josfemi ( /member /jos femi/) Jawaaz
i have never experience this before, if i increase my frequency my output
voltage remain the same and if i decrease my out put voltage still remain
the same
nickk (/member/nickk/)(author) Jawaaz
250 to 5000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)
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8 days ago Reply (CIUSRF6HRTKK6EG)
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8 days ago Reply (CM3C94IHRTKK8J9)
Thanks for this
clarification.
reach2beelal (/member/reach2beelal/)
Hi nickk,
Plz i need ur clarification can i wind my inverter transformer to 310v at d output
and brings it back to 220v using feedback to avoid voltagedrop at the output
Plz what do i do to improve ur circuit so that pin10 should dectate low battery and
shutdown
nickk (/member/nickk/)(author) reach2beelal
no it doesn't work this way. the 220v
will not drop unless the battery starts
to get empty, when this happens
nothing will bring your 220 back.
reach2beelal (/member/reach2beelal/) nickk
Hi nickk
What I mean is when I wound my
transformer to 12v input and 230v
output. When a connect the
transformer and start d inverter it
gives me 230v at the output BUT
when I connect load at the output the
voltage drops to less than the voltage
without the load. The more I add the
load the more voltage drops SO
WHAT'S IS THE PROBLEM
That is why Isaid if during winding I
increased the number of turn is the
secondary to reach may be 300v and
the used ur circuit to brings it down to
220v CAN THE INVERTER WORK
FINE
reach2beelal (/member/reach2beelal/) nickk
Hi nickk
What I mean is when I wound my
transformer to 12v input and 230v
output. When a connect the
transformer and start d inverter it gives
me 230v at the output BUT when I
connect load at the output the voltage
drops to less than the voltage without
the load. The more I add the load the
more voltage drops SO WHAT'S IS
THE PROBLEM
That is why Isaid if during winding I
increased the number of turn is the
secondary to reach may be 300v and
the used ur circuit to brings it down to
220v CAN THE INVERTER WORK
FINE
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Anthony 56 (/member /An thony56/)
Need your urgent help & urgent advise for a Solution and possible root causes &
reasons of my problem encountered here ?
Can not obtain AC output Voltage 230V AC& Output Current 2A by using500VA(500W) 12V/230V TRANSFORMER . I hv completed building thecircuit accordingly but the maximum output voltage only 83V ( SecondaryWinding of T2 ) & maximum output current 0.06A only using Load 28W 230V
AC Bulb Or 100W 230V AC Bulb,observation Bulb can light up dimly only.The Input Current of 8A (Ammeter Reading ) 12V at Primary Winding ofTransformer T2. The Transformer T2 used here bought from the shop is500VA(500 Watts) 12V/230V AC. Also Lead Acid Battery 12V DC 60A Maxused in this project.
1.
From the pin 14(SG3524) using Q2 BC337,Q4 TIP122,2N3055,4pcs 2N3773
replaced the 2N6277 that is Not available from the shop and adding a small 0.1
Ohms 10Watts Resistor in series with Primary Winding of Transformer T2.The
Load 28W 230V AC Bulb can not be lighted up without added a 0.1 Ohms 10Watts
Series Resistor. Why Need to add a 0.1 Ohms Resistor to primary winding of T2
only to obtain the 83V Output Voltage ? Not Sure Why need this additional 0.1
Ohms Resistor & Need Urgent Advise.
Wherelse from your project Original Circuit do not require this additional 0.1 Ohms
Resistor to T2 that can even produce Output Voltage 230V AC from Transformer
T2 per your circuit description & explanation ?
From pin 11(SG3524) using Q3 BC337,Q7 TIP122,2N3055,4pcs 2N3773 replaced
2N6277 that is Not available from the shop.
Attached the Photos of the 50 Hz [ Positive Cycle (pin14) & Negative Cycle (pin
11)]
Hope to hear from you all & thks in advance.
Here is my email: [email protected]
(http://cdn.instructables.com/FDC/UVBD/HRTKJ3OS/FDCUVBDHRTKJ3OS.LARGE.jpg)
nickk (/member/nickk/)(author) Anthony56
Also calibrate the frequesncy to 60Hz
instead of 50Hz which I presume you
already did.
Please send feedback.
nickk (/member/nickk/)(author) Anthony56
Hello Anthony56
(http://www.instructables.com/member
/Anthony56/)
Did you calibrate with T1 to bring the
voltage up to 220?
johann es8316 (/member/johannes8316/)
i m almost done in creating this circuit using mosfet IRFP250 as power stage but
when i test the wattage the output is too low.
1. is your figure for power stage using mosfet is the same output as power stage
transistor.?
2. and how many mosfet IRFP250 can generate 1000~1500 watt output?
250 to 5000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)
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nickk (/member/nickk/)(author) johannes8316
how much is (too low) ?, how many
did you install in parallel and what
were you expecting? how big is your
power transformer?
spilgrim1 (/member/spilgrim1/) nickk
We can power a simple hand drill but when we test the fan an Electric fan it
doesn't spin.we are making the inverter to work at atleast 1500 watts for aircondition
unit.
we install 6 parallel mosfets IRFP250 as seen on your diagram..
our transformer is 12 0 12 6 amperes..
should we replace the transformer?
how many mosfets should we add to meed the atleast 1500 watts of
output?
nickk (/member/nickk/)(author) spilgrim1
6 amperes ???? "if you read my note
#10:
"For every 1amp of 220vAC you will
be draining like 8 to 10 Amps from
the 12v battery, make your
calculations !"
for 1500w you'll need a 70 amperes
trans. !
johann es8316 (/member/johannes8316/)
hey nick..there is a problem in the output of my circuit, when i turn on the device
the output is 220 vac and then its suddenly drops to 110 vac.
what do you think is cause of the problem?
and
if its ok for you, i will send my modified design.
nickk (/member/nickk/)(author) johannes8316
did you find out what was the
problem?
lovelyfact (/member/lovelyfact/)
Hello dear,
I need 1500watts inverter for that, can i use 24volt solar panel instead of 24volt
battery?
In that inverter can i run 2HP waterbump?
Need ideas,
nickk (/member/nickk/)(author) lovelyfact
No you can't. you don't have any idea what you're doing .. do you :)
cabingas (/member/cabingas/)
250 to 5000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)
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i made this project and its
working for me thanks Nick.
very useful
nickk (/member/nickk/)(author) cabingas
You're welcome :)
vam540 (/member/vam540/)
i want this inver how much it costs
(/member/%D0%90%D0%BA%D1%80%D0%BE%D0%BC/)
Hello! At the output of your inverter sine
wave amplitude as in the socket? And could
you give all the drawings for the study?here
is my e-mail: [email protected]
Mohammedhanafy (/member/Mohammedhanafy/)
Hello Nick
I build the Mosfet inverter but i got no output
i measure the voltage on pin 11 and pin 14 it
was both together 1.5 volt ... any ideas
Kushlendr (/member/Kushlendr/)
Hello sir,
I am from (Kolkata) India. I am new here and new in electronics field, I have to
complete my college project of 300 watt inverter..I have some question to
complete this project, please sir help me to complete my 300 watt inverter.
1) can i make 300 watt inverter from this circuit ?
2) sir i have 12v 7.2AH SMF Battery, so can i use it for 300 watt inverter or i have
to buy 12v car battery ?
3) how many 2N6277 heavy duty power transistor, i will use for making 300 watt
inverter from 12v battery?
4) or if i have not found this 2N6277 transistor, then how many 2N3773 transistor
will i use?
4) for making 300 watt inverter from 12v battery, what is my transformer rating ? I
mean to say what is the amp of my 12v transformer for making 300 watt inverter ?
5) in the picture 220/12 0.5 Amp transformer is used. Is this used for battery
charger? and 0.5Amp is equal to 500MA ?
sorry for my bad English. please help me sir.
reach2beelal (/member/reach2beelal/)
Hi nickk,
Plz i need ur clarification can i wind my inverter transformer to 310v at d outputand brings it back to 220v using feedback to avoid voltagedrop at the output
Plz what do i do to improve ur circuit so that pin10 should dectate low battery and
shutdown
250 to 5000 watts PWM DC/AC 220V Power Inverterby nickk (/member/nickk/)
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grateed (/member/grateed/)
hi sir its this a pure sine wave? thank you
grateed (/member/grateed/)
hi sir its this a pure sine wave? thank you
Jawaaz (/member/Jawaaz/)
HEllo Mr. Nick,
Well I have rectified my problem now,actually I was only getting 32hz of frequency
and at that frequency ,the induction process fails and cannot transfer all of the
potential to the secondary coil,so I increased the frequency to about 60hz and the
voltage on secondary coil got increased to optimum level...I guess in a
transformer,the voltage on output side is directly proportional to the frequency of
the potential on primary side...SO FOR ALL THE PEOPLE WHO ARE GETTING
LESS OUTPUT VOLTAGE ON SECONDARY SIDE,TRY TO INCREASE THE
FREQUENCY FROM 50HZ TO 60HZ AND RECHECK YOUR SECONDARY
VOLTAGE AFTER THAT...
reach2beelal (/member/reach2beelal/)
Hi nickk, Plz I deed ur clarification on mosfet wattage n current rating becos am
comfused. Some one told me EX. 1) If u build 1000w inverter u'll need 100amp
current. So if u use IRFP150N which has( 100V,42A) So u assumed d current to b
30A instead of 42A due to temperature therefore u'll have 30A * 4(mosfet) equal to
120A on each side is it correct . 2) Or u'll have if d mosfet is
IRFP150N(100V,42A,160W)frm d datasheet u will need 160w * 7(mosfets) equal
to 1120w on each side forgetin about current. Sir which one is right
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