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My Research SMPS - LINER Inverter For Solar Application de 9W2ZSU PDF
My Research SMPS - LINER Inverter For Solar Application de 9W2ZSU PDF
com/db/9w2zsu
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
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Circuit diagram below is my full 1000W SMPS inverter circuit
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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.
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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
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For perform 1200w you will need two ferrite torodial core for high power dc-dc converter with high
switching frequency 50-60khz
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FT 37 77
OD 37mm
ID 23mm
Height 15mm
Material code -77
This single toroid capable supply load 600w continuously at 55khz frequency
Becareful..make sure double check your winding core before assamble..wrong winder will cause short
circuit or blow the power mosfet..all wire winding in one direction..follow the step number.
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Ferrite
Iron powder
Do not use iron powder toroid..or the project will failed..the iron powder has lower Q For
application dc-dc converter need high Q rating,high volume resistivity and permeability. FT
ferrite was choosen..material type 77
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The tiny ferrite FT-37 has more power if compare bulky iron core 9 0 9 400VA
Iron core 9-0-9 400va
-Price = RM 200.00 / usd 66.00 (expensive)
-Maximum watts = 400 450watts
-Efficiency = 50% or lower depend on battery voltage. only pro in high robust.
Ferrite FT-37 toroid
-Price = RM 3.00 / usd 1.00 (cheap)
-Maximum watts = 500 600watt depend on switching frequency and high efficiency 80-90%
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High RPM cooling fans..recycle aluminum SMPS casing fitted my 1200w inverter apply on my small solar
system.
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I have blow dozen of mosfet IRF740 during this research.lucky this mosfet cheaper here.
Most of fets blow because unbalance NTC resistor value..un proper cooling system and false
frequency switchingnow my inverter well perfect in term robust and power.
NOTE :
The two circuit diagram 600w and 1200w just basic heart of inverter..i never put overload
protection and low voltage shutdown coz I dont want somebody use my circuit for commercial
inverterif you want..you create you self design the two protection overload and low voltage
shutdown..
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PICTURE BELOW IS MY 1ST PROTOTYPE DC-DC CONVERTER 12V TO 320VDC FOR 1000W SMPS
1000W SMPS NEED TWO TORODIAL CORE FT-37.
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PIC BELOW 600W my SMPS portable power pack (very use full) say no to stinky noisy GEN-SET
PIC Below 1200w SMPS for small solar hybrid system. this inverter work every day power up my small
electronic workshop, my laptop, soldering iron, kitchen exhaust fan also work as power Backup if grid
failure. This small solar system also save my electric bill about rm20.00 per month.
homebrew 1200w inverter + homebrew MPPT 20a solar charger + 120w mono panel + 12v 280ah bank
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*LEFT PIC -150W PROTOTYPE USING PIC16F628A * RIGHT PIC 250W LINER INVERTER (ANALOG)
CIRCUIT DIAGRAM BELOW IS 250-500W LINER ANALOG INVERTER.Actually I like this kind of inverter in
term of ROBUST ..you can put this inverter outdoor side.hard to damage..if overload or short circuit this
inverter just suck a lot battery amps! And nothing any component part damage..the cons is efficiency is
only 50% ,unstable voltage,bulky huge,expensive to build and not suitable application in solar hybrid
system
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CONCLUSION
Lastly I suggest who want build inverter in a first step go for liner inverter before build more complicated
SMPS inverter and I repeat BUILD SMPS inverter is more COMPLICATED than expected
INVERTER most people says BETTER BUY THAN BUILD its costlyyes its true for beginning...but..in my
opinion when BUY, you only got ONE..but when you success BUILD..you can build thousand of inverter..
Cheerssorry my poor Englishun finish school..coz my teacher death early.. .thank you
By Ags Saleem , HAM callsign 9W2ZSU Malaysian.
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