5kva Ferrite Core Inverter Circuit

5kva Ferrite Core Inverter Circuit - Full Working Diagram with Calculation Details | Homemade Circu... https://www.homemade-circuits.
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Details
Last Updated on August 25, 2020 by Swagatam (https://www.homemade-circuits.com/author/swag/)
In this post we discuss the construction of a 5000 watt inverter circuit which incorporates a ferrite core transformer and therefore is hugely
compact than the conventional iron core counterparts.
Block Diagram
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5kva Ferrite Core Inverter Circuit - Full Working Diagram with Calculation Details | Homemade Circu... https://www.homemade-circuits.com/5kva-ferrite-core-inverter-circuit/
Please note you can convert this ferrite core inverter to any desired wattage, right from 100 watt to 5 kva or as per your own
preference.
Understanding the above block diagram is quite simple:
The input DC which could be through a 12V, 24V or 48V battery or solar panel is applied to a ferrite based inverter, which converts it into a
high frequency 220V AC output, at around 50 kHz.
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However, for this the H-bridge stage would need a peak value of the 220V RMS, which is around 310V DC.
This is achieved using a bridge rectifier stage, which converts the high frequency 220V into 310 V DC.
Finally, this 310 V DC bus voltage is converted back into 220 V 50 Hz using the H-bridge.
We can also see a 50 Hz oscillator stage powered by the same DC source. This oscillator is actually optional and may be required for
H-bridge circuits which do not have its own oscillator. For example if we use a transistor based H-bridge then we may need this oscillator
stage to operate the High and low side mosfets accordingly.
UPDATE: You may want to jump directly to the new updated "SIMPLIFIED DESIGN", near the bottom of this article, which explains a one-
step technique for obtaining a transformerless 5 kva sine wave output instead of going through a complex two-step process as discussed in
the concepts below:
A Simple Ferrite Cote Inverter Design

Before we learn the 5kva version here's a simpler circuit design for the newcomers. This circuit does not employ any specialized driver IC,
rather works with only n-channel MOSFETS, and a bootstrapping stage. (https://www.homemade-circuits.com/h-bridge-bootstrapping/)
The complete circuit diagram can be witnessed below:
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In the above simple 12V to 220V AC ferrite inverter circuit we can see a ready made 12V to 310V DC converter module being used. This
means you don't have to make a complex ferrite core based transformer. For the new users this design may be very beneficial as they can
quickly build this inverter without depending on any complex calculations, and ferrite core selections. (https://www.homemade-circuits.com
/ferrite-core-material-selection-guide-smps/)
5 kva Design Prerequisites

First you need to find 60V DC power supply for powering the proposed 5kVA inverter circuit. The intention is to design a switching inverter
which will convert the DC voltage of 60V to a higher 310V at a lowered current.
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When it comes to an input source of 20A it is possible to get 2 – 5A. However, the peak output voltage of this 5kva inverter is around 310V.
Ferrite Transformer and Mosfet Specifications

In regard to the architecture, Tr1 transformer has 5+5 primary turns and 18 for secondary. For switching, it is possible to use 4+4 MOSFET
(IXFH50N20 type (50A, 200V, 45mR, Cg = 4400pF). You are also free to use MOSFET of any voltage with Uds 200V (150V) along with least
conductive resistance. The gate resistance used and its efficiency in speed and capacity must be excellent.
The Tr1 ferrite section is constructed around 15x15 mm ferrite c. The L1 inductor is designed using five iron powder rings that may be wound
as wires. For inductor core and other associated parts, you can always get it from old inverters (56v/5V) and within their snubber stages.
Using a Full Bridge IC

For integrated circuit the IC IR2153 can be deployed. The outputs of the ICs could be seen buffered with BJT stages. Moreover, due to the
large gate capacitance involved it is important to use the buffers in the form of power amplifier complementary pairs, a couple of of BD139
and BD140 NPN / PNP transistors do the job well.
Alternate IC can be SG3525

You may also try to use other control circuits like SG3525 (https://www.homemade-circuits.com/sg3525-full-bridge-inverter-circuit/). Also, you
can alter the voltage of the input and work in direct connection with the mains for testing purpose.
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The input 60V could be acquired by putting 5 nos of 12V batteries in series, the Ah rating of each battery must be rated at 100 Ah.
DATASHEET IR2153 (https://drive.google.com/file/d/1JmvyZMHfo70SlDu-9SupP0ZmBhUJGDc7/view?usp=sharing)
Please do not use BD139/BD140, instead use BC547/BC557, for the driver stage above.
High Frequency 330V Stage
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First the 220V 40kHz will need to be rectified/filtered through a bridge rectifier made up of fast recovery diodes rated at around 25 amps
300V and 10uF/400V capacitors.
Converting 330 V DC into 50 Hz 220 V AC

Next, this rectified voltage which would now mount up to around 310V would need to be pulsed at the required 50 or 60 Hz through another
full bridge inverter circuit as shown below:
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The terminals marked "load" could be now directly used as the final output for operating the desired load.
Here the mosfets could be IRF840 or any equivalent type will do.
How to Wind the Ferrite Transformer TR1
The transformer TR1 is the main device which is responsible for stepping up the voltage to 220V at 5kva, being ferrite cored based it's
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Remember you may have to incorporate more than 1 E core, may be 2 or 3 E-cores together, placed side by side for accomplishing the
massive 5KVA power output from the assembly.
Use the largest one that may be available and wind the 5+5 turns using 10 numbers of 20 SWG super enameled copper wire, in parallel.
After 5 turns, stop the primary winding insulate the layer with an insulating tape and begin the secondary 18 turns over this 5 primary turns.
Use 5 strands of 25 SWG super enameled copper in parallel for winding the secondary turns.
Once the 18 turns are complete, terminate it across the output leads of the bobbin, insulate with tape and wind the remaining 5 primary turns
over it to complete the ferrite cored TR1 construction (https://www.homemade-circuits.com/how-to-design-and-calculate-ferrite-core-
transformers-for-inverters/). Don't forget to join the end of the first 5 turns with the start of the top 5 turn primary winding.
E-Core Assembly Method
The following diagram gives an idea regarding how more than 1 E-core may be used for implementing the above discussed 5 KVA ferrite
inverter transformer design:
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(https://homemade-circuits.com/wp-content/uploads/2014/07/Ecoreassembly-
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(https://homemade-circuits.com/wp-content/uploads/2014/07
/Ecoreassembly-3.png)
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(https://homemade-circuits.com/wp-content/uploads/2014/07/ecoreinvertercircuit-
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Dear All,
In the above project for the transformer, i did not use any spacers between the core pieces, the circuit worked well with the trafo cool while in
operation. I always preferred an EI core.
I always rewound the trafos as per my calculated data and then used them.
All the more the trafo being an EI core, separating the ferrite pieces were rather easy than doing away with an EE core.
I also tried opening EE core trafos but alas; i ended up breaking the core while separating it.
I never could open an EE core without breaking the core.
As per my findings, few things i would say in conclusion:
---Those power supplies with non-gaped core trafos worked best. (i am describing the trafo from an old atx pc power supply since i used
those only. The pc power supplies do not fail that easily unless its a blown capacitor or something else.)---
---Those supplies that had trafos with thin spacers often were discolored and failed quiet early.(This i got to know by experience since till date
i bought many second hand power supplies just to study them)---
---The much cheaper power supplies with brands like; CC 12v 5a, 12v 3a ACC12v 3a RPQ 12v 5a all
Such types ferrite trafos had thicker paper pieces between the cores and all failed poorly!!!---
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Step 1:
Using 5 Sealed Lead Acid batteries of 12v 10Ah

Total voltage = 60v Actual voltage
= 66v fullcharge(13.2v each batt)voltage
= 69v Trickle level charge voltage.
Step 2:
After calculation of battery voltage we have 66volts at 10 amps when full charged.
Next comes the supply power to ic2153.

The 2153 has a maximum of 15.6v ZENER clamp betwen Vcc and Gnd.
So we use the famous LM317 to supply 13v regulated power to the ic.
Step 3:
The lm317 regulator has the following packages;
1. LM317LZ --- 1.2-37v 100ma to-92

2. LM317T --- 1.2-37v 1.5amp to-218
3. LM317AHV --- 1.2-57v 1.5amp to-220
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Step 4:
We cannot supply the 66v directly to the lm317ahv package sice its input is maximum of 60v.
So we employ DIODES to drop the battery voltage to a safe voltage to power the regulator.
We need to drop about 10v safely from the maximum input of the regulator which is 60v.
Therefore, 60v-10v=50v
Now the safe maximum input to the regulator from the diodes should be 50 volts.
Step 5:
We use the regular 1n4007 diode to drop the battery voltage to 50v,
Since being a silicon diode the voltage drop of each is about 0.7 volts.
Now we calculate the required number of diodes we need which would buck the battery voltage to 50 volts.
battery voltage = 66v
calc.max input voltage to regulator chip = 50v
So, 66-50=16v
Now, 0.7 * ? = 16v
We divide 16 by 0.7 which is 22.8 i.e., 23.
So we need to incorporate about 23 diodes since the total drop from these amounts to 16.1v
Now, the calculated safe input voltage to the regulator is 66v - 16.1v which is 49.9v appxm. 50v
Step 6:
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The tantalum capacitor connected to the 2153 is an important capacitor that makes sure ic gets a smooth dc from the regulator.
Its value can be reduced from 47uf to 1uf 25v safely.
Step 7:
Rest of the circuit gets 66volts and the high current carrying points in the circuit should be wired with heavy guage wires.
For the transformer its primary should be 5+5 turns and secondary 20 turns.
The frequency of the 2153 should be set at 60KHz.
Step 8:
The High frequency ac to low frequency ac converter circuit using the irs2453d chip should be wired appropriately as shown in the diagram.
Finally completed.
Making a PWM Version

The following posting discusses another version of a 5kva PWM sinewave inverter circuit using compact ferrite core transformer. The idea
was requested by Mr. Javeed.
Technical Specifications
Dear sir, would you please modify its output with PWM source and facilitate to make use such an inexpensive and economical design to
World wide needy people like us? Hope You will consider my request. Thanking you.Your affectionate reader.
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However, the same design could be converted into a PWM equivalent sine wave inverter by injecting a PWM feed into the low side mosfets
as shown in the following diagram:
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As we can see in the above PWM based 5kva Inverter circuit, the design is exactly similar to our earlier original 5kva inverter circuit, except
the indicated PWM buffer feed stage with the low side mosfets of the H-bridge driver stage.
The PWM feed insertion could be acquired through any standard PWM generator circuit using IC 555 (https://homemade-circuits.com
/2012/12/how-to-use-ic-555-for-generating-pwm.html) or by using transistorized astable multivibrator. (https://homemade-circuits.com
/2013/04/how-to-modify-square-wave-inverter-into.html)
For more accurate PWM replication, one can also opt for a Bubba oscilator PWM generator (https://homemade-circuits.com/2014/11/sine-
wave-inverter-circuit-using-bubba.html) for sourcing the PWM with the above shown 5kva sinewave inverter design.
The construction procedures for the above design is not different to the original design, the only difference being the integration of the
BC547/BC557 BJT buffer stages with the low side mosfets of the full bridge IC stage and the PWM feed into it.
Another Compact Design

A little inspection proves that actually the upper stage does not need to be so complex.
The 310V DC generator circuit could be build using any other alternate oscillator based circuit. An example design is shown below where a
half bridge IC IR2155 is employed as the oscillator in a push pull manner.
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Again, there's no specific design that may be necessary for the 310V generator stage, you can try any other alternative as per your
preference, some common examples being, IC 4047, IC 555, TL494, LM567 etc.
Inductor Details for the above 310V to 220V Ferrite Transformer
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Simplified Design
In the above designs so far we have discussed a rather complex transformerless inverter which involved two elaborate steps for getting the
final AC mains output. In these steps the battery DC is first needed to be transformed into a 310 V DC through a ferrite core inverter, and
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section can eb eliminated.
The following image shows a simple set up for executing the above explained technique:
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an op amp stage, in which this signal is extracted from the ICs RC timing network in the form of 50 Hz triangle waves and fed to one of its
inputs to compare the signal with a fast triangle wave signals from another IC 555 astable circuit. This fast triangle waves can have a
frequency of anywhere between 50 kHz to 100 kHz.
The op amp compares the two signals to generate a sine wave equivalent modulated SPWM frequency. This modulated SPWM is fed to the
bases of the driver BJTs for switching the MOSFETs at 50 kHz SPWM rate, modulated at 50 Hz.
The MOSFEts in turn, switch the attached ferrite core transformer with the same SPWM modulated frequency to generate the intended pure
sinewave output at the secondary of the transformer.
Due to the high frequency switching, this sine wave may be full of unwanted harmonics, which is filtered and smoothed through a 3 uF/400 V
capacitor to obtain a reasonably clean AC sine wave output with the desired wattage, depending on the transformer and the battery power
specs.
The right side IC 555 which generates the 50 Hz carrier signals can be replaced by any other favorable oscillator IC such as IC 4047 etc
Ferrite Core Inverter Design using Transistor Astable Circuit
The following concept shows how a simple ferrite cored inverter could be built using a couple of ordinary transistor based astable circuit, and
a ferrite transformer.
This idea was requested by a few of the dedicated followers of this blog, namely Mr. Rashid, Mr, Sandeep and also by a few more readers.
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However after some thinking it seems I have succeeded in discovering the very simple principle associated with the functioning of such
inverters.
Lately the Chinese compact type inverters have become pretty famous just because of their compact and sleek sizes which make them
outstandingly light weight and yet hugely efficient with their power output specs.
Initially I thought the concept to be unfeasible, because according to me the use of tiny ferrite transformers for low frequency inverter
application appeared highly impossible.
Inverters for domestic use requires 50/60 Hz and for implementing ferrite transformer we would require very high frequencies, so the idea
looked highly complicated.
After some thinking I was amazed and happy to discover a simple idea for implementing the design. Its all about converting the battery
voltage to 220 or 120 mains voltage at very high frequency, and switching the output to 50/60 HZ using an push-pull mosfet stage.
How it Works
Looking at the figure we can simply witness and figure out the whole idea. Here the battery voltage is first converted to high frequency PWM
pulses.
These pulses are dumped into a step up ferrite transformer having the required appropriate rating. The pulses are applied using a mosfet so
that the battery current can be utilized optimally.
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it may be used for operating the household appliances.
Kindly note that though the circuit has been exclusively designed by me, it hasn't been tested practically, make it at your own risk and on;y if
you have sufficient confidence over the given explanations.
Circuit Diagram
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R1,R2,C1,C2 = calculate to generate 100kHz freq.

R7,R8 = 27K
C3, C4 = 0.47uF
T1----T4 = BC547,
T5 = any 30V 20Amp N-channel mosfet,
T6, T7 = any, 400V, 3 amp mosfet.
Diodes = fast recovery, high speed type.
TR1 = primary, 13V, 10amp, secondary = 250-0-250, 3amp. E-core ferrite transformer....ask an expert winder and transformer designer for
help.
An improved version of the above design is shown below. The output stage here is optimized for better response and more power.
Improved Version
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5kva Ferrite Core Inverter Circuit

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5kva Ferrite Core Inverter Circuit - Full Working Diagram with Calculation Details | Homemade Circu... https://www.homemade-circuits.

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Understanding the above block diagram is quite simple:

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A Simple Ferrite Cote Inverter Design

The complete circuit diagram can be witnessed below:

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4 από 29 29/08/2020, 01:32 π.μ.

5 kva Design Prerequisites

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Ferrite Transformer and Mosfet Specifications

Using a Full Bridge IC

Alternate IC can be SG3525

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DATASHEET IR2153 (https://drive.google.com/file/d/1JmvyZMHfo70SlDu-9SupP0ZmBhUJGDc7/view?usp=sharing)

High Frequency 330V Stage

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Converting 330 V DC into 50 Hz 220 V AC

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How to Wind the Ferrite Transformer TR1

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E-Core Assembly Method

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I never could open an EE core without breaking the core.

As per my findings, few things i would say in conclusion:

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Using 5 Sealed Lead Acid batteries of 12v 10Ah

Next comes the supply power to ic2153.

The lm317 regulator has the following packages;

1. LM317LZ --- 1.2-37v 100ma to-92

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Making a PWM Version

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Another Compact Design

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Inductor Details for the above 310V to 220V Ferrite Transformer

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section can eb eliminated.

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Ferrite Core Inverter Design using Transistor Astable Circuit

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it may be used for operating the household appliances.

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R1,R2,C1,C2 = calculate to generate 100kHz freq.

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