STUDY AND DESIGN OF POWER INVERTER

A thesis submitted in partial fulfilment of the

requirements for the award of the degree of

Bachelor of Technology

tn

Electronics & Communication Engineering

By

Abhiiit Chetia (Gau-C- I3l OI4l

Monin Kumar Boro(Gau-C-13 l024l
Under the guidance of

MR. HARADHAN CHEI

Qilt*nllil ttffi
rriith Hfl
*thlil
- -Ejlltrtril
ll,H
rt

W|l
^IF:jF'|l
tdf* ilr j
I aert I rlr rtr I
\ a* t vttilr*.r./

DEPARTMENT OF EIE TRONICS & COMMUNICATION

CE NTRAT I NSTITUTE OF TECH N OIOGY, KOKRAJ HAR-7 8337 O
 Anilfq@dr{Trdffi
CENTRAL INSTITUTE OF TECHNOLOGY KOKRAJHAR
(A centrally funded instrtute under MHRD. Governrnent of lndia)

CERTIFICATE OF APPROVAL

This is to cerlify that the work eurbodied in this project entitled "Study and Design of
Power Inverter" submitted by Abhijit Chetia (Gau-C-13/Ol4) and Monin Kumar Boro (Gau-C-
l3l024l to the depar[nent of ELECTRONICS AND COMMUNICATION ENGINEERING,
is carried out under my direct supervision and guidance. The project work has been prepared as
per the regulations of Cental Institute of Technology and I strongly reconrmend that this project
work is accepted in partial fulfillment of the subject EC89l for the requirement in the curdculum
of Bachelor of Technology in Electronics and Communication Engineering.

(Mr. Haradhan Chel)

Assistant Professor, Dept. of ECE

(Dr. sun"U$frfril"t
HoD & Associate Professor, Dept. of ECE
 ffirq@dpnaffi
CENTRAL INSTITUTE OF TECHNOLOGY KOKRAJHAR
{A centrai{v fundetj instrlute uncler t\4HRD Governrlent of indi;r}

CERTIFICATE BY THE BOARD OF EXAMII\ERS

This is to certi$ that the work embodied in this project entitled "Study and Design of
Power Inverter" submiffed by Abhijit Chetia (Gau-C-l31014) and Monin Kumar Boro (Gau-C-
131024) to the deparhnent of ELECTRONICS AND COI\{MUI{ICATION ENGIT{EERING
of Central Instifute of Technology, Kokrajhar has been examined and evaluated.

The project work has been prepared as per the regulations of Central Instihrte of
Technology and qualifies to be accepted in pardal fulfillment of the requirement for the degree
of Bachelor of Technologry in Electronics and Cornmunication Engineering.

.-,3
aA&ry "'r'
/, \8 "'
Project Co-ordinator Board of Examiners

r-,
rK
\\/'113%61
\rn
tl/v
\-/'
. \7L--
(Rajib Chetia)
Assistant Professor.

Dept. of ECE,
 DECLARATION

We hereby declare that the project work entitled "Study and Design of Power Inverter$ is an
authenticated work carried out by us under the guidance of Mr. Haradhan Chel for the partial
fulfillment of the requirements in the degree of Bachelor of Technology in Elecfionics and
Communication Engineering Gauhati University and this work has not been submitted for
similar purpose anywhere else except to Deparfinent of Electronics and Commrurication
Engineering, Central Institute of Technolory, Kolaajhar.

$*Jiitl''!t.t
Date: Abhijit Chetia
- (Roll No-Gau-C-l 3/01 4)

Place: Kokrajhar
\4oo\n K"t"nc-( Bo>ra
Monin Kumar Boro

(Rolt No-Gau- C- 13 1024)

 ABSTRACT

From the late 19ft century through the middle of the 20do century, DC to AC
power conversion was accomplished using rotary converters or motor generator
sets. In the early 20do century, vacuum tubes and gas filled tubes being used as
switches in inverter circuits. The most widely used type of tube was the
thyratron.

The origins of the electro mechanical inverters explain the source of the term
inverter. An inverter is an electrical device that converts direct current (DC) to
alternating current (AC) the converted AC can be at any required voltage and
frequency with the use of appropriate transformers, switching and control
circuits an inverter is essentially the opposite of a rectifier.

A power inverter AC power when main

uses batteries and an inverter to supply
power is not available. When main power is restored a rectifier is used to supply
DC power to recharge the batteries. This circuit works on the operation of IC.
SG3524 and MOSFETs which is to convert 12V DC to 230 V - l10V AC by
using a step down transformer.
 ACKNOWLEDGEMENT

We sincerely express our heartiest gratitude to our project guide Mr.

Haradhan Chel (Asst. Professor of Electronics aqd Communication
Engineering, Central Institute of Technology, Kokrajhar) for his valuable
guidance and vital support throughout the completion of the project.

We would also like to thank Mr. Rajib Chetia (Project Coordinatorl

Assistant Prof. Dept. of Electronics and Communication Engineering, Central
Institute of Technology, Kokrajhar) for allowing us to use the departmental
facilities for our project work

Finally we would like to express our deepest gratitude to our parents for
supporting us both morally and financially and encouraging us to give our full
dedication to our project work.
 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO

ABSTRACT A

ACKNOWLEDGEMENT b

TABLE OF CONTENTS c

LIST OF FIGURES e

1 INTRODUCTION I
2 APPLICATIONS 2

3 DIFFERENT APPROACHES 3

3.1 SQUARE WAVE & MODIFIED WAVE INVERTER 3

3.2 LOW- FREqUENCY MODIFIED SQUARE WAVE INVERTER 3

3.3 HIGH FREQUENCY NODIFIED SQUARE WAVE INVERTER 4

3.4 SINE WAVE INVERTER 4

3.5 LOW FREqUENCY MUTTISTEP SINE WAVE INVERTER 4

3.5 MIXED FREQUENCY SINE WAVE INVERTER f,

3.7 HIGH FREQUENCY SINE WAVE INVERTER f,

4 BLOCK LEVEL DESIGN 6

4.L STAGE 1 6

4.2 STAGE 2 8

BATTERY DESCRIPTION 9

5.1 CHARGING AND DISCHARGING 9

6 POWER INVERTER CIRCUIT DESIGN AND CONSTRUCTION lt

5.1 TRANSFORMER DESIGN tl
6.2 THE GENERATED EMF IN A WOUNDED TRANSFORMER 11

5.3 CHOICE OF TRANSFORMER COMPONENTS t2

6.3.1 PRIMARY WINDING t2
6.3.2 SECONDARY WINDING l3
5.3.3 SWG ESTIMATION l3
6.4 50 Hz FREQUENCY OSCILLATOR SECTION 13

5.5 SG3524 DESCRIPTION t4

7 THEORY OF OPERATION 15
7.L VOLTAGE REFERENCE 15

7.2 OSCILTATOR l5
7.3 THE OSCITTATOR SECTION 15

7.4 DRIVER SECTION t6

7.5 OUTPUT SECflON t6
7,6 PUTSE WIDTH MODUTATION PWM SECTION t7
8 PERFORMANCE EVATUATION t9
9 MAINTENANCE SAFEW AND PRECAUTION 2l
10 IMPTEMENTATION ISSUES 22

11 CONCLUSION 24

L2 REFERENCES 25
 IIST OF FIGURES

Fig. No. Title of Figure Page No.

1 SG3524 Pin L4
Configuration

2 Driver section circuit 16

diagram

3 Output Section Change L7

Over Circuit
 CHAPTERI. INTRPDUCTION

The inverter is an electrical device, wtrich is used to convert the DC power to an AC power.
The inverter for home is used for emergency backup power and used in some aircraft systems
to convert a portion of the aircraft DC power to AC. The alternating crurent mainly useO fot
electrical devices used in homes like radio, lights, motor, etc. Inverter tlpes are classified into
many based on application like a sine wave, modified sine wave, square wave, voltage source
inverter, multilevel inverteq etc.

These inverters can suit for various electricity needs. The voltage soluce inverters produce an
output voltage or a current to required ranges and frequencies. These ranges are either
positive or negative, it is known as two-level inverters. Uuttitevel inverter is to synthesize a
near sinusoidal voltage from several levels of DC voltages. Multi level inverter main
advantage is minimum hrrnonic distortion.

The domestic inverter is mainly used for household electric devices, the rating of domestic
inverter mainly depends on the home applications, wtrich are available in Oitrerent load
capacities. The basic constnrction of the inverter is, the input terminals of the inverter
connect to the output terminals of the DC battery and connected to a transformer through the
center tap of the primary winding. The contact switch is rapidly switched back and fo]th to
allow current to flow back to the battery following two alternat€ paths thrcugh one end of the
primary winding and then the other. The alternation of the voltage of the primary winding of
the tansformer produces alternating voltage in the secondary circuit. fhis will be nonnilly
maintained by 230V volts AC.

In most of the home appliance alternating electical power is required. However AC power is
not always available and the need for mobitity and simplicity a batrery driven inverter can be
used as a portable AC power. The input of the inverter is a DC batbry from an input terrrinal
ofa batlery or a solar panel as input.

Page |1
 CHAPTER 2. APPLICATIONS

Home power inverter is to provide unintemrpted pow€r to run household electric devices.
These inverters for home are available in different voltage and load capacities. trn the basic
design of the home inverter a DC Oattery) source is connected to a transformer through the
center tap of the primary winding. A switch is rapidly swirched back and forttr to allow
current to flow back to the battery following two alternate paths through one end of the
primary winding and then the other.

Power inverters are devices which can convert electrical energy of DC form into that of AC.
They come in all shapes and sizes, from low power functions such as powering a car radio to
that of backing up a building in case of power outage. Inverters can come in many different
varieties, differing in price, power, efficiency and purpose. The purpose of a DC/AC power
inverter is tlpically to take DC power supplied by a battery, such as a l1volt car battery, and
tnansform it into a 230 volt AC power source operating at 60 IIz, emulating the power
available at an ordinary household electical outlet.

Page | 2
 CHAPTER 3. DIFTERE

3. I.Square-lvave & Modined Sq uare-wave Inverter Topologies

The earliest inverters used in renewable energy applications produced a coarse square wave
AC output-fairly easy to accomplish, and therefore much cheaper. plus, they offrt"d lo*
losses. Early square-wave inverters were later replaced with an improved '?nodified"
square-
wave inverter design, which improved perbnTTce and appliance compatibility wtrile using
the same basic inverter topologies. Because of the low po*t quality, tit.* inverters .*noi
be connected to a utility grid. While most current PV systems do not use these types of
inverters, knowing how they work is important to understanding the evolution of inverter
manufacturing.

Two different group! of square-wave inverter topologies are used to make essentially the
same resulting modified square-wave AC output. There also are many additional variations
within each of these two groups, but it is easiest to divide the topologies into either a low- or
a high-frequency type.

3.2. Low-Freq uency Modi tied sq ua re-lvave Inverteru

A set of nansistors first converts the DC source into a low-voltage AC wave form. The
transistors are switched on and offabout 120 times per second d*ing each AC cycle-also
referred to as switchin g at l2A Hertz. A low-frequency transformer- steps up the low AC
voltage to the required 120 VAC. This topology is one oittre simplest inverter designs,
but is
limited to producing square.wave and modified square-wave AC ouput waveforms

These types of inverters are easily identified by their large size and weight. The relatively
large low-frequency transformer makes them heavy, but it also makes th; units rugged
ani
reliable, since the transformer also provides DC-to-AC isolation and protects the transistors
from damage, sort of like a heavy bumper on a tnrck.

Because of the simplicity of this topology and its low parts counl fairly high efficiencies-
gven at low power levels--tan be attained since the low-frequency swiiching reduces losses
in the tansistors and the tansformer. Since all of the swirching is done at low"frequencies,
no
elaborate DC or AC filt€ring is nequired to minimize interference with loads, alihough RU
radio interference is often encountered.

This topology is only used in less-expensive, battery-based inverters in occasional-use

applications such as RVs and cabin systems, as some common AC loads do not tolerate the
non-sinusoidal modified square-wave form.

Page | 3
 3J.High-Freq uency Modifi ed Sq uare-Wave Inverter

In a high-frequency inverter, the transistors are turned on and offabout 20,000 times or more
per second during each AC cycle. also referred to as switchin g at 20 kilohertz GHz). This
topology is more complex and can be used to produce a variety of AC output wave forms,
including a true sine wave.

With this topology, the DC source is first stepped up to a higher-voltage AC wave form by a
set of transistors switchingat}AkHzand a high-frequency transformer. Then, it's rectified to
an intermediate DC voltage (usually between 200 and 400 VDC), which is stored in a set of
capacitors. An additional set of output transistors switching at low frequency (120 FIz) is then
used to produce the modified squffe wave AC output from this high-voltage DC source.

These types of inverters are easily identified by their smaller size and lighter weight
(compared to low-frequency units), since the large low-frequency tnansformer has been
replaced with a much smaller high-frequency transformer. Because the output set of
transistors is not isolated by a fiansfbrmer, they also tend to be more sensitive to abuse and
voltage surges and lighuring, resulting in lower reliability.

Achieving high efticiencies (greater than 9oo/o) with this topology can be challenging when
working with low DC voltage systems, such as with battery applications. It also can be
difficult to provide high "surge" currents for a long enough time period to start larger motors.

3.4.Sine-Wave Inverter Topologies

Making a sine wave from a DC source is much more difficult than making a square wave or
modified square wave form. It takes more parts, more design, and a much more sophisticated
control system.

The biggest challenge with making a sine wave inverter is doing it in a way that provides
high efficiency. The earliest sine wave inverters were not very efticient-larticularly with
low-power loads. Advances in ftansis0ors and high-speed digital contol systems now allow
modern sine wave inverters to provide high-quality power at higher conversion efficiencies-
even at low power levels.

Sine-wave inverter topologies vary from simple to complex. Each has its benefits and
draubacks--there is no "best" topology. The ftmge of applications for sine-wave inverters is
too varied.

While many of the sine wave inverter topologies can be used for both oflgrid and grid-tied
applications, the construction and feafures utilized in a battery-based inverter are very
different than for one designed to be used only with a PV array as a source.

3.S.Low-Freq uency Ferro-Resonant Sine-Wave In vefier

The need for a higherquality AC wave form prompted inverter engineers to figure out how
to make a beffer sine-wave output from the rugged and simple low-frequency square wave
inverter topology. The modified square-wave form was just not good enough to operate the
more demanding electrical loads and also could not be used for gridaied ap,plications.

The first solution used was to add a filtering system to the output, to "round-off' the square
edges of the modified square wave form. Several manufacfurers offered ferro-resonant
transformer-based ouQut filters, which improved the compatibility with sensitive electronic
page | 4
i]

tl

ll
 loads such as laser printers, but had a big impact on the inverter's efficiency, especially when
operating at low power levels, making them unpopular for RE applications. But th.y have
been used in high-end power suppty and telecommunication markets to power sensitivi loads
when effrciency is not critical.

With these topologies, the quality of the sine wave form is very dependent on the
characteristics of the AC load being powered, since there isn't any feedback control of the
ferro-resonant hansformer, so the success of this solution was hit-and-miss. This topology
does not readily allow the inverter to correct or adjust the shape of the output *ane for;,
since the transformer operates passively and is not actively controlled.

3.6.Low-Freq uency Multistep Sine-Wave In verjer

Another solution that was developed to make the AC output closer to a tnre sine wave
involves combining several low-frequency, inverters operating at different frequencies
together in series. This allows multiple AC output voltage levels to be produce4 creating a
stepped sine-wave approximation of a sine wave form. This appioach resulted in a
surprisingly good sine wave, while still using low-frequency switching and fiansformers to
maintain ef;ficiency at low power levels while only modestly increasing the cost and
complexity.

The AC output sine wave allows some inverters using this topology to be tied to the grid,
although few manufacturers are currently using this topology due tothe high parts count and
resulting high manufacturing cost.

3.7.Mixed Frequency Sine-Wave Inverteru

This topology combines the benefits of both low-frequency and high-frequency inverters.
High-frquency switching transistors convert the DC source to a lower-voltage AC
waveform. The transistors are switched at high frequency-hundreds of times per A- cycle
or about 20,000 times a second. An inductor then smoothens the choppy, high-frequ.ory
sqwrc wave form into a smooth, low-frequency wave form-*reating i low-volage sine
wave. TherU a low-frequency hansformer steps up the AC voltage to the required 120 or 240
VAC. This type of inverter is able to produce a 'otrue" sine-wave like u ttigh-nequency
inverter, but it is simpler to build and morc reliable.

Because the DC currents are being switched at high frequency, which causes electrical noise,
a carefully designed output fitter must be included to etiminate electrical interference with
loads or clean up the power being sent into the utility grid.

Like the low-frequency modified square-wave inverters, these types of inverters are also
large and heavy. When used in a battery less grid-tied PV application with high DC input
voltages, efticiencies as high as 96Yo can be attained since the DC currents b"Lg switched
are much smaller than with low-voltage battery systems.

3.t.High-Frequency Sine-Wave fnverters

Another way of producing a high-quality sine wave uses high-frequency power conversion.
While significantly complex, it does allow a dramatic reduction in thi size and weight
compaled to low-frequency sine wave inverters.

Page | 5
The challenge with &is design is similar to the high-ftequency modified sine-wave inverter-
the cmplexity ed hi$ psts colnt cu make rtiability an issue, and efrciency at lower
psr€r levolscs be unacceptable.

This topolory is slso used by many bafiery less grid-tied PV inverters to s€nd sgrplus power
to &e sility. In fu tso-sep pont€r conversion pmcess, the cmtnol syst€,m *iicarh te
*ftuil end" cmvertcr (uthich gp€s from DC to AC
to DC and is cmprisid of tusistors, and
a trmform st4 rcctifis) to ex&rct the mo6t poffi fron &e PV urry&dlcd saxfium
pon'€r point tnacking), nfiile the second converter cmprised of fansiitors and m oueut
filter (caFcinrs and inducton) isogimized to pttr the mo* pou,€tr back into &e utility gia

Paeel6
 CHAPTER 4. BLOCK LEVEL DESIGN

An inverter generally works on fwo principles: -

1. When the AC power is on (charging)

2. When the AC pow€r is off(power loss).

4.I.STAGE T

When the AC power is on current will flow through the battery charging circuit and directly
to the load through a relay circuit. Thus the charging circuit will convert the 220 V AC to 12
V DC through a bridge rectifier circuit which will charge the banery until it gets full charged.
After the battery is fully charged a relay circuit will break the circuit.

Running on normaf AC power

Fig: Block Diagram of Charging Unit

Transformer: Transformers step down high voltage AC mains to low voltage AC. In
this step our voltage is still AC.

high voftage AC output

(mains supply) low voltage AC

Transformer Output: low voltage AC

Rectifier: A bridge rectifier is an iurangement of four diodes in a bridge configuration

that provides the same polarity of output voltage for either polarity of input voltage. Rectifier
converts AC to DC but the DC output is varying.

Transformer Rectifier Ottput: varying DC

Figure-: Function of recttfur

Page | 7
 Smoothing capacitor: Smoothing capacitors smoothen the DC from varying greatly
to a small ripple.

Transformer Rectifier Smoothing Output: smooth DC

Figure-: Function of smoothing

Regulator: Regulator eliminates the ripple by setting DC output to a fixed voltage.

Transformer Rectifier SmoSmoothing Regulator Output: regulated DC

Figure-: Function of rqulotor

LM78l2 Voltage Regulator: The reason for LM78l2 as voltage regulator was its
output voltage and output current value ranges. Output voltage is a l2V and output
currents
in excess of 10A are possible by adding external transistors. Since the current required
to
charge a battery is l0 percent of its ampere capacrty. So, this voltage regulator
is sufficient.

4.2.STAGE 2

When the AC power is off then the battery will start to loss its power through a relay circuit
to the inverter circuit and then to the load.

Over/Under-voltage. oilower loss

Page | 8
 CHAPTER 5. BATTERY DSSCRIPTION

A rechargeable battery, storage baftery secondary celf or accumulator is a tlpe of electrical

battery which can be charged, discharged into a load, and recharged many times, while a non
rechargeable or primary battery is supplied fully chargd and discarded once discharged.
It is
composed of one or more elecfiochemical cells.

The term "accumulator" is used as it accumulates and stores energy through a reversible
electrochemical reaction. Rechargeable batteries are produced in many different shapes
and
sizes, ranging from button cells to megawatt systems connected to stabilize an electrical
distribution network.

Several different combinations of electrode materials and electrolytes are used, including
lead
aci4 nickel cadmium (Nimh), tithium ion(Li-ion) and lithium ion polymer(Li-ion polyrner).

5. I.CITARGING AND DISCHARGING

During charging, the positive active material is oxidized; producing elecbons and the
negative material is reduced consuming electrons. These electrons constifute the current
flow
in external circuit. The electrolyte may serve as a simple buffer for internal ions flow
between the electrodes, as in lithium ion and nickel cadmium cells or it may be an
active
participant in the elechochemical reaction as in lead-acid cells.

The energy used to charge rechargeable batteries usually comes from battery charger
using
AC main electricity, although some are equipped to use a vehicles 12 volt DC power outlet.
Regardless to store energy in a secondary cell it has to be connected to a DC voltage
source.
The negative terminal of the cell is needed to be connected to the negative terminal
of the
voltage source and the positive terminal of the voltage source with the positive terminal
of
the battery.

Further, the voltage output of the source must be higher than that of the battery, but
not much
higher: the greater the difference between the power source and the battery,s voltage
capacity, the faster the charging process, but also the greater the risk of overcharging and
damaging the bat8ery.

Fast chargers must have multiple ways of detecting when a cell reaches
full charge to stop
charging before harmful overcharging or overheating occurs. The fastest chargers often
incorporate cooling fans to keep the cells from overheating.

For example, fiickle charging might be performed at C/20 (or a 20 hogr rate), while
typical
charging and discharging may occur at C/2(two hours of full capacity).The available
capacity
of elechochemical cells varies depending on the discharge rate. Some energy is lost in the

Page | 9
 interconnections), and the rate of
internal resi$ance of cel components (plates, electolyte,
discharge is linit€d bythe speed atnftich chicels
inthe cell cm move about

high current may still

A lead acid ceu thst can no longer sustain a usable t€rminsl voltage at
have usable cryity, if dischefged at amuch lower
rate'

Brft'ymangfrcfirer's technical notes often refer to voltage

per cell(\Fc) for the individual
12 v lea&acfol bmer5(cmtaining 6
cells frat make rp the bafiery. Fc exmple, to chrge a
asross the battery's terminds'
cells of Zveach) at 2.3 VpC requires a voltage of 13.EV
qfun new, but &is voltage droes
Nm-rechrgable alkatine zins,calton cells ouFut l.sv
with nse. Mo$ NiMH AA aod Ar{A cells are rated at lzv cm
usually b€ used in equipment

d€signed to rse eilraline bameri€s.

Page I 1O
 CHAPTER 6.

The inverter is a two operation modes device, the inverting and the charging modes.

The inverting mode comprises of the oscillator, the driver, thg output (MOSFET) section,
the
pylrt *.tioi, f"* U rtt*y / ovedoad protection circuit, and the transformer.
charging
The charging mode implements the transformer, the FET"s (internal diodes) and the
confiol circuit.
A third operation mode is the changeover modes for switching between the two
aforernentidned modes at times of auto-blck up for power failure-and
power restoration for
th; ;h*gi"g process. This rnoCr implement$ a deiay circui! elecfiomagnetic relays and
power supply circuit.

6.I.TRANSTORMER DESIGN

A transfonner is a device that couples two AC circuits magnetically and provides electrical
from
isolation between the circuits whiie allowing a transformation of voltage and current
and hence
one circuit to another i.e. it is mainly used for voltage and cunent transformation
we made use of current voltage fansformers in this project.

6.2.The Generated E.M.tr'in a wounded Transformer

In observing an ideal fiansformer with secondary opened and the- primqry connected to a
sinusoidal aftd;tdi"ott"grVt, ttre potentiat ditrenint causes-an alternating current to flow
il-tlr; ptt-rryiinir piinirry Cqii.li 'I g*ly inductive and has no guQu! but draw the
core in the
masnetiziog r,-rni-I';iy ]A"d this wiil fuqction as to magnetized the
ffiffi;.it iirnr"il in arid rae voltage vr by 900. It thgrefore pr&uces an alternating fltx
ffiiilrtriqiioo"rlo the.,-fit inprits, ririi flux is linked uy bol[nTtmry and secordarv
thaipddu.d a mutually. induced d.m.f E in secondary winpt{tB
i"itioi"gr .'rrtur; tttis iear,ag4-si
trrai-a"f,-ptrad *i,l[ 1r,ffi -agrritude proporiional to rate of change of fltx and the
number of secon@ turns.
Let Nr=Number of turns in N2- number of turns in
secondary
Nrt
The fiansforrration ratio, K - tNz

The equation for the voltage and current transformation of a transformer is given
bY l( -' Vz/Vr : lrl Iz
F:Frequency of A.C inPut (Hz)

Maximum flu in cone (WbfB *,4

Average rate of change of flux =rnanimum. Flux divided by YnF. (Wb/s or Volt.)
Now rate of change of flux per turn means induced e -m .f in Volt
Thus Averagee.m.f /tutn - 4 * F * fiunc.Fhtx
Sincethe flrx is sinusoidal,
r.m.s - form factor * Average e-m. f / tu:nt

But f orm f actor = r.m.s value /Average value =1.1l,

Page | 11
Then r.m.s value of

E.m.f :!.LL * 4F * rnalc.Fhn = 4.44F * fitlnc.Flttx,

But trlax.fhtx = Bm* A

rm.s value of E.m .f in primary turn (Tp) = 4.44 F 'r B^ * A * Tp

NOTE: B- is assumed to be 15000 Wb/m. F = 50 Hz

By inhodrrcing stacking frctor (l0t) mdTo factor (0.9) then wehave
Number of turns per volgIVT .V-L = 7 /A
63.CHOICE OF TRANSTOR}TER'S COMFONENTS

The power Rating for the Inverter transformer (KVA) :1.0KVA ,82:l2Y
Assuming the efficiency of transformer:85o/o
Then Inputrating = outPUt /Ef ficiency: 1000V4/0.85 = LL76VA
Ip: Pr / Up Vo = 260Y
Ip=1176 l2@=4.5A

/"=Po/V, Vs= LZV Ip=

1000 lLZ:83.3r{
For practical design of inverter transformer

Number of turns per volt for both primary ad secondary winding is

givenby;IVr.V-L: 7/A
Where A is the $eaof transformer fsrmer in
sq.inch
Former area A is 2.3 inch by 1.5 inch=3.45sqinc

Nr.V-L: 713.45=?,.03

N7.V-r= 2 (approximate value).

63.1. Primary Winding

Charger tapping winding tums

Npr=N1.Vr*E1 . EF220Y

Npr:2* 220 =440turns

Inverter (ou$ tapping winding turns

Nsz= Nr.Vr * E: h=ZffiY
Nsz:2* 260= 520turns
Page | 12
Difference of Inverting and Charging turns = 520 - 440: E0turns'
440 turns and an addition 80
For the primary windings, charging tapping is brought out after
tums is made for the inverter out tapping'

632.SeconderY Wndlng

Secondary turns N= Nr.Vr * Ez

Ez: lZY
JVs = 2 *L2= 24tuttts.(Bifilarwinding)
633. SWG Estimatlon
Standard Gauge Weight SGW, can be estimated as follow;
considering conduction cunpnt density J (with fixed value
of 2.5A/mmt) *d windings coil
current.
For Io: 4.5A, the conresponding guage frqn tables is 24swG
and

For I, = 83.34, the conesponding guage from tables is

13S\MG

6.4.S0HzrREQtIENcYosc[LAToRSBcTIoN
is based on the application of a
The generation of 50 I{z frequency by the oscillator section
pwM confioller IC sG35 24. T:ne tC tt* the following under listed features wtrich makes it
excellent for the aPPlication.

Complete PWM power confiol circuifry

Single ended or push - pull outpttts

Line and load regulation of 0'2o/o

t% marimum temPerature variation

Total supply current is less than 10mA

OPeration beYond lOOKI{z

APPlication 0"C to +70'C

Page I 13
6.5. SG3524 DESCRIPTION
power supply
It is a monolithic Ic that contains all the control circui$ for a regulated
r6pir qq -in * line package is the voltage
inverter or switching regulator. Included in a pulse steering flip-flop'
reference, error amplifier, osciltatot, p"r*
width modulator PwI\4 I

and shutdon'n circuitry. Fig. I below shows

dual alternsting output switches,;;fi fmiting
t

the pins definition of the IC-

u,l, t lr|cil{ll
ffl?tt f b
n T'U' Ig
o|G qtftltt flt'Etr
Ftctrtrt cf,ucrolg
Hd, |alft
co,$cr8r
*l trnBr
Cr
Srttoft
€rnr cilE[rllu

Fig. l. SG35 24 Pin conftguration

 =-

CHAPTER 7. THEORY.OF OPERATION

T.I.VOLTAGE REFERENCE

An internal series regulator provides a nominal 5V output which is used both to generate a
reference voltage -d'ir the iegulated source for all the internal timing.and gontrol circuifry.
This refe,rence-regulator mayle use0 as a 5V source for other circurtry. It proYt9gJp to
50mA of current ils"tf aoO can easily be expanded to higher current with an external PNP.

7.2. OSCILLATOR

The oscillator in the SG3524 uses an e:fiernal resistor (RT) to establish a constant charging
current into an external capacitor (CT). While this uses more current ftan a series-connected
RC, it provides a linear ramp voltage on the capacitor which is also used as a reference for
the comparator. The charging current is equal to 3.6V + Rr and should be kept within the
approximate range of 30pA to 2mA; i.e- l-8k<Rr<100k-
The range of values for Cr also has limits as the discharge time of Cr determines the pulse-
width of the oscillator ouFut pulse. This pulse is used as a btanking pulse to bott ouputs to
insure that there is no possibility of having both outputs on simultaneously during transition.

73. TIIE OSCILLATOR SECTION

The schematic diagram of the oscillatory section is as shown fig: z..lcl SG3524 is used to
I"n.r"t" the 50 fri nrqueNrcy requ{4 to generate AC supply"by the inverter: B4F V- supply
is connected to the pin-tS. Fin-fof the tdt is connected to negative tenninal of the battery-
Pin-6 and 7 of IC I are oscillator section pins.
The frequency produced depends on the value of the capacitol aod resistor at these
pins. The pin-6'timingiesistor is aiombination of a fixed resistor and a preset VRI so that
the value of the oupul frequency can be set. Signal gene,rated by the oscillator section of ICI
coupled to the flip-ilop section bf rct. This section converts the incoming tien! -.to ttflrt
;fth opposite potirity. ln a two signal with opposite polarity, when the first signal ispositive,
tfre seiind signat witt be negative and vice versa. This process is repeated 50 times per
second i.e. an alternating sienal with 50 ttz frequency is generat€d inside the flipflop
section ofthe ICl.
The 50Hz frequency alrcrnating signal is outpu! at- pin-lt fq9- 14 of ICl- This
alternating signal is calied 'tr,tos drive iignal' having a value between 3.5V and 5-5V.

The oscillator frequarcy is given by :F= L.44/(RC)

For RT : L4SK; CT = 0.1 p"F

ThusF:50l{z(approx.)

Page | 15
 7.4. DRIVER SECTION

MOS drive signal from pin-ll and 14 of ICI are c-oupled to base of transistors Tl and T2-
This result in ttre separation of the signal into two diGrent channels and an ampli{9{ion of
thr;ign;i to rofftlbnt ievel outpu! So* ttre transistors emitter.The resulting MOS dting
" of ri anO T, it coirpteO to the gate of each MOSFET in the first and second
ri-gt"i-ri*titt"i
MOSrer channels respectivelY.
n; dri;it iectioo .ade up of i1 and Tz circuit is incorporated into ttre oscillator
D( A)

D(B)

Rl = lOk Dl =lN4l4t Cl*47uf Tl = 8C557

R2 = lOk D2 - lN4@l C2 = 0.luf T2 = 8C557
R3 = lOk D3 - lN40l C3= luf
R{ = l0k D4 = IN4(I)l C4= l0Oouf
R5 :33o D5 - lN.f d)l
R6 - lO(l D6 - D.14fl)l
R7 = tOk D? = lN4C)l
Rt = lOk Dt = lMlCIl
R9-lk D9 = lN4l4t
R l0 = l20k D l0 = IN{O0l
Rll= l* I)ll = IN{OO|
Rl2= l(l D 12 = fN/001
Rl3= 5(t

Fig 2. Driver section circuit diagram

7.5. OUTPUT SECTION

The 50Hz alternating MOS drive signal reaching the MOSFET channel separately results in
the channels being alternatively ON and OFF.
Drain (D) of all the MOSFET of one channel is connected together ald one end of the
inverter bifilar winding is connected to this connection. The same is done to the second
ctrannef and the other- end of the inverters winding. Positive terminal of the battery is
connectd to the cen6e tapping of the bifilar winding.
Source (S) terminal of each MOSFET is connected to the negative terminal of the battery.
il;* pof.riry of the SotIzMOS dting signal_at-pll-l1 qn0 14 are alternatively different,
curent flows tittough the first half and s&ond half of the transformer's bifilar winding
alternatively.

Page | 15
 (Jill ^'\,\
lo

R34- 22O lr'tGl -lRF320J

R35-22O rlGl -!t,F3205
R36- 22O rrlo6? - lRF320J
nt7- 22O rvG3 -lnF320s
R39- 22O lrlGt -mFtZ)j
R{)- 22O itl66 -rRF3205
7,11- 22O l\ffif -||tF3205
Rf2- lK rrGt -IRF320J
Rtl3- IOX
R4a- lK
Ra5- IOK

Fig.3. Output Section Change Over Circuit

The alternating curent flowing will induce an AC current of 50FIz in the Z6Ov tapping of the
transformer. This tapping is connected to N/O-2 terminal of relay. When the AC mains is not
available, pole P-2 of the relay is connected to N/O-2 terminal and thus the AC voltage
produced by the inverter reaches the inverter output socket. The output
section change*,
circuit is as shown in fig. (3).

7.6.PALSE WIDTH MODULATION PWM SECTION

PWM is used to keep the inverter output to a constarfi220V AC irrespective of

a change in
the load value connected to the inverter output socket. PWM is realized
by feeding back the
AC supply generated by the inverter to the PWM IC I to keep the pulse width
output from
pin-ll and 14 constant. To provide feedback to the PWM controller IC, a bridge rectifier
circuit made of four diodes (D2, D3, Dt and D5) is connected to the drain of
the MOSFET
channels. The DC voltage from the bridge rectifier is filtered by a l0pF
capacitor and given
to pin-l of PWM IC throueh a potential divider circuit made of lOk and pWM
adjustment
preset vR2.
The PWM circuit has also been incorporated into the oscillator schematic
diagram as shown
in fig.
(2). Pin- I , 2 and 9 are three pins of an internal Op-Amp, pin- I Md Z
are input pins and pin-9
is the output pin. Pin-l is given the fedback signal; pin-z is given Z.sV regutated
ruppty.,
reference voltage through voltage divider circuii of nvo lOK iesistors.
The ieferen." ultLg"

Page I t7
 to the section that
is taken from pin-16 of the pu/I\d ICr. Pin-9 is internally connected
confrols the width of the oscillating @uency. change g
rigr"t at pin-? will rezult in a
change in the width of the output hrqo*w and this
will alwap bring back the inverter
ouQutto is original nOV.
 CHAPTER 8. PEBiLORI\4ANCp EVATUATION

The inverter was tested on a section by section basis. The output voltage of the oscillator was
obtained to be 4.24volts on each side with frequency set to approximately 50H2. The other
unit could not be tested until the final coupling had been done. The battery overcharging
protection unit, low battery cut off unit, low and high -voltage ryrg9 protection as well as the
ii*t Arf"V unitr, feedbacl unit and the overload and short cirpuit protection unit were all
tested by varying the potentiometer associated with each of them and observing the response
through the displays. the list of various settings that were made is listed overleaf;

Tabte l, Settings on tlrc Inverter

lnverter output voltage 22Ovolts

hveiler fqueticy 50I{z

Nfffium battery voltage l0.0volts

TFaximum loading caPacitY m

Nmffinm A.C. input voltage tFor/

TfaxffiumTf . input voltage 250V

After all the settings were done, tlre effect of loading was carried out on the INVERTER
system and the load test results are as follows

Page | 19
 ril
i
i
F.
:'.

Table 2. Ioad Test

Ir, tl
I

300 225

400- 2ZA

t00 220

MF 220

700 220

BOF 22fr

)00 0

Page | 20
 CEAPITN,9.

The following nainfiaance practices and safety precautions are suggested to improve the life
spm oftc sys0em and prevent hazards to the usets.
L Dead bdtcfi€s shoutd not be used with the inverter
2. The bdery terminals should not be removed too often. Wh€n it is re'move4 replacement
of corroct polarity must be e'nsured
3. The invert€r must be put in a moderate tempe'ratttra e,nvircnme,lrt.
4. The inverter should always be shut doum ufien not in use
5. The inve,rter should always be partially loaded (not mcp thnn WA of its murimurt
capacity
- will be enough).
6. The use if inductive loads like refrigerdor, induction machine e.t.c. on the inve'rter
should
be artoided
i. ftu inFS plug of the inverter should be pluggpd 1p I frrse-fin, property €artbod socked-

Page | 21
 ru

CHAPTER 10. IMPLEMENTATION ISSUpS

A permanently
o Battcry undor/Over{halge: Every battery has its charge/discharge cycle.
under-chargedor over-charged basery cannot maintain its rated lifespan- Many of the
that ensures that the
modern day inteligent lnverters have overdis/charge c$-off sensor
some of the cheap lnverters in
baffenies are not unduly over-charged or discharged. Howeve,r,
the batreries to boil
the market are not equipped with this inrclligent device, urhich causes
are over-discharged and are
when over-charged or cause suffation to set up when the batteries
lifespan srrccessfully
not constantly kept at full charge. For batteries to serve their stated
without prematue failure, they must be mainained at ftll or near full charge at all times'

for light loads-

. Over-Load: Basically, most domestic or indusrial InverGrs are designed
wattage equipment like
such as lighting; electonics ap,pliances, and fan. Heavy high

refrigerators, heating rypliances, ovens, Air conditioners and pumping machine are not

practically suitable for Inverte,rs. While many of these ap'pliances draw very
heavy current

heavy for the capacity of

ftom fire battery causing it to nm doum quickly, they can also be too

the Inverter, causing it to shutdorpn under over-load condition or even

burn the machine'

demand load must not

When calculating the toads to be connected to the trnverter, the total
made to the difference between
exceed the rating of the Inverter. Consideration must also be
name plate and the KvA rating
the Wattage rating of the appliances normally written on the

of the Inverter. Since there is a difference between (Kilowatt

(Kw) Volt Ampere (VA) and

Kilovolt Ampere (KVA), and most of the appliances are rated in KW

while most trnverters

are either rated in VA or KVA, some mathematical conversion has to be done to alrive at the

actual caPwitY ofthe machine-

. wlring circuit and cable sidng: while it is true that any road side technician can buy any
Inverter sold in the market placre md connect it, as long as it is seen to be
worlcing care must

be taken to the theoretical calculations involved in cable sizing

for a particular installation
Wrong cable size is a
and how the machine is connected to the load and the supply souroe.

Page | 22
 il
;

accident waiting to
potentisl firc dba$sr, loose tennination and wrong wiring is another
by loose termination or wrong
hrppco" Mo* fitp incid€nts in homes and indusries are caused
as the colour codes of the cables mus{ be
cable sizing. The curre,nt-carrying capacity as well
codes for cables q/hich
cuefirlly selected. There are American, British, Germu etc colour
rece'ptacles (sockets and
must be retigiously followed. Also, the size of the input and orilput

plggp) must be adequate for the load OemanC of the machine'

Page | 23
 CHAPTERIl.@

inverter at a 50Hz frequency was a

The conshrction of this 600watts (600vA), 220Volts
to testing of components- It is to be noted that the
n.adr't process from gathering of materials
the battery connected to the input
efficiency of this project depends on the power rating of
output terminals. Thus, the inverter could
and on the total po*.t of the load connected to its
deliver constant power for a calculated ngmber of
hours'

and high cost of electric

In view of the inconsistence and unreliable public power supply
power generators coupled witr the high cost of maintenance,
the inverter is found to offer a
druation- It is noiseless, hannless,
better constant additional power supply for a sustainable
and cost effective. It is also a pt"r.rro pow€r bactup
to a computer and other appliances
because it switches automatically to the battery when
the AC mains is not available' Thus
reduce system breakdonn, prevent hard disk damages and data loss- In addition, the life span
or a continuous inverter is
of the computers and other devices connected to either a standby
prolonged.

Page | 24
 F

CHAPTDR 12. RSTEBENCE

and c.
construction and lmphmentation of 1 l(vA Inverter - J. c. osuwa
F.

Peter

IOSR Journal of Applied Physics (IOSR-JAP) e{SSN:22784861.Vo1ume 6, lssue

6Ver. lll (l{or'-Dec-2OI4l, PP 56-58

of lKW (IOOOVA) Power Inverter- olusegun o.

Deslgn and construction
Omitola

Innovative Systems Design and Engineering www.iiste.org lsSN 2222-1727

(Paperl fSSN 2222-2871 (Online) Vol.S, No'2, 2Ot4

Theraja, B. L and Therap, A K. (19941. A Textbook of Electrical Technology,

21st Edition. tsBN: gL2Lg24375. New Delhi: s. chand and company Ltd,
Ram

Nagar

Hughes, A. and smith, l. M. (1995). Hughes Electrical Technology,

7th Edition.
i
I
lsBN: c/17}23p,?r']2. Longman scientific and Technical

*t*****iti****tt*r