How to Make a 2kva Ferrite Core Inverter Circuit

Within this submit we talk about the development of a 5000 watt inverter circuit which includes a ferrite core transformer thereby is significantly portable than the standard iron core alternatives.
Very first you have to discover 60V DC power supply for operating the offered 2kVA inverter circuit. The purpose is to design a switching inverter which is able to allow change the DC voltage of 60V to a higher 220V at a reduced current. The topology implemented in this particular situation is the push-pull topology which utilizes transformer on the ratio of 5:18. For voltage control which you will require, and the current limit – they may be all powered by an input voltage source. Additionally at the similar rate, the inverter expedites the current permitted. With regards to an input source of 20A you may get 2 – 5A. In spite of this, the peak output voltage of this 5kva inverter is approximately 220V.
Pertaining to the architecture, Tr1 transformer has 5+5 primary turns and 18 for secondary. For switching, you are able to utilize 4+4 MOSFET (IXFH50N20 type (50A, 200V, 45mR, Cg = 4400pF). You will be also free to employ MOSFET of any voltage with Uds 200V (150V) together with least conductive resistance. The gate resistance utilized and its effectiveness in speed and capacity needs to be excellent.
The Tr1 ferrite section is designed around 15×15 mm ferrite c. The L1 inductor was created utilizing five iron powder rings that could be wound as wires. For inductor core as well as other connected parts, you could always get it from old inverters (56v/5V) and within their snubber phases.
For built-in circuit the IC IR2153 may be deployed. The outputs of the ICs could possibly be observed buffered with BJT levels. Furthermore, as a result of the large gate capacitance included it is essential to utilize the buffers by means of power amplifier complementary pairs, several of BD139 and BD140 NPN / PNP transistors perform the job nicely.
You can even make sure to make use of other control circuits like SG3525. Also, it is possible to modify the voltage of the input and operate in direct connection with the mains for assessment purpose. The topology utilized in this circuit has the facility of galvanic isolation and working frequency is around 40 kHz. If you find you might have planned to utilize the inverter for a small operation, you don’t cooling, but for longer operation make sure to add a cooling agent making use of fans or large heatsinks. The majority of the power is lost at the output diodes and the Schottky voltage goes low around 0.5V.
The input 60V may very well be obtained by putting 5 nos of 12Vbatteries in series, the AH rating of each battery ought to be graded at 100 AH

 


The 220V acquired at the output of TR1 in the above 5kav inverter circuit still simply cannot be useful for working regular appliances since the AC content could well be oscillating at the input 40kHz frequency.
For transforming the above 40 kHz 220V AC into 220V 50 Hz or a 120V 60Hz AC, additional phases could be needed as mentioned below:
Initially the 220V 40kHz will have to be rectified/filtered by means of a bridge rectifier comprised of fast recovery diodes rated at around 25 amps 300V and 10uF/400V capacitors.
Subsequent, this repaired voltage which might now build to around 310V will have to be pulsed at the demanded 50 or 60 Hz by way of another full bridge inverter circuit as demonstrated below:

 


The terminals marked “load” could possibly be right now instantly employed as the final output for running the preferred load.
Right here the mosfets may very well be IRF840 or any parallel type will do.
Tips on how to Wind the Ferrite Transformer TR1
The transformer TR1 is the main device which can be accountable for upgrading the voltage to 220V at 5kva, being ferrite cored based it’s designed over a number of ferrite EE cores as detailed below:
Considering that the power engaged is substantial at around 5kvs, the E cores ought to be impressive in size, an E80 type ferrite E-core might be attempted.
Be aware of you might have to include a lot more than 1 E core, may be 2 or 3 E-cores with each other, positioned side by side for attaining the enormous 2KVA power output from the assembly.
Make use of the largest one that might be accessible and wind the 5+5 turns utilizing 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 start the secondary 18 turns over this 5 primary turns. Utilize 5 strands of 25 SWG super enameled copper in parallel for winding the secondary turns.
As soon as the 18 turns are finalized, terminate it across the output leads of the bobbin, insulate with tape and wind the remaining 5 primary turns over it to carried out the ferrite cored TR1 construction. Do not overlook to join the end of the first 5 turns with the start of the top 5 turn primary winding.
E-Core Set up Technique
The following diagram provides a concept concerning how greater than 1 E-core can be utilized for applying the above mentioned 2 KVA ferrite inverter transformer design: