The post helps us to design a relatively simple transformerless 3kva inverter circuit using a full bridge IC network and a SPWM generator circuit. The idea was requested by Mr. Ralph Wiechert
How can we Make a Transformerless Inverter Circuit
Greetings from Saint Louis, Missouri.
Would you be willing to collaborate on an inverter project? I would pay you for a design and/or your time, if you'd like.
I have a 2012 & 2013 Prius, and my mother has a 2007 Prius. The Prius is unique in that it has a 200 VDC (nominal) high-voltage battery pack. Prius owners in the past have tapped into this battery pack with off-the-shelf inverters to output their native voltages and run tools and appliances. (Here in the USA, 60 Hz, 120 & 240 VAC, as I'm sure you know). The problem is those inverters are no-longer made, but the Prius is still is.
Here are a couple inverters that were used in the past for this purpose:
1) PWRI2000S240VDC (See attachment) No longer manufactured!
2)Emerson Liebert Upstation S (This is actually a UPS, but you remove the battery pack, which was 192 VDC nominal.) (See attachment.) No longer manufactured!
Ideally, I'm looking to design a 3000 Watt continuous inverter, pure sine wave, output 60 Hz, 120 VAC (with 240 VAC split phase, if possible), and transformer-less. Perhaps 4000-5000 Watts peak. Input: 180-240 VDC. Quite a wish-list, I know.
I am a mechanical engineer, with some experience building circuits, as well as programming Picaxe micro-controllers. I just don't have much experience designing circuits from scratch. I'm willing to try & to fail, if needed! Anyways, let me know if you're interested.
Happy Diwali,
Ralph Wiechert
The Design
In this blog I have already discussed more than 100 inverter designs and concepts, the above request can be easily accomplished by modifying one of my existing designs, and tried for the given application.
For any transformerless design there has to be a couple of basic things included for the implementation: 1) The inverter must be a full bridge inverter using a full bridge driver and 2) the fed input DC supply must be equal to the required output peak voltage level.
Incorporating the above two factors, a basic 3000 watt inverter design can be witnessed in the following diagram, which has a pure sinewave output waveform feature.
The functioning details of the inverter can be understood with the help of the following points:
The basic or the standard full bridge inverter configuration is formed by the full bridge driver IC IRS2453 and the associated mosfet network.
Calculating the Inverter Frequency
The function of this stage is to oscillate the connected load between the mosfets at a given frequency rate as determined by the values of the Rt/Ct network. The values of these timing RC components can be set by the formula: f = 1/1.453 x Rt x Ct where Rt is in Ohms and Ct in Farads. It should be set for achieving 60Hz for complementing the specified 120V output, alternatively for 220V specs this could be changed to 50Hz.
This may be also achieved through some practical trial and error, by assessing the frequency range with a digital frequency meter.
For achieving a pure sinewave outcome, the low-side mosfets gates are disconnected from their respective IC feeds, and are applied the same through a BJT buffer stage, configured to operate through an SPWM input.
Generating SPWM
The SPWM which stands for sinewave pulse width modulation is configured around an opamp IC and a single IC 555 PWM geneartor.
Although the IC 555 are configured as PWM, the PWM output from its pin#3 is never used, rather the triangle waves generated across its timing capacitor is utilized for the carving of the SPWMs. Here one of the triangle wave samples is supposed to be much slower in frequency, and synchronized with the main IC's frequency, while the other needs to be faster triangle waves, whose frequency essentially determines the number of pillars the SPWM may have.
The opamp is configured like a comparator and is fed with triangle wave samples for processing out the required SPWMs. One triangle wave which is the slower one is extracted from the Ct pinout of the main IC IRS2453
The processing is done by the opamp IC by comparing the two triangle waves at its input pinouts, and the generated SPWM is applied to the bases of the BJT buffer stage.
The BJTs buffers switch according to the SPWM pulses and make sure that the low side mosfets are also switched at the same pattern.
The above switching enables the output AC also to switch with an SPWM pattern for both the cycles of the AC frequecny waveform.
Selecting the mosfets
Since a 3kva transformerless inverter is specified, the mosfets need to be rated appropriately for handling this load.
The mosfet number 2SK 4124 indicated in the diagram will actually not be able to sustain a 3kva load because these are rated to handle a maximum of 2kva.
Some research on the net allows us to find the mosfet: IRFB4137PBF-ND which looks good for operating over 3kva loads, due to its massive power rating at 300V/38amps.
Since it is a transformerless 3kave inverter, the question of selecting transformer is eliminated, however the batteries must be appropriately rated to produce a minimum of 160V while moderately charged, and around 190V when fully charged.
Automatic Voltage Correction.
An automatic correction can be achieved by hooking up a feedback network between the output terminals and the Ct pinout, but this may be actually not required because the IC 555 pots can be effectively used for fixing the RMS of the output voltage, and once set the output voltage can be expected to be absolutely fixed and constant regardless of the load conditions, but only as long as the load does not exceed the maximum power capacity of the inverter.
gulab says
Hello!dear swag sir I complete 3 kva transformer less circuit but facing two problems 1st,ic 2354d over heating 12 &15 volt both tried 2ndly there is 150 volt out put how to phase split for getting 220 volt out put input is 230 v DC Rt is 470 ohm CT is 100 nf 104 please guide me
Thanks
Swag says
Hello Gulab, I am glad you could finish the project.
If your ICs are getting hot, make sure you are using 12V for the Vcc of the ICs, and make sure you have reverse diodes connected across the mosfets.
The output voltage will depend on how the transformer is selected in accordance with the PWM RMS. For more info you can read the following post:
https://www.homemade-circuits.com/inverter-voltage-drop-issue-how-to-solve/
gulab says
Hello, yes I completed as per schematic of 5 kva ,but supply 220 v dc through solar panels , in result of giving 240 v DC from s.panels I got 160 v ac and secondly ic 2353 d getting hot .
Swag says
what is the voltage across the Vcc and ground? make sure it is not more than 15V or 12V preferably, also connect a 1000uF capacitor across these pins.
gulab says
Hello dear swag sir,I checked completely before questioning to you ,all as per scheematic but still I’m facing there’s two problems first ic become hot mybe this happens and secondly out but is 150 v ac while I m giving 240 vdc directly from s,panels ,because I’m trying to make ac220 directly from s,panels through ur circuit ,please guide me how I can get result of 220 v ac
Thanks
Swag says
Hello Gulab,
Could you tell me how did you convert the panel voltage to 15V for the IC?
For getting 220V from SPWM based circuit you must provide a 310V DC input to the mosfet bridge. A 220V input will only result in producing around 150V
gulab says
sir, I used 10 k 10 watt resistance and 15 v 2watt zener for ic now I got ur answer for 220 v ac I must give 310 v in input as u answered Thank to u I later try then tell u
Swag says
OK no problem!
gulab says
Hello swag ,sir I want to replace sg3525 against irs2453d can I ,is it is possible
Swag says
Hello Gulab, sorry that may not be possible, because irs2453d is a full bridge driver while the SG3525 is a push-pull driver
gulab says
sir,very kindly thankfull to you for Guidance
Ravindra Kashyap says
Hi,
I built the 3KVA transformerless inverter. initially I had problem that the IRS2453D would not oscillate, Once i grounded the pin no.5 it started oscillating. Now My problem is I am getting a square wave output and not sine wave as needed. What suggestion can you give. For the supply to Ic’s I have used a small 12 V 1 amp SMPS whose primary I connected to 160V D.C. input as its a universal input it works fine. your comment on this?
Swag says
Yes, pin#5 which is the shut down pin needs to be grounded, I’ll correct the diagram soon.
For getting sinewave PWM you must implement everything that has been shown in the diagram, right from the opamp, IC 555 stages to the low side BJT connections….you will have do it stage wise by checking and verifying each of the stages separately.
abioye says
sir my inverter ic is sg3525 can i join the pin6 (RT) of the sg3525 to pin3 of ic741,and join the output of lm555 with pin2 of ic741 while the output of ic741 goes to the bjt/fets to turn it to pure sinewave inverter
Swag says
abioye, you will have to show a schematic to enable me to quickly understand it….if possible draw a schematic and send it my email address…
Lubos Leitman says
Hello Mr Swagatam,
I would need to extend the circuit to a suitable MPPT optimizer.
Swag says
Hello Lubos, that will make the design much complicated and huge.
swarna says
We need to design a 1KVA transformerless inverter can we know the specifications of the circuit
Swag says
the specifications solely depend on the mosfet rating, and the input supply rating, and these can be tweaked as per user preference.
The IC basically works with 12V DC
David Alexander says
Just as the original requester mentioned, Prius’s are still being manufactured but the 200 VDC 120VAC inverter isn’t. I’m a computer geek and photographer, with no experience or expertise in building these types of devices. Is there anyone out there who would be willing to build this for $100 to $300+/- and I’m probably not the only one who would be willing to pay to get this. 🙂 Thanks for any help.
Swag says
Thanks for your interesting feedback Davis, I hope somebody will read this and respond to fulfill your request.
Neil Jackson says
Hi interesting article , Is any one out there interested in developing a 4 kw single phase with high dc voltage input .. 800 vdc . must be off grid My company requires 6000 next year as well as 1000 3 phase units same input
over the next 4-5 yrs we will need some 200,000 units
please contact me directly on my email neil@uk-esc.com
Swag says
Hi, Thanks for the offer, I have sent you an email to learn more about the specification.
Prashant says
Sir,
Actually, I am designing 3 kva transformerless inverter as per your circuit and there are 160v DC input and 230v output. Now there are 15v DC supply is required to operate 555, 741 and IRS2453 ics. Now my question is that how can I providing 15v DC to that ics from 160v DC input.
Swag says
Prashant, you will have to do it as suggested in my previous “48V inverter” link…use MJE13005 for the BC546, for the resistor use 10K 5watt, and 12V zener for the zener, and instead of 48V you will supply it with 160V and obtain 12V across the emitter side….measure it with a load connected
Prashant says
Can I directly connect 6RI100E-080 rectifier to 230v AC supply for generating DC supply?
Swag says
yes you can, but make sure the load current is much less than the rectifier current rating, or vice versa….
Prashant says
There are some questions related 3 kva inverter.
1. At full load, only 4 mosfet enough or required more!
2. 741 op amp required negative voltage, so how can generate it?
3. DC voltage is 160v and 555 & 741 required 15v. So how can generate it?
4. What is the values of 10k preset pot set?
5. In circuit diagram, mje13005 indicated. So what is the use of it in this circuit?
Swag says
1) The total current of the mosfet on each channel must be higher than the output max current, this you will have to verify from the datasheet, by the way I have already provided the mosfet details in the article.
2) IC 741 will not require a dual supply, just make sure that the leakage or the offset voltage from pin#6 is appropriately blocked, the attached 3V zener should be hopefully able to do it.
3) 12V for the ICs can be achieved using an emitter follower design, as depicted in the following 48V inverter circuit:
https://homemade-circuits.com/48-v-inverter-circuit/
for 160V replace the 10k with 100K, and replace the BC546 with a TIP122, the zener can be a 12V zener
4) 10K presets are normal presets, use good quality ones, multiturn type.
5) MJE13005 is a mistakenly shown, please ignore it.
Prashant says
My dear Sir,
In 48v dc ckt, how can I apply 220v AC at transformer side without AC supply?
Swag says
sorry, I did not understand what you are referring to?
Swag says
220V is the output from the transformer…48V is the DC from battery, I hope you have understood now!
K.Musthaffa says
Dear Swagatam sir,
I regularly watch , try to learn and enjoy your informative site.
I would like to do a 50v dc in 600w inverter , using mosfet full bridge and transfo with out center tap.
I plan to use 2 nos LM5109, half bridge gate driver and 4 Nos mosfet STP80100., and a transformer.
Regarding LM5109, half bridge gate driver, i need to know about the input to be provided at pin 2 and 3. Request you to give me this information.
Swag says
Thank you dear Musthafa,
you can use any standard IC 4047 oscillator circuit and use its two outputs to feed pin#2/3 of the your half bridge driver IC…but remember the second bridge IC should be fed with an anti-phase signals from the IC 4047…this may be done by using NPN BJT stages or by using NOT gates.
K.Musthaffa says
So kind of you sir.
I have used one of your ckt,Pure Sine Wave Inverter Circuit Using IC 4047, feeding the 4047 otputs to the LM5019 Full bridge half bridge gate drive,Q to left top, Q Not to right top, q to right low and q Not to left low.
In this arrangement, how can I add voltage feedback control for getting a stable output?
Swag says
You can add the following concept with the low side mosfet gates for getting a constant output
https://homemade-circuits.com/automatic-output-voltage-regulator/
but make sure to do it with proper understanding.
By the way which 4047 circuit did you use??
K.Musthaffa says
Dear sir,
Thank you very much for your kind and quick reply
.I have emailed to homemadecircuits@gmail.com , the schematic that I plan to use, utilising your 4070 (by mistake mentioned it as 4047) oscillator circuit, with 555 ic generated pwm for sinewave, as input to the LM5109, x 2 nos gate drivers for controlling a full bridge mosfet inverter.; also output voltage regulation schematic.
Kindly correct me the mistakes, in the attatched circuit that I have concluded.
I will be thankfull, and appreciate, if you could post the circuit after refinement, in your website.
Swag says
Dear Musthafa, the wiring is correct except the following:
use 1K resistors for the low side mosfets, otherwise the voltage regulator circuit will short circuit the IC outputs directly.
In parallel with the 1K resistors put 1n4148 diodes, cathode towards the IC and anode towards the gate
and I hope you would be using only the 4047 stage and exclude the lower PWM stage because it is not required.
by the way you have used a 4047 circuit and not 555/4017 circuit in your diagram, which is correct and the recommended design
rest all looks fine.
tubagus says
Hi Swagatam,
im wondering is there any refferences diagram to make andj V and A ps using dc input around 50v, its unknown amperage, so i wish to have it (PS) as the maximum as possible V and A from the source. i cant find transistor LM317HV or K D718 on local electronic store, i only have IRF 540 and 530, also 555.
Swag says
Hi Tubagus, you can try the following concept
https://homemade-circuits.com/100-amp-variable-voltage-power-supply/
Ralph Wiechert says
Hi Swagatam,
Thanks for the post! So I am not able to meet the circuit requirement that the fed input DC supply must be equal to the required output peak voltage level. So if I’m interested in using a transformer design instead, can you point me to one of your former projects that I can study? As another option, I’m wondering if using some Vicor V300A48C500B modules to convert the 200 VDC to 48 VDC would be easier (though perhaps more expensive) and then running the 48 VDC into an off-the-shelf 48 VDC (solar?) inverter. Thanks for the help!
Swag says
Thanks Ralph,
You mentioned 200VDC, you can use this DC for operating the above inverter circuit. 200V may be slightly higher than the the required 160V specs, however it can be adjusted by suitably adjusting the PWM pots associated with the IC 555. By the way could you specify the source of this 200V DC, will it be from the batteries?
If you think a readymade option would be better, you can go ahead with it as that would save you from making this complex design and all the hard work. 200V to 48V converter would be fine but it could cause some unnecessary power dissipation, and waste precious watts in the process.