12VDC / 220VAC VOLTAGE CONVERTER WITH 250W.

The designed converter is a system enabling power supply to devices requiring 220V AC power
supply in the event of a power grid failure or in situations where there is no access to it. The advantages of
the inverter will be appreciated by those who spend their holidays in a tent or camping.

The converter has been checked in practice and has worked properly with the following
receivers:
• TV and radio receivers,
• bulbs, fluorescent lamps,
• central heating circulation pumps,
• power tools (drills, grinders),
• computers
• power supplies.

PRINCIPLE OF OPERATION
The schematic diagram of the converter is shown in Fig. 1. The 220VAC voltage was obtained by
alternating keying of the TS1 transformer windings. Two MOSFET power transistors with n-T2 and T3
channels work as keys. These transistors are controlled directly by the US3 integrated circuit (SG 3524).
This system is an integrated PWM generator designed for use in voltage converters. The frequency at
which it works properly is quite wide and is in the range from 10 Hz to 300 kHz.

In the case of the converter described here, this frequency is 50 Hz, i.e. it corresponds to the
frequency of the power network. This frequency is determined by means of elements C6 and R15. The
ability to adjust the pulse width generated by the US3 system has been used to stabilize the 220VAC
output voltage.

One of the voltage stabilization circuits are elements D6, D7 and the resistance divider R12 and
R13, from which the voltage signal goes to the input of the error amplifier (IN- terminal) of the US3 system.
This voltage is compared with the correspondingly divided reference voltage available at the V terminal Ref. This
allows the generator to "tune" to the voltage present at the battery terminals.

The second stabilization circuit consists of elements D8, R6, PR1, US2, R7, R8, and C4, which are
responsible for providing a feedback signal proportional to the voltage at the converter output.

A converter without stabilization would give an output voltage depending on the load power and the
battery discharge level. This voltage would range from 170V ~ to 270V ~. Thanks to the stabilization
circuits mentioned above, the converter output voltage should be 220 V ~ in all conditions. Assuming the
most unfavorable situation, which may be partial discharge of the battery and load of the inverter with full
power of 250 W, the output voltage should not fall below 220 V ~.
 The T2 and T3 keying transistors are blocked by capacities C8 and C9, whose task is to
reduce overvoltage pulses generated when the T2 and T3 keys are turned off. Additional diodes
existing in the structures of MOSFET transistors are an additional protection.

At converter loads of 200W or 250W, significant currents flow through the final transistors. They can
cause joints to rise to dangerously high temperatures. Therefore, the inverter has been equipped with an
active cooling system. If the heat sink temperature reaches 40 ° C (which roughly means that the structure
temperature is 70 ° C), the resistance of the temperature sensor - which is a PTC thermistor - will increase.
This will cause the US5 comparator to change the output state to the opposite, thereby controlling the
transistor T4 in whose collector circuit a cooling fan is mounted, mounted on the heat sink.

The inverter system is protected against incorrect connection of the battery poles. This protection
was implemented by means of the D1 diode in the PK1 relay control system. This circuit also serves as
protection against excessive battery discharge. If the value of the input supply voltage drops below 10.5 V,
the supply voltage will appear at the 6 US1 terminal, thereby blocking the operation of the T1 transistor
and, consequently, disconnecting the PK1 relay contacts.

The D5 diode signals the converter operation, while the D4 informs that the battery is
excessively discharged.

The inverter's overload protection system has been deliberately abandoned, since in most
cases the system only works with one load, whose power is selected appropriately. However, short
circuit protection in the form of B1 and B2 fuses should be sufficient.

INSTALLATION AND START-UP OF THE SYSTEM

ATTENTION!! The inverter produces 220V alternating voltage, which is just as dangerous to
life and health as the power supply voltage. Therefore, the system should be started with extreme
caution. Preferably in the presence of a second person who is able to turn off the device and
provide first aid.

The converter system is assembled on one circuit board, which is shown in Fig. 2. The
arrangement of the elements is shown in Fig. 3.
The T2 and T3 keying transistors are not mounted on the board but mounted on a suitable heat
sink and connected to the transformer. A PTC thermistor was also mounted directly on the heat sink.
The situation is similar when it comes to B1 and B2 fuses, which are accessible from the outside.

The converter built of functional components should work immediately after connecting the battery.
The whole system regulation boils down to proper setting of PR1 and PR2 potentiometers. Using PR1, we
set the inverter output voltage to 220V ~. It is worth paying attention to the problem of proper
measurement of the RMS voltage of 220V ~ from the inverter. Since the output waveform is not
sinusoidal but close to rectangular,
some instruments may not read the RMS output voltage correctly. Therefore, to measure this voltage is
best to use a meter equipped with a converter " True RMS ", or use an oscilloscope.

Set the second PR2 potentiometer so that the fan works at a heat sink temperature of about 40 °
C.

The transformer used is a toroidal transformer with two symmetrical voltages of 10 V (secondary
winding) and one 220 V (primary winding). The converter without load should draw a current of approx.
300mA. If the current consumed is much higher, this may indicate an asymmetry of the windings of the TS1
transformer or different opening times of the T2, T3 key transistors.

Finally, a few words about the cooperation of the converter with a battery. When choosing a
battery for the converter, pay special attention to two parameters. The first is the maximum current
drawn from the battery, which depends on the power of the device powered by the inverter. Each 10W of
inverter load means a current consumption of 1A from the battery. The second element is the battery
capacity. The converter operating time must take into account this important battery parameter.

List of items

Resistors: capacitors: Semiconductors:

R1 - 470 Ω C1 - 100 μ F / 16V US1 - LM741
R2 - 1 k Ω C2 - 220 μ F / 16V US2 - CNY17
R3 - 10 k Ω C3 - 100 nF US3 - SG3524
R4 - 820 Ω C4 - 47 μ F / 16V US5 - LM741
R5 - 1 k Ω C5 - 4.7 μ F T1 - BC308
R6 - 130 k Ω C6 - 100 nF / 63V T2 - IRFP 240
R7 - 5.1 k Ω C7 - 100 nF / 400V T3 - IRFP 240
R8 - 2 k Ω C8 - 100 nF / 100V T4 - BC 337
R9 - 2 k Ω C9 - 100 nF / 100V D1 - 1N4007
R10 - 2 k Ω D2 - Zener diode C10V
R11 - 4.7 k Ω D3 - 1N4007
R12 - 10 k Ω D4 - LED (red)
R13 - 5.1 k Ω D5 - LED (green)
R14 - 6.8 k Ω D6 - 1N4007
R15 - 130 k Ω D7 - 1N4007
R16 - 6.8 k Ω D8 - 1N4007
R17 - 2 k Ω D9 - 1N4007
R18 - 10k Ω D10 - 1N4007
R19 - 10k Ω D11 - 1N4007
R20 - 10 k Ω
R21 - 10 k Ω
PR1 - 220 k Ω
PR2 - 10 k Ω
Other elements:
PK1 - RM 83Z
B1 - 30A (automotive) B2 - T2A / 250V TS1 - U sec = 2x10V,
U pri = 220V, P = 250VA PTC - 10k thermistor Ω

On - Switch off
M - 12VDC fan

Drawings

Figure 1. Schematic diagram of the inverter.

 Figure 2. Printed circuit.

Figure 3. Arrangement of elements.