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DG5SGA

PowerInverters12Vto230V

contents:constructionplans,technicaldescription

VersionofNov.8th,1999

Rev.3.1

Fig.1:1000VAInverter12Volt>230Volt

Aninverterallowestheuseof230Velectricalappliancesfromacarbatteryorasolarbattery.Itmustthereforsupplya
voltagethatcorrespondstoanrmsof230Voltssinewavelikehouseholdmainsupplyorsimilar.Sinewavevoltagesare
noteasytogenerate.Theadvantageofsinewavevoltagesistthesofttemporalriseofvoltageandtheabsenceofharmonic
oscillations, which cause unwanted counter forces on engines, interferences on radio equipment and surge currents on
condensers.Ontheotherhand,squarewavevoltagescanbegeneratedverysimplybyswitches,e.g.electronicvalveslike
mosfettransistors.Informertimeselectromagneticalswitches,thatoperatedlikeadoorbellwereusedforthistask.They
werecalled"choppercartridge"andmasteredfrequenciesupto200cyclespersecond.Theefficiencyofasquarewave
inverter is higher than the appropriate sine wave inverter, due to its simplicity. With the help of a transformer the
generatedsquarewavevoltagecanbetransformedtoavalueof230Volts(110Volts)orevenhigher(radiotransmitters
e.g.).

Fig.2:Sinewavevoltageandconventionalsquarewavevoltagewithboth230Voltrms

Fig.2showsasineaswellasasquarewavevoltagewithineachcaseanrmsof230Volt.Inbothcasesanelectriclamp
wouldlightwiththesameintensity.Thisis,asweknow,thedefinitionofrms.AswerecognizeinFig.2,howeverthe
peakvalueofthesinewavevoltageis325Volts,i.e.factor2morethanrms.Forelectriclampsthisisinsignificantand
electricenginesareappropriateforit.Electronicdeviceswereevendesignedforthepeakvoltageofsinewavevoltage,
becauseinternallytheygenerateDCvoltagefromtheACsupplyvoltage.Acondenserwillbeloadedonexactlythepeak
valueofthesinewavevoltage.Electronicdevicestherebyusuallycannotbeoperatedon230Voltsquarewavefromfig.

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2.Theindustryneverthelessmanufacturedsquarewaveinvertersaccordingtothisprincipleinformertimes.

Ourinverterworkswithatrick,toobtainthesameresultsfromsquarewavevoltageasforsinewavevoltage.

Fig.3:Squarewavevoltagewithdutycycle25%for230Voltrms("modifiedsine")

Squarewavevoltageinfig.3developesthesamepeakvalueassinewavevoltageof230Volts,i.e.230Volt*2=325
Volts and nevertheless thereby obtains the demanded rms of 230 V. Square wave voltage as shown in fig. 2 (full half
wave)withpeakvalueofthecorrespondingsinewavevoltagewouldcausedoubleamountofelectricalpoweronelectric
consumers.Theelectricalpowerrisesbysquareofvoltage,andsquareof2resultsinfactor2.Thetrickis,toswitchthe
outputpoweronlyforonehalfofeveryconductingcycle,thusresultingonadutycycleof25%onbehalfofthecomplete
oscillationperiod.Ifthecalculateddoubleamountofelectricpowerwillbegeneratedonlyhalfthetime,effectivepower
remains the same. Industry called this cam shape "modified sine", in order to be able to differentiate the devices from
conventionalsquarewaveinverters.

Theinvertermayfeednearlyallelectricalappliances,designedfor230Volts,withexceptionofrotaryfieldengines,that
use condensers for generation of an auxiliary phase (condenser engines). Engines of this type are used in most
refrigerators,washingmachines,dishwashersandsomefewmachinetools.Fluorescentlampswithaseriesinductivityto
limittheoperatingcurrentalsowon'tworkcorrectlyonourinverter.Thisproblemcanbesolvedbyincreasingtheduty
cycle on more than 25% while decreasing the peak voltage to 275 Volts. Instead fluorescent lamps with electronics
(energy saving lamps) will work very well on the inverter. There may also be problems with some small plug power
supplies. An increased magnetizing current results on square wave voltages, while there would be an predominantly
inductiveload(cos<<1).Dutycycle25%andcos=0willresultinloadcurrentsuptofactor/2(approx.factor1.5).
Butdon'tbeconfused:Cosfmostelectricalappliancesisbetween0.8and1andwouldbeharmless.

Ourinverterissuitablefor:

electricdrills,fretsaws,circularsaws,electricchainsaws,grinders

Vacuumcleaners,coffeemachines,irons,dryers,mixers,sewingmachines,electricrazors,etc.

lamps,energysavingslamps

Electronicdevices,e.g.musicamplifiers,batterychargers

Computersandaccessories,UPS

Televisionsandradios

hamradiotransmitters,highvoltagegenerators,amongotherthings
Schematicdiagram:

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Descriptionoffunction:

Theinverterchopsthe12VoltDCBatteryvoltageintoasquarewavevoltageof50cyclespersecondanddutycycleof
25%,transformedbytransformerTr1to230Voltrms.IC1formstheoscillatorwith100cyclespersecond(120cyclesper
secondfor60cyclesoutput).FrequencyisdeterminedbyC1andtheresistorsR4andR5.ResistorR6determinsthetime
oftheflybackoftheoscillatorandaffectslikewisethefrequency.Inaddition,R6affectsthermsoftheoutputvoltage,
which must be considered if necessary, if the circuit shall be used for other frequencies. 60 cycles per second can be
achieved by alignment, higher frequencies require changes in the frequencydetermining parts. For high stability of
frequency, special attention must be spent on condenser C1. Ceramic capacitors are not usefull, due to their high
sensitivityontemperature.Mostfoilcondensersmaykeepthefrequencyquiteconstant,evenagainststrongtemperature
variations.

IC2determinesthepulsewidthandthusrmsoftheoutputvoltage.TheregulaterconsistsoftransistorT1,whichreceives
itssignalfromthediodesD4andD5,takenfromtheprimarytranformercoil.Theregulatoradjuststheoutputvoltageby
changingthepulsewidth.Itpreventsalsorisingofrmsoninductiveorcapacitiveload.Thecharacteristicsofregulation
can be adapted by changing D4 (important on 24 Volts applications!). Lower voltage level of D4 results in "softer"
regulation,i.e.anreductionoftheproportionalfactor.

Againstearlierversionsoftheinverter,IC8nowwillbeswitcheddirectlybytheoscillatorsignal,thusavoidingerrorsby
unexpectedoscillationsofthePWMIC2.Herethealternateallocationoftheimpulsesforbothtransistorlines,i.e.forthe
positive and the negative half wave of the output voltage takes place. The final frequency of 50 cycles per second
develops.FlipflopIC7storesaswitchingoffinstructionofthecurrentlimiterfortherestofthehalfwave.Fromthegates
IC5(4093III)andIC6(4093IV),thecontrolsignalarrivesatthecomplementaryMOSFETdriverstagetransistorsT5/T6
andT7/T8.T6andT7areNchannelenhancementmosfetsandT5andT8arethecomplementaryPchannelenhancement
mosfets. These transistors correspond to the wellknown CMOS basic circuit (CMOS = Complementary MOS), which
representsthebasicoftheCMOSlogicfamily(CMOSinverters).OnlytheresistorsR44toR47arenewinthiscircuit.
Theyprovidecurrentlimitationduringshiftingprocessandprotectincasesofdisturbances.Thecontrolunitistsuitable
forinvertersupto10kWoutputpower.ThedriverstagetransistorsT5toT8providethesignalsforthepowermosfets,
whichalternatelymagnetizetransformerTr1.Inductiveidlecurrents,howtheyareneedede.g.byelectricmotors,canbe
returned to the battery, thanks to the integrated antiparallel recirculating diodes of the transistors. Thus they do not
generateunnecessarylosses,contrarytoearlyinverters.

ThemostimportanttaskinourinverterisdonebythemosfettransistorsT13toT28.Theyareconnectedintwogroups,
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eachof8transistors.Theygeneratealternatinglythepositiveandnegativewaveoftheoutputvoltage.Eachtransistorline
works on ist own transformer coil. After a transistor line is beeing switched off, the magnetic energy stored in the
magneticfieldofthetransformerreturnsbacktothebatterybytheintegratedrecirculationdiodesofthesecondtransistor
line.Theidlecurrentofconsumerswithinductiveloadtakesthesameway.Incaseofstrongheatingupofthetransistors,
whichshouldonlyhappenondefectsintheequipment,thebimetalthermalswitchF2shutsoffthecontrolelectronics.In
normaloperation,temperatureoftheheatsinkshouldbeaslow,thatyoucouldtouchitbyyourhands.

ThesourcecurrentsofthemosfettransistorspassoverresistorR20withtheverylowvalueof0.001ohms.Loadcurrents
of 100 amperes thus produces a voltage drop of only 0.1 Volt, according to an energy dissipation of 10 Watts. The
electroniccurrentlimiterbecomeseffectiveforcurrentsabove350Amperes,i.e.onvoltagedropsonR20ofmorethan
0.35 Volts. Main cause for such high currents are shortcircuits or consumers with "large" inductances, e.g. welding
transformers or large battery chargers, which exhibit remanence magnetism. Also large electrolytic capacitors from
switchingpowersuppliescauseimmensepeakcurrents(computerscreen),justasasymmetricalloadofdeviceswithsingle
periodrectifiersorthyristorregulaters,whichcauseamagneticalbiastothetransformeroftheinverter.

TheelectronicoverloadprotectionbyIC9isaspecialfeatureofourinverter.Itneedsaadditionalnegativesupplyvoltage,
whichisproducedbyachargepump,consistingofIC10andthetransistorsT9andT10.IC9worksasthresholdswitch
(Schmitttrigger).SensitivitycanbeaffectedbychangeofthevalueofR22.Avalueof1.5kOhmmeanse.g.shutdownat
lowercurrents(forinverterswithsmallerpoweroutput.

Whilestartingtheinverter,thenegativesupplyvoltagefromthechargepumpwillbemissing.Thisleadstoimmediate
shutdownofthepowermosfets,indicatedbytheredLED1.Thusindefinablecontrolsignals,thatcouldresultinunwanted
switching,whichwouldforcesmallbatteriestobreakdown,areprevented.Ourinverterthereforerequestsnomaximumor
minimum battery size it works on any 12 Volt power supply. If the electronic overload protection becomes active, a
positive output signal will be present at pin 6 of IC9. Through resistor R13 the flipflop IC7 is set, which keeps the
blockageuprightuntilthenexthalfwaveonpin11appeares.IC7maybeclosedlikewisebytransistorT3,whichreceives
itssignalfromtheoptional"loaddetection".Ifnoloadisdetected,theinverterwillbeshutdownbythiscircuitryinorder
tosavebatterypower.

Sensitivity of the shutdown circuitry may be tested by disconnecting the lead to resistor R20 and applying variable
voltagesatconnector"C"intherangeof0...1Volt(important:transformerTr1mustalsobedisconnected!).Atapprox.
0.35VoltstheredLED1wouldlightupandwouldgetdarkagainatvoltagesofscarcelymorethan0Volt.Parallelto
resistorR20a100uAmeasuringinstrumentmaybeattachedfordisplayofloadcurrents.

The optional "load detection" shall not be described here in detail. It consists of the circuit parts around resistor R33,
transformer Tr2, relay1 and the ICs 12 and 13. If this part of the circuit shall not be used, the inverter would work in
continuous operation. Thus T3, R10, R9, D6, R15 and D3 would be obsolete. The 230 Volts load would be connected
directlytoclamp5and6oftransformerTr1.The"loaddetection"recognizesanactiveloadbyasmallDCthroughthe
contactsofrelay1andresistorR43.Theinverterwillbeswitchedonforapprox.5seconds.Ifthenaloadcurrentwould
appearonR33,theinverterwillremainswitchedon,indicatedbyLED2(yellow).Thelimitationoftheoutputpowerof
3000 Watts is due to power dissipation of R33. Instead of the "amateursolution" of R33 and Tr2, a typical current
transformer may be used. Some loads do not switch on the inverter, e.g. energysaving lamps. For this the manual
activationatport"G"isintended.Asmall1VAtransformerinparalleltotheenergysavinglampwouldalsocauseaDC
currentandthuswouldsolvetheproblem.

Data:

supplyvoltage:12Volt

batterysize:dependinguponload,otherwisenorestriction

outputvoltage:230Voltsrms(squarewavevoltagewithdutycycleTp=25%"modifiedsine")

goodforresistive,inductiveand"pseudocapacitive"load(e.g.computers)

efficiency:underfullloadapprox.95%

quiescentcurrentofcontrolelectronics:approx..0.05A...0.1A

total:0.5Ato2,5A,dependinguponqualityandmax.inductionoftheusedtransformer

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pulsewidthregulationforthestabilizationofrmsoftheoutputvoltage

currentlimiterincaseofshortcircuitanthermalprotection

option:loaddetection

Documentsfordownload:

Schematicdiagram(approx.53kB)

Partslist(approx.4kB)

Layoutforprintingboard(approx.118kB)

Complementplan(approx.148kB)

Transformer:

Wecanmakethetransformerbychangingthewindingsofanoldtransformer.

fig.4:shelltypetransformercoretransformer

Atransformerwillprovidebestcharacteristicswhentheprimarycoil,thattakesovermagnetizationoftheironcore,fits
closelyaroundthecore.Forindustrialtransformersthiswouldbethe230Voltscoil,onourinvertershoweveritwillbe
the12voltcoil.

fig.5:"EI"sheetmetalsofa850VAshelltypetransformer

Forthecomputationofthenumbersofturnsthefollowingconsiderationapplies:

Thepeakvalueoftheprimarilygeneratedalternatingvoltageisgivenbythebatteryvoltage.Thisdeterminesthenumber
of the primary windings of the transformer. On the secondary side of the transformer likewise the peak value must be
takenalsoforcomputation,i.e.325Volt.Inthecaseofafullyloadedbatterythesupplyvoltageoftheinverteramountsto
13.8Volts.Thepeakvalueofthe230Voltsoutputvoltagemaynotexceedthatoftheusualsupplynetworks,evenifthe
rmscouldbeheldon230Voltsbyreductionofthedutycycle.Thefollowingtablefortheoutputvoltageresults(without
pulsewidthregulation):

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Batteryvoltage Upeak Urms(secondary)

(secondary)
11,8Volt 297Volt 210Volt
12,35Volt 311Volt 220Volt
12,7Volt(accord.9Vrms 320Volt 227Volt

12,9Volt 325Volt 230Volt

13,5Volt 340Volt 240Volt

The table applies to fixed duty cycle of 25% and/or sinewave voltage and without consideration of the magnetization
energy.Ourinverterwillkeeptheoutputvoltageconstantonanrmsof230Volts,duetoitspulsewidthregulation,evenif
thepeakvaluewilldroporrise,duetothebatteryvoltage.Thepeakvaluewillnotexceed350Volts(247Vrmsforsine
wavevoltage),criticalforelectronics,evenincaseoffullyloadedbattery.Theoretical,withoutpulsewidthregulation,the
rms could rise again up to the theoretical factor of 2, according to a duty cycle of 50%, because of the magnetization
energy.Therecirculatingmagnetizationenergyalreadyformsthebeginningofthenexthalfwaveoftheoutputvoltage
(see fig. 6). But without load there is no rms by definition, so this consideration is only of theoretical nature, with one
exception:Ameasuringinstrument,calibratedonrmswouldindicateawrongoutputvoltageandsmallconsumers,who
needlessthanthemagnetizingenergyofthetransformer,couldgetdamaged.

fig.6:outputvoltagewithnoloadorinductiveload

Thetableshows,thatthetransformerneedsaratioofwindingsof1:25.Theschematicdiagramshows,thatithastwo
primarywindingsandonesecondary.Bothprimarywindingshavethesamenumberofturnsandthesecondarywinding
musthavebyfactor25moreturns(110Volts:factor13).

Hereaselectionofusedtransformers:

Length Width Deep Power Primarily Secondary idlecurrent

150mm 125mm 50mm 460VA 2x13W 325W 1,4Ampere
150mm 125mm 50mm 460VA 2x14W 350W 1,2Ampere
150mm 125mm 67mm 600VA 2x10W 250W 2,2Ampere
150mm 125mm 67mm 600VA 2x11W 275W 1,6Ampere
150mm 125mm 67mm 600VA 2x12W 300W 1,4Ampere
150mm 125mm 95mm 1000VA 2x9W 225W 1,4Ampere
2000VA 2x11W 275W 2,2Ampere
170mm 140mm 80mm 850VA 2x12W 300W 1,5Ampere
170mm 140mm 75mm 850VA 2x13W 325W 1,3Ampere
175mm 140mm 60mm 750VA 2x13W 325W 1,2Ampere

Length:lengthofthe"I"fromfig.5

Deep:thicknessofpileofallironsheetmetals

Power:ratedoutput

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Thetableshows,thatthenumberofturnsisnotparticularlycritical.Onlytheratioofprimarywindingstosecondarymust
becorrect.ThermsoftheoutputvoltagewillbefinallyadjustedbytheautomaticcontrollerwithR16tothevalueof220
or230Volts.Itisofgreatimportancehowever,thatbothprimarycoilsareabsolutelysymmetrical.Theymustbewound
bifilar,sothattheyareveryclosetoeachother.Whileonewindingwillmagnetizethecore,thecorrespondingwinding
will return the magnetizing energy. If there is no close coupling of both primary coils, energy losses will result by
overvoltage,causingavalancheeffectsonthetransistors.Despitecompletelysymmetricalstructureofthewindings,the
transformer will show a small magnetical bias (DC biasing), recognizable from the asymmetrical magnetizing currents,
whichcanbewatchedonR20withanoscilloscope.Thisbiasingwillchangeoneverychangeofload,inparticularwith
stronginductiveloads.Thiseffectiscompletelynormalforsquarewavevoltagesatinductancesandisconnectedwiththe
heavynonlinearityofferromagneticalmaterials.Thesecondhalfwaveoftheoutputvoltageappliesothermagnetizing
conditions to the ferromagnetic transformer core due to the remaining remanence. (only with sinewave voltages an
equilibrium can adjust itself after several oscillations, due to hysteresis losses, see "Rush effect"). Critical unbalances,
whichdevelope.g.afteranimpactshortcircuit,areeliminatedsurelybytheelectronicshutdownsystem.

Wirestrength:

Current densities from 3.5 A/mm2 to 4 A/mm2 are used on industrial transformers. If our inverter is not beeing used
excessivly,currentdensitiesmayevenbehigher.Atransformerwith1000VAneedsapprox.84amperefromthe12Volt
batteryonnominalload.Sincethetwoprimarycoilsalternatemutually,wemaycountfrom42amperes.(Thisisstrictly
not correct, since the acceptance applies only if both windings would exhibit double surface for heat emission). For a
round wire this would mean a diameter of 4 mm. Such wire is hardly to wind, also automats can't do it perfectly. A
solutionmaybewireswithrectangularcrosssectionorseveralsmallerwiresinparallel.

After winding the transformer, the sheet metals must be inserted again. With each layer we change the direction of the
sheet metals, while in the original condition several sheet metals were probably summarized into packages, in order to
increasetheairgapandlinearizemagnetizingcurrents.Thiseffectisn'tneededforourinverter.Magnetizingcurrentsare
always extremely nonlinear in square wave transformers, and they are asymmetrical also. This has no effect on the
performanceoftheinverterandtheoutputvoltage.

After the transformer has been built, it should first be tested. Therefore we attach its 230 Volts windings to public
electricitymainsoranyother230Voltssource.Eachlowvoltagecoilshouldnowshow9Volts.Nowwecanconnectthe
beginningofone"primary"coilwiththeendoftheother.Atthefreeendsavoltageof18Vnowshouldappear.Ifthis
voltagewouldbe0V,thewindingshavebeenconnectedthewrongway.

Themakingofatransformerisaverylaboriouswork.Nobodylikestotakeatransformerapartforasecondtimetocorrect
thewindings.Withunknowntransformersitisadvisabletoapplyfirstasamplecoilofthinandeasytohandlewireand
testthepowerinputonidle.Thewindingsofthesamplecoilcanbechangedwithoutdividingthetransformer.Forthistest
thetransformerdoesnotneedthesecondary230Voltscoil.Onlytheelectronicsmustbeadjustedcorrectly(testedwith
another,correcttransformeroranoscilloscope:dutycycle25%).

Transforercomputation:

For the first regard, it appears difficult to seize the obscure and for precisive computation not accessible magnetization
proceduresinthemagneticcoreofatransformer.Iwanttoshow,thatinourcasethisisnotnecessary.Asthetablewith
thenumbersofturnsshows,atranformermaybebuiltondifferentnumbersofturns,onlytherelationtoeachothermust
beexact.

Wespecifythemaximummagneticinductiononavalueof1.5Tesla.Forcomputationnowonlytwosimpleequationsare
necessary:

1. Uind=nx/tconverted:1')n=Uindxt/

2. =BxA

Uind=inducedvoltage n=numberofturns

=magneticflux t=transistorswitchontime
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B=magneticinduction A=crosssectionareaoftransformercore

Forpowerelectronicsresistiveloadshallnotcalculateonenergyconversion.Thusthewholebatteryvoltagewillapplyon
thetransformercoilforthewholeswitchontimeofthetransistor.Theswitchontimeresultsin5milliseconds,dependend
ontheperiodofthe50cycles/secondoscillationandadutycycleof25%(periodofa50cycleoscillationis1/50Hz=
20milliseconds).

Samplecalculationfortheabovedescribed850VAtransformer:

ThecrosssectionareaofthetransformercalculatestoA=60mmx80mm=4,8x103m2

Uind=12.7Volt B=1.5Tesla=1.5Vs/m2
t=5ms A=4.8x103m2

Withequation2)themagneticfluxcalculatesto=BxA=1.5Vs/m2x4.8x103m2=7.2x103Vs

setinequation1')results

Numberofturnsn=Uindxt/=12.7Vx5x103s/(7.2x103Vs)=8.82(roundedup9turns).

BytryingIbuiltthetransformerwith2x12turns.Thelosseswereclearlysmallerthereby.Thecalculatedfluxinthiscase
wasonly1.1Tesla.

HighloadresistorR20:

fig.7:resistor0,001Ohmmadeofhighgradesteelsheetmetal

ResistorR20takesupthewholeloadcurrentoftheinverterandthusenablestheelectronicshutdowncircuitbyevaluation
ofasmallvoltagedrop.Iwasveryastonishedtolearn,thatdifferentsteelgradeshaddifferentelectricalresistance.High
gradesteelexhibiteda2.5higherresistancethanconventionalsteelandthat'swhyIusedit.Thedataforothersteeltype
maydiffer,soherewhatIexperienced:

valueoftheresistor:0,001ohms

length:110mm

Width:40mm

Thickness:1mm

Distanceofthescrewsforloadcurrent:80mm

Diameterofscrewconnections:6mm

Distanceofsoldertaps:55mm(actualmeasuringsectionwith0,001ohms!)

Theactualvalueoftheresistorbetweenthescrewconnectionsislittlemorehigherthanbetweenthesoldertaps,theactual
measuringsection.Atthesolderpointsadditionallyasmall100uApanelmetermaybeattached.

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Alignmentoftheresistor:

Foranunknownsteelgradeorthedesireforparticularlyhighaccuracyoftheresistorvalueanalignmentwithadefined
examiningcurrentisrecommendet,e.g.byacarlampatthelabpowersupplyunit.Theloadcurrentwouldbeadjustedto
e.g.5amperes.Nowwemayfindwiththetestprodsofasensitivemillivoltagemeasurementinstrumentthosetwopoints
ontheresistor,forwhichthevoltagedropwillbeU=I*R=5A*0,001Ohm=5mV.Thesepointswouldbemarkedby
afelttippen.Atthesepointsthesoldertapswillbefixedbyscrews.

Controlelectronics:

Theuseofapredrilledprintboardismostcomfortable.Inthepastmostinvertershavebeenbuiltonstripholeplates,in
smallbatchmanufacturing.

fig.8:controlelectronicsonstripholeplate(previousversion)andPCBofthe"professionaledition"

Assemblyofthemosfettransistorsontheheatsink:
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fig.10:heatsink,mosfettransistors,connections

Testing:

MOSFETtransistors:

Thetransistorsontheheatsinkmaybetestedwhiletheyarenotyetconnectedtothetransformerandthecontrolunit.First
we touch with one hand the source connections of the transistors and with the other the gate connections. This will
dischargethegates.Nowthesource/drainconnectionsmustbehavelikeadiode,whichwecantestwithanohmmeter.
Forthenexttestweconnectacarlampbetweenthedrainconnectionsofthetransistorsandthepositivepoleofabattery.
Thenegativepolewillbeconnectedtothesourceofthetransistors.Thegatemustbeopen.Ifwenowtouchwithonehand
thepositivepoleofthebatteryandwiththeotherthegates,thelampwilllightup.Nowwetouchthenegativepoleofthe
batteryandsimuntanouslythegatesandthelampwillbeswitchedoff.Ifthistestispositive,thetransistorsareo.k.

Control unit: For testing the control unit, clamp "G" and clamp "C" must be connected to ground (minus pole). This
preventstheloaddetectioncircuitfromswitchoff.Theoutputs"A"and"B"willshowanoutputvoltagebetween3.5and
4volts.Theoreticallytheexactvalueshouldbe2.5volts,accordingtoadutycycleof25%,butthetransformerisnotyet
connectedandsothepulsewidthregulatorwillgeneratemaximumvalue.Ifafrequencycounterandanoscilloscopeare
available, the control signals may be checked and adjusted to 50 cycles or 20 milliseconds (period of the 50 cycle
oscillation)attheseoutputs.Duringnormaloperationthetransformergeneratespeakvoltagesupto28voltsonclamp"D".
Thepulsewidthregulatormaybetested,ifvariableDCvoltagesfrom12Vto28Vwillbeappliedtothisconnection.For
testingthecurrentlimiter,variableDCvoltagemaybeappliedtoclamp"C"(0...1Volt).Theswitchoffshouldtakeplace
atabout0.35volts.

Thecontrolunitmayalsobetestedinconnectionwiththemosfettransistors.Insteadofthetransformer,autolampswould
beconnected.ThebrightnessofthelampsmaynowbeadjustedbyturningresistorR16orconnectingaDCvoltageto
clamp"D"asdescribedabove.

Theautolampalsomakespossibleaverysimpletesttoadjustthefrequency.Thereforeweputinserieswiththelampthe
12 volts output of a small tranformer, connected primarily to the mains supply. Both alternating voltages will now be
addedorsubtracted,dependentonthephaseshift.Thelampwillflicker.Thegoalis,tomakethisflickeringveryslowly.

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Attention:Theautolampmustbe24voltsortwolampsinseries.

Finalassembly:

fig.11:1500VAinverterwith2paralleltransformersand1000VAinverter

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