Sheet 1
48v DC to 240v 50Hz 1 KW Inverter Logic.
Copyright: Max Cottrell
6.0
1 of 6
1
Aug 2010
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4001
[U?]
Quad 2-input NOR
4
VDD
VSS
I1
I2
O1
I3
I4
O2
I5
I6
O3
I7
I7
O4
02
[U?]
Quad NOR gates
4
VCC
GND
1A
1B
1Y
2Y
2A
2B
3Y
3A
3B
4Y
4A
4B
R
[R?]
Resistor
1
NPN2
[Q?]
Bipolar transistor, small
1
RT
[R?]
Resistor Trimmer
1
R
[R?]
Resistor
1
C
[C?]
Capacitor
1
D
[D?]
Diode
1
4011
[U?]
Quad 2-input NAND
4
VDD
VSS
1A
1B
1Y
CONTACT-IN
[C?]
Contact in
1
R
[R?]
Resistor
1
GND
[G?]
Chassis ground
1
4011
[U?]
Quad 2-input NAND
4
VDD
VSS
1A
1B
1Y
LED3
[D?]
small LED
1
GND
[G?]
Chassis ground
1
R
[R?]
Resistor
1
CAP
[C?]
Electrolitic Capacitor
1
+
-
LM5532
[U?]
OpAmp
2
RT
[R?]
Resistor Trimmer
1
VREG
[U?]
Fixed V 3-term reg
1
Gnd
Out
In
R
[R?]
Resistor
1
C3
[C?]
Small Capacitor
1
GND
[G?]
Chassis ground
1
D
[D?]
Diode
1
K
A
ARROW
[T?]
Arrow for anotations
1
R
[R?]
Resistor
1
SWITCH2
[S?]
Single Pole Switch
1
GND
[G?]
Chassis ground
1
CAP
[C?]
Electrolitic Capacitor
1
+
-
ZENER2
[D?]
small zener
1
RELAY-1-NO
[R?]
Relay single pole contact NO
1
L5
[L?]
Inductor with core
1
R
[R?]
Resistor
1
SCR
[D?]
Silicon Cont. Rect.
1
g
NMOS
[Q?]
N-Channel Insulated Gate FET
1
SOURCE
DRAIN
GATE
C
[C?]
Capacitor
1
NPN2
[Q?]
Bipolar transistor, small
1
PNP2
[Q?]
Bipolar, small
1
C
[C?]
Capacitor
1
ARROW
[T?]
Arrow for anotations
1
ARROW
[T?]
Arrow for anotations
1
4001
[U?]
Quad 2-input NOR
4
VDD
VSS
I1
I2
O1
I3
I4
O2
I5
I6
O3
I7
I7
O4
4001
[U?]
Quad 2-input NOR
4
VDD
VSS
I1
I2
O1
I3
I4
O2
I5
I6
O3
I7
I7
O4
OPTOCOUPLE
[Q?]
Optocoupler, optoisolator
1
E
C
B
A
K
D
[D?]
Diode
1
K
A
ARROW
[T?]
Arrow for anotations
1
T5
[T?]
Dual Sec. Transformer
1
PNP2
[Q?]
Bipolar, small
1
ARROW
[T?]
Arrow for anotations
1
ARROW
[T?]
Arrow for anotations
1
ARROW
[T?]
Arrow for anotations
1
1
0
FF0000
0000FF
000000
000000
208000
000000
4040C0
208020
FFFFFF
Clock Oscillator 25.6 KHz
39uS
12
4040 Bin Divider
Pulse Width Modulator
100Hz Shaper
12v
7
8
5
6
24 Amp Current overload signal
0.7v max
4
IC3
IC3
IC3
IC2
IC2
IC2
IC2
IC3
IC5
16
+12v
0v
+
+5v Ref
Over/under voltage Inverter Protection Circuit
6.15 nominal
s
g
a
k
0v
Power MosFet Drive
Power MosFet Drive
39uS
12v
7
8
5
6
4
IC3
IC3
IC1
IC3
IC5
+12v
0v
+
0v
10 ms
10 ms
Pulse width modulated
Pulse width modulated
78usec
on
on
off
off
Equal on off times at zero crossover
sine near maxima
Longest on time when
Longest on time when
MosFet 2
25.6 KHz
25.6Khz
39uS
12v
7
8
5
6
4
IC3
IC3
IC3
IC5
+12v
0v
+
d
Power MosFet Drive
Power MosFet Drive
39uS
9
10
11
0v
Q1 off:Pw=37uS = 1v
Q1 on:Pw=1.0uS = 10v
2
3
1
12v
7
8
5
6
4
IC4
IC3
IC3
IC5
8
+12v
+12v
0v
+
+
+12v
+48v converter
12v supply to logic
Panel Reset switch
0
12v
+18v trips logic supply(low)
+12v
+12v
10 ms
10 ms
Pulse width modulated
Pulse width modulated
78usec
on
on
off
off
Equal on off times at zero crossover
minimum off/on = 0 us
maximum on/off = 37 usec
Longest on time when
sine near maxima
Longest on time when
MosFet 1
25.6 KHz
Ferrite flux direction is reset by each alternate Mosfet
switching thus reversing the flux direction equally
PWM at 50Hz
100Hz
IC5 LF353
IC4 HEF4040
1N4148
a
k
1N4148
a
k
1N4148
a
k
IC1,2,17 HEF4011
IC3, IC6 HEF4001UB
1N4148
a
k
* Indicates heat sink mounted
a
g
k
Tip106D scr
source
gate
drain
02N60P mosfet
ZTX510 pnp switch
e
b
c
a
g
k
Tip106D scr
source
gate
drain
02N60P mosfet
ZTX510 pnp switch
e
b
c
a
g
k
Tip106D scr
source
gate
drain
02N60P mosfet
ZTX510 pnp switch
e
b
c
a
g
k
Tip106D scr
source
gate
drain
02N60P mosfet *
ZTX510 pnp switch
e
b
c
Green
Skt B
0v
Push Start
Push Stop
+12v
IC1
IC1
0v
Push Start
+12v
IC1
IC1
0v
Push Start
+12v
IC1
IC1
+12v
0v
Start - Stop Latch
Push Start
+12v
IC1
IC1
Run=High
+12v
+12v
Stop
Run
TP2/2
o Scope monitor
Half Sine wave
9v p/p triangle
5v
6v
set max pulse
freq
1.5v
9v
o
test voltage
12v
6.25v 1:1
o
TP1/1
50hz
IC1
on
on
off
off
on
on
off
off
+12v
TP2/1
25.6Khz
>
<
o
Alternate gated
Drive sigs
Clock/2 gate
+12v reg trips supply at +13.6v
Protection circuits :
Output
Input
Ground
78M12 *
10v P/P
ov
4.3v
12.8kHz
13
100Hz
s
g
d
ZVN1306 n chan mos fet
To secondary opto
Isolators zero crossover
Delay 78 usecs
o
50Hz
10mS
10mS
VN10KM n chan mos fet(Drain is sink).
Txfr Fets Source M4
IC6
Q1 VN10KM
Q2 BC548
Q3 TIP106D
Q4 02N60P
Q5 ZVN1306
Red
Supply on
Power On
5
6
8
2
3
5
6
8
2
3
12v
+
+
+12v
Half hz sensor
zero crossover trip Stop relay
Zero crossover
commutation(sheet 2)
Low 48 Volts trip
Zero crossover control gate
IC9
IC10
o
o
TP5/1
TP4/1
TP3/1
o
5v
+5v ref
25.6k hz phase ctrl detector latch
grid sync
Tp6/1
0.35v
o
o
o
Logic Supply
Auto on linked:
12v logic on at +20v generator in
Overvolt Q12 on at +56v converter
2
3
1
L
N
IC6
IC6
IC6
Converter Clock
o
o
o
Tp6/2
Tp6/3
6
7
5
18v
+12v
Grid sync Indicator
+12
o
Redundant)
set R67 auto on/off hysteresis
Grid relay
switch on
o
o
RL3
Gen too high (Power off)
>
+12v
+12v
+12v
Nominal 28.8v
0v
Loop stable after 30 secs
PCB 173mm x 193mm
100mA
Run
Stop
Led Ind
Led Ind
o
M5
txfr lag correction
230v
(Pcb
12v fan
Gen(Low V Cutoff) 65v max.
o
o
o
Link Auto
Power on
Low volts signal
Push Pull Protection (Power off)
Gen low voltage (Power off)
Sheet 2
48v DC to 240v 50Hz 1 KW Inverter Power.
Copyright: Max Cottrell
6.0
2 of 6
1
Aug 2010
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2
000000
1
-1
000000
0
000000
R
[R?]
Resistor
1
C
[C?]
Capacitor
1
L2
[L?]
Inductor with core
1
a
b
NMOS
[Q?]
N-Channel Insulated Gate FET
1
SOURCE
DRAIN
GATE
D2
[D?]
small diode
1
ARROW
[T?]
Arrow for anotations
1
L_C
[L?]
Coil Core
1
ARROW
[T?]
Arrow for anotations
1
GND
[G?]
Chassis ground
1
C
[C?]
Capacitor
1
L2
[L?]
Inductor with core
1
a
b
R
[R?]
Resistor
1
D
[D?]
Diode
1
FUSE1B
[F?]
Fuse, small
1
C
[C?]
Capacitor
1
OPTOCOUPLE
[Q?]
Optocoupler, optoisolator
1
E
C
B
A
K
OPTOCOUPLE
[Q?]
Optocoupler, optoisolator
1
E
C
B
A
K
GND
[G?]
Chassis ground
1
GND
[G?]
Chassis ground
1
LED3
[D?]
small LED
1
BR
[BR?]
Bridge Rectifier
1
+
-
D2
[D?]
small diode
1
BR
[BR?]
Bridge Rectifier
1
+
-
BR
[BR?]
Bridge Rectifier
1
+
-
ARROW
[T?]
Arrow for anotations
1
RELAY-1-NO
[R?]
Relay single pole contact NO
1
ZENER2
[D?]
small zener
1
SCR
[D?]
Silicon Cont. Rect.
1
g
ARROW
[T?]
Arrow for anotations
1
LAMP
[Lmp?]
Lamp, incandescent
1
PNP2
[Q?]
Bipolar, small
1
1
0
FF0000
0000FF
000000
000000
208000
000000
4040C0
208020
FFFFFF
Battery 0v
15T
S
S
G
D
18 swg(1.2 mmDia) 13.2 ohm/1000yds
0.7v Current overload signal
48v Supply to logic board
Equal & alternate Logic drive signals
MosFet Dummy Loads = 27 ohm
Push Pull Drive
s
s
f
f
16v
t on:95nS t off:58nS
S
G
D
Operating at 25.6khz
<
>
39usec
L obtained from ( (1/2*3.142*Freq)^2)/C test circuit
o
Toroid Inductance Test Circuit
200W=264 ohms
Note:1:1 test Square wave will produce +/- 320V
25.6KHz
G
D
Bifilar wound 0.36tpv 15T resonant freq 330khz
14 swg(2.0mmDia) 4.77 ohm/1000yds
240v 50Hz
13A Socket
s
s
f
f
s
s
f
f
o
G
D
S
t on:95nS t off:58nS
Rd on 1.2 ohm @ 4 Amps
S
G
D
Input Cg=2475pf
max I= 8 A cont.
Vds = 1000
<
>
39usec
o
Scope Ring freq
24 Amp limit 25 mohm
48T 6mH, XL= 1000 Ohms(1.95@50Hz)
G
G
N Channel
+
-
+
-
EPCOS E55 Core
csa = 3.57 sq cm
insulated winding layers
EPCOS E55 Core
insulated winding layers
Secondary 126T bifilar wound 24swg
18swg
18swg
24 swg(0.55 mmDia) 63 ohm/1000yds
22 swg(0.71 mm Dia) 39 ohm/1000yds
26 swg(0.5 mmDia) 94 ohm/1000yds
32 swg(0.25 mmDia) 262 ohm/1000yds
Vo= +320v
Vo= -320v
16v
100Hz alternate opto inputs are
+
-
1Kv wkg
1Kv wkg
+/- 330v
+/- 330v
16v
8
6
5
3
2
5
6
8
2
3
Vcc
Vcc
s
s
d
d
g
g
delayed by 78u Secs to prevent
FQA8N100C
Lost Hz opto isolators
volt meter
o
K
A
K
MUR8100E
Switching Diode
1000VW
enabled on zero crossover start
disabled on zerocrossover stop
PK6E440CA
PK6E440CA
Commutator Opto Isolators
8 amp
D38
D39
o
o
o
o
o
o
25.6KHz
s
s
f
f
Rd on 0.068 ohm @ 16Amps
S
G
D
S
G
D
Input Cg=1700pf
Vds = 200v
N Channel
PCB = 173mm x 193mm
o
M4
18T 1.18mH filter XL= 200
39T 4.2mH filter XL=625
60W = 881 ohms
100W = 529 ohms
320W =160 ohms
o
Battery 0v
15T
S
S
G
D
18 swg(1.2 mmDia) 13.2 ohm/1000yds
0.7v Current overload signal
48v Supply to logic board
Equal & alternate Logic drive signals
Push Pull Drive
62T 12mH, XL= 2000 Ohms(3.9@50Hz)
s
s
f
f
16v
t on:95nS t off:58nS
S
G
D
Operating at 25.6khz
<
>
39usec
o
200W=264 ohms
Note:1:1 test Square wave will produce +/- 320V
25.6KHz
G
D
Bifilar wound 0.36tpv 15T resonant freq 330khz
14 swg(2.0mmDia) 4.77 ohm/1000yds
s
s
f
f
s
s
f
f
o
G
D
S
t on:95nS t off:58nS
S
G
D
Input Cg=2475pf
max I= 8 A cont.
Vds = 1000v
<
>
39usec
o
o
50Hz
1Kw = 58 ohms
38v to 65v
24 Amp limit 25 mohm
G
G
+
-
+
-
EPCOS E55 Core
csa = 3.57 sq cm
insulated winding layers
EPCOS E55 Core
insulated winding layers
Secondary 126T bifilar wound 24swg
18swg
18swg
24 swg(0.55 mmDia) 63 ohm/1000yds
22 swg(0.71 mm Dia) 39 ohm/1000yds
26 swg(0.5 mmDia) 94 ohm/1000yds
32 swg(0.25 mmDia) 262 ohm/1000yds
Vo= +320v
Vo= -320v
16v
o
o
+
-
Grid Current Signal
1Kv wkg
1Kv wkg
+/- 330v
+/- 330v
16v
8
6
5
3
2
5
6
8
2
3
Vcc
Vcc
s
s
d
d
g
g
both Secondary Fets from being on
at the same time during crossover.
Lost Hz opto isolators
o
K
A
K
MUR8100E
Switching Diode
1000VW
enabled on zero crossover start
disabled on zerocrossover stop
PK6E440CA
PK6E440CA
Commutator Opto Isolators
8 amp
D38
D39
o
o
o
o
o
o
25.6KHz
s
s
f
f
FQA32N20C
t on:270nS t off:210ns
S
G
D
S
G
D
max I= 32 A
N Channel
o
M4
60W = 881 ohms
100W = 529 ohms
320W =160 ohms
current txfr
Grid 230v
to regulator(0-16v)
Opto FB
Neut
Line
SCR's sync'd to 1/2 Hz for correct
current direction( Inv to grid only)
IC1/4 (Power On Latch)
IC6/3
IC6/4
Commutate signals(Lo=Off)
~1.2kHz
~1.2kHz
a
g
k
Tip106D scr(400v)
a
g
k
a
g
k
a
g
k
Igt 30ma max.
It 25a cont 250a pk
800v 50v/us
o
A
G
o
K
A
M6
1:1
1:1
Igt 60-200uA
dv/dt 10v/uS(1k)
2 amp cut off limit
Disconnect grid load
& check cct voltage
& current when sync'd
At low currents thermister
increases delta V to ~ 10v
IC13/5
+12v
Soft start grid tie
TO3PN
Auto off at zero gate drive
Sheet 3
25v to 48v converter
Copyright: Max Cottrell
6.0
3 of 6
1
Aug 2010
-10
0
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
-1
000000
4001
[U?]
Quad 2-input NOR
4
VDD
VSS
I1
I2
O1
I3
I4
O2
I5
I6
O3
I7
I7
O4
02
[U?]
Quad NOR gates
4
VCC
GND
1A
1B
1Y
2Y
2A
2B
3Y
3A
3B
4Y
4A
4B
R
[R?]
Resistor
1
RT
[R?]
Resistor Trimmer
1
C
[C?]
Capacitor
1
D
[D?]
Diode
1
NPN2
[Q?]
Bipolar transistor, small
1
PNP2
[Q?]
Bipolar, small
1
L2
[L?]
Inductor with core
1
a
b
NMOS
[Q?]
N-Channel Insulated Gate FET
1
SOURCE
DRAIN
GATE
GND
[G?]
Chassis ground
1
GND
[G?]
Chassis ground
1
R
[R?]
Resistor
1
CAP
[C?]
Electrolitic Capacitor
1
+
-
LM5532
[U?]
OpAmp
2
RT
[R?]
Resistor Trimmer
1
ARROW
[T?]
Arrow for anotations
1
D2
[D?]
small diode
1
D
[D?]
Diode
1
CAP
[C?]
Electrolitic Capacitor
1
+
-
GND
[G?]
Chassis ground
1
ARROW
[T?]
Arrow for anotations
1
D2
[D?]
small diode
1
ARROW
[T?]
Arrow for anotations
1
LED3
[D?]
small LED
1
PMOS
[Q?]
P-Channel Insulated Gate FET
1
SOURCE
DRAIN
GATE
SCR
[D?]
Silicon Cont. Rect.
1
g
ARROW
[T?]
Arrow for anotations
1
ZENER2
[D?]
small zener
1
NPN2
[Q?]
Bipolar transistor, small
1
FUSE1B
[F?]
Fuse, small
1
1
0
FF0000
0000FF
000000
000000
208000
000000
4040C0
208020
FFFFFF
Clock Oscillator 25.6khz
Fet on:Pw=1.0uS Vg= 2.5v,Vs = 25 mV
TP3
2
3
1
Adj max.pulse width.
IC14
+
+12v
25.6KHz
S
G
D
Charge L
o
38-56v Converter Out
0v
+5v
S
G
D
Input Cg=1600pf
o
max I=20A
30A Current limit
For 43813TC core=1.25sq cm U=750,A/L=3500
N=1000*Sqr(L(mh)/A/L) = 1000*Sqr(.2/3500)
o
G
D
S
IC4/10
BC548
e
b
c
o
K
A
K
FFPF30UP20S
30A, 200V,30nSec
s
g
d
VN10KM
5v
approx 200 mV/ uSec
+12v
soft start
60w lamp Is=100mv/0.1 Vo=47.9v
60w + 60w series s= 80mv/0.1 Vo=48.1
No Load Is=40mv/0.1 Vo=48.3
Duty cycle = 50%
@25v, peak I=25amps for 48v &27ohm load
E(joules)=(CV^2)/2
Clock Oscillator 25.6khz
Fet off:Pw=22 uS Vg = 0.9 Vs = 3 mV
Fet on:Pw=1.0uS Vg= 2.5v,Vs = 25 mV
TP3
2
3
1
Adj max.pulse width=22usec.
IC14
+
+12v
S
G
D
o
0v
Charge C
+25 to +56v
FDP39N20 200v
t on:150nS t off:210nS
Rd on .066 m ohm 14 Amps
S
G
D
o
For 43813TC core=1.25sq cm U=750,A/L=3500
N=1000*Sqr(L(mh)/A/L) = 1000*Sqr(.2/3500)
o
G
D
S
6
5
7
IC4/10
BC548
e
b
c
* Nom 4.9v
o
K
A
K
FFPF30UP20S
30A, 200V,30nSec
s
g
d
5v
+12v
16T
No Load Is=40mv/0.1 Vo=48.3
e/L=0.21amp/usec. L=25/.021A = 1.19mH
e = L di/dt
E(joules)=(LI^2)/2
1Joule=1Watt-Sec
IC14
IC14
65v limit to converter
Test resuts:
150v, 36A, P Chan
>65v disconnect
max I= 39amps
IRF521PBF 100v 40A alternative
XL= 18.6ohm at 25khz
L/R=20usec
48v regulation amp
* 48v changes at 1.6v per mV
s
g
d
2N3820
s
g
d
Pfet
Mos
fet
current meter
As wind speed increases, converter will
reduces voltage boost for given load.
At 10mph converter delivers approx 100watts
With convert power at 250 watt(5amp) pk = 10amps
If Inverter load is too high for reduced wind speed,
converter will pass high current causing failure.
R69 dissipates 2 watts.
from IC1/3
M1
o
M2
M3
o
Wind Generator Input
1ma meter
o
o
o
o
o
o
o
o
o
o
o
o
o
o
Meter Circuit
+
-
Gen volts M1
Inverter volts M3
Inverter current M4
Grid Sync M5
Conv. Current M2
12v
SU354
Opto link
Meter Bridge
230v panel
L
N
Low = Power on
Set conv 38v
(Gen 20v)
Grid tie
+
Gen 0-56v
Grid Current Signal
<20v 0.25A 60w
>20 v<30v 0.5A 125w
>30 v<40v 1A 230w
>40 v<50v 2A 460w
>50 v 3A 690w
1-5v
0.5-4.5v
inc output
1) Regulation is off & 230v is low for soft start
Loading should match wind speed (Voltage Gen):
At 60 Watt load converter output set for 33.7v
5v
Regulation:
feedback
0-16v
Grid tie
sync sig
3) Current f.b. overides voltage f.b. when current flows.
Grid tie current M6
2) Grid tie initial load voltage f.b. set to feed 0.25A
Set tie current
M6
nom 5.6v
inc output
0-3A
4) Grid sync failure inhibits current fb
Increases converter output as load increases
or generater output voltage falls.
o
Panel Reset switch
Sheet 4
Inverter Timing Diagram
Copyright: Max Cottrell
6.0
4 of 6
1
Aug 2010
-10
0
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-16
7
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-11
5
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
-13
6
400
0
0
0
0
Arial
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
000000
1
-1
000000
ARROW
[T?]
Arrow for anotations
1
ARROW
[T?]
Arrow for anotations
1
ARROW
[T?]
Arrow for anotations
1
1
0
FF0000
0000FF
000000
000000
208000
000000
4040C0
208020
FFFFFF
+12v
0
0
+48v
Q25 Gate 1
Q25 Drain 1
IC3/3
IC4/10 Divider Input
IC4/9 Clock Div by 2 gate
IC3/11 Modulated
IC2/4 Gated out
25.6KHz Clock
>
>
>
>
>
>
<
<
<
<
<
<
>
>
>
>
>
>
<
<
<
<
<
<
IC1/11 Inverted Gate
>
<
IC3/3 Gated out
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
IC2/10 Gate Drive
IC2/11 Gate Drive
pwm zero to 0.94*39usecs(37us)
outputs multiplexed
+12v
0
0
+48v
Q26 Gate 2
Q26 Drain 2
78 uSec
78 uSec
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
MosFet Drain 1
MosFet Drain 2
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
Secondary Output
96v
96v
336v*0.95 = 320v
-336v*0.95 = -320v
pw max
+12v
Gate 1
Drain 1
IC3/3
IC4/10 Divider Input
IC4/9 Clock Div by 2 gate
IC3/11 Modulated
IC2/4 Gated out
25.6KHz Clock
>
>
>
>
>
>
<
<
<
<
<
<
>
>
>
>
>
>
<
<
<
<
<
<
IC1/11 Inverted Gate
>
<
IC3/3 Gated out
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
IC2/10 Gate Drive
IC2/11 Gate Drive
>
>
>
>
>
>
<
<
<
<
<
<
>
>
>
>
>
>
<
<
<
<
<
<
Rectified Full Wave +168v
>
>
>
>
>
>
<
<
<
<
<
<
>
>
<
<
>
>
>
>
<
<
<
<
<
<
>
>
Rectified Full Wave -168v
0v
0v
pwm zero to 0.94*39usecs(37us)
L
N
Balanced output
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
MosFet Drain 1
MosFet Drain 2
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
Secondary Output
240rms = 273v peak
168v*0.95 = 160v
-168v*0.95 = -160v
120v rms = 169 peak
120v rms = 169 peak
pw 37us
pw 37us
pw37us
pw37us
160v
160v
Gate 1
Drain 1
IC3/3
IC4/10 Divider Input
IC4/9 Clock Div by 2 gate
IC3/11 Modulated
IC2/4 Gated out
25.6KHz Clock
>
>
>
>
>
>
<
<
<
<
<
<
>
>
>
>
>
>
<
<
<
<
<
<
IC1/11 Inverted Gate
>
<
IC3/3 Gated out
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
IC2/10 Gate Drive
IC2/11 Gate Drive
>
>
>
>
>
>
<
<
<
<
<
<
>
>
>
>
>
>
<
<
<
<
<
<
Rectified Full Wave +168v
>
>
>
>
>
>
<
<
<
<
<
<
>
>
<
<
>
>
>
>
<
<
<
<
<
<
>
>
Rectified Full Wave -168v
0v
0v
pwm zero to 0.94*39usecs(37us)
L
N
Balanced output
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
MosFet Drain 1
MosFet Drain 2
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
Secondary Output
240rms = 273v peak
168v*0.95 = 160v
-168v*0.95 = -160v
120v rms = 169 peak
120v rms = 169 peak
pw 37us
pw 37us
pw37us
pw37us
160v
160v
+12v
0
0
+48v
Gate 1
Drain 1
IC3/3
IC4/10 Divider Input
IC4/9 Clock Div by 2 gate
IC3/11 Modulated
IC2/4 Gated out
25.6KHz Clock
>
>
>
>
>
>
<
<
<
<
<
<
>
>
>
>
>
>
<
<
<
<
<
<
IC1/11 Inverted Gate
>
<
IC3/3 Gated out
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
IC2/10 Gate Drive
IC2/11 Gate Drive
>
>
>
>
>
>
<
<
<
<
<
<
>
>
>
>
>
>
<
<
<
<
<
<
Rectified Full Wave +168v
>
>
>
>
>
>
<
<
<
<
<
<
>
>
<
<
>
>
>
>
<
<
<
<
<
<
>
>
Rectified Full Wave -168v
0v
0v
pwm zero to 0.94*39usecs(37us)
L
N
Balanced output
+12v
0
0
+48v
Gate 2
Drain 2
78 uSec
78 uSec
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
MosFet Drain 1
MosFet Drain 2
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
>
<
Secondary Output
96v
96v
240rms = 273v peak
168v*0.95 = 160v
-168v*0.95 = -160v
120v rms = 169 peak
120v rms = 169 peak
pw 37us
pw 37us
pw37us
pw37us
160v
160v
pw max
pw min
pw min
pw min
pw min
>
>
>
>
>
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Rectified Full Wave +320v
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Rectified Full Wave -320v
0v
0v
0v
Opto isolater drive positive
Opto isolater drive negative
In phase with Tp2
In phase with Tp2
IC5/1 Modulator Signal
78 uSec delay
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78 uSec delay
Some distortion on sine wave from modulator
IC6/3
IC6/4
Soft start/stop
IC6/10
Commutate 'on' delay 78usec
Clock/Pwm crosstalk
330v
Output wave shape, load dependant
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10mSec
50hz
10mSec
10 mSec
glitch by IC3
Sheet 5
Converter- Inverter Block Schematic
Copyright: Max Cottrell
6.0
5 of 6
1
Aug 2010
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ARROW
[T?]
Arrow for anotations
1
ARROW
[T?]
Arrow for anotations
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25.6Khz Oscillator
Dividers
Pulse Width Modulator
Transformer Drive
Alternate Gating
Push Pull Transformer
Phase error Detection
Grid Mains 50Hz
50 Hz
18v, 50Hz
100 hz
Sync to Grid
25.6K hz
12.8 Khz
Half sine shaper
25.6K hz
Zero Crossover control
50 Hz
100 Hz
Secondary Rectifiers
Secondary Commutation
+/- 325v
-/+ 325v
Half Sine PWM
Low Pass Filter
50 Hz
Start/Stop Latch
& Delay Gating
Auto Stop Sensing RL1
1.Txfr Current overlod
2. Lost half hz detector
Logic
3. 56v high turn off
Over/ under voltage
protection
48v supply to Volt Regs
48v Supply
230v 50Hz
Output lost half hz signal
TVS &
Txfr Current overload
230v Push Start/Stop
converter clock
Isolation Txfr signal
L
N
IC3
IC3, IC5
IC2
IC11, IC17
IC4
IC5
IC6
Q25, Q26
& TVS Protection
Q27, Q28
Opto Isolators
IC1
Converter PW Control
IC13, IC14
Q20
L- C Driver
Converter Current limit
Converter voltage control
+12v & +5v logic supply
230v out none grid tie loads (L)
Wind Generator Input
22v to 56v
Q12, Q14, RL2
zero crossover turnoff
Lost half Hz detect
M1
M2
M3
o
o
o
o
M4
o
M5
Txfr phase lag correction
G83 Tests summary:
Harmonics: 2nd,3rd,5th,7th,9th,11th,13th
Voltage Fluctuations on start/stop & running(10mins/2hrs)
DC injection(half hz unbalanced), Power factor 212v 230v 248v 0.95 lag/lead max.
Under/over freq switch off
Under/over voltage switch off
Loss of mains(isolation relay).
Reconnect time(Sync delay) 3mins maximum
Grid Tie Scr's
Voltage Regulation
Current Regulation
Tie/none tie Regulation
Grid 230v ac (L)
SCR Commutate
triggers
M6
33 ohm ntc thermister
analog 'OR'
o
Sheet 6
Converter- Inverter Block Schematic
Copyright: Max Cottrell
6.0
7
1
April 2010
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3. Scope IC4: pin 10=25.6 kHz, 9=12.5Khz,13=100Hz,12=50Hz.
7. Push 'Start' & scope TP2/1 for pulse width modulated square wave 0.5us to 37us changing.
9. Verify TP4 & TP5 have alternate drive signals present which can be disabled by the Drive Stop button.
10.Apply 0.8v in place of the current overload signal & check IC5 pin 7 falls low & Drive is disabled.
Basic Test Procedure
11. Link Tp6/2-3 & set RV5 for 25.6khz 1:1 driver signals at TP2/1.
17. Verify test lamps light. Measure 16v dc for opto isolators present. Confirm opto input/output signals present & +/- 320v DC is present at rectifiers
1. Disconnect Q25/Q26 4 way driver connection. Apply 25v supply & verify +12v & +5v present , Led indicates.
6. Link Tp6/1-2. Adj RV2 DC level at IC5 pin 2 input approx 6v & scope IC 5 pin 1 for signal shown.Adjust levels.
13. Push Start & Scope Mosfets Driver Drains are switching between 0v and +48v with 27 ohm dummy load. Push stop drive.
20. Push Start & measure approx 240v rms at filter output. If necessary re adjust RV2 & RV10 for best sine wave. Check Secondary switch Fets operation
8. Scope TP2/2 test point for half sine wave 9v p/p. Adjust modulater RV10 & RV2 as required for best shape.
16. Connect two 60 watt 240v test lamps in series across rectified outputs. Re connect 48v supply & push Start Button.
18. Disconnect 48v supply, remove test lamp, Link Tp6/2-3 modulated signal, Reconnect MosFet . Connect 48v supply.
24. Disconnect TP5 4 way driver link & grid tie 230v 50hz supply load . Plug grid sync 230v 50hz & measue pri-sec phase delay, correct if needed. Push start & verify IC11/17 phase cct functions.
5. Link Tp6/2-3. Adj RV5 & check min/max pw at TP2/1. Set IC6 delay circuit for 78uSec opto drive delay.
14. The following tests require extreme precaution as +320v and - 320v will be present at the secondary rectifiers.
15. Disconnect 48v, dummy loads & reconnect output transformer. Disconnect commutation Fets.
4. Remove RL1. Temp ground Q1 gate, push 'Start' & set IC3 max delay = 37usecs. Remove ground.
2. Temp. ground Q21 gate & set max on time to 22usecs. Adj RV8 for operation from 20v to 52 v. Set at 48v.
3. Scope IC4: pin 10=25.6 kHz, 9=12.5Khz,13=100Hz,12=50Hz.
7. Push 'Start' & scope TP2/1 for pulse width modulated square wave 0.5us to 37us changing.
9. Verify TP4 & TP5 have alternate drive signals present which can be disabled by the Drive Stop button.
10.Apply 0.8v in place of the current overload signal & check IC5 pin 7 falls low & Drive is disabled.
12. Disconnect supply, connect 27 ohm dummy load in place of transformer primary, reconnect 4way driver link. Re connect 48v supply.
19. Adjust control 'Set Inverter volts' for 34 volts using RV8. This will increase in value to regulate the loaded output.
23. Measure the 240v +/- 10% output, loaded conditions 60,120, 500, 1K Watts & with the correct input supply voltage. Verify output txfr does not saturate core.
Basic Test Procedure
11. Link Tp6/2-3 & set RV5 for 25.6khz 1:1 driver signals at TP2/1.
17. Verify test lamps light. Measure 16v dc for opto isolators present. Confirm opto input/output signals present & +/- 320v DC is present at rectifiers
1. Disconnect Q25/Q26 4 way driver connection. Apply 25v supply & verify +12v & +5v present , Led indicates.
6. Link Tp6/1-2. Adj RV2 DC level at IC5 pin 2 input approx 6v & scope IC 5 pin 1 for signal shown.Adjust levels.
13. Push Start & Scope Mosfets Driver Drains are switching between 0v and +48v with 27 ohm dummy load. Push stop drive.
20. Push Start & measure approx 240v rms at filter output. If necessary re adjust RV2 & RV10 for best sine wave. Check Secondary switch Fets operation
8. Scope TP2/2 test point for half sine wave 9v p/p. Adjust modulater RV10 & RV2 as required for best shape.
16. Connect two 60 watt 240v test lamps in series across rectified outputs. Re connect 48v supply & push Start Button.
18. Disconnect 48v supply, remove test lamp, Link Tp6/2-3 modulated signal, Reconnect MosFet . Connect 48v supply.
21. Measure MosFet source currents & check with 230v 12 watt lamp load is less than 0.2A peak. Replace RL1 & confirm phase failure detection operates.
5. Link Tp6/2-3. Adj RV5 & check min/max pw at TP2/1. Set IC6 delay circuit for 78uSec opto drive delay.
14. The following tests require extreme precaution as +320v and - 320v will be present at the secondary rectifiers.
15. Disconnect 48v, dummy loads & reconnect output transformer. Disconnect commutation Fets.
4. Remove RL1. Temp ground Q1 gate, push 'Start' & set IC3 max delay = 37usecs. Remove ground.
25. Replace TP5 4 way driver link only and compare inverter 50Hz & Grid 50Hz for zero phase delay. Confirm SCR commutation circuits are feeding trigger pulses when sync'd.
22. Note: Voltage regulation will not occur over the full load range unless the correct input voltage is supplied. Do not overload Q20, verify regulation circuit compensates.
26. With 20v converter input, place a 60 W dummy lamp load in place of the grid tie load. Adjust RV9 to just begin to illuminate. This is the threshold for grid tie current regulation.
27. Increase converter input voltage to 25v & confirm IC13B causes and increase in illumination of the 60w dummy load lamp.
28. disconnect the 230v grid at the supply & replace the dummy load lamp as the correct grid tie load. Use an NTC thermister in series with Grid-Inverter linking cct.
29. Measure the grid tie current & vary the converter input voltage over the range of 20 to 50 volts confirming the grid tie current is increased according to the power curve.
30. Finally verify that no excess heat is generated by internal components by running a series of load tests with lengthening 'on' times.
Sheet 7
Druim Dearg Power Module Wiring
Copyright: Max Cottrell
6.0
6 of 6
1
Aug 2010
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Conv
Ind
0v
25-50v
230v out
L
N
Inverter
Transformer
Meter
connect
IC14
IC1
IC2
IC3
IC4
IC5
IC6
IC7
IC8
IC9
IC10
IC11
IC13
IC15
IC16
IC17
RL1
RL2
RL3
+48v
230v 50Hz grid
L
N
Start
Q20
D16
Q14
Q25
Q26
D20
D21
D22
D23
Q27
Q28
Fan
connector
Wind Gen
Grid 230v
Inverter 230v
Grid Tie circuit SCR's
Wind Gen Connector
+
-
C27
C40
Inverter
Conn
Volts
230v Inv meter
V-A Meter
Reset
Push Start
Push Stop
Meter switch
General Wiring Diagram
dropper
5A Fuse
grid sync
48v
12v Logic
1/2 Hz
1/2Hz
Common link
grounded
screen
gnd
scr
Screen Stop connection
NTC
33 ohm
SCr's
Current
txfr