Medi DSP based Compact Domestic Sinewave

UPS-cum-Inverter with Charger

2009 model
Isolated sensing of Mains
Cycle-Cycle current Limiting
Low cost driver
LED/7-segment/LCD display

Document Revision 1.00-B / 11th October 2008

 Medi Microcontroller based sinewave UPS/Inverter with charger
Introduction
MEDI has developed a new micro-controller based digital sine wave inverter using DSP (Digital Signal
Processor) with full bridge configuration topology MOSFET switches. This is a modified version of our
2008 Model with added features like:

• Isolated sensing of Mains: This will ensure that even if Phase-Neutral connection is reversed at the
input side there will not be any electric shock on the PCB or battery.
• Cycle-Cycle current Limiting: This is a enhanced protection method for the short circuit / heavy
load condition.
• Low cost driver: The costly driver with TLP250 is replaced with discrete components on the PCB
• LED/7-segment/LCD display: The PCB is designed with provision for LED, 7-segment display or
LCD display.

This inverter is best suited for manufacturing for domestic applications as it is simple and easy. It consists
only few components which are easily available, have only 3 smd components and with a single sided pcb.
There are no windings which can possibly cause any error such as DC-CT or EE-16 transformers.
Mounting of heatsink along with mosfets and soldering few components will complete this board. It
consists of a LCD which will display all the parameters of the system and indicates any error during the
functioning of the inverter. A low cost 16 character single line LCD will be of scrolling type, showing the
status of the inverter such as batt voltage, mains voltage, inverter output voltage, inverter standby on/off,
charger on/off, mains/ solar charging and many more. It is very simple to handle and very easy to set the
values in the menu driven set-up mode.

This inverter is a very robust design which will not fail in any extreme conditions.
1. If 440V is applied to the AC input, it will not fail. It will indicate high voltage cut-off and restart
when voltage is normal.
2. If AC mains is given to the inverter output, it will not fail. It will indicate phase input output
reverse and continue to work after it is rectified.
3. It has fold-back current limiting for short circuit and heavy loads. At short circuit or heavy loads,
current limiting action will take place instead of tripping which will lead to more reliability.
Features
 LCD display for indicating various status of the system like inverter voltage, mains voltage, battery
voltage, % of load, overload/short circuit status, battery low status, charger status etc.
 LCD based Menu driven setup of various parameters like battery full charge voltage, battery low
voltage, load condition, Inverter output voltage, charging current etc.
 Protections against: Overload, short circuit, battery deep discharge, battery over charge, mains over
voltage, reverse connection of phase in – phase out, reverse connection of phase and neutral of mains
input. In all these error conditions will be shown in the LCD display.
 Priority solar charging facility: When solar charger is connected mains charger will be in stand-by and
priority will be for solar charger.
 Delayed inverter cutoff for conditions like battery low, overload, short circuit etc. The system will
automatically restart from cutoff after a few second buzzer beeps. The system will go to permenant
cutoff if the error condition exists even after 4 restart.
 Bill of materials: Main PCB 850VA – Rs. 750/- or less, Transformer 850VA – Rs. 2000/-

1. LCD will display –

• Battery voltage
• Inverter output voltage
2
 • Percentage of load
• Mains voltage
• Changer on/off
• Solar charging /mains charging
• Inverter standby on/off
• UPS mode / inverter mode
• Phase input output reverse : whether mains is connected to inverter output
• Neutral and phase reverse : whether neutral and phase is connected reverse
• Overload : if load is above 100% and below 300%
• Heavy : if load is above 300%
• Short circuit
• Overload trip
• Heavy load trip
• Short circuit trip

2. Menu driven set-up. There is no preset, the parameters such as battery low, charging current, inverter
output voltage, load etc can be set by scrolling up and down keys and press enter.

3. Priority solar charging

4. Inverter/UPS selection switch, micro switch or ordinary switch selectable.

5. Inbuilt SMPS type constant current charging with full charge cut-off.

6. 20KHz operating frequency while inverter and charging, absolutely no sound.

7. Pure sine wave output

8. DSP based very low component cost design

9. Single sided pcb, easy to assemble without any smd components

10. Ideal for Mixed load application

Specification
 Battery Input voltage : 12V DC – 48V DC
 Mains Input voltage : 230V AC, 50Hz.
 Mains input range : 0V – 440V, 45Hz-65Hz
 AC Output (Inverter) : 230V +/- 3%, 50Hz
 Inverter topology : Bridge type center aligned switching. MOSFET based.
 Inverter output power : 300VA - 3000VA
 Battery charging : Constant current SMPS charging with full charge cutoff
 Charging current : Settable upto 15A
 Charger working range : 120V – 270V AC Mains input

3
Highlights
Full bridge configuration based on power MOSFETs
1. DSP based intelligent control
2. LCD based display for user-friendly display of parameters and status
3. Protection against 440V mains input
4. Protection against reverse polarity
5. Dynamic short circuit protection with fold-back current limiting.
6. Protections against all possible errors like battery low, over load, heavy load, short circuit etc.
7. Early warning for battery low and overload conditions. System continue normally if the error is
corrected.
8. Cutoff and auto restart with permanent cut after 5 consecutive cutoff.
9. SMPS type constant current charger with full charge cutoff.
10. Pure sinewave output resulting in silent operation of motor and fans. Safe to all kind of loads.
11. Ideal for Mixed load application
12. Indigenous design with proven technology.
13. Auto detect of LCD and LED. Can change between LED / LCD while the system is powered.
14. Protection against accidental output feedback disconnection.

4
Circuit Description

Schematic of dsPIC signal section

The schematic above describes the ADC and other signaling section. The IC U1 is the DSP. Its pins 2
through 7 are the ADC pins. Pin 9 and 10 are the oscillator pins. The details are given in next page:

5
 Pin Functional Description
Numbe
r
1 Reset pin of microcontrollerΣ
2 ADC pin for AC input
3 ADC pin for AC output
4 ADC pin for load sensing
5 ADC pin for battery sensing
6 ADC pin for Temperature sensing
7 ADC pin for switch sensing
8 GND pin
9 Oscillator pin, Crystal connection goes to this pinΣ
10 Oscillator pin, Crystal connection goes to this pinΣ
11 Relay driving pin
12 Buzzer pin
13 Supply pin +5V
14 Fan control. When this pin become +5V fan switch ON
15
16
Pins for controlling LCD display
17
18
19 GND pin
20 Supply pin +5V
21
Pins for controlling LCD display
22
23
Drives the MOSFETs. Pin 23, 25 drive the GND side
24
mosfet and pins 24, 26 drives the upper side
25
MOSFETs
26
27 GND pin
28 Supply pin +5V
Σ
These pins are very sensitive. Do not touch these pins or extend wires from them, which can cause
unwanted reset of DSPIC.

6
 ADC section
AC input and output sensing
The AC input and AC output sensing resistor network is similar to each other. The 3 Nos of 100K resistors
in series is used to divide the AC voltage to a smaller voltage measurable by the controller. If the
value of any of these resistors is increased then the voltage sensed by the controller will be reduced
(and vice versa). A dry soldering or loose connection in this resistors also will cause the same results.

The two numbers of 2K2 resistors to +5V and GND are for keeping the sensing voltage at the acceptable
range. If any of this resistors drift considerably then the measurement will not be proper. In addition to
that the ‘No Load Set’ menu in the setup mode will not be completed properly.

Earlier the value of the sensing resistors were 1M X 3 Nos + 22K X 2 Nos. Now it is
changed to 100K and 2K2. More than that a capacitor C25 connected from pin 2 to GND. If
you are using earlier PCB simply change the values of 1M-22K combination and put a disc
capacitor between pin 2 to 27. This is essential for stable sensing of mains input

Load Sensing
The load sensing is through the current transformer (CT) T1. You can use CT1200 or the equivalent. The
shunt resistor R40 determine how much voltage is sensed for the load. A recommended value for this
resistor is 100 Ohm divided by KVA. That is, for 1KVA R40 = 100 / 1 = 100 Ohms. For 500VA R40
= 100 / 0.5 = 200 = 220 Ohms or 180 Ohm. The resistors R38 and R37 make the voltage at the
microcontroller pin at a measurable level. Drift in the values of these resistors will effect proper
sensing of the load and will result in failure of completion of ‘No Load Set’ menu in the setup mode.

Note: When mains is absent and inverter is switched off the voltage at pin 2, 3 and 4 will be very near to
2.5V. If the voltage is not as expected then the ‘No Load Set’ menu in the setup mode will not be
completed.

Battery Sensing
The battery sensing is through a simple resistor divider with R41, R42. The capacitor C10 is used for a
filtering. The values of the resistors if not critical because the system has battery voltage calibration.
But much drift in the values of the sensing resistors will result in improper sensing of the battery
voltage. A usual mistake that found is that for 2 battery system the manufacturer put R41 = 47K which
is the value of single battery. In this case when the battery reach near full charge the ADC input will
reach its peak voltage and further increase in the battery voltage will not be sensed. The formula for
R41 is:

R41 = 47 + 51 X (N-1) where N = number of batteries.

With this formula you get the resistor value in Kilo Ohms.

It is expected that the voltage appear at pin 5 = ‘battery voltage / K’. For one battery K = 4.92. For
example when battery voltage = 12V voltage at pin 5 = 12/4.92 = 2.44V. If number of battery = 2, the
value K = 4.92 X 2 = 9.84. So when battery voltage = 24V the voltage at pin 5 is same 2.44V. If the
battery voltage divider resistor values are changed the battery voltage sensing will be improper.

The usual error happen is the capacitor across R42 has a leakage and hence the sensing
voltage at pin 5 is much below the expected voltage. In this condition the battery voltage
calibration can not be completed as expected. Other error that manufacturers make is the
value of R41 is not increased when number of battery = 2. This will make the voltage at pin

7
 5 above 5V. In this condition the system will not sense the battery voltage if it rise above
25V (approximate) and hence the full charge will not be sensed.

Temperature sensing
Temperature is sensed with an NTC only. From the schematic you can see that when the temperature rises
the value of the resistor will reduce and voltage at pin 6 drops. With R47 = 6K8 and 10K NTC the
following readings are observed.

The fan will switch on when the voltage at pin 6 = 2.44 V or less
The fan will switch off when the voltage at pin 6 = 2.76 V or more
The system assume excess temperature when the voltage at pin 6 = 1.5 V or less
The system assume improper temperature sensor when the voltage at pin 6 = 4.4 V or more

Note that if you decrease the value of R47 you can shift up the fan related temperature levels. Similarly if
you increase the value of R47 you can shift down the fan related temperature levels.

Sensing of Switches
The switches are sensed through one ADC pin itself. This is for saving the controller pin. Resistances R43,
R44, R45 and R46 form a divider network. The values of these resistances are selected in such a way
that the voltage at pin 7 of the controller will be significantly different in different possible
combination of the switches.

The 3 switches that can be connected to the connector CN3 are:

1. ON/OFF switch
2. Solar charger / Mains Charger selection switch
3. UPS / Inverter selection switch.

Also note that if needed we can change the function of Solar charger / Mains Charger selection switch.
This switch can be used for Automotive battery / Tubular battery selection. If one function is selected then
the other function will not be available. For more details see the description of Option menu in setup
mode.

Relay driving
Pin 11 is for relay driving. This is done through a transistor BC639. Also note that a torroid core T12.5 is
used to suppress the conducted noise from the relay. This is described in the section ‘Winding of torroidal
transformer’ in page 19 (or around). In order to speed up the changeover the relay switch on is done with a
separate circuit. This is shown in the next page.

Buzzer
Pin 12 is for buzzer control. You can use a good quality B20 buzzer. It was practically found that low
quality buzzers available in market which will fail without any reason after few weeks.

Fan control
Pin 14 is for fan controlling. It is driven through a transistor. A regulator IC 7812 is used to assure that the
voltage for fan does not go above 12V. This is recommended for reliable operation.

The fan should be placed as close as possible to the heatsinks, in such a way that air from
the fan blow directly towards the heatsinks.

8
The fan is controlled as per the temperature sensed with the sensor connected to pin 6 of the controller.
More details are given in section ‘Temperature sensing’ in the previous page.

9
LCD control
The six pins 15 to 18, 21 and 22 are used for LCD driving. These pins along with +5V, GND and a
contrast control pin is coming to the connector CN1 which is used to connect the LCD. The wiring of LCD
is given somewhere in the following pages of this document.

While powering the system for the first time the LCD may not show anything. Most
probably this may be because the contrast adjusting preset is not adjusted correctly. Turn
clock-wise to increase the contrast. Also see the LED/LCD auto sensing description in page
16.

MOSFET driving and display handling

Pins 23, 24, 25 and 26 are used to drive the MOSFETs. The schematic of mosfet driving section is given
below

Schematic of MOSFET driving section. Relay fastening section also shown

The schematic of mosfet driving section is direct and self explaining. There is nothing more to explain
with the MOSFET driving circuit. The relay fastening is done through the connector CN4, resistor
R53, diodes D1, D2, zener D18 and capacitor C18. A 45V winding from the transformer is to be
connected to CN4. This winding can be done with very thing guage wire.

The MOSFET driving from pins 23 – 26 are done in such a way that MOSFETs get drive when the
corresponding microcontroller pin is low (0V). The drives are disabled when the microcontroller pin
10
 is high (5V). This is called inverted drive. In the circuit for 12 Nos of MOSFETs the drive is direct.
That is, MOSFETs get drive when the corresponding microcontroller pin is high (5V). The drives
are disabled when the microcontroller pin is low. This is called direct drive. This means that
microcontroller for small PCB (4 MOSFETs) is different from that for the big PCB. The
microcontroller for big PCB should not be used in small PCB and vice versa.

View of the system from the user side

As per the wiring given in the following pages the system has two terminals for battery connection, 3
terminals for AC input, AC output and Neutral. The LCD and switch wiring is to be connected as
shown.

The 3 switches that can be connected to the connector CN3 are:

1. ON/OFF switch
2. Solar charger / Mains Charger selection switch
3. UPS / Inverter selection switch.

Also note that if needed we can change the function of Solar charger / Mains Charger selection switch.
This switch can be used for Automotive battery / Tubular battery selection. If one function is selected then
the other function will not be available. For more details see the description of Option menu in setup
mode. If the switch is selected as Solar charger / Mains Charger selection switch then the system will work
in Tubular battery mode.

Normally the ON/OFF switch is provided in the front panel. The UPS/Inverter selection switch is placed at
the rear panel. Solar charger / Mains charger selection is not connected to a switch but is driven from the
solar charger circuit. When the solar charger is active and charging the battery (there is sufficient sunlight
to charger the battery) the solar charger will make the solar charger selection pin low. At this time the
inverter will disable mains charger.

When this switch is used for Automotive battery / Tubular battery selection the switch can be placed at the
rear panel of the system.

The +ve connection of the battery taken from the big heatsink and the -ve wire taken from the PCB should
have sufficient thickness to carry the battery current. When the battery is connected the system will
start with a special beep, like: beep-beep-beep-beep. This indicates the power on of the controller.
This beep will be heard only when the battery is connected. After that this kind of beep will not be
heard until the battery is disconnected and connected again.

If the above said power-on beep is heard during normal working of the system it means that
the system got an unwanted reset. This can happen if the high current / high voltage wiring
is taken near the low current signal wiring (LCD / switch wiring). This also result when the
capacitors from pin 9 and 10 are not soldered. There is a chance to miss this capacitors
since they are SMD parts fixed under the PCB. Also take care to fix the LCD without any
electrical contact with the cabinet. It is wise to use not metal front panel and fix the LCD on
it.

When the mains is in acceptable range the system will bypass mains and will charge the battery. The
battery charging current will depend on the set value. When the battery voltage reach the full charge level
the charging will be stopped automatically. When the battery voltage drops by ‘T’ volt the charging
restarts. The magnitude of T depends on the type of battery selected (Automotive battery / Tubular battery
selection). If tubular battery is selected T = 2.4V per battery. If automotive battery is selected T = 1.44V
11
per battery. Also note that this depends on the correctness of the resistors R41, R42 connected to pin 5 of
the microcontroller.

Fan controlling
The fan is controlled as per the temperature sensed with the NTC connected to connector CN2.
Temperature is sensed and fan controlling is done in mains as well as inverter mode. Without connecting
the temperature sensor the system will not function. In case of excess temperature also the system will be
inactive. The display will show the status. See the section temperature sensing at page 8 (or around).

The system will consider the mains voltage as OK when the mains is within a specified range. In inverter
mode the acceptable range is from 100V to 285V and in UPS mode this is from 180V to 265V. When the
mains voltage cross this range the system will activate the inverter if the standby mode is ON (front panel
switch is ON). The software is giving a hysterisis gap for the changeover voltages. For example in UPS
mode if the mains voltage is dropped below 180V the system will changeover to inverter but the system
will return to mains if the mains voltage rises above 190V. That is, there is a gap of 10V. This is for the
stability of the changeover. For low voltage changeover the hysterisis gap is 10V and in high voltage
changeover the gap is 5V. This is because high voltage changeover will have a natural hysterisis.

In UPS mode the changeover to inverter will be fast and in synchronous with mains waveform. In inverter
mode the changeover will be comparatively slow, but will be in synchronous with mains waveform.

Slow starting of the system is done if the mains is already absent and the standby mode is switched on in
the absence of mains.

Fast changeover considerations

The mains-inverter and inverter-mains changeover will be in synchronous with the mains waveform. For
correct synchronous changeover the system should properly sense the polarity of the transformer
connection. This is done by the No Load Set menu. After assembling the system and connecting the
transformer this test should be run at least once. See the details at setup section.

In UPS mode the relay fastening voltage is very important for the fast changeover from mains – inverter.
This is connected through 2 pin connector CN4. Without this support there is a risk of mosfet failure.

Even when the front panel switch is off (standby off) the system will switch on the relay and will
forcefully switch off the charger if the mains voltage is very high. This is for protecting the transformer
and the MOSFETs from high voltages.

Inverter mode
When the system is in standby mode the inverter will start if the mains is not in acceptable range. As stated
above the smooth start will be done if the standby mode is switched on in the absence of mains. In inverter
mode the system will be continuously checking the mains and if the mains is acceptable the system will try
to synchronous the inverter waveform with mains. The inverter to mains changeover will happen only after
the mains-inverter synchronization is correct.

Note that the AC sensing resistor network is critical in properly sensing the AC input. See the description
AC input and output sensing in the ADC section in page 7 (or around). Improper values will increase the
mains sensitivity. This can lead to frequent change-over to and from inverter / mains modes and unwanted
sense of mains fail even when mains is stable and acceptable.

12
If the load is within the overload limit, the output voltage will be maintained at the set value. Even if the
output is accidentally disconnected the system will not boost the output voltage, but instead will sense ‘no
feed back’ error and will drop the output voltage.

In inverter mode the system will be continuously sensing overload and battery low voltage conditions.
These levels are user settable in setup mode. When the error conditions exist the system will display the
status and will give buzzer beep also. If the error condition continues for more time then the system will
activate cutoff. The system will automatically restart from cutoff mode after a delay. In case of battery low
cutoff there will be only one restart allowed. In case of overload cutoff system will give 5 restart chances.
After all restart chances system will activate permanent cutoff. System will come out of cutoff mode /
permanent cutoff mode if the front panel switch is turned off or if the mains is restored.

13
Battery Low Sensing
As described in ADC section above, battery voltage is sensed with a simple resistor divider. Proper values
of these resistors are very important for correctly sense the battery voltage. Calibration of battery voltage
display also required for proper sensing.

Overload sensing
The system sense the load through the current transformer CT1200. The value of shunt resistor across the
CT determine the proper sensing of load as well as overload / short circuit condition. The load should be
properly calibrated using calibrate menu in setup mode.

In setup mode there are 2 parameters that determine the overload sensing level. (1) load calibration under
calibration menu and (2) Inv Load level in parameter menu. For example for a 500W system you can
calibrate the load by connecting a 300W and making the display = 300. Then you can make the load limit
parameter = 500.

When the system is set for 500W load limit the overload sensing will start from 12% above the level, that
is 500+12% = 560W. The software is designed to limit the current through the CT at the rated current
only. That is, if the load is set for 4A through the CT then the system will limit the output voltage so that
the current through the CT will not exceed 4A. This means that when overloaded the output voltage will
be dropped. But voltage dropping will not be done for the first 2 seconds of the overload.

When overloaded the output voltage is not limited for around 2 second. After that limiting starts. When a
heavy load or short circuit is detected the output is suddenly made to very low voltage and from there
smooth starting is applied. The smooth start will stop when the output voltage is sufficiently high for the
rated current through CT.

Cutoff mode
The system enter cutoff mode in case of battery low, over load, short circuit or no feedback conditions.
System will stay in cutoff mode for few second and will restart automatically. If the error condition still
exist the system will enter cutoff mode again and will restart again. In case of cutoff due to battery low,
system allow only one restart. Other cutoff will have 5 restart chances. If the system fail to work even after
the last restart then permanent cutoff is done. When the system is in cutoff mode or permanent cutoff
mode, quick restart will happen if the front panel switch is turned off or if the mains is applied.

Inverter-Mains changeover
In inverter mode when the mains is restored the system will first try to synchronous the inverter waveform
with mains waveform. The ac input sensing network and the capacitor between pin 2 and 27 are very
important for the proper sensing and synchronization of the waveform. When the mains and inverter
waveform are in phase the system will activate the changeover. The relay will be switched off and the
display will show the changeover message. If battery low or overload condition was present at the
time of changeover these conditions will be stopped and buzzer beep will be paused.

If the no-load set is properly run during setup mode the system will do a perfect inverter-to-mains
changeover without any waveform distortion.

14
Connection diagram
The connection diagram is given in the next page.

While connecting the LCD it is very important that the GND connection of the LCD
SHOULD NOT come in contact with the cabinet through the fixing screws. If this happens
the microcontroller will get unwanted resets and sometimes will hang, resulting in strange
behaviors. These sometimes cause damage to the LCD. It is recommended to use plastic front
panel instead of metal.

The connection to the LCD display can be done with thin wire. The connection of 0-250 winding of the
transformer to the PCB and connection of AC terminals to the PCB is to be done with 40/36 guage (0.75
sq mm) wires. The connection of battery –ve, 7.5V winding of the transformer are to be done with 10mm2
wire.

The connection between LCD and PCB is exactly same as our previous microcontroller based sinewave
designs. As done earlier a 10E ¼ W resistor is connected between pin 5 and pin 1 of the LCD display. This
connection is needed for proper working of the display. If the LCD is showing a half display the reason
will be most probably the absence of this resistor.

The 40A relay used in the PCB is having high current terminals on the relay itself. It is recommended to
take the Phase-In, Phase-Out connections from these high current terminals. For neutral connection a
similar connection tag is provided on the PCB. Phase-in can be taken from the NC contact of the relay and
Phase-Out can be taken from COM contact.

The connection diagram shown is the one used in the finished product. During setup mode exactly the
same connection can be followed but connector CN3 for on/off switch connection will be used for setup
switches. This will be explained later.

There are 3 switches that select various modes of the system. These are: ON/OFF switch, Solar/Mains
charger selection switch and UPS/Inverter selection switch. The switches are connected from CN3
connector. ON/OFF switch can be a microswitch or ordinary rocker type switch. The two other switches
will be always ordinary rocker type switches. Whether to use microswitch or ordinary rocker type switch
for ON/OFF switch can be programmed during setup mode.

If the user prefer, Solar/Mains charger selection switch can be programmed for battery selection (Tubular
battery or Automotive battery). If it is programmed for battery selection then the Solar/Mains charger
selection will not be available. See setup mode for details.

The 3 switches used to browse through the menu during setup mode are connected to the same CN3
connector. During setup mode:

1. UPS/INV selection switch will function as Up switch.

2. ON/OFF switch will function as Down switch.
3. Mains/Solar charger selection switch will function as Enter switch.

Also note that during setup mode all the three switches are microswitches. (press to ON, release to OFF
type switch). There is no meaning to use rocker switch.

15
16
Complete wiring diagram. Note how the wiring is done through the CT (current transformer)
LED connection
The software is designed to automatically sense when the LED or LCD PCB is plugged while the system
is powered. When the LED pcb is plugged it is sensed immediately and LEDs are driven accordingly.
When LED PCB is unplugged and LCD is plugged the system will sense it immediately but it may take
few seconds to display something. This is due to the LCD re-initialization delay.

The LED as well as LCD is connected from the same connector CN1. The diagram below shows the
connection for LEDs. The ground pin (away from the preset) is considered as Pin 1.

Connection of LEDs.

All LEDs are connected through the limiting resistor 560E. Note the 4K7 resistor across the
CUT led. This is required for auto-sensing of LED PCB. If this resistor is not present the
LED PCB will not be sensed and the system will stay permanently in LCD mode. This will
be indicated by some periodic flashes in the LEDs. Similarly if the pin corresponding to
CUT led is having some unwanted resistor connected to ground then the system will not
sense the LCD PCB. This will make the LCD blank.

During Setup-Mode the system will be permanently in LCD mode only, because LCD is essential in setup
mode.

17
How to do Setup
To do the setup no special type connection is required. The setup switched are to be connected to
connector CN4 to which normally the ON/OFF, Battery Type selection and UPS/INV selection switches
will be connected. During setup there will be 3 switched: UP, DOWN and ENTER. The connections of
these switches are as shown below.

There will be a default value already set for parameters such as battery low, battery full
charge etc. So, there is no need to change these values. Only the calibration of the meter is
required by entering the calibrate mode. Also after the wiring and finishing of the inverter in
the cabinet, the no-load set should be done.

To enter setup simply press Enter switch and then power on the system.

The display will show ‘Enter Setup? N’. Note that the default choice is ‘No’ which prevents accidental
entry to setup mode. To change the choice to Yes, press the Up or Down switch. Pressing Up swith again
and again will toggle the choice between Yes and No. While the choice is Yes (display is showing: ‘Enter
Setup? Y’) press Enter switch. Now the system is in setup mode. While the system is asking ‘Enter
Setup?’ question, if the user do not press any key for around 15 seconds the system will come back to
normal working without entering setup mode even if the selected choice is Y (yes).

When you enter setup (by pressing Enter switch while display is showing: ‘Enter Setup? Y’) the display
will show the software version number for a while. Then the menu will be shown. Navigating through the
menu driven setup is exactly same as our earlier microcontroller based sinewave designs. Details are given
from the next page onwards.

18
Alternate way to enter setup
This method of entering setup is introduced to make it possible to enter setup without disconnecting the
battery. While the system is in normal working mode and inverter is switched off, press the following
special key combination:

1. Enter 2. Up 3. Enter 4. Up 5. Enter 6. Down 7. Enter 8. Down

When this combination is pressed the system will produce a long beep. Before this beep ends keep Enter
switch pressed. Then the display will show 'Enter Setup N'. You can enter setup as usual.

If the key press sequence is correct you can hear a short beep on the 4th, 5th, 6th and 7th key press. On 8th key
press you will hear a long beep. Now release the down switch and keep pressing the Enter switch until the
buzzer stop and display show

'Enter Setup N'

Now release enter switch and proceed as explained in the previous page.

While pressing the above special key combination, you should take care that the gap between two
successive key press should not be more than 4 second. Also note that Enter Switch is functioning as
battery selection switch also. When pressing the special key sequence the display will show messages like
Automotive Battery / Tubular battery. But from the 5th switch onwards this message will be hidden. The 6th
and 8th switches are Down switch which also function as inverter ON/OFF switch. But inverter ON/OFF
will not happen if the key sequence is correct.

While pressing the above special key combination if any key is wrongly pressed, wait for around 5 or 6
second. Then start pressing the special key combination again from the beginning.

19
Menu driven setup
We have provided a very user friendly menu driven setup procedure. The menu style is as below:

Main Menu
1. Calibrate Sub Menu 1
2. No Load Set Do NoLoad test 1.1 Bat V
3. Options 1.2 AC Out
4. Parameters Sub Menu 3 1.3 Inv Load
5. Discard 3.1 Microswitch 1.4 AC In
6. Done 3.2 Solar Switch 1.5 Char Amp
3.3 LCD Lines 1.6 Exit
3.4 Exit

Discard changes & Exit

Sub Menu 4
4.1 Bat Low
4.2 Bat Too Lo
4.3 Bat Full T
Save changes & Exit 4.4 Bat Full A
4.5 Inv Volt
4.6 Inv Load
4.7 Char Amp
4.8 Factory Set
4.9 Exit

When you enter setup you are starting at Menu1: Calibrate. If you press up switch you will see menu 2:
No Load Set. Up switch is for going to the next item while Down switch is for going to the previous item.
Menu is having auto-wrap facility, means: While displaying the last item in a menu if up switch is pressed
then the first item is displayed. Similarly while displaying the first item in a menu if down switch is
pressed then the last item is displayed.

To enter a menu just press the enter switch while the menu is displayed. For example if you want to enter
the calibration menu: While you are in the main menu, press up or down switches until the display show 1.
Calibrate and then press enter. From the sub menu if you want to go back to the main menu: press up or
down switches until the display show ‘Exit’ and press Enter.

1. Calibrate Menu
The first menu if for calibrating various parameters that the microcontroller reads. For example the battery
voltage is given to the microcontroller through a resistance divider network which scale down the voltage
to 0.2034. Due to the variation of resistance value this scale down may not be correct. So the system may
show slightly different reading. To make the reading correct we have to do the calibration. Calibration is
required for Battery voltage, AC input volt, AC output volt, Inverter load and charging current.

2. No Load Set menu

This is for a kind of self test of the system. After doing the wiring you need to run the No-Load test at least
once. This is required for correct functioning of the system.

20
3. Options Menu
This menu is for setting various Options. At present two options are given : Microswitch/Rocker switch
selection and Solar switch or Battery switch selection. This is explained below in detail.

4. Parameters menu
This menu is for setting various parameters like battery full charge voltage, battery low voltage etc.
Normally these voltages will be automatically set by the microcontroller at power on time. Normally there
is no need to change any parameters.

5. Discard Menu
Execute this menu if you have somehow done some unwanted changes in the setup values so do not want
to write this to the non-volatile memory. The changes you have made will be discarded and the old values
will be restored.

6. Done Menu
Execute this menu if you have done the necessary changes in the setup and want to write this to the non-
volatile memory.

Sub Menus
Sub-Menus of Calibration Menu
Calibration menu has five sub menus (plus one exit menu to go back to main menu). They are:
►1.1 Bat V, ►1.2 AC Out, ►1.3 Inv Load, ►1.4 AC In and ►1.5 Char Amp. The two numbers
separated by dot in the display indicate the menu number and sub menu number. For example 1.3 Inv
Load means Sub menu 3 of main menu 1.

The calibration menu is given for correcting the reading shown by the system. That is, if the battery
voltage is 12.3V but the system shows 12.8V then we can use the calibration menu to correct the display.
You have to use a good multimeter while doing the calibration. After assembling the PCB it is
recommended to do the calibration because there is a good chance for slight variations in the display of
various parameters due to the tolerance of resistors.

While doing the calibration of different parameters the display may seem not increasing /
decreasing. For example when doing the battery calibration suppose the display shows 10V
and you need to make it 12V. If you press UP switch the display may not increase as
expected. But do not give up!. Just press and hold the switch. The display will change slowly.
This is because the range of the calibration is too wide.

1.1 Bat V
This menu if for calibrating the battery voltage reading. To enter this menu press Enter while the display
shows this menu. Inside this menu the display will show the present battery voltage. Suppose the display
show 13.0V but with a good multimeter you measure the actual battery voltage as 12.5V. Now press Down
switch to correct the reading. When the reading is OK press Enter switch.

1.2 AC Out
This menu if for calibrating the AC output reading. To enter this menu press Enter while the display shows
this menu. The inverter will start with an output around 200V. During this working of inverter there will
not be any AVR correction and output will vary as per battery voltage and load. It is expected to run this in
no-load condition. Inside this menu the display will show the present inverter output voltage. Suppose the

21
display show 180V but with a good multimeter you measure the actual inverter output voltage as 202V.
Now press Up/Down switch to correct the reading. When the reading is OK press Enter switch.

1.3 Inv Load

This menu if for calibrating the inverter load reading. To enter this menu press Enter while the display
shows this menu. The inverter will start and the output will be at the set inverter voltage. Inside this menu
the display will show the present inverter load. You have to connect some considerable load to get good
calibration. A load near the full load is recommended. Suppose you have connected 400W but the display
show 380W. Now press Up/Down switch to correct the reading. When the reading is OK press Enter
switch.

1.4 AC In
This menu if for calibrating the AC input reading. To enter this menu press Enter while the display shows
this menu. User should connect the mains while running this setup. To get good calibration, it is
recommended to input an AC voltage above 200V. Inside this menu the display will show the present
mains voltage. Suppose the display show 230V but with a good multimeter you measure the actual AC
input voltage as 238V. Now press Up/Down switch to correct the reading. When the reading is OK press
Enter switch.

1.5 Char Amp

This menu is for calibrating the charging current. To enter this menu press Enter while the display shows
this menu. The charger mode will start. Note that you have to connect a good ammeter in series with the
battery and input the mains supply. Charger will function irrespective of the battery voltage. There will not
be any full charge cutoff. You have to connect an ammeter in series with the battery. The battery and
ammeter connection should be very firm. Any battery side loose contact will cause excess voltage accross
the MOSFET since the charger is functioning without any full charge cutoff. This will cause MOSFET
damage.

Inside this menu the display will show the charging current you have set in the parameter menu. For
example if you have set 8A in the parameter menu then the display will show Char Amp = 8A. The display
will be constant and will not change. Initially the ammeter connected in series with the battery will show
0A. Press up key for a long time and the ammeter will start showing the current. Using UP and DN
switches bring the current to the desired value. Press Enter when done. The mains should be
disconnected only after pressing the Enter switch.

1.6 Exit
This menu is to exit the submenu and go back to the main menu Calibration.

Menu 2: No Load Set

Inside this menu the system takes some readings that are important for the correct working of the inverter.
It is very important to run this menu at least once. During no load set the system also take some readings
which are important for proper sensing of ac input, ac output and load feedback. For proper working of
inverter and charger these parameters are important.

While doing no load set the mains should not be connected. If mains is present the system
will not complete no load set. It is supposed that voltage at pin 2, 3 and 4 should be around
2.5V. If the voltage is not within +/- 2% the system will not complete no-load set.

22
Very Important: If you replace the transformer or change the primary or secondary
connection of the transformer you should run the No Load Set at least once. This is
important because inside this menu the system sense the polarity of the transformer.
It is needed for correct line interactive changeover. Incorrect polarity can cause the
re-boot of the computer and sometimes damage the MOSFETs.

23
Sub-Menus of Options Menu
Options menu has only two sub menus (plus one exit menu to go back to main menu). They are:
►3.1 Microswitch ►3.2 Solar Switch

3.1 Microswitch
This menu is used to select whether the user needs microswitch or simple switch for inverter ON/OFF. To
enter this menu press Enter while the display shows this menu. Inside this menu the display will show
‘Microswitch Y’ or ‘Microswitch N’. If Y is selected it means microswitch type ON/OFF switch. If N is
selected it means ordinary ON/OFF switch. User can change between Y ◄► N with up or down switches.
When the correct option is selected press enter switch.

3.2 SolarSwitch
This menu is used to select whether switch 2 should function as solar / mains charger selector or Tubular /
automotive battery selector. To enter this menu press Enter while the display shows this menu. Inside this
menu the display will show ‘SolarSwitch Y’ or ‘SolarSwitch N’. If Y is selected it means switch 2 will
function as solar charger / mains charger selection switch. If N is selected it means switch 2 will function
as tubular battery / automotive battery selection switch User can change between Y ◄► N with up or
down switches. When the correct option is selected press enter switch.

Tubular battery / Automotive battery selection

If user has selected switch 2 to function as Tubular battery / Automotive battery selection switch then
Tubular battery will be selected if switch is closed. Automotive battery will be selected if switch is open.
When tubular battery is selected Bat Full T voltage (selected in menu 4.3) will be considered as battery
full charge voltage. Bat Full T-1.0V will be considered as battery reconnect voltage. When automotive
battery is selected Bat Full A voltage (selected in menu 4.4) will be considered as battery full charge
voltage. Bat Full A-0.6V will be considered as battery reconnect voltage.

Solar Charger Mains charger selection

If user has selected switch 2 to function as Solar Charger / Mains charger selection switch then solar
charging will be selected if switch is closed. Mains charging will be selected if switch is open. This is
exactly as our old sinewave models. When the system is in solar charging mode, mains charger will be
forcefully disabled irrespective of battery voltage. When mains charger is selected the charger will
function as usual. The zero drop solar charger circuit we have provided can automatically switch to solar
charging when sunlight is present.

Note: When switch 2 is selected as Solar Charger / Mains charger selection switch, the
system will assume the battery as Tubular battery. So the Bat Full T voltage (selected in
menu 4.3) will be considered as battery full charge voltage. Bat Full T-1.0V will be
considered as battery reconnect voltage.

3.3 LCD Lines

This is a new menu item added from version 4.0 onwards. When entering this menu the display will show
the number of lines in LCD. You can use 1 line, 2 line or 4 line LCD. With up/down switches the number
of lines can be selected. There is no meaning to select more than 4 number of lines. If selection is more
than 4 then the system will take lines = 4.

Sub-Menus of Parameter Menu

Paremeter menu has eight sub menus (plus one exit menu to go back to main menu). They are:

24
►4.1 Bat Low, ►4.2 Bat Too Lo, ►4.3 Bat Full T, ►4.4 Bat Full A, ►4.5 Inv Volt, ►4.6 Inv Load,
►4.7 Char Amp and ►4.8 Factory Set. The two numbers separated by dot in the display indicate the
menu number and sub menu number. For example 4.3 Bat Full T means Sub menu 3 of main menu 4.

4.1 Bat Low

This menu is for setting the battery low voltage (that is, the battery voltage level at which the battery low
warning should start). To change this simply press enter while this menu is displayed. The display will
show the present setting. Press Up or Down switches to change to the desired value and press enter. The
default value for this parameter is 10.0V. Normally you need not change this.

4.2 Bat Too Lo

This menu is for setting the battery low too voltage (that is, the battery voltage level at which the system
go to immediate cut). To change this simply press enter while this menu is displayed. The display will
show the present setting. Press Up or Down switches to change to the desired value and press enter. The
default value for this parameter is 9.0V. Normally you need not change this.

4.3 Bat Full T

This menu is for setting the battery full charge voltage for Tubular battery (that is, the battery voltage level
at which charger turns off). Note that we have an option to use switch 2 for battery selection (see option
menu). To change this simply press enter while this menu is displayed. The display will show the present
setting. Press Up or Down switches to change to the desired value and press enter. The default value for
this parameter is 14.0V. Normally you need not change this.

For tubular battery, system automatically select the battery charge reconnect voltage as Bat Full Voltage –
1.0V

4.4 Bat Full A

This menu is for setting the battery full charge voltage for Automotive battery (that is, the battery voltage
level at which charger turns off). Note that we have an option to use switch 2 for battery selection (see
option menu). To change this simply press enter while this menu is displayed. The display will show the
present setting. Press Up or Down switches to change to the desired value and press enter. The default
value for this parameter is 13.8V. Normally you need not change this.

For Automotive battery, system automatically selects the battery charge reconnect voltage as Bat Full
Voltage – 0.6V

4.5 Inv Volt

This menu is for setting the output voltage of inverter. To change this simply press enter while this menu is
displayed. The display will show the present setting. Press Up or Down switches to change to the desired
value and press enter. The default value for this parameter is 220V. Normally you need not change this.

4.6 Inv Load

This menu is for setting the inverter load. To change this simply press enter while this menu is displayed.
The display will show the present load setting. Press Up or Down switches to change to the desired value
and press enter. The default value for this parameter is 500W.

25
4.7 Char Amp
This menu is for setting the charging current. To change this simply press enter while this menu is
displayed. The display will show the present load setting. Press Up or Down switches to change to the
desired value and press enter. The default value for this parameter is 8A.

4.8 Factory Set

Pressing Enter in this menu will load the default factory settings for the parameters.

4.9 Exit
This menu is for exiting from the sub menu and go back to the main menu Parameters.

26
27
Schematic Diagram
Component Layout

28
 Winding of torroidal transformer
(For noise suppression)

Winding of T12.5 torroid (noise suppressor)

To wind suppressor with 2 winding, take 2 wires of different colours and wind them together on a torroid
core T12.5 or nearer size. Wind 5 or 6 turns. The number of turns is not critical. Connect to the PCB as
shown below.

29
Parts List
Name Value Name Value
BZ1 or BZ2 BUZZER B20 H1
C1 220p disc H2 F-type Heatsink. Dimensions given in
C2 15p 1206 pack SMD H3 separate page.
C3 220p disc
C4 10u / 25V electrolytic Q1
C5 10u / 25V electrolytic Q2
Main MOSFETS
C6 10u / 25V electrolytic Q3
C7 10u / 25V electrolytic Q4
C8 15p 1206 pack SMD Q5 BC 639
C9 10u / 25V electrolytic Q6 BC 639
C10 1u / 25V electrolytic Q7 BC 639
C11 10u / 25V electrolytic Q8 BC 639
C12 1000 / 25V electrolytic Q9 BC 640
C13 1000 / 25V electrolytic Q10 BC 640
C14 10u / 25V electrolytic Q11 BC 640
C15 0.1 disc Q12 BC 640
C16 10u / 25V electrolytic Q13 BC 639
C17 10u / 25V electrolytic Q14 BC 548
C18 470uF/50V electrolytic Q15 BC 548
C19 0.1 disc Q16 BC 548
C20 1/400V X2 grade capacitor Q17 BC 548
C21 1000 / 25V electrolytic Q18 BC 548
C22 0.1uF 1206 pack SMD
C23 220p disc RL1 GU-SS-112DF Relay
C24 220p disc CN1 9 pin relemate for DISPLAY
C25 22nF disc CN2 2 pin relemate for 10K NTC
D1 1N4007 CN3 4 pin relemate for SWITCH
D2 1N 4007 CN4 2 pin relemate for 45V
D3 5V CN5 2 pin relemate for FAN
D9 BA157
D10 BA157
D11 1N 4148 U1 PIC30F2010
D12 1N 4148 U2 7805
D13 1N 4148 U3 7812
D14 1N 4148 X1 6.144 MHz crystal
D15 1N 4007
D16 1N 4007
D17 1N 4148
D18 39V
D19 1N 4148
D20 1N 4148

30
Parts List continued
Name Value Name Value
R1 6K8 R31 100K 100 K recommended instead
R2 6K8 R32 100K of 1M
R3 6K8 R33 22K
Earlier these resistors were
R4 6K8 R34 22K
22K. But 2K2 is
R5 47E R35 22K
recommended.
R6 47E R36 22K
R7 4K7 R37 22K
R8 4K7 R38 22K
R9 47E R39 4K7
R10 22K R40 SHUNT
R11 47E R41 47K
R12 22K R42 12K
R13 6K8 R43 6K8
R14 6K8 R44 12K
R15 4K7 R45 22K
R16 6K8 R46 47K
R17 4K7 R47 6K8
R18 6K8 R48 4K7
R19 47E R49 47K
R20 47E R50 330E
R21 22K R51 10K
R22 22K R52 100E
R23 4K7 R53 1K 2Watt
R24 4K7 R54 560E
R25 47E R55 1K5
R26 47E R56 4K7
R27 100K Earlier these resistors were R59 47K
R28 100K 1M. But 100K is
R29 100K recommended. P1 10K
R30 100K
Shunt = A recommended value for this resistor is 100 Ohm divided by KVA. That is, for 1KVA R40 =
100 / 1 = 100 Ohms. For 500VA R40 = 100 / 0.5 = 200 = 220 Ohms or 180 Ohm.

31
Higher KVA Systems
The PCBs with more mosfets and different driver module suitable for more than 12V battery is designed
by us. Although the PCB is changed, the connection diagram, working and setup mode are exactly similar.

Schematic diagram of Higher KVA system

32
33
Component Layout
on Higher KVA PCB
 Wiring of higher
KVA system
The LED connection is exactly same as the lower wattage PCB. See page 16.

34
 Higher KVA Parts List
Name Value Name Value
BZ1 or BZ2 BUZZER B20 D1 4007
D2 4007
C1 Not needed. Leave blank D9 4007
C2 15p SMD 1206 pack D10 4007
C3 Not needed. Leave blank D11 4148
C4 10u D12 4148
C5 10u D13 4148
C6 10u D14 4148
C7 10u D15 4007
C8 15p SMD 1206 pack D16 4007
C9 10u D17 4148
C10 1u D18 39V
C11 10u D19 4148
C12 Bat V cap. Use maximum possible value D20 4148
C13 10u D21 12V
C14 10u
C15 0.1 CN1 DISPLAY 9 pin Relemate
C16 10u CN2 10K NTC 2 pin Relemate
C17 10u CN3 SWITCH 4 pin Relemate
C18 470/50 CN4 45V 2 pin Relemate
C19 0.1 CN5 FAN 2 pin Relemate
C20 1uF/275V X2 capacitor
C21 Bat V cap. Use maximum possible value M1 CS2 Module
C22 0.1 SMD 1206 pack P1 10K Preset small horizontal type
C23 10uF/16V
C24 22nF / disc
C25 10uF/16V
C26 Bat V cap. Use maximum possible value
C27 Bat V cap. Use maximum possible value
Q13 C639
Q1 Main MOS Q14 C639
Q2 Main MOS Q15 Main MOS
Q3 Main MOS Q16 Main MOS
Q4 Main MOS Q17 Main MOS
Q5 C639 Q18 Main MOS
Q6 C639 Q19 Main MOS
Q7 C640 Q20 Main MOS
Q8 C639 Q21 Main MOS
Q9 C640 Q22 Main MOS
Q10 C640 Q23 TIP122
Q11 C639 Q24 Not needed. Leave blank
Q12 C640 Q25 Not needed. Leave blank
There are several choices for Main Mosfets.
The components that depend on the number of battery are: C21, C26, C27, R40, R41, R64 and the
MOSFETs.

For 48V battery the regulator based on TIP122 will not be sufficient. You have to use an
external higher power voltage regulator mounted on sufficient heatsink.

35
Higher KVA Parts List continued
Name Value Name Value
R1 6K8 R33 2K2
R2 6K8 R34 2K2 Earlier these resistors were
R3 6K8 R35 2K2 22K. But 2K2 is recommended.
R4 6K8 R36 2K2
R5 47E R37 22K
R6 47E R38 22K
R7 4K7 R39 4K7
R8 4K7 R40 SHUNT = 100/KVA Ohms
R9 47E R41 47K
R10 22K R42 12K
R11 47E R43 6K8
R12 22K R44 12K
R13 4K7 R45 22K
R14 4K7 R46 47K
R15 4K7 R47 6K8
R16 Not needed. Leave blank R48 4K7
R17 4K7 R49 47K
R18 Not needed. Leave blank R50 330E
R19 47E R51 10K
R20 47E R52 100E
R21 22K R53 1K
R22 22K R54 560E
R23 Not needed. Leave blank R55 47E
R24 Not needed. Leave blank R56 47E
R25 47E R57 47E
R26 47E R58 47E
R27 100K R59 47K
R28 100K R60 47E
Earlier these resistors were
R29 100K R61 47E
1M. But 100K is
R30 100K R62 47E
recommended.
R31 100K R63 47E
R32 100K R64 1K2 (FOR 24V)

RL1 GU-SS-112DF. Goodsky relay U1 dsPIC 30F2010

T1 CT-1200 U2 7805
T3 T12.5 Torroid, 3 coils, 4 or 5 Turns U3 7812
T5 T12.5 Torroid, 2 coils, 4 or 5 Turns X1 6.144 MHz Crystal
Heatsink dimensions given in separate documents
The components that depend on the number of battery are: C21, C26, C27, R40, R41, R64 and the
MOSFETs.

36
 DSP Sinewave inverter. Module component layout

OLD PCB. DO NOT

USE
Component Side

Solder Side
(All components on solder side are 1206 SMD pack)

In an old model of the PCB there are some minor change in the solder side components as below:
1. 4 Nos of 390 E are placed in different locations. Note that these resistors are connected in series
with pin 2 of the IC.
2. There is a resistor connected between pin 5 and 6 of the ICs (totally 4 resistors). Do not put these
resistors (leave blank)
3. 4 Nos of 10uF capacitors are connected between pin 5 and 8 of the IC. In case of any doubt count
the pins and check the connection.

37
DSP Sinewave inverter Module

Schematic

38
 DSP Sinewave inverter. Module component layout
In the old PCB since the capacitor across pin 5 and 8 of TLP250 was not sufficient for good driving. These
capacitors changed to 100uF. Since there is no 100uF capacitor in 1206 SMD package, the PCB
redesigned.

Component Side

Solder Side
(All components on solder side are 390E, 1206 SMD pack)

39
Changes between various battery voltage
If you are using the small PCB (only 4 MOSFETs) then you can use only one battery. So there is no
question of changes for various battery voltage. The big PCB with 12 MOSFETs can be used for 12, 24,
36 and 48 V batteries. The changes in the PCB are as below:

Item 12V 24V 36V 48V

Q23 and associated Not needed. Use Needed Needed Use external
R64, C25, C23, R64 = 10E and put
D21 a jumper between
base-emitter of
Q23
R41 47K R (in K Ohm) = 47 + 59(N-1) where N = number of batteries.
MOSFETs Use 30V Mosfet Use 55V Mosfet Use 70V Mosfet Use 100V Mosfet

For 48V battery the on board regulator TIP122 (Q23) will not be sufficient to handle the power loss and
heat dissipated in it. So you have to use an external

External Series regulator for higher battery voltage

For 24V battery the on-board TIP122 based regulator is OK. But when using 36V of 48V battery it is
recommended to use external series regulator instead of regulator TIP122. The external circuit has only
three connections which are +IN, GND and +OUT. These are taken from on-board TIP122 and associated
components as this section is free now.

Note that 2N3773 will produce heat and require good heatsink.

A 10 Ohm or 22 Ohm / 5W resistor can be connected in series with the battery + connection. This will
drop some voltage and thus reduce the voltage input to transistor 3773. The heat in 3773 will be reduced
and the new resistor will share that heat.

40
 Transformer details

Copper Wire
Transformer (500VA)
Item Specification
Core Type Type 16, Stack 2 ½ inch, CRGO. Split Bobbin ****Split bobbin****
Voltage Turns Guage
Primary 7.5V 14T 11 SWG X 2 Split area 1
Secondary 0-250V 0-467T 22 SWG Split area 2
Relay boost 0-40 0-75T Very thin wire Split area 2

Transformer (750VA)
Item Specification
Core Type Type 43, Stack 2 ½ inch, CRGO. Split Bobbin ****Split bobbin****
Voltage Turns Guage
Primary 7.5V 13T 12 SWG X 4 Split area 1
Secondary 0-250V 0-433T 19 SWG Split area 2
Relay boost 0-40 0-69T Very thin wire Split area 2

Split Bobbin is very important

Split bobbin is very important for the transformer. Non-split transformer will have slightly
good regulation, but it will result more MOSFET current and thus produce more heat, in
inverter as well as charger mode. For split bobbin the no load current from battery in inverter
mode will be less than 1 AMP. But in case of non-split bobbin it is found to be more than
2.5A.

Transformer (500VA) Aluminium Wire

Item Specification
Core Type Type 43, Stack 2 inch, CRNO. ****Split bobbin****
Voltage Turns Guage
Primary 7.5V 13T 9 SWG Split area 1
Secondary 0-250V 0-433T 19 SWG Split area 2
Relay boost 0-40 0-69T Very thin wire Split area 2

41
 Heatsink of low power PCB

Requirement for the product code CS1.

All dimensions are in MM

42
Heatsink for PCB with 12 Nos of MOSFETs
Product Name CS2

1 No per Product

43
Product Name CS2

2 Nos per Product

44
 Vendor List
Item Item available from
MOSFETs and other 1. Tomson Electronics, Ernakulam
electronic compinents Phone 0484 2356973

2. M/s Valiya, Bangalore. Phone 0988679 1511

3. M/s Asianic Sales, Ernakulam. 098472 80448

Cabinet M/s Feromat, Ernakulam.
093886 09498, 0484 3208172
Heatsink PERFECT METAL WORKS
#339/1-4, ANANTHA RAMAIAH WOOLLEN
FACTORY COMPOUND
OPP:SATELLITE BUS TERMINAL
MYSORE ROAD, BANGALORE -560 026
TELE : 080-26756936
TELE FAX : 080-26753163
EMAIL : sureshnahar@[Link]
CONTACT PERSON: SURESH KUMAR NAHAR / MAHIPAL
NAHAR
M/s Anatal systems, No. 291, Shanivar Pet, New Guru Prasad Apartment,
Bapat Wadi, Pune – 30. Phone 020 2439 2683, 098221 97845.
Contact Mr. Shailesh Desh Pande
Transformer M/s Transformers and Allied Electricals, Ernakulam
Mr. Satheesh. Phone 0484 2489507
PCB 1. M/s Micro Tracks. Ernakulam. Mr. Binoy 09349810154
2. M/s Power Line, Ernakulam. Mr. Vinod : 093884 76517
LCD display Leopenta, Capital Towers, 2nd Floor, Patturaikkal, Trissur
Mr. Rajan - 94474 67177, 0487-232 2008
CT-1200 Shah Electronics, Mr. Hitesh,, Phone: 098240 69274, 07922 820 421
CT Specification is 1200 Turns, 5A PCB Mountable.
You can give our reference.

45
Clipping of waveform
For a single battery inverter (12V) we are recommending primary winding of 7.5V and secondary winding
of 270V. By calculation we can find that even when the battery = 9V the system can maintain output
sinewave shape at no-load. In loaded condition the system can maintain the sinewave shape at 10V or so.

But this is not needed for some cases. You may increase the primary winding (for example 8.5V instead of
7.5V). Then when the battery voltage drops, the system will start clipping the sinewave shape for
maintaining the output. This clipping will not cause any noise in the system. The only thing is that the
wave shape is detectable with an oscilloscope. But since the primary voltage is increased the current
through the MOSFETs will be reduced. This is an advantage.

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Wiring of zero drop solar charger
Buck SMPS

For 48V or above battery voltage it is better to use SMPS for the board supply. We are giving the design of
a 3 terminal buck-only SMPS

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Wiring:
The In terminal should be connected to battery +ve. The out is to be connected to 12V. COM is connected
to GND.

There is no need to put the following components on the main PCB

Q23 = TIP122
R64 = 2W resistor. Put a jumper instead of this (See the wiring picture below)
C23 = 10uF capacitor
D21 = 12V Zener

Wiring of 3-wire SMPS with the main PCB

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