Wiring Material: 12v

Showing posts with label 12v. Show all posts

Saturday, October 4, 2014

500W low cost 12V to 220V Inverter

Using this circuit you can convert the 12V dc in to the 220V Ac. In this circuit 4047 is use to generate the square wave of 50hz and amplify the current and then amplify the voltage by using the step transformer.

Attention: This Circuit is using high voltage that is lethal. Please take appropriate precautions

How to calculate transformer rating

The basic formula is P=VI and between input output of the transformer we have Power input = Power output

For example if we want a 220W output at 220V then we need 1A at the output. Then at the input we must have at least 18.3V at 12V because: 12V*18.3 = 220v*1

So you have to wind the step up transformer 12v to 220v but input winding must be capable to bear 20A.

Tuesday, September 23, 2014

Automotive 12V to 20V converter for audio amplifier

The limitation of car supply voltage (12V) forces to convert the voltages to higher in order to power audio amplifiers.
In fact the max audio power x speaker (with 4 ohm impedance) using 12V is (Vsupply+ - Vsupply-)^2/(8*impedance) 12^2/32 = 4.5Watts per channel, that is laughable...
For powering correctly an amplifier the best is to use a symmetric supply with a high voltage differential. for example +20 - -20 = 40Volts
in fact
40^2/32 = 50 Watts per channel that is respectable.
This supply is intended for two channels with 50W max each (of course it depends on the amplifier used). Though it can be easily scaled up or the voltages changed to obtain different values.

Overview - How it works
It is a classic push-pull design , taking care to obtain best symmetry (to avoid flux walking). Keep in mind that this circuit will adsorb many amperes (around 10A) so take care to reinforce power tracks with lots of solder and use heavy wires from the battery or the voltage will drop too much at the input.
The transformer must be designed to reduce skin effect, it can be done using several insulated magnet wire single wires soldered together but conducting separately. The regulation is done both by the transformer turn ratio and varying the duty cycle. In my case i used 5+5 , 10+10 turns obtaining a step up ratio of 2 (12->24) and downregulating the voltage to 20 via duty cycle dynamic adjust performed by the PWM controller TL494.
The step-up ratio has to be a little higher to overcome diode losses, winding resistance and so on and input voltage drop due to wire resistance from battery to converter.

Transformer design
The transformer must be of correct size in order to carry the power needed, on the net there are many charts showing the power in function of frequency and core size for a given topology. My transformer size is 33.5 mm lenght, 30.0 height and 13mm width with a cross section area of 1,25cm^2, good for powers around 150W at 50khz.
The windings , especially the primary must be heavy gauged, but instead of using a single wire it is better to use
multiple wires in parallel each insulated from the other except at the ends. This will reduce resistance increase due to skin effect. The primary and secondary windings are centertapped, this means that you have to wind 5 turns, centertap and 5 windings again. The same goes for the secondary, 10 turns, centertap and 10 turns again.
The important thing is that the transformer MUST not have air gaps or the leakage inductance will throw spikes on the switches overheating them and giving a voltage higher than expected by turn ratio prediction, so if your voltage output (at fully duty cycle) is higher than Vin*N2/N1 - Vdrop diode, your transformer has gap (of course permit me saying you that you are BLIND if you miss it), and this is accompanied with a drastical efficiency reduction. Use non-gapped E cores or toroids (ferrite).

Output diodes, capacitors and filter inductor
For rectification i preferred to use shottky diodes since they have low forward voltage drop, and are incredibly fast.
I used the cheap 1N5822, the best alternative for low voltage converters (3A for current capability).
The output capacitors are 4700uF 25V, not very big, since at high frequency the voltage ripple is most due to internal cap ESR fortunately general purpose lytics have enough low esr for a small ripple (some tens of millivolts). Also at high duty cycle they are feed almost with pure DC, giving small ripple. The filter inductor on the secondary centertap furter increases the ripple and helps the regulation in asymmetrical transients

Power switch and driving
I used d2pak 70V 80A 0.004 ohms ultrafets (Fairchind semiconductor), very expensive and hard to find. In principle any fet will work, but the lower the on-resistance, the lower the on-state conduction losses, the lower the heat produced on the fets, the higher efficiency and smaller the heatsinks needed. With this fets i am able to run the fets with small heatsinks and without fan at full rated power (100W) with an efficiency of 82% and perceptible heating and with small heating at 120W (some degrees) (the core starts to saturate and the efficiency is a bit lower, around 75%)
Try to use the lowest resistance mosfet you can put your dirty hand :-) on or the efficiency will be lower than rated and you will need even a small fan. The fet driver i used is the TPS2811P, from Texas instruments, rated for 2A peak and 200ns. Is important that the gate drive is optimized for minimal inductance or the switching losses will be higher and you risk noise coupling from other sources. Personally i think that twisted pair wires (gate and ground/source) are the best to keep the inductance small. Place the gate drive resistor near the Mosfet, not near the IC.

Controller
I used the trusty TL494 PWM controller with frequency set at around 40-60 Khz adjustable with a potentiometer. I also implemented the soft start (to reduce powerup transients). The adjust potentiometer (feedback) must be set to obtain the desired voltage. The output signals is designed with two pull-up resistors on the collector of the PWM chip output transistor pulling them to ground each cycle alternatively. This signal is sent to the dual inverting MOSFET driver (TPS2811P) obtaining the correct waveform.

Power and filtering
How i said before the power tracks must be heavy gauged or you will scarify regulation (since it depends of transformer step up ratio and input voltage) and efficiency too. Dont forget to place a 10A (or 15A) fuse on the input because the car batteries can supply very high currents in case of shorts and this will save you face from a mosfet explosion in case of failture or short, remember to place a fuse also on the battery side to increase the safety (accidental shorts->fire, battery explosion, firemen, police and lawyers around). Input filtering is important, use at least 20000uF 16V in capacitors, a filter inductor would be useful too (heavygauged) but i decided to leave it..

Final considerations
This supply given me up to 85% efficiency (sometimes even 90% at some loads) with an input of 12V because i observed all these tricks to keep it functional and efficient. An o-scope would be useful, to watch the ripple and gate signals (watching for overshoots), but if you follow these guidelines you will avoid these problems.
The cross regulation is good but keep in mind that only the positive output is fully regulated, and the negative only follows it. Place a small load between the negative rail and ground (a 3mm led with a 4.7Kohm resistor) to avoid the negative rail getting lower then -20V. If the load is asymmetric you can have two cases:
-More load on positive rail-> no problems, the negative rail can go lower than -20V, but it is not a real issue for an audio amplifier.
-More load on negative rail-> voltage drop on negative rail (to ground) especially if the load is only on the negative rail.
Fortunately audio amplifiers are quite symmetrical as a load, and the output filter inductor/capacitors helps to maintain the regulation good during asymmetrical transients (Basses)

FOR FIRST TESTING USE A SMALL 12V power supply and use resistors as load monitoring switches heat and current consumption (and output) and try to determine efficiency, if it is higher then 70-75% you are set, it is enough. Adjust the frequency for best compromise between power and switching losses, skin effect and hysteresis losses

Bill Of Materials
=================
Design: 12V to 20V 100W DC-DC conv
Doc. no.: 1
Revision: 3
Author: Jonathan Filippi
Created: 29/04/05
Modified: 18/05/05

Parts
2 R1,R2 = 10
4 R3,R4,R6,R7 = 1k
1 R5 = 22k
1 R8 = 4.7k
1 R9 = 100k
2 C1,C2 = 10000uF
2 C3,C6 = 47u
1 C4 = 10u
3 C5,C7,C14 = 100n
2 C8,C9 = 4700u
1 C12 = 1n
1 C13 = 2.2u
1 U1 = TL494
1 U2 = TPS2811P
2 Q1,Q2 = FDB045AN
4 D1-D4 = 1N5822
1 D5 = 1N4148
1 FU1 = 10A
1 L1 = 10u
1 L2 = FERRITE BEAD
1 RV1 = 2.2k
1 RV2 = 24k
1 T1 = TRAN-3P3S

author: Jonathan Filippi
e-mail: jonathan.filippi@virgilio.it
web site: http://www.cool-science.tk

Monday, September 22, 2014

Automotive 12V to 20V converter for audio amplifier descriptiona and circuit diagram

Circuit diagrams

Bill Of Materials
=================
Design: 12V to 20V 100W DC-DC conv
Doc. no.: 1
Revision: 3
Author: Jonathan Filippi
Created: 29/04/05
Modified: 18/05/05

author: Jonathan Filippi
e-mail: jonathan.filippi@virgilio.it
web site: http://www.cool-science.tk

Sunday, September 21, 2014

500W low cost 12V to 220V inverter

Circuit diagram
author: Ashad Mustufa
e-mail: mustufa66@hotmail.com
web site: http://www.electronics-lab.com

How to calculate transformer rating
The basic formula is P=VI and between input output of the transformer we have Power input = Power output
For example if we want a 220W output at 220V then we need 1A at the output. Then at the input we must have at least 18.3V at 12V because: 12V*18.3 = 220v*1
So you have to wind the step up transformer 12v to 220v but input winding must be capable to bear 20A.

Tuesday, September 16, 2014

12V Powered 12V Lead Acid Battery Charger with Indicator

Some of you might wonder why a charger is needed at all, to charge a 12 Volt battery from a 12 Volt source! Well, firstly the "12 Volt" source will typically vary anywhere from 11 Volt to 15 Volt, and then a battery needs a controlled charge current and voltage, which cannot result from connecting it directly to a voltage source. The charger described here is intended for charging small 12 Volt lead acid batteries, such as the gelled or AGM batteries of capacities between about 2 and 10 Ah, using a cars electrical system as power source, regardless of whether the car engine is running or not. I built this charger many years ago, I think I was still in school back then. On request of a reader of my web site, Im publishing it now, despite being a rather crude schema.

12V

It works, it is uncritical to build, and uses only easy-to-find parts, so it has something in its favor. The downside is mainly the low efficiency: This charger wastes about as much power as it puts into the battery. The charger consists of two stages: The first is a capacitive voltage doubler, which uses a 555 timer IC driving a pair of transistors connected as emitter followers, which in turn drive the voltage doubler proper. The doubler has power resistors built in, which limit the charging current. The second stage is a voltage regulator, using a 7815 regulator IC. Its output is applied to the battery via a diode, which prevents reverse current and also lowers the voltage a bit.

12V

The resulting charge voltage is about 14.4V, which is fine for charging a gelled or AGM battery to full charge, but is too high as a trickle charger, so dont leave this charger permanently connected to a battery. If you would like to do just that, then add a second diode in series with D3! There is a LED connected as a charge indicator. It will light when the charge current is higher than about 150mA. The maximum charge current will be roughly 400mA. There is an auxiliary output, that provides about 20V at no load (depending on input voltage), and comes down as the load increases. I included this for charging 12V, 4Ah NiCd packs, which require just a limited current but not a limited voltage for charging.

12V

Note that if the charge output is short-schemaed, the overcurrent protection of U2 will kick in, but the current is still high enough to damage the diodes, if it lasts. So, dont short the output! If instead you short the auxiliary output, the fuse should blow. I built this charger into a little homemade aluminum sheet enclosure, using dead-bug construction style. Not very tidy, but it works. Note the long leads on the power resistors. They are necessary, because with shorter leads the resistors will unsolder themselves, as they get pretty hot! The transistors and the regulator IC are bolted to the case, which serves as heat sink. The transistors dont heat up very much, but the IC does.

Source by Streampowers

Tuesday, September 2, 2014

12v Light Dark Switch Wiring diagram Schematic

Often, for certain low voltage lighting systems; you would like to turn off the lights during the bright light of the day. Most commercial day/night switches are designed for AC lighting. This hobby schema below was designed for a 12v DC system. But, it could be modified for other voltage as well. It uses an inexpensive photo-transistor as the light detector. An n-channel FET is used to switch power to the lights. A transistor schema is included to provide some hysteresis.

This keeps the schema from fluttering the light during the transition from day to night and night to day. It is recommended that a plastic tube be placed over the transistor to prevent it from being illuminated by the lights it is controlling. By selecting the appropriate power FET, the schema could control over 100 watts worth of 12v lighting. (July 22, 2008)

Source: DiscoverCircuits

Sunday, August 17, 2014

100 Watt Inverter 12V DC to 220V AC

Electronic schematic diagram for 100 Watt Inverter 12V DC to 220V AC.

The IC1 Cd4047 wired as an astable multivibrator produces two 180 degree out of phase 1/50 Hz pulse trains.These pulse trains are are preamplifes by the two TIP122 transistors. The out puts of the TIP 122 transistors are amplified by four 2N 3055 transistors (two transistors for each half cycle) to drive the inverter transformer. The 220V AC will be available at the secondary of the transformer. Nothing complex just the elementary inverter principle and the schema works great for small loads like a few bulbs or fans. If you need just a low cost inverter in the region of 100 W, then this is the best.

Notes:

A 12 V car battery can be used as the 12V source.
Use the POT R1 to set the output frequency to 50Hz.
For the transformer get a 12-0-12 V, 10A step down transformer. But here the 12-0-12 V winding will be the primary and 220V winding will be the secondary.
If you could not get a 10A rated transformer , don’t worry a 5A one will be just enough. But the allowed out put power will be reduced to 60W.
Use a 10 A fuse in series with the battery as shown in schema.
Mount the IC on a IC holder.
Remember, this schema is nothing when compared to advanced PWM inverters.This is a low cost schema meant for low scale applications.

Design Tips:

The maximum allowed output power of an inverter depends on two factors. The maximum current rating of the transformer primary and the current rating of the driving transistors.

For example ,to get a 100 Watt output using 12 V car battery the primary current will be ~8A ,(100/12) because P=VxI. So the primary of transformer must be rated above 8A.

Also here ,each final driver transistors must be rated above 4A. Here two will be conducting parallel in each half cycle, so I=8/2 = 4A .

These are only rough calculations and enough for this schema.