Empowering Electronics: Building a 400-Watt High-Power Inverter Circuit with Precision

"DIY Guide: Building a 400 Watt High Power Inverter Circuit: Step-by-Step Instructions, Components, and Efficiency"

Do you want to build your own power converter with a built-in charger? This post includes a simple 400 watt inverter circuit with charger that may be readily built and optimised. Read the entire debate with helpful examples.

Introduction

This article uses circuit schematics to explain a large 400 watt power inverter with built-in charger circuit. A straightforward calculation for evaluating transistor base resistors has also been described.

I've talked about how to build a few nice inverter circuits in some of my past articles, and I'm really delighted by the huge feedback I'm getting from readers. In response to popular demand, I created another intriguing, more powerful circuit of a power inverter with built-in charger.

The current circuit, while similar in operation, is more intriguing and advanced since it includes a built-in battery charger that is totally automatic.

The suggested circuit, as the name implies, will generate a gigantic 400 watts (50 Hz) of power output from a 24 volt truck battery, with an efficiency as high as 78%.

Because it is totally automatic, the unit can be permanently attached to the alternating current mains. As long as the input AC is available, the inverter battery is constantly charged, keeping it in a charged, standby state.
When the battery is fully charged, an internal relay immediately switches the battery into inverter mode, and the linked output load is instantly powered by the inverter.

When the battery voltage falls below the predetermined level, the relay toggles and the battery enters charging mode, and the cycle begins again.

Without further ado, let us dive right into the construction process.
The circuit diagram's parts list
You will need the following components to build the inverter circuit:

Unless otherwise specified, all resistors are 14 watt, CFR 5%.

R1----R6 = To be estimated - See the conclusion of the article for more information.

R7 = 100K (50Hz) and 82K (60Hz).

R8 = 4K7, R9 = 10K, P1 = 10K, C1 = 1000/50V, C2 = 10/50V, C3 = 103, CERAMIC, C4, C5 = 47/50V, R8 = 4K7

T1, 2, 5, and 6 = BDY29, T3, 4 = TIP 127, and T8 = BC547B.

D1-----D6 = 1N 5408, D7, D8 = 1N4007,

SPDT IC1 - N1, N2, N3, N4 = 4093, RELAY = 24 VOLT

INVERTER TRANSFORMER = 20 - 0 - 20 V, 20 AMPS, IC2 = 7812. OUTPUT: 120V (60Hz) OR 230V
(50Hz),
CHARGING TRANSFORMER: 0 - 24V, 5AMPS. MAINS AC INPUT = 120V (60Hz) OR 230V (50Hz)
Circuit Operation
We already know that an inverter is made up of an oscillator that drives the subsequent power transistors, which in turn alternately switch the secondary of a power transformer from zero to the maximum supply voltage, producing a powerful stepped up AC at the transformer's primary output.

The major oscillating component in this circuit is IC 4093. One of its gates, N1, is wired as an oscillator, while the other three, N2, N3, N4, are wired as buffers.

The buffers' oscillating outputs are routed into the bases of the current amplifier transistors T3 and T4. Internally, these are designed as Darlington pairs to boost the current to a reasonable level.

This current is needed to power the output stage, which is comprised of power transistors T1, 2, 5, and 6.

In reaction to the alternating base voltage, these transistors can move the full supply power into the transformer's secondary winding to provide an equivalent level of AC output.

A separate automatic battery charger component is also included in the circuit.
How Do You Build?
The construction portion of this project is rather simple and may be performed in the following steps:

Begin the building process by making the heat sinks. Cut two pieces of aluminium sheet 12 by 5 inches in size with a thickness of 12 cm each.

Bend them into two narrow "C" channels. Drill a pair of TO-3 sized holes in each heat sink; use screws, nuts and spring washers to snugly fit the power transistors T3---T6 over the heat sinks.

You can now proceed with the fabrication of the circuit board using the provided circuit diagram. Insert all of the components, including the relays, and solder their leads together.
Keep transistors T1 and T2 apart from the other components so that you can place the TO-220 kind of heat sinks over them.

Connect the base and emitter of the T3, 4, 5, and 6 to the corresponding places on the circuit board next. As illustrated in the circuit picture, connect the collector of these transistors to the transformer secondary winding with thick gauge copper wires (15 SWG).

Clamp and secure the entire assembly within a well-ventilated, robust metallic cabinet. Using nuts and bolts, secure the fittings completely.
Fit the external switches, power cord, output sockets, battery terminals, fuse, and so on over the cabinet to complete the device.

This brings the construction of this power inverter with built-in charger device to a close.
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