150W Inverter

150W Inverter

D/N: WAS-1997EN

Introduction
The Holtek 150W inverter solution, combined with the SPWM dedicated Flash MCU HT45F5V, is able
to convert a DC input of 10.5V~14.5V into a 220V/50Hz or 110V/60Hz AC output. The HT45F5V
includes a multi-channel 12-bit A/D converter and a sine wave PWM generator. Multiple timer modules
are included providing timing, pulse generation and PWM generation functions. The MCU also provides
over voltage protection, over current protection and AC zero-cross detection functions.

Figure 1

Application Areas
Car inverters, energy storage boxes, UPS power supplies.

Solution Features
1. Simplified components: integrated over current protection, over voltage protection and AC
detection circuits.
The HT45F5V integrated over current and over voltage protection circuits can react quickly
to protect the device while reducing the number of required peripheral components. An
internal AC detection circuit is also provided to implement timely feedback and adjustment to
the output waveform.

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2. Multiple protection functions: input under/over voltage protection, over load protection and
output short circuit protection.
This solution has multiple protection functions which can provide real-time detection of the
device operating status in order to protect the device and users. Protection functions include
input under voltage protection, input over voltage protection, over temperature protection,
hardware over current protection, output short circuit protection, over load protection and DC
450V over voltage protection.

Functional Description
Inverters are devices that convert DC inputs into AC outputs. By applying a low voltage DC power
at the input side, a standard sine wave AC power can be obtained from the output side. This inverter
solution can control the soft start time of the output waveform to 3s or 1.5s, and the AC output to
220V/50Hz or 110V/60Hz. Physical pictures of the product are shown in Figure 2 and Figure 3
below.

Figure 2

Figure 3

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Operating Principles
This Holtek inverter solution is mainly composed of the MCU HT45F5V, a push-pull driving circuit,
a high frequency transformer and an H-bridge inverter circuit. The MCU is mainly used to generate
the high frequency pulses which drive the push-pull circuit, generate an SPWM waveform and
fundamental waveform to drive the H-bridge inverter circuit and adjust the output waveform
through the feedback loop.

Hardware Description

Figure 4

The circuit diagram of the whole device is shown in Figure 4. Based on the SPWM area equivalence
principle, the inverter uses the MCU to generate high frequency pulses to drive the push-pull circuit,
and then uses a high frequency step-up transformer to boost a low voltage DC signal into a high
voltage DC signal, which is applied to the upper arm of the inverter H-bridge MOS driver. The
SPWM waveform and fundamental waveform generated by the MCU each control one arm of the
inverter H-bridge. A sine wave AC signal is generated by the MOS transistor turning on and off
and finally a pure sine wave AC output is generated using an LC filter circuit. The AC output is fed
back to the MCU through an AC detection circuit and then the MCU will adjust the output
waveform using PID calculations.

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Figure 5

Figure 6

Figure 5 shows an LDO voltage regulator circuit, where the HT7550 is a low power, high voltage
regulator which supports a maximum input voltage of 30V and an output of 5.0V. The IR2106S
shown in Figure 6 is a high voltage, high speed power MOSFET half-bridge driver with
independent high and low side reference output channels, which are in phase with the inputs. Its
gate drive supply is in a range of 10V~20V. Only one power supply is required and the floating
power supply for the high voltage side is implemented using a bootstrap capacitor.

Figure 7

The LM393 circuit shown in Figure 7 is an over current hardware protection circuit. There are two
comparators in the LM393, which are mainly used for protection under high current conditions.
Combined with software, they can implement short circuit protection, etc. When an over current
condition occurs, OUT1 will output a low level which forces IN2+ to change from high to low.
Therefore, OUT2 will output a low voltage, which through the diode can reduce the SPWM signal
and fundamental wave signal in order to turn off the inverter output to protect the device.

Figure 8

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The AN9 channel shown in Figure 8 is used for input voltage detection. The input voltage after
division is sampled and detected by the MCU via this AN9 channel. An input voltage less than
10.5V is considered to be an under voltage and a voltage greater than 14.5V is considered to be an
over voltage. In both situations the inverter output will be turned off. The OVP circuit is a bus over
voltage protection circuit, which is used to detect the boosted and rectified voltage. If the voltage
is greater than 450V, it is considered to be an over voltage and the inverter output will be turned
off.

Figure 9

Figure 9 shows an NTC temperature detection circuit. A fan will be turned on if the temperature is
higher than 40°C and the inverter output will be turned off if the temperature is higher than 65°C.

Figure 10

Figure 10 shows an output current detection circuit. The output current is detected by the OCP
detection function of the MCU. If the peak value of the output current is greater than 1.414A, the
OCP protection will be triggered to turn off the inverter output.

Layout and Hardware Considerations

Figure 11 and 12 respectively show the front and back sides of the PCB layout.

Figure 11. PCB Layout Front Side

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Figure 12. PCB Layout Back Side

PCB BOM List

Table 1

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Software Description

Main Program

Start

Initialisation

UART
communication

PID calculations

Y
500µs timing? Task_500µs();

Y
2ms timing? Task_2ms();

Y
10ms timing? Task_10ms();

Y
100ms timing?
計時100ms Task_100ms();

Y
1000ms timing? Task_1000ms();

Figure 13

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PID Calculation Subroutine

PID calculations

Sample the A/D value of

the present AC voltage

Record sine wave positions

Record SPWM positions

PID adjustment on
SPWM duty cycle

Update the max. and min.

AC voltage values

Return

Figure 14

500µs Subroutine

Task_500µs();

N
f_PowerOn==1 ?

Y
1.5s
f_SOFTSTART==1 ?
soft start

3s soft start

Soft start N
time finished ?

f_PowerOn=0

Return

Figure 15
As shown in Figure 15, a 500µs subroutine is used to implement a soft start function when the
device is powered on to avoid device damage during power-on.

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2ms Subroutine

Task_2ms();

10ms timing

N
f_PowerOn==0 ?

Peak and valley values of N

output voltage are sampled ?

PID calculations on
peak-to-peak value

Return

Figure 16
As shown in Figure 16, a 2ms subroutine is used to implement 10ms timing and execute PID
calculations on the peak-to-peak value of the output voltage. Two loops are used to adjust the output
waveform.

10ms Subroutine

Task_10ms();

Update related
cofiguration

250ms Y
LED control
time is up ?

100ms, 1000ms timing

Return

Figure 17
A 10ms subroutine shown in Figure 17 is used to determine whether the UART communication
needs to re-copy the relevant initial configuration and then perform LED status control and execute
the 100ms and 1000ms timing.

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100ms Subroutine

Task_100ms();

Temp. sampling

Y N
Over Temp. flag==1 ?

N N
Temp. > 65°C ? Temp. < 55°C ?

Y Y

Turn off output; Clear over temp.

Set over temp. flag to 1 flag to 0

N Temp. > 40°C ? Y

Clear fan turning on Set fan turning on

flag to 0 flag to 1

Input 12V voltage

sampling

Y Turn off
<10.5V or >14.5V ? inverter output

Calculate effective
current, voltage, power

Return

Figure 18
As shown in Figure 18, the 100ms subroutine mainly implements temperature detection and 12V
input voltage detection. When the input voltage is lower than 10.5V or higher than 14.5V, the
inverter output will be turned off.

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1000ms Subroutine

Task_1000ms();

Y
Fan turning on flag==1 ? Turn on fan

Turn off fan

Return

Figure 19
As shown in Figure 19, the 1000ms subroutine is mainly used to turn on/off the fan. The fan is
turned on if the temperature is higher than 40°C and turned off when less than 40°C.

SPWM Interrupt Service Subroutine

SPWM_ISR

Y Y Output fundamental
Is output waveform Transit from positive to
wave negative half
zero crossing ? negative half cycle ?
cycle
N N
Output fundamental wave
Count = 0
positive half cycle

N Output is 60Hz ? Y

Read 50Hz Read 60Hz

sine wave table sine wave table

Output waveform in
N 2/4 or 4/4 cycle ? Y

Y Y
SPWM count < 1/4 cycle ? SPWM count > 0 ?

N N

Look up sine wave Invert positive/negative half cycle flag; Look up sine wave
Output wave enters
table in positive output wave enters 1/4 or 3/4 cycle; table in reverse
2/4 or 4/4 cycle
sequence output waveform is zero crossing sequence

Fill in SPWM duty value;

count + 1

N
Count > 4 ?

Return

Figure 20

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The SPWM interrupt service routine, as shown in Figure 20, is mainly used to reload the SFIFO
register pair which uses a 4-level FIFO structure. Four groups of data storage are allowed each time
and one set of duty cycle data is stored every four sampling periods. When the 4-level FIFO duty
cycle data is read, an interrupt is generated to inform the MCU to write the next four duty cycle
data into the SFIFO register pair. An SPWM table for a 1/4 sine wave cycle has been implemented
in the program. This will be looked up in positive sequence for the 1/4 and 3/4 cycles and in reverse
sequence for the 2/4 and 4/4 cycles.

OCP Interrupt Service Subroutine

OCP_ISR

OCP count + 1

Y
OCP count > 50 ? Turn off output

Return

Figure 21
As shown in Figure 21, it is considered that an over current situation will have occurred when the
OCP count is greater than 50, in which case the inverter output will be turned off.

OVP Interrupt Service Subroutine

OVP_ISR

OVP count + 1

OVP count Y
Turn off output
> 50 ?

Return

Figure 22
As shown above, it is considered that an over voltage situation will have occurred when the OVP
count is greater than 50, in which case the inverter output will be turned off.

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Operating Description
Apply a 12V DC voltage to the input side. After pressing the control switch, a 220V AC voltage
will be output.

Status LED indicator description:

Conditions Red LED Blue LED
Normal Operation Off Always On
Over Temperature Protection On 0.5s, Off 0.5s Always On
Over Current Protection Always On On 0.5s, Off 0.5s
Input Under Voltage Always On On 0.25s, Off 0.25s
Input Over Voltage On 0.5s, Off 0.5s On 0.5s, Off 0.5s
High Voltage Over Voltage Always On Off

Test Data
220V/50Hz output under no-load condition:
Input Voltage (V) Output Voltage (V) Input Power (W) THD (%)
10.6 214 4.88 1.25
11.0 218 5.28 1.21
11.5 220 5.87 1.11
12.0 221 6.36 1.12
12.5 224 7.00 0.99
13.0 226 7.54 0.96
13.5 227 8.24 0.91
14.0 230 8.82 0.88
14.5 231 9.43 0.84
Table 2

110V/60Hz output under no-load condition:

Input Voltage (V) Output Voltage (V) Input Power (W) THD (%)
10.6 106 5.09 1.21
11.0 110 5.50 1.25
11.5 115 5.87 1.27
12.0 120 6.36 1.28
12.5 121 6.88 1.26
13.0 121 7.28 1.26
13.5 121 7.70 1.35
14.0 120 8.12 1.34
14.5 121 8.70 1.38
Table 3

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220V/50Hz output under a 150W load condition:

Input Voltage (V) Output Voltage (V) Output Efficiency (%) THD (%)
11.5 212 89.17 3.85
12.0 215 89.73 3.47
12.5 217 89.85 3.19
13.0 220 89.52 2.98
13.5 221 90.31 2.75
14.0 223 89.88 2.62
14.5 226 89.48 2.58
Table 4

110V/60Hz output under a 150W load condition:

Input Voltage (V) Output Voltage (V) Output Efficiency (%) THD (%)
11.5 121 88.43 4.02
12.0 121 86.38 3.86
12.5 121 87.55 3.64
13.0 121 87.31 3.59
13.5 120 86.31 3.43
14.0 120 86.45 3.41
14.5 114 85.91 3.53
Table 5

Conclusion
This text has introduced a Holtek pure sine wave inverter solution based on the HT45F5V master
control MCU. The HT45F5V is mainly responsible for driving the push-pull circuit to convert a
low voltage DC signal into a high voltage DC signal, generating an SPWM waveform and
fundamental waveform for the H-bridge inverter circuit on/off control and then to adjust the output
waveform in real time using an AC detection circuit.

Reference Material
Reference file: HT45F5V Datasheet.

For more details, refer to the Holtek website: www.holtek.com.

Version and Modification Information

Date Author Issue Modification Information
2024.01.31 黃世宇 V1.10 Update the circuit diagram
2019.09.27 李恩進 V1.00 First Version

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