READERS PROJECTS

Sinewave Inverter
with Power Factor Correction
By Michael Kiwanuka (UK)
Power inverters are used to generate AC
powerline voltages like 230 VAC or 115 VAC
in the field, using high capacity 12 V or 24 V
vehicle batteries. They come in a wide vari-
ety of output powers (anything between
15 and 1,000 watts) and quality of the AC
output voltage (anything from abominable
to pure sinewave). Some models even have
output voltage regulation. Few however
combine power factor correction (PFC) with
‘pure-sine-wave-out’, hence a suggested
design appears in this article, along with a
light theoretical background.

Into the circuit

With reference to circuit diagram in Fig-
ure 1, IC2 and crystal Q1 form a 4.096 MHz
high frequency clock. The Type CD4060
14-stage binary divider together with IC3,
a Type CD4017 Johnson counter, scale down from the notch by IC6.D. tors C11 and C25 are connected across the
the basic clock frequency to a 50 Hz square IC13 and associated components is a com- secondary of the transformer to filter out
wave. For 60 Hz output, the quartz crystal parator which compares a DC signal with the high switching frequency. Note that we
frequency has to be changed accordingly. the output of the comparator to give a call the 9-V winding ‘the primary’ and the
The clock signal is then processed by IC5 pulsewidth modulated signal which in 230-V (115-V) winding ‘the secondary’ and
and IC6.A which with their associated net- turn drives IC14, a Type IR2104 half bridge not the other way around as is customary
works that together form a soft start unit. driver. The half bridge proper consists of with AC power transformers.
IC6.B with its twin-T filter network selects power FETs T2–T3 and T4–T5, the latter The secondary’s inductance of the trans-
the 50 Hz (or 60 Hz) fundamental fre- being optional for higher output powers former doubles as a power factor correction
quency which by Fourier analysis is a pure when required. (PFC) element when driving energy saving
sine wave. The half bridge topology drives the primary lamps, which tend to have a leading power
The next component in the chain, IC6.C, of a 9 V 16 A power transformer to give a factor (see inset).
acts as Schmitt trigger transforming the 230 V (or 115 V) rms output voltage with a In terms of additional components seen in
basic high frequency unipolar signal into a rated power of 100 VA. A 100 μH inductor the circuit, IC16 is used as a level detecting
symmetrical square wave signal. This is inte- (Bourns 23000L; for vertical mounting) is network for the batteries. IC17A, IC17B and
grated and mixed with the 50 Hz sine wave inserted in series with the primary. Capaci- FETs T6-T7 form a battery charger with an

Power factor correction and the Osram lamp

The power factor of a typical Osram energy saving lamp is 0.6 ca- Hence Qa (amount to be corrected) = 17.9 VA leading
pacitive (i.e. leading). For a 21-watt lamp, the I/P power S1 = 21/0.6 Now, for the transformer’s secondary inductance,
= 35 W. The ‘VA’ value Q1 can be calculated vectorially as:
Ls = V2 / (2p × 50 × 17.9) = 9.45 H
From measurements, Lp = 12.32 mH.
Q1 = √(352 – 212) = 28 VA
Let the power factor = 0.9 after correction, then
Ls = n2Lp = 9.49 H, for n of 28 as deduced from knowledge of the
S2 = 21 / 0.9 = 23.3 VA number of turns on the transformer. Hence the inverter transformer
Q2 = √(23.32 – 212) = 10.1 VA provides a PF correction of 0.9.

Note. Readers’ Projects are reproduced based on information supplied by the author(s) only.
The use of Elektor style schematics and other illustrations in this article does not imply the project having passed Elektor Labs for replication to verify claimed operation.

68 10-2011 elektor
 READERS PROJECTS

100 watts, 24 VDC to 230 VAC rms

pure sine wave out
IRF3700
T6

R42

R43 R35 IC17 = LT1211

1k
C16

1k
8

100R
R38
2u2 3
1k
1
IC17.A
2 SP+
+5V
T7
5
7 SP–
C4 C15 R7 C13 R36 IC17.B
D2 6
1R 2N7000
2x 4
1k

100n 100n 100n R48

BZX84C13 R37
16 16 16
D3

500R
1k
VDD VDD VDD
3 12 X0 R8 R6
CTR14 7 0 14
3 2 13 X 100k 100k
CTRDIV10/ 1 X1
5
R1 IC2 4 DEC 4 2 Y0 IC5 R24
4 2 15 3
1k 5 7 1 Y 100k R4
!G Y1
R2 10 6 IC3 3 1 5
RX 6 10 5 Z0 R27 IC6.A 9k1 R12 C3
9 14 4 4 2 7
CX 7 Z 3k3 IC6.B 10k
10M

14 1 3
Q1 11 + CT 13 & + 5 Z1
6
RCX 8 5 10u
15 6 4053N
9 13 6 6 C8 C9
1 7 INH
11 9 11
4.096MHz 8 A
12
12
2 4017N
CT=0 11 10 R11 100n R13 100n
3 9 B
4060N 13 15 12 9 33k 33k
CT=0 CT 5 C
VSS VSS R26 VEE VSS R5 R14 R10 R9
C5 C12 C14
8 8 7 8
15k
150R
100k
1k

5R
10p 10u 150n

R3
4R7
10W
+12V S2.A
C
A
R111 +15V
T2 B
180k

B1+
+5V D9 CA
R41 C25
C29 +5V +12V 1N914 4R7 BT1
R15 R30 1N
+5V R22 T3 C11 680n
100n D1 C30 IRF2804 4007 12V
R20 220k
1k

1k

R45 R40
R16 27k C27 +5V 1 8 1u
1u 4R7
8 VCC VB 7
2k

HO TR1
100R

9 230V
R21 C26 R18 10n V+
IC14 IRF2804
8 13 2 L1 B1–
R19 IC6.C 4k7 1k5 R47 IN+ IC13 7 2 6
10 14 3 OUT IN VS
1k 1u IC6.D 4k7 IN– 100uH 9V E
12 LT1011 5 IR2104 IRF2804 16A
D7 R23 R17 BAL 3 5 D
C10 1 6 SD LO B2+
GND BAL/STRB COM R55
T1
470R
7k5

S2.B
V- 4 4R7 R33 F
100n BT2
2V7 4 IRF2804
T5
1k

D10 CB 12V
C28 2N3904 R56
R44 R25 D4
4R7
+15V 100n 1N
180k
7k5

C7 4007
T4
B2–
100n 4
IC6 IC6 = LT1212N –15V
C6 11

100n
–15V +5V +12V IC12 +10V +15V +12V
R53
R58 LM317L
7 8
+5V IC15 = 4093 7 C1+ +VOUT
1M4

C2
330k

R28 C21
V+ ADJ IC11 IC1
IC15.C 3 S1 IC15.A IC15.B 1u 1
IC16
240R

8 IN+ 8 2 5 C1-
1u 78L05 +5V
10 4 OUT 3 4 6
9 & IN– 1 & 6 & VIN
LTC1440 2 C22
5 C20 C2+
C33 14 R39 HYST R57 R29
IC15.D 6 C34 C23 C24 LT1026 C1
IC15 12 REF 1u
1u 3 4
240R

C2- -VOUT
4k7

11
100k

V– GND
100n 7 13 & 1u GND
2 1 1u 100n 1u
5
–15V
100677 - 11

Figure 1. The circuit diagram of the power inverter is rather elaborate due to the use of standard integrated circuits and transistors (from
Farnell) rather than dedicated converter ICs.

elektor 10-2011 69
READERS PROJECTS

The output filter

The output filter is
configured to pass a band (ω M )2
R1 X22 − X2 + R22 = 0
of frequencies beyond X12
(R)
R2 which the signal is greatly
L1 (R) C1 attenuated. This may be (ω M )2 1 (ω 2 M 2 )2
X2 = ± 2 − 4 R22
L L2 C achieved by connecting 2 X1 X12
(L) a capacitor across the
secondary winding as shown
But X1 = X2(N1/N2)2 and remembering the expression for Q as well as
in the circuit diagram.
noting L1/L2 = (N1/N2)2, we have (for Q>>1):
It can be shown that the
X2 = k 2 R2 Q
input impedance looking into the primary terminals is given by:

Z1 = R1 + jX1 + Z 2 For the transformation from series to parallel we have

R2 = Rp/Q2, where Rp is the resistance in the primary and R2 that in
(ω M )2 R2 (ω M )2 X 2 the secondary.
Z1 = R1 + jX1 + − j
R22 + X22 R22 + X22 Either X2 = 0,

With the secondary resonating at wo we have Rp k 2

or X2 =
Q
(ω M )2
Z1 = R1 = jX1 + 0
R2
or X2 = k R2Q
2
Thus just above wo, Ipr is proportional to 1/w.
Now consider w considerably higher than wo
Thus at a second transition, substituting X2 and noting that the im-
X1 − (ω M )2 X22 (ω M )2 R2
Z1 = R1 + j + 2 aginary part is zero
R2 + X2 R2 + X 2
(ω M )2
At a second resonance Z1 = R1 +
R2 × (1 + k 4Q 2 )
(ω M )2 X2
X1 − =0 Therefore Ipr is roughly proportional to 1/w2 for w >> wo, which is very
R22 + X 2
desirable.

output voltage of 25–26 V. IC11 and IC12 Practical matters along with tooling data for a Type KOH10-
form a ±15 V symmetrical supply for the The introductory photo shows an early pro- KOR2-160-ME-SL enclosure from Fischer
operational amplifiers, and IC1 is a stand- totype of the inverter, which is being devel- Elektronik (UK distributor: Dau Components
ard 5 V regulator for the logic. Schmitt trig- oped further aiming to go into actual pro- Ltd.). PCB tracks carrying high current (refer
ger gates IC15A and IC15B form a power on duction. The power FETs in the bridge are to circuit diagram) should be strength-
reset (POR). Capacitors CA and CB are ‘off secured to a Type SFP100 heatsink which ened by soldering 1.5 mm2 c.s.a. (approx.
board’ parts because of their size — their acts as the top side of the case. Two nuts 16 AWG) massive copper wire along their
value has to be established experimentally. on the side panel secure the large electro- paths.
The prototype of the inverter worked best lytics CA and CB, which are electrically iso- (100677)
using two Evox/Rifa 22,000 μF, 25 V electro- lated using special materials the author is
lytic, aluminium can capacitors with stud/ willing to share. Internet Link
nut mounting. [1] www.elektor.com/100677 (PCB design
The thicker lines in the circuit diagram indi- A circuit board was designed by the author and case drilling data)
cate PCB tracks, pads and connectors suit- and the artwork files (silk screen and cop-
able for carrying DC currents up to 32 A. per track) may be downloaded from [1],

70 10-2011 elektor