DSP 2010 based Compact Domestic Sinewave

UPS /INVERTER
Isolated sensing of Mains
Cycle-Cycle current Limiting
Low cost driver
LED/LCD display
Microcontroller based sinewave UPS/INVERTER with builtin charger
Introduction
This micro-controller based digital sine wave inverter using DSP (Digital Signal Processor) with full bridge
configuration topology MOSFET switches with added features are as follows
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 on the PCB
LED/LCD display: The PCB is designed with provision for LED, 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*1 Or 16*2 LCD will be of scrolling type, showing the
status of the inverter such as battery 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, 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. Once battery attains full charge of set voltage changes over to ups mode
(Care to taken while using this mode as sufficient solar panels are to be provided to the customer)
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.
1. LCD will display Battery voltage
Inverter output voltage
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 :
Mains Input voltage

12V DC - 48V DC
:

230V AC, 50Hz.

Mains input range

0V - 440V, 45Hz-65Hz

AC Output

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

(Inverter)

Highlights
1.

Full bridge configuration based on power MOSFETs

2.

DSP based intelligent control

3.

LCD based display for user-friendly display of parameters and status

4.

Protection against 440V mains input

5.

Protection against reverse polarity

6.

Dynamic short circuit protection with fold-back current limiting.

7.

Protections against all possible errors like battery low, over load, heavy load, short circuit etc.

8.
Early warning for battery low and overload conditions. System continue normally if the error is
corrected.
9.

Cutoff and auto restart with permanent cut after 5 consecutive cutoff.

10.

SMPS type constant current charger with full charge cutoff.

11.

Pure sinewave output resulting in silent operation of motor and fans. Safe to all kind of loads.

12.

Ideal for Mixed load application

13.

Indigenous design with proven technology.

14.

Auto detect of LCD and LED. Can change between LED / LCD while the system is powered.

15.

Protection against accidental output feedback disconnection.

Circuit Description
The circuit is given section by section as it is more convenient to explain.

The schematic above describes the ADC and other signaling section. The IC U7 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:

Pin Number

Functional Description

Reset pin of microcontroller

ADC pin for AC input

ADC pin for AC output

ADC pin for load sensing

ADC pin for switch sensing

ADC pin for Temperature sensing

ADC pin for battery sensing

GND pin

Oscillator pin, Crystal connection goes to this pin

10

Oscillator pin, Crystal connection goes to this pin

11

Buzzer pin

12

Fan control. When this pin become +5V fan switch ON

13

Supply pin +5V

14

Solar Switch

15

Relay Drive

16

Fault Pin for short circuit protection.

17

Pin for LCD / LED control.

18

Pin for LCD / LED control.

19

GND pin

20

Supply pin +5V

21
22

Pin for LCD / LED control.

23
24
25

Drives the MOSFETs. Pin 23, 25 drive the GND side

mosfet and pins 24, 26 drives the upper side MOSFETs

26

27

GND pin

28

Supply pin +5V

These pins are very sensitive. Do not touch these pins or extend wires from them, which can cause
unwanted reset of DSPIC.

ADC section
AC input and output sensing
The AC input and AC output sensing is with the sense module. The resistors R44-R49 and R51-R56
determine the scale-down of the mains voltage. It is recommended to use metal film resistors for these
parts. The module scale down the voltage and give to the dsPIC. It was found that it is better to put a
filtering capacitor of 0.1uF disc from the mains sensing pin to GND. (From pin 2 to Pin 27). This give
better stability for mains sensing. Whenever this capacitor is connected or removed the mains input is to be recalibrated.

Load Sensing
The load sensing is through the current transformer (CT) T1. You can use CT1200 or the equivalent. The shunt
resistor R61 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.
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 R43, R69. The capacitor C31 is used for a
filtering. The values of the resistors is 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 R43 = 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 R43 is:
R43 = 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 7 = 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 C31 across R69 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 R43 is not increased when number of battery = 2 or more. This will make the
voltage at pin 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 or dedicated temperature sensing IC MPC9701. We recommend to use
MCP9701 because non standard NTC cause improper working. The MCP9701 is placed near the heatsink
with it flat surface facing the heatsink so that it can be tightned to the big heatsink. See the figure below

Sensing of Switches
The switches are sensed through one ADC pin itself. This is for saving the controller pins. Resistances
R57, R58, R59 and R70 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 CN4 are:
1.

ON/OFF switch

2.

Automotive battery / Tubular Battery selection switch

3.

UPS / Inverter selection switch.

Also note that if needed we have provided seperate switch for Solar charger / Mains Charger selection .
This switch is connected to the last pin of CN4. If the solar selection is not needed 4 pin connector can be
used for CN4. If 4 pin connector is used the connection is exactly same as the old model dsPIC inverter.

Relay driving
Pin 15 is for relay driving. This is done through Q26 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 11 through a transistor 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 12 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 screwed to the heatsinks, in such a way that air from the fan blow
directly towards the heatsinks. The small heatsinks are aligned in such a way that a
commonly available 3 inch fan can be screwed to the heatsink.
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.

LCD control
The six pins 17, 18, 21 and 22 are used for LCD driving. These pins along with +5V, GND coming to the
connector CN5 which is used to connect the LCD driving PCB. The wiring of LCD is given somewhere in the
following pages of this document.

MOSFET driving signals 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 CN3, resistor R40, diode
D17 and capacitor C26. A 45V winding from the transformer is to be connected to CN4. This winding can
be done with very thing guage wire.

MOSFET driving and short circuit sensing

The circuit shows one side drives of the MOSFETs. The upper and lower drives are shown. The upper and
lower drives of the other side is exactly similar to this. The circuit also shows the current sensing and short
circuit signaling section based on LM393 (U3)

MOSFET drive to the ground side MOSFETs is done with 4 transistors Q24, Q14, Q12 and Q22. Similar
circuit is used to drive the other lower side MOSFETs. Higher side drive is with opto-coupler and its
associated circuit.

Current sensing
High speed sensing of MOSFET current is done with diodes D7, D8, D9, D10 and resistors R22, R23.
Common point of D7 and D8 will have the voltage corresponding to the MOSFET current. This is
compared by the opamp U3 (LM339) and the signal is given to pin 16 of the dsPIC. Note that this is only
for the hazard current sensing of MOSFETs. The load measurement is done with current transformer
CT1200.

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 CN4 are:
1.

ON/OFF switch

2.

Automotive / Tubular battery selection switch

3.

UPS / Inverter selection switch.

One more connection terminal is present in the CN4 which is used for solar charger selection. Note that
solar charger / mains charger selection is not done manually, but automatically by the solar charger circuit.
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.
The Automotive battery / Tubular battery selection 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
per battery. Also note that this depends on the correctness of the resistors R43, R69 connected to pin 7 of
the microcontroller.

Fan controlling
The fan is controlled as per the temperature sensed with the MCP9701. Temperature is sensed and fan
controlling is done in mains as well as inverter mode. 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 get 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 polarity of the transformer connection should be correct. This is
automatically done by the system whenever the inverter is turned on. If the polarity is OK the inverter work
normally. If the polarity is not correct the buzzer beeps continuously. If it happens, switch off the inverter and
reverse the primary connection of the transformer.
In UPS mode the relay fastening voltage is very important for the fast changeover from mains - inverter.
This is connected through 2 pin connector CN3. Without this support there is a risk of computer ree-boot and
rare chance for 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.
If the load is within the overload limit, the output voltage will be maintained at the set value. Even if the
output feedback 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.

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
is essential 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. A heavy
load or short circuit is detected by the dedicated circuit explained in page 10. The short circuit signal from
the IC U3 will trigger a current limiting section in the dsPIC and will immediately limit the voltage.
Compared to our earlier design the present method for short circuit sensing is different. Earlier the short
circuit sensing was done with software. In case of heavy load or short circuit the output will be dropped to
very low level and will be smooth started from there. Now the short circuit protection is done with
hardware + software. In case of a heavy load the output is limited but it is immediately restored when the
load is removed.

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.

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 40A relay used in the PCB is having high current terminals on the top side of 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 CN4 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, automotive /
tubular battery selection switch and UPS/Inverter selection switch. The switches are connected from CN4
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.
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.

Automotive / tubular battery 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.

Complete Wiring Diagram

LCD PCB physical mounting

The LCD driver PCB is mounted at the back side of the 16X1 (or 16X2 or 16X4) LCD in such a way that
the components on the driver PCB is facing the rear side of the LCD PCB. See the photograph below.

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 CN5. The diagram below shows the
connection for LEDs. The ground pin (near to the relay) is considered as Pin 1.
During Setup-Mode the system will be permanently in LCD mode only, because LCD is essential in setup
mode.

LCD display PCB component layout

Wiring with separate Control PCB and Power PCB

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.

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.

Menu driven setup

We have provided a very user friendly menu driven setup procedure. The menu style is as below:
Main Menu
1. Calibrate
2. No Load Set

Sub Menu 1
Do NoLoad test

3. Options

1.1 Bat V
1.2 AC Out

4. Parameters

Sub Menu 3

1.3 Inv Load

5. Discard

3.1 Microswitch

1.4 AC In

6. Done

1.5 Char Amp

3.2 LCD Lines

1.6 Exit

3.3 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.
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 nonvolatile
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
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 across
the MOSFET since the charger is functioning without any full charge cutoff. This can 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 steady 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.

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.

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 3.3 LCD Lines
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
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:
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.
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.

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.

Changes in the PCB for various battery voltages

For PCB (12MOSFET model) 12V Battery:
1.

IC 7812 (U5) is not required. You have to 12 volts circuit

2.

Battery sensing resistor R43 should be 47K

3.
MOSFETs should be minimum 30V or more. The suitable part numbers are: 90NF03, IRL3713,
80NF55, 55NF06 etc. 90NF03 and IRL3713 can be used for 800VA. 80NF55 van be used for 750VA.
55NF06 can be used for 500VA. But if you use 90NF03 / IRL3713 for 500VA you will get better result.
4.
The capacitors C4, C5, C6 and C7 connected across the battery should be 25V or more. Maximum
micro farad available in the size can be used.
For PCB (12MOSFET model) 24V Battery:
1.
IC 7812 (U5) is required. Use bigger heatsink because it is common for 7805 and 7812.
Alternatively Falcons 3 terminal SMPS can be used for 7812 and 7805. There is no need of heatsink.
2.

Battery sensing resistor R43 should be 100K

3.
MOSFETs should be minimum 50V or more. The suitable part numbers are: 80NF55, 55NF06 etc.
80NF55 can be used for 1500VA. 55NF06 can be used for 1000VA.
4.
The capacitors C4, C5, C6 and C7 connected across the battery should be 35V or more. Maximum
micro farad available in the size can be used.

For PCB (24MOSFET model control) 36V Battery:

1.

IC 7812 (U5) is not required. You have to connect 12 volts circuit

2.

Battery sensing resistor R43 should be 150K

For PCB (24MOSFET model control) 48V Battery:

1.

IC 7812 (U5) is not required. You have toconnect 12 volts circuit

2.

Battery sensing resistor R43 should be 220K

For PCB (24MOSFET model) 36V Battery

1.
All 24 MOSFETs should be minimum 75V or more. The suitable part numbers are: 80NF10. You
can go up to 2000VA with this MOSFET.
2.

Diodes D7, D8, D9 and D10 should be 1N4935, 1N4936 or BYV26E.

3.
The capacitors C3, C5, C6, C7, C8 and C9 connected across the battery should be 50V or more.
Maximum micro farad available in the size can be used
.

For PCB (24MOSFET model) 48V Battery

1.1.1. All 24 MOSFETs should be minimum 100V or more. The suitable part numbers are:
80NF10. You can go up to 3000VA with this MOSFET.
1.1.2. Diodes D7, D8, D9 and D10 should be 1N4935, 1N4936 or BYV26E.
1.1.3. The capacitors C3, C5, C6, C7, C8 and C9 connected across the battery should be 100V or
more. Maximum micro farad available in the size can be used

4 Stage Battery Charger

4 Stage Charger
Stage1: This is constant current charger. This stage will be in effect until the battery voltage reach full
charge level.
Stage2: When battery voltage reach the full charge level stage 2 starts. In this stage battery voltage is kept at
the full charge level. Due to this the charging current will slowly come down. When the charging current
comes below 1/4th of the set charging current the 3rd stage starts. If system continue in stage 2 for more than 5
hours then stage 3 is forcefully started.
Stage 3: It is nothing but charger off mode. As a result the battery voltage will start falling. When the
voltage drops below the reconnect level stage 4 starts.
Stage 4: Stage 4 is float charging stage in which the controller give a very low charging current to keep the
battery voltage at the re-connect level itself. System continue in this stage as long as the mains is present.
From any stage the system will restart with stage 1 if mains fail and restore after some time.

1. In Setup Mode there is a new menu for selecting Charger type. You can select 4 Stage Charger or old 2
stage Charger. Under the Options menu a new item named 2-Stage?. If you select Y (Yes) for that
then the charger will be 2-Stage. By default the charger will be 4-Stage.
2. In the Parameter menu there are two new items: Inv Start At and Inv Stop At. These are useful for
automatically starting inverter when solar charger is present. When battery become full with solar
charger it is desirable to switch to inverter mode even when mains is present. When inverter is running
from battery and battery voltage is dropped to certain level the system should come back to mains
mode. The working is as below:
a. Suppose the Inverter Start At level is 14V and Inverter Stop At level is 11V.
b. In solar charger mode (the Charger Active signal from external solar charger is present) when the
battery reach 14V the system will forcefully start inverter even when mains voltage is good. Note
that front panel ON/OFF switch should be in ON position.
c. The inverter will work until the ON/OFF switch is turned off or when the battery voltage drop to
11V. The normal activities like overload / short circuit sensing will be present in this mode also.
d. If you do not need this feature just make the Inverter Start At level to a high level, say 18V.

Transformer details
Copper Wire
Transformer (500VA)
Item

Specification

Core Type

Type 16, Stack 2 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 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

Vendor List
Item

Item available from

MOSFETs and other

electronic components

Cabinet
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@gmail.com

CONTACT PERSON:
NAHAR

SURESH KUMAR NAHAR

Transformer
PCB

Nimishambha Electronics Bangalore

LCD display
CT-1200
5A PCB Mountable.
.

MAHIPAL

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.