Build Instructions

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• 1

  Four DIY Power Electronics Projects – SG3525 Inverters and NCP1653 PFC Circuits

  For the past few years, I've been designing and building power electronics circuits as both a hobby and a learning experience. In this project, I'd like to share four of my favorite designs that have been thoroughly tested and successfully operated.

  The collection includes two inverter designs based on the SG3525 controller and two Power Factor Correction (PFC) circuits based on the NCP1653. Together, they cover everything from a compact portable inverter to a high-power 2.5 kilowatt PFC converter.

  All of the PCB boards shown in this project were manufactured by JLCPCB.
  

• 2

  2.5 Kilowatt Inverter

  The second project is a much larger inverter capable of delivering up to 2.5 kilowatts.

  Instead of using a single transformer, the design employs two transformers together with an H-bridge PWM output stage, allowing the inverter to handle much heavier loads.

  Several protection features are included:

  • Soft start / soft shutdown
  • Input overvoltage protection
  • Input undervoltage protection
  • Over-temperature protection

  The inverter can comfortably power motors, fans, power tools, and many other high-power AC loads.

• 3

  2.5 Kilowatt PFC

  The final project is a high-power 2.5 kilowatt PFC converter.

  It is based on the same NCP1653 controller but uses a totem-pole MOSFET driver to achieve significantly higher output power.

  The control circuit is powered by a separate 15–24 volt auxiliary power supply, while the boost inductor is constructed using two stacked ferrite cores to support the higher current without sacrificing efficiency.

  This design has proven to be very stable during testing and is suitable for demanding high-power applications

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