MAKE INVERTER TRANSFORMER

Inverter transformers are just like any other power transformers except that inverter transformers works in the reversed form of the standard transformer.

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Standard step down transformers receives high voltage and small current at the primary winding and produce low voltage with high current at the secondary side. In this case the output is taken from the secondary winding.

On the other hand, Inverter transformers receives high current with low voltage on the secondary windings and produces low current with high voltage at the primary windings. It can therefore be said that, the inverter transformer is a typical step up transformer. The output of an inverter transformer is taken from the primary windings.   

MAKE INVERTER TRANSFORMER

To select copper size for pure sine wave inverter the following steps must be followed. Please know that pure sine wave inverter transformers don't have center tap.

HOW TO SELECT COPPER WIRE SIZE FOR INVERTER TRANSFORMER

EXAMPLE: MAKE 24V 6000W INVERTER TRANSFORMER

1. Calculate maximum DC current to be switched by mosfets [ 6000W ÷ 24V = 250 A.]

2. Now select copper gauge that can handle 250 A of current. From the current chart above, [ 10 guage copper can handle 50 A] so you will need to add 5 together [ 5 x 50 =250] and wind it in the secondary side of the transformer (that is using single transformer core)

Or  you can use 3 of 10 gauge copper [ 3 x 50 = 150 A ] to wind / make the secondary of 2 different transformers and connect those two transformers in parallel.

Please know that you can use any size of copper gauge. The most important thing is to combine or add it until it can handle the current you are looking for.

3. The secondary voltage of the transformer should be between 13V to 16.5V 

(I prefer 13.5V)  

4. The primary copper size should be able to handle your primary current.

You can find that by dividing transformer power power by your primary voltage. 

That is [ 6000W ÷ 220V = 27.27A ]

From the chart above, the right gauge is 12 for a single core transformer.

for parallel transformers you can use 14 gauge for each of the two transformers which will be connected in parallel. 

So  this is all you need to select your wire size.

The next thing is to calculate the number of turns for your selected core which is covered by many posts online. 

SECONDARY VOLTAGE OF PURE SINE WAVE INVERTERS

The secondary voltage of all pure sine wave inverter transformers is always half of the battery system. This is to enable the output of the inverter to be regulated and made stable using high frequency modulated PWM signals.

By making the transformer half of the battery system, The output can stay regulated when load is connected as well as when the battery is draining. It also prevents humming when load is connected.

TYPICAL EXAMPLE OF TRANSFORMERS FOR SOME INVERTER SYSTEMS

12V system uses 6-8V transformer

24V system uses 12-16V transformer 

48V system uses 24V-28V transformer

96V system uses 48V-52V transformer

If there is anything you want me to add as well as questions, kindly write it in the comment section and I will write about it or add it to the post as well as reply you.

Thank you.