5V to 2000W DC !! High Power 2000W DC to DC Boost Conveter, DC 5v to 232v DC Converter

 

 

5V to 2000W DC !! High Power 2000W DC to DC Boost Conveter, DC 5v to 232v DC Converter

A simple 9V to 230V, 1000 watt DC-DC boost converter circuit based on IC UC3845 and an IRFP260 MOSFET is presented here. The circuit is very nominal and of practical value. Given its features, the design could be considered versatile. All components have been explained below step by step:

1. Circuit Overview

 The boost converter stores energy in an inductor during the on state of the MOSFET and then transfers this stored energy into a higher voltage capacitor during the off state. The MOSFET switching is controlled by the UC3845 PWM controller, which also senses the feedback in order to modify the switching of the output voltage at 230V.

 2. Component Functions

 IRFP260: 200V  50A N-channel MOSFET for the boost converter that is capable of handling high current and power levels.

UC3845: The UC3845 IC is a PWM controller, for adjusting the duty cycle of the MOSFEt controlling the switching frequency and maintaining stability and protection mechanisms in place.

 **UC3845AN Pin Out**

MUR3060: The MUR3060 diode is a rapid recovery Schottky diode utilized in the rectification phase to enable flow during MOSFET downtime.

 

Toroidal Coil: The toroidal coil, with a 40 uH value functions to store energy when the MOSFET   is, in its phase aiding in regulation and voltage enhancement.

 

Capacitor: Input capacitors 2200uf/35v and Output capacitor 220uf/250-400v, Capacitor with values of 2200µf and 220µf  play a role, in filtering and refining the input and output voltage.

 

Resistor: Different types of resistors, like 100k and 10k ohms play roles in circuits such, as feedback loops and timing controls.

 

Potentiometer (10k): It is utilized for tuning the output voltage level.

Diode: Diode 40007 is commonly used for protection. To provide flyback functionality in circuits.

Here is a list of the components mentioned:

1. MOSFET: IRFP260

2. IC (Controller): UC3845

3. Diode: (MUR3060 )

4. Diode: (1N4007)

5. Inductor: Toroidal Coil 30-60 uH

6. Resistors:

    >100 k Ohm/.25W

    >33 k Ohm/.25W

    >10 k Ohm/.25W

    >560 R/.25W

    >220 R/.5W

    >10 R/.5W

    >0.1 R/2W

    > 4.7 R/2W

7. Capacitors:

   >102J (1 nF) ceramic capacitor

   >103J x 2 (10 nF) disc capacitors

   >2200 uF/35V electrolytic capacitor

   >220 uF / 250V electrolytic capacitor

8.Potentiometer: 10k Ohm pot

This should be all the components needed for your circuit design based on the parts you listed.

***Circuit Diagram 1***

 

At first the DC input ranging from 9 to 14 volts flows into the mosfet (IRFP260) causing it to alternate between, on and, off states quickly.The shaped inductor then stores energy. Boosts the voltage level significantly.

 

PWM Control Explanation: The UC3845 is configured to regulate the switching of the MOSFET by modifying the duty cycle in response, to feedback received from the output voltage.The UC3845 functions, at a switching frequency usually ranging between 50kHz and 100kHz.

 Rectification and Filtering Explanation: The MUR3060 diode ensures that current flows, in the direction when the MOSFET  is turned off and capacitors help to smooth out any high frequency ripples while storing energy to keep an output at 230 volts.

3.Feedback:

The resistors in the feedback loop help keep the voltage regulated just right. There’s a comparison between the feedback and a reference voltage in the UC3845 . This way, it adjusts the PWM signal to keep a steady 230V output.

4. Winding the Toroid:

When winding the toroidal coil, getting the right inductance, which is 30-60 uH, is super important for it to work well. Also, check that the wire gauge can manage the expected current, which can go up to 40A .

***Circuit Diagram 2***

    5. Safety Considerations:

You’re boosting to 230V at high power (1000W), so all parts need to handle those voltages and currents. It’s essential to use proper heat sinks for the IRFP260. Don’t forget good insulation around high-voltage areas . Adding protections against overvoltage, overcurrent, and thermal issues is smart too.

6. Assembly:

First, mount the UC3845, MOSFET, diode, and other passive components on a PCB. Designing that feedback loop carefully is key for stability. Tight coupling of components is required too; this reduces parasitic effects .

By sticking to this design plan, you’ll get a high-efficiency DC-DC boost converter . It can easily take a 9-15V input and turn it into 230V at 1000W power!