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Simple 1/3 phase inverter with PFC

Tatalek 21393 36

TL;DR

  • A compact single-phase-to-3-phase inverter for a about 400 W motor uses the FNA41560 module and delivers 3x 230 V from 230 V AC.
  • The design adds input PFC with an MC33262 boost stage and uses space vector modulation to maximize DC-link utilization.
  • The transistors switch at 5 kHz, the adjustable frequency spans 1 Hz to 80 Hz, and the DC bus sits near 430 V no-load.
  • The inverter runs the motor, and an LC filter of 3x 1.5 mH plus 3x 0.68 uF made the audible noise a bit quieter.
  • The mains-connected, non-isolated supply is potentially life-threatening, and the remaining parts cost about PLN 200, far more than the cheap FNA41560.
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  • #31 20737294
    DJ MHz
    Level 26  
    Posts: 1136
    Help: 36
    Rate: 241
    The control element is very similar to the xns15s93f6 system, which is often popular in cheap frequency converters from a friend of mine. I am about to present such equipment in the article.
    It was with such a system that I noticed strong vibrations of the motors at a lower frequency, maybe a similar phenomenon can be seen in your first video?
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  • #32 20737355
    zdziwiony
    Level 28  
    Posts: 1976
    Help: 64
    Rate: 301
    DJ MHz wrote:
    Control element very similar to the xns15s93f6 system,
    Thanks for the info. I went this route and found the XNS25S12FT 1200V 25A ipm module for a edible price. If I manage to buy it, I will use it for the inverter for the 1f engine.
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  • #33 20772439
    111lisu
    Level 16  
    Posts: 404
    Help: 1
    Rate: 52
    Such a small question how to add support for p33FJ32MC102 to mplab? (v5.3.7)
    And with what to program this cube some usb-asp?
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  • #34 20772785
    Tatalek
    Level 12  
    Posts: 41
    Rate: 342
    You can use PICKIT3 or SNAP to program the dspic33FJ32MC102. The first proposal cheaper the second more expensive.
    Micro controller is selected when setting up the project , or you can change in an existing project by selecting properties
    New project
    Screenshot of the MPLAB X IDE software with a new project creation dialog open.


    In existing project
    Screenshot of MPLAB X IDE software with project properties window open.



    Was that what you wanted ?
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  • #35 20775165
    111lisu
    Level 16  
    Posts: 404
    Help: 1
    Rate: 52
    I have no such dice to choose from

    Screenshot of a configuration window selecting dsPIC33F device.

    And my program looks somehow different
  • #36 20775312
    Tatalek
    Level 12  
    Posts: 41
    Rate: 342
    I installed on my computer MPLAB X IDE v 5.35 to check . In this version of the program you can choose such a microcontroller. Screenshot of MPLAB X IDE version 5.35 with the device selection window displayed.

    In such a situation it is difficult for me to help.
  • #37 20775517
    111lisu
    Level 16  
    Posts: 404
    Help: 1
    Rate: 52
    I already have MPLAB X IDE v6.15, but it ate up a chunk of my disk ;) . I need to add a little more here, maybe because it's Linux:

    Code: text Expand Select all Copy to clipboard
    + Configuration "default" load error: dsPIC33F-GP-MC_DFP 1.2.35 is used in the configuration and it is not installed
Resolution: Click on the below link to resolve the same version of DFP
Resolve DFP for configuration: default 
warning: Configuration "default" builds with "XC16 v1.50", but indicates no toolchain directory.
error: Configuration "default" builds with "XC16 v1.50", but no toolchains of that type are installed.
Errors have occurred while loading one or more configurations.
If a specific error is not shown above, this may happen when you import a project from another computer.
    + You can add language tools in Tools->Options embedded tab.
    + You can change which language tool to use in the project properties dialog.


warning: Configuration "default" builds with "XC16 v1.50", but indicates no toolchain directory.
error: Configuration "default" builds with "XC16 v1.50", but no toolchains of that type are installed.
Errors have occurred while loading one or more configurations.
If a specific error is not shown above, this may happen when you import a project from another computer.
    + You can add language tools in Tools->Options embedded tab.
    + You can change which language tool to use in the project properties dialog.


warning: Configuration "default" builds with "XC16 v1.50", but indicates no toolchain directory.
error: Configuration "default" builds with "XC16 v1.50", but no toolchains of that type are installed.
Errors have occurred while loading one or more configurations.
If a specific error is not shown above, this may happen when you import a project from another computer.
    + You can add language tools in Tools->Options embedded tab.
    + You can change which language tool to use in the project properties dialog.
    .
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Topic summary

✨ The discussion revolves around the design and functionality of a simple 1/3 phase inverter intended for a 400W three-phase motor, powered by a single-phase 230V supply. Users inquire about the inverter's suitability for high-speed applications, such as electrospindles, and discuss the costs associated with components like capacitors and chokes. The author shares insights on the inverter's construction, including the use of the FNA41560 control element and the MC33262 PFC chip. Issues with motor noise and output voltage stability are addressed, with suggestions for capacitor values and circuit modifications. The conversation also touches on the potential for using alternative control elements and the integration of microcontrollers for enhanced functionality.
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FAQ

TL;DR: Inverter converts 230 V single-phase to 3 × 230 V, drives ≈ 400 W loads; parts bill ≈ PLN 200 (€43) [Elektroda, Tatalek, post #18953875] “The inverter has high temperature protection set at 105 °C” [Elektroda, Tatalek, post #18953619] Space-Vector Modulation yields ~15 % higher phase voltage than SPWM [Elektroda, Tatalek, post #18953619]

Why it matters: DIY builders can match commercial 0.4 kW VFD performance while learning modern PFC and SVM techniques.

Quick Facts

• Power stage: FNA41560 IPM, 600 V/15 A IGBT bridge [Elektroda, Tatalek, post #18953619] • Input PFC: Boosts DC bus to 430 V no-load, 400 V @ 400 W [Elektroda, Tatalek, post #18953619] • Output frequency: 1–80 Hz, 0.1 Hz resolution; useful above 5 Hz [Elektroda, Tatalek, post #18953619] • Switching frequency: 5 kHz, 1.2 µs dead-time optimized for IPM [Elektroda, Tatalek, post #18953619] • Protections: 105 °C over-temp, 5 A cycle-by-cycle short, 460 V over-voltage [Elektroda, Tatalek, post #18953619]

What parts drive the cost to PLN 200?

Electrolytic filter capacitors and the PFC choke account for ≈ PLN 70; the remaining PLN 130 covers the IPM, MCU, passives, PCB and connectors [Elektroda, Tatalek, post #18953875]

Which choke is used and was it hand-wound?

A ready-made DTMSS-47/0.22/15-V ferrite choke is used; only three extra turns were added for MC33262 power [Elektroda, Tatalek, post #18953875]

Can I replace MC33262 with cheaper L6562 in the PFC?

Yes, both are average-current boost PFC controllers; component values must be recalculated because L6562 uses different sense/zero-current thresholds [ST, 2018 ‘AN5193’]. Ensure gate-drive rating suits your MOSFET.

Why did the motor buzz at low speed and how was it fixed?

Noise came from a DC component caused by false FLT triggers; adding a 1.5 nF capacitor from FLT to ground eliminated the glitch [Elektroda, Tatalek, post #18956999]

Is the design safe for continuous speed control of an induction motor?

Yes within ratings. It offers U/f compensation above 5 Hz and thermal, over-current and over-voltage protections [Elektroda, Tatalek, post #18953619] Avoid running below 5 Hz for long; cooling airflow is low and torque drops.

How do I start the board without damaging D11?

  1. Solder PFC parts and add two 100 W/230 V bulbs in series across the DC bus.
  2. Power through two NTC6D-15 thermistors to limit inrush.
  3. Verify ≈ 400 V across capacitors before adding the IPM. [Elektroda, Tatalek, post #18953619]

What happens if FLT stays low during programming?

FVO pin pulls low when Vcc < 12 V, lighting the fault LED and disabling PWM. Remove programmer power and apply 15 V to the IPM to clear the fault [Elektroda, Tatalek, post #18953619]

Can this inverter be adapted to FSAM20SM60A modules from air-conditioners?

Yes. FSAM20SM60A uses active-low gate signals; invert the MCU’s PWM outputs in code or with inverters before feeding the module [Elektroda, Tatalek, post #20735214]

Edge-case: what failure can destroy the PFC diode?

Directly connecting the board to mains without inrush limiting can over-stress diode D11 and capacitors, leading to immediate failure [Elektroda, Tatalek, post #18953619]

Which programmer and MPLAB version support dsPIC33FJ32MC102?

Pickit 3 or SNAP program the device. MPLAB X IDE ≥ v5.35 lists the MCU; install XC16 compiler and the dsPIC33F GP/MC Device Pack to resolve DFP errors [Elektroda, Tatalek, post #20775312]

How low can I slow an induction motor?

With constant voltage below 5 Hz, torque falls sharply. Practical minimum speed is about 10 % of nominal while maintaining cooling and avoiding stall [NEMA MG1-2018].

What’s the benefit of SVM over sine PWM here?

SVM raises maximum phase-to-phase voltage from 0.866·Vdc to nearly Vdc, adding ~15 % headroom without higher bus voltage [Elektroda, Tatalek, post #18953619]
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