TL494 Regulated 1200Watts Power Inverter Circuit with HVDC output

TL494 HVDC regulated Power Inverter Supply

Bill Of Materials for TL494 1200W SMPS for Power Inverter 12-320V DC
DC CONVERTER

Design Title TL494 1200W SMPS for Power Inverter 12-320V DC DC CONVERTER

Author ELECTROBUFF YouTube Channel

Document Number 1.0

Revision 1.0

Design Created Tuesday, 24 August 2021

Design Last Modified Wednesday, 25 August 2021

Total Parts In Design 43

0 Modules

Quantity References Value Stock Code Unit Cost

Sub-totals: Ksh0.00

7 Capacitors

Quantity References Value Stock Code Unit Cost

1 C1 2.2nF CAPACITOR GENERIC NON POLARISED CUSTOM USER DEVICE

1 C2 4700uF 35V CAPACITOR POLARISED ELECTROLYTIC

1 C3 100uF 25V CAPACITOR POLARISED ELECTROLYTIC

2 C4-C5 0.1uF CAPACITOR GENERIC NON POLARISED CUSTOM USER DEVICE

1 C6 2200uF 400V Digikey P13670-ND

1 C7 100nF CAPACITOR GENERIC NON POLARISED CUSTOM USER DEVICE

Sub-totals: Ksh0.00

17 Resistors

Quantity References Value Stock Code Unit Cost

5 R1-R3,R16-R17 10k M10K

2 R4-R5 4.7k M10K

6 R6-R11 39R M10K

2 R12-R13 27R M10K

1 R14 470k M10K

1 R15 2.7k M10K

Sub-totals: Ksh0.00

0 Integrated Circuits

Quantity References Value Stock Code Unit Cost

Sub-totals: Ksh0.00

10 Transistors

Quantity References Value Stock Code Unit Cost

2 Q1,Q3 BD139

2 Q2,Q4 BD140

6 Q5-Q10 IRF3205

Sub-totals: Ksh0.00

6 Diodes

Quantity References Value Stock Code Unit Cost

4 D1-D4 UF5403 DIODE RECTIFIER GENERIC USER DEVICE

2 D5-D6 FR107 DIODE RECTIFIER GENERIC USER DEVICE

Sub-totals: Ksh0.00

3 Miscellaneous

Quantity References Value Stock Code Unit Cost

1 L1 220uH 5A

1 RV1 10k

1 RV2 100k

tl494 1200W smps dc dc converter power inverter supply

The TL494 is an integrated circuit (IC) that serves as a pulse-width modulation (PWM) controller. Developed by Texas Instruments, the TL494 has been widely used in various power supply and motor control applications. It is renowned for its versatility, efficiency, and reliability in generating precise PWM signals. Here are some of its key features and common uses:

Features:

PWM Control:
- The TL494 is primarily designed for PWM control applications, making it suitable for regulating the pulse width of a signal.
- It operates in a voltage mode control, adjusting the duty cycle of the output waveform based on the input voltage.
Voltage Reference:
- The IC incorporates an internal voltage reference, typically 5.1V, providing a stable reference for the PWM circuitry.
Error Amplifier:
- It includes an error amplifier that compares the feedback voltage (representing the output voltage) with a reference voltage. This allows for precise regulation.
Soft-Start Function:
- A soft-start function is integrated to gradually increase the duty cycle during power-up, preventing overshooting and minimizing stress on the components.
Dead-Time Control:
- The TL494 includes provisions for dead-time control, preventing shoot-through in complementary push-pull configurations, which is crucial for high-efficiency power converters.
Shutdown Function:
- It features a shutdown pin that can be used to disable the PWM output, enabling power savings and protection in certain scenarios.
Output Control:
- The IC provides dual outputs (complementary) suitable for driving external power switching transistors.
Wide Operating Voltage Range:
- The TL494 can operate over a wide voltage range, making it adaptable to various power supply configurations.

Common Uses:

Switched Mode Power Supplies (SMPS):
- The TL494 is commonly employed in the design of switch-mode power supplies, including offline AC-DC converters and DC-DC converters. Its precise PWM control allows for efficient power conversion.
Inverters:
- In motor control applications, the TL494 is utilized in the design of inverters for controlling the speed and direction of motors. It facilitates the conversion of DC power to AC power.
Battery Chargers:
- Battery chargers often use the TL494 to implement PWM control for efficient charging and to regulate the output voltage.
Uninterruptible Power Supplies (UPS):
- UPS systems employ the TL494 to regulate and control the charging of batteries, ensuring a stable and reliable power source during outages.
Voltage Regulators:
- The IC can be part of voltage regulation circuits, providing a stable output voltage in various electronic devices.

The TL494 is a versatile PWM controller widely employed in power electronics applications. Its features, such as precise PWM control, soft-start, and dead-time control, make it a popular choice for engineers designing efficient and reliable power supply and motor control systems.

TL494 Current-Mode PWM Controller IC Explained: Pinout, Equivalent, Sample Circuits, Applications, Features

TL494 PWM IC Pinout DIP Package electrobuff.blogspot.com

TL494 Current-Mode PWM Controller

TL494 Pinout

The TL494 IC is a fixed frequency current-mode PWM controller IC with all the functions that are required in the construction of the pulse-width modulation (PWM) control circuit on a single chip.

TL3843 Pinout Configuration

Pin Number	Pin Name	Description
1	1IN+	Noninverting input to error amplifier 1
2	1IN-	Inverting input to error amplifier 1
3	FEEDBACK	Input pin for feedback
4	DTC	Dead-time control comparator input
5	CT	Capacitor terminal used to set the oscillator frequency
6	RT	Resistor terminal used to set the oscillator frequency
7	GND	Ground Pin
8	C1	The collector terminal of BJT output 1
9	E1	The emitter terminal of BJT output 1
10	E2	The emitter terminal of BJT output 2
11	C2	The collector terminal of BJT output 2
12	VCC	Positive Supply
13	OUTPUT CTRL	Selects single-ended/parallel output or push-pull operation
14	REF	The 5-V reference regulator output
15	2IN-	Inverting input to error amplifier 2
16	2IN+	Noninverting input to error amplifier 2

TL494 Specifications & Features

Supply Voltage: 7V to 40V
Number of Outputs: 2 Output
Switching Frequency: 300 kHz
Duty Cycle - Max: 45 %
Output Voltage: 40 V
Output Current: 200 mA
Fall Time: 40 ns
Rise Time: 100 ns
Available in 16-pin PDIP, TSSOP, SOIC and SOP Packages

Equivalent/Substitute for TL494: UC3843, TL3842

Alternatives PWM controller IC: UC2842, SG2524

Where to use the TL494 PWM Controller IC

The TL494 fixed frequency PWM Controller can be used for DC to DC conversion regardless of buck or boost topology. TL494 can be used to provide a constant current by varying the output voltage to the load. This IC feature an output control circuit, a flip flop, a dead time comparator, two different error amplifiers, a 5V reference voltage, an oscillator, and a PWM comparator.

So if you are looking for an IC to produce PWM signals for controlling a power switch based on the current flowing through the circuit, then this IC might be the right choice for you.

How to use TL494 IC

A test circuit from the TL494 datasheet is shown below.

TL494 PWM IC Circuit Application and Pinout electrobuff.blogspot.com

Non inverting pins are connected to the Ref pin while inverting pins are connected to the ground. Test inputs are given to DTC and FEEDBACK pins. External capacitor and resistor are connected to pin 5 & 6 to control the oscillator frequency. The error amplifier compares a sample of the 5-V output to the reference and adjusts the PWM to maintain a constant output current

Applications of TL494

Desktop PCs
Microwave Ovens
Server PSUs
Solar Micro-Inverters
Washing Machines: Low-End and High-End
E-Bikes
Power: Telecom/Server AC/DC Supplies:
Smoke Detectors
Solar Power Inverters

2D-Model of TL494

Dimensions for TL3494 IC is given below. These dimensions are for the PDSO package. If you are using a different package IC, please refer to the TL494 datasheet.