Rather than a theoretical guide, this article will walk you through a specific hands-on project. You won’t find coding snippets, formulas, or tables here—just a practical narrative of how to build and understand a high-functioning inverter unit using this crucial component, making it ideal for anyone passionate about DIY electronics with a real-world goal.
Understanding the Core of the Project: FCPF20N60S
Before we dive into the build, it’s important to appreciate the component that will be at the heart of the inverter—the FCPF20N60S. Manufactured by ON Semiconductor, this is a 600V, 20A N-channel SuperFET MOSFET. It integrates a fast recovery body diode, enabling better efficiency, especially under high-speed switching conditions. This makes it well-suited for high-frequency applications like inverter systems, switch-mode power supplies, and motor drivers.Our project leverages these capabilities to handle DC-to-AC conversion efficiently, turning a low-voltage DC source into usable AC power—ideal for powering tools, lights, or small appliances in an off-grid or emergency setting.
Project Overview
The goal is to build a 12V DC to 220V AC inverter system using four FCPF20N60S MOSFETs. This system will take power from a 12V lead-acid or lithium-ion battery and output a stable 220V AC waveform using a transformer-based design. While we’re not incorporating a microcontroller or writing any control code, the focus will be on the hardware and signal-driving methodology using analog control.Components and Materials
The primary components of this project include:● Four FCPF20N60S MOSFETs
● 12V DC battery (50Ah or higher recommended)
● Ferrite core high-frequency transformer (custom-wound for this project)
● Oscillator circuit based on a 4047 IC or similar (for generating the switching signals)
● Gate driver transistors and resistors
● Heat sinks and fans for cooling
● Diodes (fast recovery type for protection)
● High-voltage capacitors for filtering
● Copper wires, perfboard or PCB, and insulating hardware
● Multimeter, oscilloscope (optional but recommended), soldering iron, and basic hand tools
Step-by-Step Build Description
1. Setting Up the Power Stage
Begin by constructing the power stage where the FCPF20N60S devices will switch the transformer’s primary winding. Each MOSFET will be mounted on a heat sink because power dissipation and thermal management are key in high-power switching. Make sure the back of each MOSFET is electrically isolated if mounted to a common heat sink, using thermal pads or mica insulators.Arrange the four MOSFETs in a full-bridge topology. This setup allows for alternating current to flow through the transformer’s primary winding, effectively simulating an AC waveform from the 12V DC source.
2. Constructing the Oscillator and Gate Driver Circuit
For driving the MOSFETs, we’ll use a simple analog oscillator like the CD4047 IC, which is a versatile monostable/astable multivibrator. In astable mode, it can provide two outputs 180 degrees out of phase—perfect for driving an H-bridge.The output from the 4047 is not strong enough to drive the MOSFET gates directly, so you’ll use a pair of NPN-PNP transistor drivers (like BC547 and BC557) for each MOSFET. The driver stage boosts the current, ensuring the gates are charged and discharged quickly, which reduces switching losses and improves performance.
Take care with the gate resistors, usually ranging between 10 to 33 ohms, to prevent ringing or overcurrent during switching.
3. Transformer Selection and Wiring
The transformer is a critical component in stepping up the voltage. This project uses a ferrite-core transformer instead of an iron-core one, because ferrites operate more efficiently at high frequencies. You'll need to wind your own transformer or repurpose one from an old UPS or inverter. The primary should be designed for 12V input at high frequency (usually 30–50kHz), while the secondary winding should be capable of delivering around 220V AC after filtering.Use thick copper wire for the primary winding to handle high current, and thinner but well-insulated wire for the high-voltage secondary.
Be cautious with the insulation and spacing of windings—this is not a place to cut corners. Label each winding clearly and secure them with tape or epoxy.
4. Building the Filter and Output Stage
The output from the transformer is a high-frequency square or modified sine wave, which is not ideal for many appliances. To smooth it, install a simple LC filter (inductor and capacitor combination) at the output. This filter helps to eliminate high-frequency spikes and smooth the waveform, making it more appliance-friendly.Use high-voltage polypropylene capacitors and a toroidal core inductor to keep the filter compact and efficient. This also reduces EMI (electromagnetic interference), improving the safety and performance of your system.
Thermal Management and Protection
Even though FCPF20N60S is known for its efficiency, switching losses still generate heat—especially under continuous load. Use aluminum heat sinks with thermal grease, and consider adding a small fan for active cooling. Thermal switches or sensors can be used to shut down the inverter in case of overheating.Also, incorporate fast recovery diodes in reverse-bias across the MOSFETs for transient voltage protection. Fuses or circuit breakers on the input side will prevent major failures in case of a short or overload.
Assembly and Enclosure
Mount everything on a strong non-conductive base. A fiberglass or acrylic sheet works well. Arrange components neatly to avoid signal interference and ensure good airflow. Place the control circuit far from the transformer and power MOSFETs to minimize noise coupling.Use standoffs for mounting the PCB and insulate all high-voltage sections carefully. Once everything is secured and tested, enclose the system in a ventilated metal or plastic box to protect the electronics and users.
Testing and Fine-Tuning
Before connecting any real loads, use a multimeter to check continuity, voltage levels, and shorts. Power up the oscillator circuit alone and confirm the output signals are present and alternating. Then, apply 12V DC to the inverter and observe the waveform at the transformer’s output using an oscilloscope if available.Gradually apply a load (like a 60W bulb) and monitor voltage stability, temperature rise, and MOSFET switching behavior. Increase the load step by step up to 500W, ensuring that nothing is overheating or showing abnormal behavior.
Potential Improvements and Future Expansion
Once the basic inverter is running smoothly, there are several ways to expand or refine the project:● Add a low-voltage disconnect circuit to protect the battery.
● Incorporate an automatic fan controller.
● Use a pure sine wave filter design to further smooth the output.
● Include a display for voltage and current monitoring.
● Upgrade to a microcontroller-based PWM driver for fine-tuned waveforms and better efficiency.
Final Thoughts
Building a high-efficiency inverter using the FCPF20N60S is a deeply satisfying project for any electronics enthusiast. Not only do you learn how power conversion works, but you also get to appreciate the balance between performance, heat management, and safety.This project can serve as a foundation for more advanced energy systems like solar inverters, battery backup systems, or even mobile power units for field use. The key is in understanding and respecting the power involved—both electrical and creative.
So next time the lights go out, imagine flipping on your own handmade inverter. That soft hum and warm glow? All powered by your own hands, and of course, the humble but mighty FCPF20N60S.
US 13533 
GB 11160 
CA 9260 
AU 8287 
IE 5021 
BR 2801 
NZ 1291 
SG 1236 
