600W – 230VAC – High Voltage DC Motor Speed Controller – Heater Controller – Lamp/LED Dimmer

  • Rajkumar Sharma
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This is a very powerful DC Motor speed controller for DC motors up to 330V DC and current up to 2A. Basically, the project is a high voltage PWM source with adjustable frequency and adjustable PWM duty cycle range 0 to 99%.  The board has been designed considering many applications and the circuit can be used as a heater controller, DC Motor speed controller, LED dimmer, Lamp dimmer, and High voltage PWM driver. The circuit can handle load up to 600W (330V DC @ 2A). The operating input supply is 100V AC to 250V AC or 100V to 330V DC. It is important to provide the input supply as per the operating power supply of the load. Trimmer pot PR1 is provided to adjust the frequency, and P1 to adjust the PWM duty cycle.

Connector CN2 is used for AC or DC load voltage supply, F1 Fuse for protection, R1 NTC to control inrush-current, C2 and C6 for EMI noise, C7 and C8 DC Bus filter capacitor for load supply, R12 Current sense resistor for overcurrent protection feedback circuit (CSC), R3 Temperature monitor (NTC) divide resistor for temperature feedback output, C3, C4 logic supply filter capacitors, CN1, R2 pull up resistor for Fault (VFO), SG3525 PWM Generator, Q1 BC847 to inverse the PWM, D1 power LED, U1 5V regulator.

FBA42060 – Intelligent Power Module (IPM)

The project is built using the FBA42060 IPM chip. This IPM chip is made for power factor correction, and consists of an inbuilt bridge rectifier, diode for back-EMF protection for inductive loads, IGBT to drive the loads, and IGBT gate driver and on chip NTC temperature monitor.

Precautions for High Voltage

This project should be installed, adjusted, and assembled by a qualified person familiar with the construction and operation of the project and the lethal voltage involved. Failure to observe this precaution could result in severe injury.

The project can be used in a standalone mode or with a microcontroller interface.

Standalone Mode

Solder all components from PWM block, driver chip block, and regulator LM7805. The circuit requires 15V DC to driver logic supply, and Load supply as per operating supply of load.

  • Logic Supply 15V DC (Connector CN1 Pin1 and Pin 2)
  • Load Supply CN2, 100V – 250V AC or 100V to 330V DC (load Supply will depend on Operating Voltage of Load)
  • Fault Output is available at PIN 4 of CN1, normally this pin is high 5V TTL, goes low when fault condition arrives
  • Frequency Approx. 20 Khz When Trimmer Pot is in Middle (Range 3Khz to 60Khz)
  • Duty Cycle 0 to 99% (Speed Control/Dimmer), P1 Trimmer Potentiometer provided to adjust the duty cycle
  • CN3 to connect the Load
  • LED D1, Power LED
  • PCB Jumper J1 Closed
  • PCB Jumper J2 Open
  • Soft Start Feature active
  • Inbuilt Overcurrent circuit is active

Microcontroller Interface

Do not solder components from PWM blocks, use only drive chip block, use current feedback circuit, if current output required.

  • Logic Supply 15V DC (Connector CN1 Pin 1 and Pin2)
  • CN1 Pin 3 PWM Input Duty Cycle 0 to 100%
  • CN1 Pin 3 VFO, Fault Output, normally this pin is High-5V TTL, goes low when a fault condition occurs
  • CN1 Pin 4 VT – Over temperature feedback, refer to the datasheet of the chip for more information
  • CN1 Pin 5 CO – Current Feedback Optional
  • CN1 Pin 6 – GND
  • CN1 Pin 7- 5V DC Output

Testing and using this project

It is important to use an isolated logic supply of 15V. It is important to take proper precautions to handle and use this project, especially while adjusting the PWM and frequency since lethal high voltage DC is used. Don’t touch the PCB tracks and pads until and unless the DC bus capacitors are fully discharged, high voltage is present for some time even when power is in an OFF state.

The board operates at lethal voltages and has bulk capacitors that store significant charge. Accidental contact can lead to lab equipment damage, personnel injury, and may be fatal. Please be exceptionally careful when probing and handling this board. Always observe normal laboratory precautions.

Schematic

Parts List

NO.QNTY.REF.DESC.MANUFACTURERSUPPLIERSUPPLIER PART NO
11CN18 PIN MALE HEADER PITCH 2.54MMWURTHDIGIKEY732-5321-ND
21CN23 PIN BARRIER BLOCKS PITCH 9.53MMTEDIGIKEYA98482-ND
31CN33 PIN BARRIER BLOCKS PITCH 9.53MMTEDIGIKEYA98482-ND
41C1220uF/25VNICHICONDIGIKEY493-15236-3-ND
52C2,C61K/2KVTDKDIGIKEY445-175512-ND
62C3,C120.1uF/50V SMD SIZE 0805MURATA/YAGEODIGIKEY
71C410uF/25V SMD SIZE 1206 OR 1210MURATA/YAGEODIGIKEY
81C50.33uF/275VX2KEMETDIGIKEY399-11486-ND
91C7680uF/450VNICHICONDIGIKEY493-7535-ND
101C8330uF/450VNICHICONDIGIKEY493-6112-ND
112C9,C10100PF/50V SMD SIZE 0805MURATA/YAGEODIGIKEY
121C1110uF/25V ELECTROLYTICNICHICONDIGIKEY493-17428-3-ND
134R4,R5,R13,C131K 5% SMD SIZE 0805MURATA/YAGEODIGIKEY
145U4,R14,C14,R15,C15DNPDON’T USE
5R16,C16,R17,C17,R18DNPDON’T USE
5R19,R20,R21,R22,R23DNPDON’T USE
151J1OPEN-SOLDER JUMPERPCB JUMPER PCB JUMPER
161J2CLOSED-PCB JUMPERPCB JUMPER
172PR1,P1100K TRIMMER POTENTIOMETERNIDECDIGIKEYCT6EW104-ND
181Q1BC847NEXPERIADIGIKEY1727-2924-2-ND
191R15-OHMS 20MM DIAMETER NTCSEMITECMOUSER954-5D2-18LCS
201R24K7 5% SMD SIZE 0805MURATA/YAGEO
212R3,R710K 5% SMD SIZE 0805MURATA/YAGEO
221R610E 5% SMD SIZE 0805MURATA/YAGEO
231R82.2K 5% SMD SIZE 0805MURATA/YAGEO
241R90E SMD SIZE 0805MURATA/YAGEO
251R1020K 1% SMD SIZE 0805MURATA/YAGEO
261R111.8K 5% SMD SIZE 0805MURATA/YAGEO
271R120.1E/2WOHMITEDIGIKEY12FR100E-ND
281U1LM7805ON SEMIDIGIKEYMC78M05CDTGOS-ND
291U2FBA42060-DON SEMIDIGIKEY1990-FBA42060-ND
301U3SG3525AON SEMIDIGIKEY497-6479-1-ND
311F1FUSE HOLDERWURTHDIGIKEY732-11376-ND
321F1FUSE HOLDER CLIP COVERWURTHDIGIKEY732-11379-ND
331F1GLASS-FUSEWURTHDIGIKEY507-1270-ND

Connections

Block Diagram

 

Gerber View

Photos

Video

FBA42060 Datasheet

FBA42060-D

PCB

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