High Voltage DC Power Supply for Intelligent Power Modules

  • Rajkumar Sharma
  • 656
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  • medium
  • Tested

Although this power supply design is specific to the Intelligent Power Modules (IPM), the concepts and circuit design may be used for any power supply that requires high voltage output up to 400V DC and 6 A. It is an unregulated power supply, DC output is dependent on AC input.  The circuitry includes a passive EMI filter consisting of elements C5, C6, C7, C8, C9, C10, T1, and a BR1 25 A/600V rectifier block, R3 NTC for inrush current protection, and a relay RL1 for soft powering up and reducing conduction losses in steady-state operation. 2 x electrolytic capacitors C3, C4 are used for buffering the rectified DC bus voltage. It is advisable to use a heatsink on the bridge rectifier. Inrush current circuit requires 12-15V DC @ 50mA power supply. Choose appropriate fuse as per current requirement.

Safety precautions

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.

Features

  • Nominal Input Voltage 220V-240V AC
  • Output 330V DC (Approx.)
  • Output Current Continued 3A (Maximum 6 A)
  • On Board EMI Filter
  • On Board NTC for inrush Current
  • On Board Relay for soft powering up and reducing Power Losses
  • On Board Fuse for Short Circuit/Over Current Protection
  • Screw Terminals for Easy Connections
  • PCB dimensions: 98.50 x 85.88 mm

Schematic

Parts List

NO.QNTY.REF.DESCMANUFACTURERSUPPLIERSUPPLIER PART NO
11BR1BRIDGE DFB2560 ON SEMIDIGIKEYDFB2560-ND
21CN14 PIN MALE HEADER 2.54MM PITCHWURTHDIGIKEY732-5317-ND
32CN2,CN33 X 2 PIN BARRIER STRIPTE CONNECTIVITYDIGIKEYA113421-ND
41C110uF/25VNICHICONDIGIKEY493-17428-3-ND
51C24.7uF/25VNICHICONDIGIKEY493-11353-3-ND
62C3,C4470uF/450VNICHICONDIGIKEY493-3239-ND
72C5,C60.47uF/275V X 2KEMETDIGIKEY399-12744-ND
84C7,C8,C9,C101KPF/2KVTDKDIGIKEY445-175190-3-ND
92D1,D21N4007SMC DIODEDIGIKEY1655-1N4007FLTR-ND
101F1FUSE HOLDERWURTHDIGIKEY732-11376-ND
111F1FUSE HOLDER CLIP COVERWURTHDIGIKEY732-11379-ND
121F1FUSEWURTHDIGIKEY507-1270-ND
131Q1BC847ALNEXPERIADIGIKEY1727-2924-2-ND
141RL1RelayTE CONNECTIVITYDIGIKEYPB2531-ND
151R110K 5% SMD SIZE 0805MURATA/YAGEODIGIKEY
161R22K2 5% SMD SIZE 0805MURATA/YAGEODIGIKEY
171R3NTC5D/20AMTHERMDIGIKEY570-1268-ND
181R4330K 5% 3WTE CONNECTIVITYDIGIKEYA131571CT-ND
191R5DNPOMIT
201T1TXWURTHDIGIKEY732-1449-ND

Connections



Gerber View

Photos

Video

DFB2560 Datasheet

DFB2505-D

PCB

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