Power-Electronics (Page 2)

This is a mains 230V AC voltage indicator and is a LIVE CIRCUIT, so take care. The Resistor has to be a fusible ceramic wire wound and the capacitor 630V AC or higher capacity.

More at my Home Made Circuits.

Mains Voltage LED Indicator

This circuit has been drawn from my memory and i have not tried it out again, just see if it is ok and then try. You should use the fuse of 100mA a slow blow if you want but it is very important. This circuit has to be enclosed in a plastic sealed enclosure to avoid contact.

This is a mains 230V AC load current indicator and is a LIVE CIRCUIT, so take care. The Resistors have to be a fusible ceramic wire wound.

More at Mains Voltage and Power Circuits

Mains Current LED Indicator

This circuit has been drawn from my memory and i have not tried it out again, just see if it is ok and then try. You should use the fuse of 1A a slow blow if you want but it is very important. You can design the shunt R3 and Fuse rating as required by your load.

Note that this circuit is to be put in series with the load like an ammeter. If you put it across the supply like a voltmeter it will fuse out or burn out. This circuit has to be enclosed in a plastic sealed enclosure to avoid contact.

The circuit uses opto-coupler MOC3041 of Motorola and the Triac BTA16-600 of STMicro as a solid state switch or relay. Four Switches boost or buck the mains voltage, keeping output within limits.

Power Electronics Design Methods

It also uses the LM324 quad opamp from National Semiconductor which is low power and single supply. As the MOC3041 switches the Triac at zero crossover there is no inter-winding short of transformer on crossover hopefully, the control circuit is designed in such a way that more than one triac will not be turned on at a time, i would like you to give feedback.

555 multivibrator like power oscillator

This circuit is a design concept, not tested by me and i did it just to explain some ideas.

Solid-State Stabilizer Step up 110V AC

The triac will switch at zero cross over because of MOC3041, hence no problem of an interwinding short, but then control circuit may fail or malfunction, so use fuse as shown . Also a snubber made of a 47E resistor and 0.02uF 630V pl cap in series must be placed across each triac.


Battery and Energy Management

Use heatsinks for all parts that heat, air circulation. Use Presets with series resistor as required so that you can test or calibrate. This Stabilizer should not be used with Inductive loads like motors or solenoids it may be ok for lighting and small electronics. If input voltage is 230V put the two 110V windings in series in proper polarity. BTA16600 is a ST part, metal tab is electrically insulated, 16A and 600V.

All mains wiring and connections should be designed for high voltage and current, They should be isolated visually from control circuits by 10 mm or more.

It can Stabilize Mains voltage to around +/- 10% . It can be used for both 110V AC or 220V AC inputs with modifications. The Output is 220V AC. There is an overload, under voltage and over voltage trip circuit.

Mains Stabilty and Supply Regulation

U2A and U2B are two comparators which controls relays K2 and K3 Respectively. One Boosts the voltage (Step-up) when mains supply is low. The other Bucks the voltage (Step-down) when mains voltage goes beyond a limit.

UPS Power Inverter and DC to AC

U2C and U2D work like a window comparator to trip the unit above and below certain preset limits. This circuit is clubbed with a Mains control relay K1 which can be Turned ON-OFF with two pushbuttons.

Stabilizer Step up 110V AC to 230V AC 500VAThis circuit is a design i did, not tested by me as yet.With some tweaks and modifications it might work.

Put a 0.1uF 1KV pl cap across all relay contacts to avoid sparking. Relay current paths should be large and direct to supply, or when relay operates ground will lift and cause malfunction.All mains wiring and connections should be designed for high voltage and current, They should be isolated visually from control circuits by 10 mm or more. If input voltage is 230V put the two 110V windings in series in proper polarity.

Electric double layer capacitor an eFlywheel

Put one LED with resistor for boost and buck indication if required. Use Presets with series resistor as required so that you can test or calibrate. The 1M dead band or hysteresis resistor can be varied from 330K to 10M as performance demands, this resistor stops oscillation or chattering of relays.

This is an incomplete version of the power supply used for the Alertness Monitor with hourly LED Display. This circuit used a Dual Color LED. Green meant Alert and Red meant No Alert or acknowledge press.

Power Supply with Battery Backup

I can write here only in “Electronic English”. Focus on the tech not grimmer. It may be like Pascal with a touch of Acronyms, codes and circuit axioms.

The top part is a 5V regulator with 0.7 Diode boost, means 5.7 V DC. The battery was floating on this point above the zener Z4, that connection comes from outside. A protection fuse maybe needed in case Zener draws more current. The Zeners were test selected to get above 6V along with the diode.

The second supply is to drive the LED array and Relay. This second battery supply was needed to prevent the RAM from losing data and also the CMOS logic getting reset, when the relay solenoid operates. Even when the Display Now switch is pushed, the current is large and the pulse could reset digital circuit.

The battery was used very less, it worked during the power failures for short duration between mains and generator switching. This circuit is not meant for in situations when battery drains are high.

I will just explain part of this circuit. D9 and D10 provide a low cost -1.4 from -5 V. This is needed to reach near 0.00 for LM317 Min. setting. An LED also can be used with proper bias. Note that there is a Temperature Coefficient in ppm, see The Unusual Diode FAQ. but it may not matter upto 8 bits accuracy.

TIP2955, TIP3055 (NPN), TIP2955 (PNP) Complementary Silicon Power Transistors. It is a Darlington, that means good current gain. See Darlington transistor – Wikipedia. When current in R1 10E goes more than 50mA a voltage of 50mA X 10E = 500mV is applied across Emmiter-Base junction. So lower than 500mV no bias the tap is turned off, 500mV-700mV the tap starts turning on depending on type of transistor. The transistor is like a water Tap. So TIP2955 carries the major current burden thru the load allowing LM317 to do the decision making when to turn-on or off. It is analog control, it is not On-Off but linear-proportional. The LM317 is very cool as the burden is passed off to TIP2955 who will need a heatsink to keep going and deliver the power you want.

WorkBench Dual Power SupplyPut the filter caps appropriately. The Hum-Noise will be filtered. The cap after the regulator should be a small guy. The main filter cap after the Bridge can be as big as your cabinet or budget.

If you build it and wire it without designing a PCB, then make all wiring and connection very sound. The test of this ability you can know easily, If your project stops working after the last screw of the cabinet is tightened, Then we need to improve.

This is dual 555 multivibrator like power oscillator. This is my contraption and conception but couple of decades old. It appears to have errors. It worked but the document fixing after design worked, not done. This can be used to make a small inverter, for powering 230V gadgets of low power. The transformer is used in step-up mode. It may make a sound if the laminations are not of good quality.

This circuit can be modified using 7555 and switching transistors like BD139 driving a Ferrite 100 kHz transformer to build a Fluorescent Lamp of 10W to 20W.

From Schematics of delabs

Fluorescent lamps can be fired and lit at high frequency at relatively lower voltages. Experiment both with frequency and pulse width to get nominal lighting at good efficiency. One of the reasons CFL lamps -230V and emergency lamps 12V fail, is failure of the switching devices. These have to be overrated thrice or more, the switching heat dissipation should not be underestimated, during low/high voltage and keep a aging allowance.

Designing a working circuit is no big deal. But making a batch of reliable and robust power electronics products, which are idiot proof and abuse resistant is a challenge for engineering. Then they will need it at an affordable price too… Checkmate !

This is a SMPS Circuit application very close to the Application Note in the book SGS Motion Control Application Manual. This worked well. Read about SG2525 – SG3525 – PWM SMPS Regulator Chip.

Some Notes Related to the Project

  • In main circuit do not link different grounds.
  • Main circuit can be used both for 110 AC and 230 AC
  • Ferrites are partial conductors use proper insulation before winding.
  • For main transformer TRX2 use split bobbin for good/safe isolation.
  • Epoxy coated toroids have to be further insulated before winding.
  • Line of isolation between primary and secondary circuits should be explicit.
  • Primary components like Q1, Q2 tabs R5, R6 etc can give shock take caution.
  • Each main module is 500W and can be used in parallel for more current.
  • Q1 and Q2 should have appropriate isolated heatsinks TO220 type 50sq cm
  • Schottky diodes D5, D6 should have heatsinks TO220 type 100sq cm.
  • Diodes D5, D6 eg D83004 are TOP3 packages are used 2 in parallel.
  • For 200W and above R2=0.1e 5W in the main circuit fusible ceramic.
  • C10, C11… Add 4.7uF 100v more in parallel to reduce ripple.
  • C13, C14 can be 250V for better safety margin.
  • TRX1 SEC1 and SEC2 dot polarity is anti-phase if same phase danger!!

100kHz Half Bridge Convertor - SG3525
Zoom Image

Magnetics Design

All Transformers Isolation 1kV PRI To SEC / SEC To SEC / PRI,SEC To Core. Use Yellow Mylar Tape Insulation or better for all. Vacuum Impregnate all Magnetics in Epoxy or Varnish. All Power Tracks on PCB reinforce with Copper Braid.

TRX1 Mosfet Drive Transformer

T25.0 MGQ-5L Hitachi – Type Torroid – 100khz Signal

  • PRI1 20 Turns #22 Awg
  • SEC1 9 Turns #22 Awg
  • SEC2 9 Turns #22 Awg

486T250-3C8 Ferroxcube – SEC1 And SEC2 Antiphase

TRX2 Stepdown Invertor Transformer

EC52 Siemens/Hitachi – Can Be ETD/EER Cosmo Ferrites

  • PRI1 22 Turns 2 Layers (44 Turns) – 2* #16 Awg(18 Swg) In Parallel.
  • SEC1 4 Turns Ct Copper Strap 0.01″ * 0.8″ Copper Strap

Coper Strap/Ribbon used, cause Hi-Freq Skin Effects, PRI 2 Wires paralleled for same reason.
EC52-3C8 Ferroxcube Phillips

Trx3 Current Feedback Trx

T25.0 MGQ-5L Hitachi – Type Torroid – 100khz Signal

  • PRI1 1 Turn 4 Amps Max
  • SEC1 20 Turns #22 Awg CT.
  • Ceter Tap 10T-CT-10T

486T250-3C8 Ferroxcube

L1 Series 60A-80A Inductor

Type EC/ETD/EER EC42 Hitachi – Air Gap In Inductor Core Both Sides
100khz Power IF30-3C8 Ferroxcube – 6 Turns 4*#12 AWG In Parallel

4 Wires Of 12 AWG Twisted & Wound For 6 Turns (Use Less AWG For Less I)

TRX5 50hz Transformer Small

  • PRI1 & PRI2 115v
  • SEC1 24V 0.2A
  • JP2 2-3 Short 230V
  • PRI1 & PRI2 In Parallel For 110V
  • JP1 1-2 Short 230V 2-3 Short 110V

TRX4

This is A 10mH Common Mode Filter

The Reference Application on ST Half Bridge Convertor – SG3525

PCB Layout

The PCB of module will be added later, if i locate it. It is small and be designed easily.