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

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

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.

Schematic

Parts List

Connections

Block Diagram

Gerber View

Photos

Video

FBA42060 Datasheet

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