Continuous Conduction Mode Pre-Converters Module for Power Factor Controller

This is a Phase-Shifted Full-Bridge PWM LM5046 carrier board that contains all of the features necessary to implement a phase-shifted full-bridge topology power converter. All inputs and outputs pins are accessible using the header connector. High efficiency DC-DC converter can be created using LM5046 carrier board + External H-Bridge and Transformer. Refer to the datasheet of LM5046 and schematic to configure the frequency, current feedback, delays, etc.

Project provides 1.2 to 20V DC output with current limiter adjustable to 0-5A. I have tested the circuit with 250mA output without a heat sink. Project is capable to drive 3A continues load and 5A peak, large size heat sink required for full load. The tiny power supply based on low cost OPA548 high-voltage and high-current operational amplifier is ideal for driving a wide variety of loads. The project provides excellent low-level signal accuracy and high-output voltage and current. The circuits operate with single supply 24V DC and logic supply 5V DC. The IC is internally protected against over-temperature condition and current overload. Trimmer potentiometer PR1 sets the output voltages, PR2 helps to set the current limit 0 to 5Amps.

This is an automotive-grade self-oscillation 50% duty cycle half-bridge module built using the AUIR2085S chip from Infineon. The project consists of 2 x N-channel MOSFETs, and the module provides a primary side control solution to enable Half-Bridge DC-bus converters. The module is a self-oscillating half-bridge driver with 50% duty cycle ideally suited for 10V – 15V half-bridge DC-bus converters.   The board is also suitable for push-pull converters. Each channel frequency is equal to f_OSC, which can be set by selecting RT (R2+PR1) & CT-(C7), Dead-time can be controlled through proper selection of C_T range from 50ns to 200ns. Internal soft-start increases the pulse width during power-up and maintains pulse width matching for the high and low outputs throughout the start-up cycle. Typically, the soft-start duty cycle varies beginning from 5-10% ramping up to about 50% over 1000 cycles.  The AUIR2085S initiates a soft start at power up and after every overcurrent condition. Undervoltage lockout prevents operation if V_CC is less than 7.5V.

This is a single-channel, fully-protected, high-side power switch with programmable current-limit. Full diagnostics and high-accuracy current-sense features enable intelligent control of the load. A programmable current-limit function greatly improves the reliability of the whole system. High-accuracy current sensing allows a better real-time monitoring effect and more-accurate diagnostics without further calibration. A current mirror is used to source 1/K of the load current, which is reflected as voltage on the CS pin. K is a constant value across the temperature and supply voltage. The current sensing function operates normally within a wide linear region from 0 to 4 V. The CS pin can also report a fault by pulling up the voltage of the Vs active drain and a source voltage clamp is built in to address switching off the energy of inductive loads, such as relays, solenoids, pumps, motors, and so forth. During the inductive switching-off cycle, both the energy of the power supply (EBAT) and the load (ELOAD) are dissipated on the high-side power switch itself. With the benefits of process technology and excellent IC layout, the TPS1H100BQ-Q1 device can achieve excellent power dissipation capacity. When a fault condition occurs, CS works as a diagnostics report pin. When an open load or short to battery occurs in the on-state, VCS almost equals 0. When the current limit, thermal shutdown/swing, open load, or short to battery in the off-state occurs, the voltage is pulled up to VCS.

Although this power supply design is specific to the Intelligent Power Modules (IPM) VFD drives, high voltage boost converters, high voltage battery chargers, etc, the concept and circuit design may be used for any power supply that requires a high voltage output of up to 800V DC and 4 A. Since it is an unregulated power supply the output will depend on AC input voltage. The circuitry includes a passive EMI filter consisting of elements C8, C9, C4, T1, and L1.  Bridge rectifier D1, R1 for inrush current protection, and a relay RL1 for soft powering up and reducing conduction losses in steady-state. 4 x electrolytic capacitors C2, C3, C6, C7 are used for buffering the rectified DC bus voltage, bleeding resistors R1, and R2 provided to discharge the DC bus capacitor after power off. It is advisable to use a heatsink for the bridge rectifier. Inrush current circuit requires 12-15V DC @ 80mA. Choose appropriate fuse as per current requirement. The relay takes care of the inrush current. It is important to switch ON the 12V-15V DC and 3phase power same time.