Phase-Shifted Full-Bridge PWM Controller Module – LM5046 Breakout Board

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 compact module shown here is a Continuous Conduction Mode (CCM) Power Factor Correction Step up Pre-Converter. All-important inputs and output pins are broken out for use in your application, making this board hackable! Please refer to the datasheet of the NCP1654 chip for easy alteration and configuration of the board as per requirements. This board controls the power switch conduction time (PWM) in fixed frequency mode and is dependent on the instantaneous coil current. This module drastically simplifies the PFC implementation scheme. It also integrates high safety features that make the NCP1654 module ideal for robust and compact PFC stages like an effective input power runaway clamping circuit. Please refer to the application schematic to create a powerful PFC using this pre-driver module. The chip is available with various options for frequency such as 65Khz, 133Khz, and 200Khz. Choose the appropriate chip as per frequency requirement This project is tested with a 65Khz oscillator chip.

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.