Thanks to wide input voltage range, the CF-DIC can works with both AC mains voltage. Therefore, measurements for Vin = 230 Vac are presented in the first place. Its behavior with the lower input voltage is shown only if it is significantly different.

 

Table of contents

 

QR Flyback

The following measurements are for no external load connected to any of QR flyback outputs; i.e. it is powering only LED indicator and CF-DIC sections.

 

Fig. 1: Power up VIPer35 DRAIN voltage

 

Fig. 2: AUX secondary output (not rectified)

 

Fig. 3: VIPer35 ZCD input

CF-DIC power on with and without connected load

Observing the CF-DIC's power output voltage when power is applied is used to check if overshoot exists. A small overshoot is intentionally left since the main purpose of this converter is power pre-regulation and connected load cannot see such voltage disturbance. Having a small overshoot could improve output ripple and noise. Power on without load is shown on Fig. 4. With output voltage set to 25 V. Power on with max. current (5 A) and output voltage set to 48 V is shown in Fig. 5.

 

Fig. 4: Power on, Vout = 25 V, no load connected

 

Fig. 5: Power on, Vout = 48 V, resistive load connected, Iout = 5 A

The more demanding scenario is start up when traditional lamp is connected as a load. Its filament, when is cold, has a very low resistance and represents almost a short circuit. The converter has built-in protection against short-circuit (i.e. request to deliver huge current) and it is not tolerated for more then a few hundreds of milliseconds. If connected lamp cannot warm enough during that period, the LM5041B will be shut down and input power recycling is needed for initiate new start of operation.

Such scenario is shown on Fig. 6. for 230 Vac and Fig. 7. for 120 Vac. In both cases the protection acts before connected lamps (four 12 V halogen lamps connected in series) could warm up enough.

Once again, such behavior is intentionally provided, and is not an issue when converter is used as a power pre-regulator.

 

Fig. 6: Power on, Vout = 48 V with halogen lamps connected

 

Fig. 7: Power on, Vin=120 Vac, Vout = 48 V with halogen lamps connected

Power on with shorted output

On Fig. 8. is shown HV buck output on start up with shorted output until the protection is tripped. We can see that shut down comes a little bit earlier then with lamps connected since their initial resistance is slightly higher.

 

Fig. 8: HV buck output on start up with shorted output

Power off

The power off should happen smoothly, without surprisingly high disturbance of the output voltage regardless if the load is connected or not. The Fig. 9. shows output voltage drop with connected bleeder resistor (R70) of 4.7 kΩ and Fig. 10. with resistive 10 Ω load connected.

 

Fig. 9: Power off, Vout = 25 V with bleeder resistor connected (R70)

 

Fig. 10: Power off, Vout = 25 V, Iout = 2.5 A with 10 Ω load connected

Synchronous Rectification Controller

The IR11688 controller incorporates gate voltage regulation function and the gate output shape will vary with connected load. The measurements that follows shown how it looks like for Iout = 1, 2 and 3 A.

 

Fig. 11: IR11688 GATE output for Iout = 1 A

 

Fig. 12: IR11688 GATE output for Iout = 2 A

 

Fig. 13: IR11688 GATE output for Iout = 3 A

An example of voltage across SR MOSFET under load is shown on Fig. 14., and one of IR11688's controller VR input on Fig. 15.

 

Fig. 14: SR MOSFET Vds for Vout = 48 V, Iout = 5 A

 

Fig. 15: SR VD input (filtered with 1 kΩ + 47 pF), Vout = 40 V

Output voltage programming

The CF-DIC's output voltage, when is working as power pre-regulator, is externally programmed with control voltage applied on its U_Ctrl input (pin 4 and 5 on X2 connector). The following two measurements shows how it is responding on 8 Hz square waveform that produce 4 V (Fig. 16.) and 16 V (Fig. 17.) step on the output. In both case 10 Ω load was connected, causing 0.4 A and 1.6 A change in delivered current. The second case is especially demanding with Vin = 230 Vac: because the feedback loop speed is limited, with such sharp change in output voltage and considerable load, it could easily drive CF-DIC into very dangerous zone (HV buck duty will rise considerably in short time) and damage some of the parts. But, thanks to the implemented Active Duty limiter, it can accept safely such programming sequence for prolonged period of time.

 

Fig. 16: Output programming (4 V step) with 10 Ω connected load

 

Fig. 17: Output programming (16 V step) with 10 Ω connected load

Output ripple and noise

It is mentioned in the Introduction section that CF-DIC project is initiated by need to replace “off-the-shelf” AC/DC off-line converter. Therefore it is interesting to find out how its output ripple and noise looks in comparison with e.g. Mean Well LRS-150-48 that was used in the EEZ H24005 power supply. The used methodology for testing ripple and noise is rather simple and limited, but if both converters are tested under equal conditions, measured results can be used at least for relative comparison, i.e. to judge which one is “louder” then the other.

The ordinary Rigol x10 probe with spring ground tip is used to measure voltage output across 15 uF (elco) + 100 nF (MFCC) capacitors connected in parallel as shown on Fig. 18. Input bandwidth is limited to 20 MHz.

Output voltage is set to 48 V and output current to 3 A (Mean Well) and 5 A (CF-DIC). The measured level of output ripple and noise in case of CF-DIC is significantly lower for both Vin = 230 Vac (Fig. 19.) and 120 Vac (Fig. 20.).

 

Fig. 18: Output ripple and noise test points

 

Fig. 19: Output ripple and noise for Vin = 230 Vac

 

Fig. 20: Output ripple and noise for Vin = 120 Vac

 

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Hardcopy of this text is part of the EEZ H24005 complete kit.

 

IMPORTANT NOTICE

 

EEZ H24005 is a completely open source project covered by GPL v3 (http://gplv3.fsf.org) and TAPR v1.0 (http://www.tapr.org/OHL) licenses. Its parts are subject to continuous development and improvements.

 

EEZ H24005 kit is not an end user product. As such it has not undergone any conformance testing and it may not comply with some or all technical or legal requirements that are applicable to finished products including, but without limitation, directives regarding electromagnetic compatibility, recycling (WEEE), FCC, CE, or UL.

By using the kit, the user acknowledges and agrees that any use of assembled EEZ H24005 is solely at the user’s own risk, and that user is solely responsible for compliance with all legal and regulatory requirements in connection with such use.

 

Envox d.o.o. supplies EEZ H24005 kit AS IS, without any warranties, with all faults, at the buyer’s and further users’ sole risk. The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user indemnifies Envox d.o.o. from all claims arising from handling or using any part of the EEZ H24005 neither assembled nor in kit form.

 

All documents, manuals, and information on the EEZ H24005 power supply project official website (please start with document: http://bit.ly/2ua4p7J) and GitHub repository (www.github.com/eez-open) are intended only to assist the reader in the assembly and use of the product. Envox d.o.o. shall not be liable for any loss or damage arising from the use of any information or any error or omission in such information or any incorrect use of the product.

 

Please note that while EEZ H24005 power outputs are of low voltages (below 50 Vdc), they may still pose a threat of personal injury. Further, AC mains power voltages may be involved when assembling and using the EEZ H24005. High voltages can be lethal and in the worst case may lead to electrocution and death. Assembling and using the EEZ H24005 requires an understanding of electronic circuits and basic computer programming skills.

 

If you need assistance, please contact us using Contact us (http://bit.ly/2ptLouB) or post your problem on the EEVblog forum (http://bit.ly/2oG4YFD).

Feel free to open a New issue in GitHub (hardware related: http://bit.ly/2oFRc5P or firmware: http://bit.ly/2sNHwty). Please check first to see if a similar issue already reported.

 

See also CrowdSupply’s Proclamation of users rights: http://bit.ly/2oPaWV4

 

 

 

 

 

 

 

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1. Ethernet cable

Total length

250 (± 5) mm

 

 

Type

4 pairs Ethernet, stranded wire

TME

HELUKAT100-FTP-FP or e.g. cut CA00600.00C01 to size

Farnell

1602385 or e.g. cut 1734894 to size

Connectors

Side A

X8

Side B

X18

Housing type

Receptacle, 0.1”

Housing type

See side A

TME

NSR-08

TME

See side A

Farnell

865667

Farnell

See side A

 

wh01.png

 

 

wh02.png

 

Pin:

Female

Pin

See side A

Pin quantity

8

Pin quantity

7

TME

NDR-T

TME

See side A

Farnell

1022219

Farnell

See side A

 

wh03.png

 

 

wh04.png

 

 

 

Polarising key

Position #3

 

 

TME

NSDR-KEY

 

 

Farnell

512023

 

 

 

wh05.png

 

Wiring

 

Name

Position

Color / description

Position

Color / description

LED link

1

Brown-white

1

Brown-white

LED act

2

Brown

2

Brown

Shield

3

Blue-white

3

Polarising key

RX+

4

Orange-white

4

Orange-white

RX-

5

Orange

5

Orange

TX+

6

Green-white

6

Green-white

TX-

7

Green

7

Green

+3.3V

8

Blue

8

Blue

 

Picture

2. Cooling fan cable

Total length

100 (± 5) mm

 

 

Type

3 wire, already mounted on the cooling fan

Fan:

TME: MB60251V1-G99

 

wh06.png

 

 

 

Connectors

Side A

X6

Side B

N/A

Housing type

Receptacle, 0.1”

Housing type

N/A

TME

MX-6471-031

TME

N/A

Farnell

143127

Farnell

N/A

 

wh07.png

 

 

 

Pin

Female

Pin

N/A

Pin quantity

3

Pin quantity

0

TME

MX-0850-0114

TME

N/A

Farnell

2063734

Farnell

N/A

 

wh08.png

 

 

 

Additional info

Fan is already equipped with cable that has to be cut to size and terminated with connector

 

Wiring

Name

Position

Color / description

12 Vdc

1

Red

GND

2

Black

Sense

3

Yellow

 

Picture

3. AUX temperature sensor cable

Total length

145 (± 5) mm

 

 

Type

Max. 0.35 mm2 singe wire, stranded

TME

E.g. brown: LGY0.35/25-BR (or any other color)

Farnell

E.g. brown: 2425402 (0.22 mm2)

NTC

TME: NTCLE100E3103JB0, Farnell: 1187031

Wire

TME: LGY0.35/25-BR, Farnell: 2425402

Connectors

Side A

X17

Side B

N/A

Housing type

Receptacle 0.1”

Housing type

N/A

TME

MX-6471-021

TME

N/A

Farnell

143126

Farnell

N/A

 

wh09.png

 

 

 

Pin

Female

Pin

N/A

Pin quantity

2

Pin quantity

0

TME

MX-0850-0114

TME

N/A

Farnell

2063734

Farnell

N/A

 

wh10.png

 

 

 

Additional info

The temperature sensor is already equipped with cable that has to be terminated with connector

 

Wiring

Name

Position

Color / description

MCU_VCC

1

Any color

NTC

2

Any color

 

Picture

4. AC switch patch cables

Total length

45 (± 5) mm

 

 

Type

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

Brown: LGY0.75/25-BR, Blue: LGY0.75/25-BL

Farnell

Brown: 2528103, Blue: 2528092

Connectors

Side A

AC output

Side B

AC Switch input

Pin

Female quick disconnect

Pin

See side A

Pin quantity

2

Pin quantity

See side A

TME

BM01148 or ST-003/2

TME

See side A

Farnell

3625424

Farnell

See side A

 

wh11.png

 

 

 

Additional info

Required for Schurter 4304.6090 IEC inlet (C14, 6765, 10A)

 

Wiring1

Name

Position

Color / description

Position

Color / description

Line

1

Brown

1

Brown

 

Wiring2

Name

Position

Color / description

Position

Color / description

Neutral

1

Blue

1

Blue

Picture

 

 

5. Cable set #1

5.1. Section A: Power board (CH2) X1 cable

Length

420 (± 5) mm

 

 

Type

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

Red: LGY0.75/25-RD, Black: LGY0.75/25-BK

Green-Yellow: LGY0.75/25-YL/GR

Farnell

Red: 2528175, Black: 2528082, Green-Yellow: 2528140

Connectors

Side A

Power board X1 (Ch2)

Side B

AC/DC module power output

Housing type

Male, Mini-Fit Jr.

Housing type

Ferrule, single wire

TME

MX-5557-03R2

TME

H0.75/14D/GY

Farnell

9963480

Farnell

841195

 

 

 

wh12.png

 

Pin

Female

Quantity

2

Pin quantity

3

Housing type

Ferrule, twin entry

TME

MX-5556-T3L

TME

H0.75/15D2/GY

Farnell

9732675

Farnell

1121751

 

wh13.png

 

 

wh14.png

 

 

 

Quantity

1

Wiring

Name

Position

Color / description

Position

Color / description

Earth

1

Green-Yellow

N/A

Ferrule, twin entry

Vin-

2

Black

N/A

Ferrule

Vin+

3

Red

N/A

Ferrule

5.2. Section B: AC/DC module Earth

Length

70 (± 1) mm

 

 

Type

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

LGY0.75/25-YL/GR

Farnell

2528140

Connectors

Side A

AC/DC module Earth output

Side B

AC/DC module Earth (in)

Housing type

Use twin entry ferrule, See B side, Section A

Housing type

Ferrule, twin entry

 

 

TME

H0.75/15D2/GY

 

 

Farnell

1121751

 

 

 

wh15.png

 

 

 

Quantity

1

5.3. Section C: Chassis Earth

Length:

170 (± 5) mm

 

 

Type:

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

LGY0.75/25-YL/GR

Farnell

2528140

Connectors

Side A

AC/DC module Earth (in)

Side B

Chassis Earth (bottom plate)

Housing type

Use twin entry ferrule, See B side, Section B

Housing type

Non-insulated, Ring terminal, 3 mm

 

 

TME

BM 91103

 

 

Farnell

7356528

 

 

 

wh16a.png

 

 

 

Quantity

1

5.4. Section D: Arduino Shield Earth

Length:

350 (± 5) mm

 

 

Type:

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

LGY0.75/25-YL/GR

Farnell

2528140

Connectors

Side A

Chassis Earth (bottom plate)

Side B

Arduino Shield Earth input (J3)

Housing type

Use ring terminal, See B side, Section C

Housing type

Female quick disconnect

 

 

TME

BM01148 or ST-003/2

 

 

Farnell

3625424

 

 

 

wh17.png

 

 

 

Quantity

1

6. Cable set #2

6.1. Section A: Power board X1 cable

Length

330 (± 5) mm

 

 

Type

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

Red: LGY0.75/25-RD, Black: LGY0.75/25-BK

Green-Yellow: LGY0.75/25-YL/GR

Farnell

Red: 2528175, Black: 2528082, Green-Yellow: 2528140

Connectors

Side A

Power board X1 (Ch1)

Side B

AC/DC module power output

Housing type

Male, Mini-Fit Jr.

Housing type

Ferrule, single wire

TME

MX-5557-03R2

TME

H0.75/14D/GY

Farnell

9963480

Farnell

841195

 

 

 

wh19.png

 

Pin

Female

Quantity

2

Pin quantity

3

Housing type

Ferrule, twin entry

TME

MX-5556-T3L

TME

H0.75/15D2/GY

Farnell

9732675

Farnell

1121751

 

wh20.png

 

 

wh21.png

 

 

 

Quantity

1

 

Wiring:

 

Name

Position

Color / description

Position

Color / description

Earth

1

Green-Yellow

N/A

Ferrule, twin entry

Vin-

2

Black

N/A

Ferrule

Vin+

3

Red

N/A

Ferrule

6.2. Section B: AC/DC module Earth

Length

165 (± 5) mm

 

 

Type

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

LGY0.75/25-YL/GR

Farnell

2528140

Connectors

Side A

AC/DC power module Earth (in)

Side B

AC inlet Earth

Housing type

Use twin entry ferrule, See B side from Section A

Housing type

Female quick disconnect

 

 

Quantity

1

 

 

TME

BM01148 or ST-003/2

 

 

Farnell

3625424

 

 

 

wh22.png

 

6.3. Section C: AUX PS module Earth

Length

115 (± 5) mm

 

 

Type

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

LGY0.75/25-YL/GR

Farnell

2528140

Connectors

Side A

AC inlet Earth

Side B

AUX PS module (X3)

Housing type

Use Female quick disconnect terminal, See B side, Section B

Housing type

Male, Mini-Fit Jr.

 

 

TME

MX-5557-05R2

 

 

Farnell

9963502

 

 

 

wh23.png

 

 

 

Pin

Female

 

 

Pin quantity

5

 

 

TME

MX-5556-T3L

 

 

Farnell

9732675

 

 

 

wh24.png

 

 

Wiring:

 

Name

Position

Color / description

Position

Color / description

Female quick disconnect

1

Earth

6.4. Section D: Lower AC/DC module power input

Length

200 (± 5) mm

 

 

Type

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

Brown: LGY0.75/25-BR, Blue: LGY0.75/25-BL

Farnell

Brown: 2528103, Blue: 2528092

Connectors

Side A

AUX PS module (X3)

Side B

Lower AC/DC module power input

Housing type

See Side B, Section C

Housing type

Ferrule, twin entry

TME

-

TME

H0.75/15D2/GY

Farnell

-

Farnell

1121751

 

 

 

wh25.png

 

Pin

Female

Quantity

2

Pin quantity

2

 

 

TME

MX-5556-T3L

 

 

Farnell

9732675

 

 

 

wh26.png

 

 

 

 

Wiring:

 

Name

Position

Color / description

Position

Color / description

Neutral

2

Blue

N/A

Ferrule, twin entry

Line

3

Brown

N/A

Ferrule, twin entry

6.5. Section E: Upper AC/DC module power input

Length

75 (± 1) mm

 

 

Type

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

Brown: LGY0.75/25-BR, Blue: LGY0.75/25-BL

Farnell

Brown: 2528103, Blue: 2528092

Connectors

Side A

Lower AC/DC module power input

Side B

Upper AC/DC module power input

Housing type

Use twin entry ferrule, See B side, Section D

Housing type

Ferrule, single wire

 

 

TME

H0.75/14D/GY

 

 

Farnell

1121751

 

 

 

wh27.png

 

 

 

Quantity

2

6.6. Section F: AUX PS module power input

Length

110 (± 5) mm

 

 

Type

0.75 mm2 singe wire, stranded, min. 250 VAC

TME

Brown: LGY0.75/25-BR, Blue: LGY0.75/25-BL

Farnell

Brown: 2528103, Blue: 2528092

Connectors

Side A

AUX PS module (X3)

Side B

Lower AC/DC module power input

Housing type

See Side B, Section C

Housing type

Female quick disconnect

TME

-

TME

BM01148 or ST-003/2

Farnell

-

Farnell

3625424

 

 

 

wh28.png

 

Pin

Female

Quantity

2

Pin quantity

2

 

 

TME

MX-5556-T3L

 

 

Farnell

9732675

 

 

 

wh29.png

 

 

 

 

Wiring:

Name

Position

Color / description

Position

Color / description

Neutral

4

Blue

N/A

Female quick disconnect

Line

5

Brown

N/A

Female quick disconnect

 

7. Pre-assembled cables

7.1. Arduino shield power cable

 

Length

300 mm

 

 

Type

Ribbon cable with IDC connectors; 10x28AWG

TME

FC10300-0

Farnell

N/A

 

Picture

 

Pinout:

 

Name

Position

Description

Gnd

1

Ground

Gnd

2

Ground

PWR_DIRECT

3

Triac control (continuous power)

PWR_SSTART

4

Triac control (soft-start)

FAN_SENSE

5

Tachometer output

FAN_PWM

6

Fan PWM speed control

DOUT2

7

Power relay control

+5V

8

+5 V for Arduino Shield

Gnd

9

Ground

+5V

10

+5 V for Arduino Shield

 

7.2. Arduino USB cable

Length

300 or 500 mm

 

 

Type

USB Micro to 5-pin receptacle cable

TME

N/A

Farnell

N/A

AliExpress

e.g. High Quality 50CM micro usb 5pin male to 1x 5Pin Female 0.1" USB header PCB motherboard cable

 

Pinout:

 

Name

Position

Color

Description

VCC

1

Red

+5 Vdc

D-

2

White

Data -

D+

3

Green

Data +

GND

4

Black

Ground

Shield

5

Black

Shield

 

8. BOM

Type

Part (Farnell)

Part (TME)

Total

 

Receptacle

865667

NSR-08

2

wh30.png

 

Receptacle

143127

MX-6471-031

1

wh31.png

 

Receptacle

143126

MX-6471-021

1

wh32.png

 

Receptacle Mini-Fit Jr.

9963480

MX-5557-03R2

2

wh33.png

 

Receptacle Mini-Fit Jr.

9963502

MX-5557-05R2

1

wh34.png

 

Pin

1022219

NDR-T

15

wh35.png

 

Polarising key

512023

NSDR-KEY

1

wh36.png

 

Pin

2063734

MX-0850-0114

5

wh37.png

 

Pin

9732675

MX-5556-T3L

11

wh38.png

 

Female quick disconnect

3625424

BM01148 or ST-003/2

6

wh39.png

 

Ferrule

841195

H0.75/14D/GY

6

wh40.png

 

Ferrule, twin entry

1121751

H0.75/15D2/GY

5

wh41.png

 

Ring terminal

7356528

BM 91103

1

wh42.png

 

Cat5e cable

1602385

HELUKAT100-FTP-FP

0.25 m

 

0.75 cm2 cable (Brown)

2528103

LGY0.75/25-BR

0.43 m

 

0.75 cm2 cable (Blue)

2528092

LGY0.75/25-BL

0.43 m

 

0.75 cm2 cable (Red)

2528175

LGY0.75/25-RD

0.75 m

 

0.75 cm2 cable (Black)

2528082

LGY0.75/25-BK

0.75 m

 

0.75 cm2 cable (Yellow-Green)

2528140

LGY0.75/25-YL/GR

1.61 m

 

0.35 cm2 cable

2425402

LGY0.35/25-BR

0.29 m

 

12 Vdc cooling fan

MB60251V1-G99

1

wh43.png

 

NTC

1187031

NTCLE100E3103JB0

1

wh44.png

 

IDC ribbon cable

FC10300-0

0.3 m

 

USB Micro cable

Shenzhen Wonderwing Electronics Ltd. or search e.g. Aliexpress

0.5 m

 

 

Files:
Wire harness r5B12 HOT

Wire harness for EEZ H24005 programmable power supply.

License CC BY-SA 4.0 Author This email address is being protected from spambots. You need JavaScript enabled to view it. Website Website Date 2017-04-26 Language  English File Size 829.1 KB Download 764 Download

 

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