8

MAIN CIRCUIT NOTES ST_AF_01 INTERNAL CIRCUIT OF DEL400 # IN MAIN CIRCUIT DO NOT LINK DIFFRENT GROUNDS. JP1 BERG 10 1 2 3 4 5 6 7 8 9 10 THIS IS SYMBOL OF EARTH GROUND

500W, 100kHz, half bridge convertor off line.

THIS IS SYMBOL OF SIGNAL GROUND

D

DRV2 104 CD PIN 12 OF U1

# MAIN CIRCUIT CAN BE USED BOTH FOR 110AC AND 230AC # FERRITES ARE PARTIAL CONDUCTORS USE PROPER INSULATION BEFORE WINDING. # FOR MAIN TRANSFORMER TRX2 USE SPLIT BOBBIN FOR GOOD/SAFE ISOLATION. 2 # EPOXY COATED TORROIDS HAVE TO BE FURTHER INSULATED BEFORE WINDING. C1 SD 1 PIN 15 OF U1 +25V VCC # 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 # SCHOTKY DIODES D5, D6 SHOULD HAVE HEATSINKS TO220 TYPE 100SQ CM. 1 # DIODES D5, D6 EG D83004 ARE TOP3 PACKAGES ARE USED 2 IN PARALLEL. R3 4.7E 2 DRV1 2 R1 10E # 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 ANTIPHASE IF SAME PHASE DANGER!! 1

GND

FBK IN

REF IN

R6 1 1K 2

MAGNETICS DESIGN U1 OUTB OUTA OSC VREF SD COMP CSS DISC RT CT 14 11 4 16 10 9 8 7 6 5

USE YELLOW MYLAR TAPE INSULATION OR BETTER FOR ALL

ALL TRANSFORMERS ISOLATION 1kV PRI TO SEC / SEC TO SEC / PRI,SEC TO CORE

PIN 13 OF U1 TRX4 THIS IS C3 1 2 A 10mH COMMON MODE FILTER T25.0 MGQ-5L HITACHI/JINANICA TYPE TORROID 100kHz SIGNAL PRI1 2 47pF CD SEC1 SEC2 20 TURNS #22 AWG SEC1 9 TURNS #22 AWG 9 TURNS #22 AWG 4 TURNS CT COPPER STRAP 0.01" * 0.8" COPPER STARP
B

TRX1 MOSFET DRIVE TRANSFORMER

TRX2 STEPDOWN INVERTOR TRANSFORMER EC52 SIEMENS/HITACHI JINANICA CAN BE ETD/EER COSMO FERRITES/TEXONIC PRI1 22 TURNS 2 LAYERS (44 TURNS) 2* #16 AWG(18 SWG) IN PARALLEL.

3 1 2

SYNC -V +V SG3525

1uF 35V TANT R4 10E C4 1

COPER STRAP/RIBBON USED CAUSE HI-FREQ SKIN EFFECTS, PRI 2 WIRES PARALLED FOR SAME. EC52-3C8 FERROXCUBE PHILLIPS

R2 27K R5 1 2 3.3K 2

VACUUM IMPREGNATE ALL MAGNETICS IN EPOXY C5 1 2 OR VARNISH

486T250-3C8 FERROXCUBE SEC1 AND SEC2 ANTIPHASE

TRX3 CURRENT FEEDBACK TRX L1 SERIES 60A-80A INDUCTOR T25.0 MGQ-5L HITACHI/JINANICA TYPE TORROID TYPE EC/ETD/EER EC42 HITACHI/JINANICA 100kHz SIGNAL PRI1 1 TURN 4 AMPS MAX 20 TURNS #22 AWG CT. 100kHz POWER IF30-3C8 FERROXCUBE CETER TAP 10T-CT-10T 6 TURNS 4*#12AWG IN PARALLEL 486T250-3C8 FERROXCUBE 4 WIRES OF 12AWG TWISTED & WOUND FOR 6 TURNS (USE LESS AWG FOR LESS I) AIR GAP IN INDUCTOR CORE BOTH SIDES

1nF ML PLASTIC C2 1 2 330pF

A

SEC1 ALL POWER TRACKS ON PCB REINFORCE WITH BRAID

R6 USE FOR 5V OUTPUT ONLY POT THIS MODULE IN EPOXY AFTER TESTING. IF R6 NOT USED 'REF IN' PIN 4 OF JP1 TO PROTECT CIRCUIT AND FOR RELAIABILITY SHOULD BE GIVEN EXTERNAL REF. 'FBK IN' PIN 3 OF JP1 CONNECT TO OUTPUT OF SMPS ATTENUATE IF OUTPUT > 10 VOLTS

TRX5 50Hz TRANSFORMER SMALL PRI1 & PRI2 115V SEC1 24V 0.2A JP2 2&3 SHORT 230V

JP1 1-2 SHORT DACT Elektrotech Size B Date:

230V

2-3 SHORT 110V

Document Number DACT0005 Tuesday, August 05, 2003

2

Rev 0 Sheet 1
1

PRI1 & PRI2 IN PARALLEL FOR 110V of 1

8 7 6 5 4 3