FLYBACK CONVERTER TRAINER

Table of contents

1. Introduction 2. Technical Specifications 3. Front Panel Controls 4. Operating Instructions 5. Warranty

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INTRODUCTION
DC-DC converters are electronic devices used whenever we want to change DC electrical power efficiently fromone voltage level to another. They.re needed because unlikeAC, DC can.t simply be stepped up or down using atransformer. In many ways, a DC-DC converter is the DCequivalent of a transformer. Typical applications of DC-DC converters are where 24V DC from a truck battery must be stepped down to 12V DCto operate a car radio, CB transceiver or mobile phone;where 12V DC from a car battery must be stepped down to 3V DC, to run a personal CD player; where 5V DC on apersonal computer motherboard must be stepped down to 3V, 2V or less for one of the latest CPU chips; where the 340V DC obtained by rectifying 240V AC power must bestepped down to 5V, 12V and other DC voltages as part of a PC power supply; where 1.5V from a single cell must be stepped up to 5V or more, to operate electronic circuitry; where 6V or 9V DC must be stepped up to 500V DC or more, to provide an insulation testing voltage; where 12V DC must be stepped up to +/-40V or so, to run a car hifi amplifier.s circuitry; or where 12V DC must be stepped up to 650V DC or so, as part of a DC-AC sinewave inverter. In all of these applications, we want to change the DC energy from one voltage level to another, while wasting as little as possible in the process. In other words, we want to perform the conversion with the highest possible efficiency. An important point to remember about all DCDC converters is that like a transformer, they essentially just change the input energy into a different impedance level. So whatever the output voltage level, the output power all comes from the input; there.s no energy manufactured inside the converter. Quite the contrary, in fact . some is inevitably used up by the converter circuitry and components, in doing their job. We can therefore represent the basic power flow in a converter with this equation: Pin = Pout + Plosses where Pin is the power fed into the converter, Pout is the output power and Plosses is the power wasted inside the Conceptually, switching regulators are not difficult to understand. When viewed as a blackbox with input and output terminals, the behavior of a switching regulator is identical to that of a linear regulator. The fundamental difference is that a linear regulator regulates a continuous flow of current from the input to the load in order to maintain a constant load voltage. The switching regulator regulates this same current flow by chopping up the input voltage and controlling the average current by means of the duty cycle. When a higher load current is required by the load, the percentage of on-time is increased to accommodate the change. Two basic types of switching regulators constitute the foundation of all of the pulsewidthmodulated (PWM) switching regulators. These types are the forward-mode regulators and the flyback-mode regulators. The name of each type is derived from the way the magnetic elements are used within the regulator. Although they may resemble each other schematically, they operate in quite different fashions.

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TECHNICAL SPECIFICATIONS

FLYBACK CONVERTER TRAINER

INPUT OUTPUT : 24V TO 36V DC OR AC : 5V DC

USING TL494 PWM CONTROLLER IC SWITCHING FREQUENECY :100KHZ

Build in input voltage source to study the input line varriations Bulid in varriable output loading arrangement

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Front panel controls

Power

: Toggle switch selects instrument switch on.

Output Load : Selectable fixed resistors in five steps. Output reference points. 1. input voltage measurement terminals. 2. Terminal at flyback transformer to observe switching pulses. 3. Ref voltage output terminal from IC TL494. 4. Oscillator ouput terminal from IC TL494. 5. PWM Gate drive signal from ic terminal.

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FLYBACK CONVERTER TRAINER

Operating instructions
1. Connect the input voltage source (BUILD IN) circuit and also to voltmeter. 2. Connect the output of RECTIFIER to flyback transformer terminal. 3. Connect the output of the converter to output voltmeter T o study the input line voltage regulation. Plot the graph input line voltage vs output voltage. Set the input line voltage to the trainer from variac such that say 200v and observe the input dc voltage at input terminal. observe the output voltage, it should be +5v dc. and varry the input voltage with different settings ie, 200v, 205v, 210v, 215v, 220, 225 and 230v. Record the input dc voltages at the input terminals with digital voltmeter. and also the output voltage. The output must be 5v DC constant. This is input line regulation.

To study the output load regulation, Plot the graph output voltage vs output current. Set the input voltage to say 24v AC at input terminal. Now the output is +5v. Then connect the output to load through ammeter. Now varry the load and observe the output voltage and current. plot the graph.

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WARRANTY
We guarantee the instrument against all manufacturing defect during 24 months from the date of sale by us or through our dealers. The guarantee covers manufacturing defects in respect of indigenous components and material to the warrnty extented to us by the original manufacturer and defect will rectified as for as lies within our control. The guarantee does not cover prishable items like cathode ray tubes, crystals, batteries, photocells etc. The guarantee will become INVALID. 1. If the instrument is not operated as per instruction given in the instruction manual. 2. If the agreed payment terms and other conditions of sale are not followed. 3. If the customer resells the instrument to another party. 4. Provided no attempt have been made to service and modity the instrument. The non working of the instrument is to communicated to us immediately giving full details of the complaints and defects noticed specifically mentioning the type and sr.no of the instrument, date of purchase etc The repair works will be carried out, proided the instrument is despached securely packed and insured. Name of the Equipments:........................................ Model No:............................................................. Serial No: ............................................................. Date of Purchase:.................................................. Invoice No:.......................................................... D.C No:.............................................................. Dealers Name and Address: ........................................................ ........................................................ ....................................................... ........................................................

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ALPHA

Manual for

FLYBACK CONVERTER TRAINER

( Sr. No:............................)

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FLYBACK CONVERTER TRAINER

The input voltage AC or DC 24 TO 36V is fed through a fusable high watt resister and fuse to the circuit. This fusable resistor limits the in-rush current when switching on the supply. The fuse is for protecting overload conditions. This input voltage is then pass through a EMI filter. This EMI filter, filters the switching spikes emitted by flyback transformer and avoid this spikes return to line voltage. Then the input voltage rectified if it is AC and filtered by capacitor. This unregulated DC Voltage is applied to flyback transformer primary side. Here we use PWM CONTROLLER IC TL494 for control section. This IC contains self REF output ie 5v. Self oscillator, current sense and output voltage sensing and pwm output to drive switching elements like transistor or mosfets. Pin 12 is VCC. (8 T0 24V). Input is given to this pin through a resistor and zener diode which limits the input voltage at 15v VCC supply. Pin 14 is Reference output. It is 5 v. The resistorat pin 6 and capacitor at pin 5 which determines the oscillator switching frequency. Pin 16 is used to sense the current at the mosfet source terminal through current sensing shunt a fusable resistor. The voltage across this resistor is sensed by the ic at pin 16. If this voltage is more than 0.8v, then the pwm output will shut down. Pin 1 is output voltage sensing pin. The converter output voltage is isolated and sensed with help of opto coupler and reference voltage, voltage divider . Pin 10 is the pwm output which drives the gate of mosfet IFR540N which inturns drives flyback transformer. The secondary of the flyback transformer is rectified by high frequency schotty diode and filter by capacitor and inductance.

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