High Voltage DC Power Supply for Intelligent Power Modules

Rajkumar Sharma
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SKU: EL111012
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Although this power supply design is specific to the Intelligent Power Modules (IPM), the concepts and circuit design may be used for any power supply that requires high voltage output up to 400V DC and 6 A. It is an unregulated power supply, DC output is dependent on AC input. The circuitry includes a passive EMI filter consisting of elements C5, C6, C7, C8, C9, C10, T1, and a BR1 25 A/600V rectifier block, R3 NTC for inrush current protection, and a relay RL1 for soft powering up and reducing conduction losses in steady-state operation. 2 x electrolytic capacitors C3, C4 are used for buffering the rectified DC bus voltage. It is advisable to use a heatsink on the bridge rectifier. Inrush current circuit requires 12-15V DC @ 50mA power supply. Choose appropriate fuse as per current requirement.

Safety precautions

The board operates at lethal voltages and has bulk capacitors that store significant charge. Accidental contact can lead to lab equipment damage, personnel injury, and may be fatal. Please be exceptionally careful when probing and handling this board. Always observe normal laboratory precautions.

Features

Nominal Input Voltage 220V-240V AC
Output 330V DC (Approx.)
Output Current Continued 3A (Maximum 6 A)
On Board EMI Filter
On Board NTC for inrush Current
On Board Relay for soft powering up and reducing Power Losses
On Board Fuse for Short Circuit/Over Current Protection
Screw Terminals for Easy Connections
PCB dimensions: 98.50 x 85.88 mm

Schematic

Parts List

NO.	QNTY.	REF.	DESC	MANUFACTURER	SUPPLIER	SUPPLIER PART NO
1	1	BR1	BRIDGE DFB2560	ON SEMI	DIGIKEY	DFB2560-ND
2	1	CN1	4 PIN MALE HEADER 2.54MM PITCH	WURTH	DIGIKEY	732-5317-ND
3	2	CN2,CN3	3 X 2 PIN BARRIER STRIP	TE CONNECTIVITY	DIGIKEY	A113421-ND
4	1	C1	10uF/25V	NICHICON	DIGIKEY	493-17428-3-ND
5	1	C2	4.7uF/25V	NICHICON	DIGIKEY	493-11353-3-ND
6	2	C3,C4	470uF/450V	NICHICON	DIGIKEY	493-3239-ND
7	2	C5,C6	0.47uF/275V X 2	KEMET	DIGIKEY	399-12744-ND
8	4	C7,C8,C9,C10	1KPF/2KV	TDK	DIGIKEY	445-175190-3-ND
9	2	D1,D2	1N4007	SMC DIODE	DIGIKEY	1655-1N4007FLTR-ND
10	1	F1	FUSE HOLDER	WURTH	DIGIKEY	732-11376-ND
11	1	F1	FUSE HOLDER CLIP COVER	WURTH	DIGIKEY	732-11379-ND
12	1	F1	FUSE	WURTH	DIGIKEY	507-1270-ND
13	1	Q1	BC847AL	NEXPERIA	DIGIKEY	1727-2924-2-ND
14	1	RL1	Relay	TE CONNECTIVITY	DIGIKEY	PB2531-ND
15	1	R1	10K 5% SMD SIZE 0805	MURATA/YAGEO	DIGIKEY
16	1	R2	2K2 5% SMD SIZE 0805	MURATA/YAGEO	DIGIKEY
17	1	R3	NTC5D/20	AMTHERM	DIGIKEY	570-1268-ND
18	1	R4	330K 5% 3W	TE CONNECTIVITY	DIGIKEY	A131571CT-ND
19	1	R5	DNP			OMIT
20	1	T1	TX	WURTH	DIGIKEY	732-1449-ND