Switched Mode Power Conversion Laboratory Manual

28 August 2020
 1 Table of Contents
1 7.5W Constant Current Load .............................................................................................. 5
1.1 Circuit Diagram ......................................................................................................................... 5
1.2 Circuit Description ................................................................................................................... 5
1.3 Bill of Materials ......................................................................................................................... 7
2 7.5W 15V Voltage Regulator with Current Limits .............................................................. 9
2.1 Circuit Diagram ......................................................................................................................... 9
2.2 Circuit Description ................................................................................................................... 9
2.3 Bill of Materials ...................................................................................................................... 11
3 7.5W Constant Current Constant Voltage Regulator ....................................................... 13
3.1 Circuit Diagram ...................................................................................................................... 13
3.2 Circuit Description ................................................................................................................ 13
3.3 Bill of Materials ...................................................................................................................... 14
4 7.5W Non-Isolated Boost Converter ................................................................................ 17
4.1 Circuit Specification ............................................................................................................. 17
4.2 Circuit Description ................................................................................................................ 17
4.3 Practical Waveform of the Boost Converter ............................................................... 22
4.4 Bill of Materials ...................................................................................................................... 23
5 7.5W Non-Isolated Fly-back Converter ........................................................................... 26
5.1 Circuit Specification............................................................................................................... 26
5.2 Circuit Description.................................................................................................................. 26
5.3 Practical Waveform of the Fly-back Converter ......................................................... 32
5.4 Bill of Materials ...................................................................................................................... 33
6 7.5W Non-Isolated Forward Converter ............................................................................ 35
6.1 Circuit Specification ............................................................................................................. 35
6.2 Circuit Description ................................................................................................................ 35
6.3 Practical Waveform of the Forward Converter ......................................................... 41
6.4 Bill of Materials ...................................................................................................................... 43
7 7.5W Current Mode Control of Boost Converter ............................................................. 45
7.1 Circuit Specification ............................................................................................................. 45
7.2 Circuit Description ................................................................................................................ 45
7.2.1 Control Circuit: ............................................................................................................. 45
7.2.2 Power Circuit: ............................................................................................................... 46
7.3 Practical Waveform of the CMC-Boost Converter .................................................... 49
7.4 Bill of Materials ...................................................................................................................... 50
8 7.5W Current Mode Control of Forward Converter ......................................................... 52
8.1 Circuit Specification ............................................................................................................. 52
8.2 Circuit Description ................................................................................................................ 52
8.2.1 Control Circuit: ............................................................................................................. 52
 8.2.2 Power Circuit: ............................................................................................................... 53
8.3 Practical Waveform of the CMC-Forward Converter .............................................. 56
8.4 Bill of Materials ...................................................................................................................... 57
9 7.5W Quasi-Resonant Converter ZVS - Boost Converter ................................................. 59
9.1 Circuit Specification ............................................................................................................. 59
9.2 Principle of Operation ......................................................................................................... 59
9.3 Circuit Description................................................................................................................ 60
9.4 Practical Waveform of the ZVS-Boost Converter ...................................................... 63
9.5 Bill of Materials ...................................................................................................................... 65
10 7.5W Quasi-Resonant Converter ZCS - Buck Converter .............................................. 67
10.1 Circuit Specification ............................................................................................................. 67
10.2 Principle of Operation ......................................................................................................... 67
10.3 Circuit Description................................................................................................................ 68
10.4 Practical Waveform of the ZCS-Buck Converter ....................................................... 71
10.5 Bill of Materials ...................................................................................................................... 73
 Organization of the Lab Module:
No of Experiment/Simulation to be conducted Experiment No
Weeks (as per this
Manual)
1 to 3 (a) Simulation of Constant Current Load 1, 2 & 3
(b) Simulation of voltage regulator with current limit
(c) Simulation of constant voltage constant current
regulator
(d) Experiment of Constant Current Load
(e) Experiment of voltage regulator with current limit
(f) Experiment of constant voltage constant current
regulator
4 to 5 (a) Simulation of non-isolated Boost Converter 4
(b) Experiment of non-isolated Boost Converter
6 to 7 (a) Simulation of non-isolated Fly-back Converter 5
(b) Experiment of non-isolated Fly-back Converter
8 to 9 (a) Simulation of Current mode control Boost 7
Converter
(b) Experiment of Current mode control Boost
Converter
10 to 11 (a) Simulation of Quasi resonant Converter ZVS 9
Boost Converter
(b) Experiment Quasi resonant Converter ZVS Boost
Converter
Altern (a) Simulation of non-isolated Forward Converter 6
ative (b) Experiment of non-isolated Forward Converter
6 to 7
Altern (a) Simulation of Current mode control Forward 8
ative Converter
(b) Experiment of Current mode control Forward
8 to 9
Converter
Altern (a) Simulation of Quasi resonant Converter ZCS Buck 10
ative Converter
(b) Experiment Quasi resonant Converter ZCS Buck
10 to 11
Converter
12 to 13 Back-up days + Lab Examination -
 Experiment 1

1 7.5W Constant Current Load

1.1 Circuit Diagram

Figure 1-1: Constant Current Load

1.2 Circuit Description

The circuit shown in Fig 1.1 is a constant current load on the 15V input. A MOSFET is used
in the linear mode with closed loop control to achieve constant current performance. The
resistor R8 is a variable resistor. The current drawn from the source is proportional to the
voltage across R8 (0 to 0.5A for R8 varying from 0 to 10k Ω).The mathematical relationships in
the converter are as follows:

The voltage across 𝑅6 is

𝑉𝑠 = 𝑖𝑅6

Where 𝑖 is the current through the MOSFET ‘M1’. Assume the variable point of the POT
divide the resistance 𝑅8 as 𝑅8𝑡 and 𝑅8𝑏 . For zenor diode fixed voltage 𝑉𝐺 ,
𝑅8𝑏
𝑉𝑟𝑒𝑓 = 𝑉𝐺 .
𝑅8
Opamp based PI controller mathematical expression can be written as
𝑍𝑓 𝑍𝑓
𝑉𝐴 = 𝑉𝑟𝑒𝑓 [1 + ] − 𝑉𝑠 .
𝑍𝑖 𝑍𝑖
1
𝑉𝐴 = Output of LM324, 𝑍𝑓 = 𝑠𝐶 and 𝑍𝐼 = 𝑅7 .
1
The gate voltage of the MOSFET is given by
𝑅5
𝑉𝑔 = 𝑉𝐴 [ ]
𝑅4 + 𝑅5
The gate source voltage is thus
𝑉𝐺𝑆 = 𝑉𝑔 − 𝑉𝑠
Finally,
𝑉𝑇 2
𝑖 = 𝐼 [1 − ]
𝑉𝐺𝑆
The last equation is the VGS vs ID characteristics of a MOSFET in the active region. From the
device characteristics, I and VT can be evaluated. For example for the device IRF540 (IRF540),
consider the pair of operating points (Vgs = 5V, Id = 15A, Vds = 5V; and Vgs = 7V, Id = 70A, Vds
= 5V). From this data, one can find I and Vt. For IRF540, these parameters are 396A and
4.023V.

Figure 1-2: Typical Output Characteristics

Under ideal and stable operating conditions, with an integrator in the control loop, the output
current is very nearly
𝑉𝑟𝑒𝑓
𝑖=
𝑅6
Questions:
 Find the dynamic model of the converter.
 Evaluate the steady state voltage of every node in the circuit and the current in every branch
in the circuit. Verify the same in the assembled circuit.
 For the device used in the circuit, evaluate the parameters I and VT from the data sheet.
 Evaluate the small signal model of the circuit at the operating point with the potentiometer
R8 set at 50% setting and input voltage at 15V.

1.3 Bill of Materials

Table 1-1: Bill of Material
SL
NO REFERENCE DESCRIPTION VALUE QTY
1 C1 CAP SMEB 10nF,50V BOX 1
2 C3,C2,C4 CAP SMEB 0.1uF,50V BOX 3
3 C5 ELECTRLYTIC 10uF/63V 1
5 F1 FUSE 0.5A,250V 1
6 J1,J2 CONNECTOR 3 WAY PSC 2
8 M1 MOSFET IRFZ44N/TO220 1
9 Z1 ZENER 5.1V ,1/2 W 1
10 R1 RESISTOR 1.8K(MFR) 1
11 R9,R10 RESISTOR 3.3K(MFR) 2
12 R6,R3 RESISTOR 10E,5W(RMC) 2
13 R11 NC NC
14 R4,R7 RESISTOR 10K(MFR) 2
10K POT SINGLE
15 R8 RESISTOR(POT) TURN 1
16 R5 RESISTOR 47K(MFR) 1
17 U1 OP-AMP LM324 1
18 LD1,LD2 LED 3mmLED(RED) 2
14 PIN IC BASE
19 U1 base IC BASE ROUND 1

20 HS1 HEAT SINK PI-51(25mm) 1

21 TP3,TP9 TEST POINTS TURRETS TT 52 2
22 TP1,TP2,TP4,TP5,TP6P7,TP8, TEST POINTS 1 PIN BERG STICK 7
23 JMP1 BERGSTICK 2PIN BERG 1
24 FUSE HOLDER FUSE HOLDER PBF-4 1
25 WIRES,Green(2),Red,Orange WIRE,CRIMPING WIRES 1FT 4
26 SCREWS SCREWS (Nickle)M3/8 3
27 PLAIN WASHER PLAIN WASHER (Nickle)M3 3
28 STARE WASHER STAR WASHER (NICKLE ) M3 1
29 NUT NUT (NICKLE) M3 1
30 FIBER WASHER FIBER WASHER M3 2
31 SHORTING LINKS SHORTING LINKS SHORTING LINKS 1
32 PCB 7.5W CCL V4.0 PCB SIZE 9.0 X 6.5cm 1
 Experiment 2

2 7.5W 15V Voltage Regulator with

Current Limits

2.1 Circuit Diagram

Figure 2-1: Voltage Regulator with Current Limits

2.2 Circuit Description

The circuit shown in Fig. 1 is a BJT based series pass regulator. A BJT (Q3) is used in the
linear mode with closed loop control to achieve constant output voltage. The resistor chain R4
and R5 determine the feedback ratio of the output. The feedback is compared with the reference
voltage provided by D1 (a 5 V Zener). Q1 acts as the feedback amplifier. The base bias for the
output pass transistor is provided by the constant current drive Q4. Current limit is provided by
spill over diodes D4 and D5.
The mathematical relationships in the converter are as follows.

The reference voltage and the feedback voltage are given by respectively,
 𝑉𝑟𝑒𝑓 = 𝑉𝐷1
𝑅1
𝑉𝐹𝐵 = 𝑉𝑂𝑈𝑇 [ ]
𝑅1 + 𝑅4
Here 𝑅4 is taken as the resistance combining 𝑅4 and below the potentiometer (𝑃1 ) variable
point. From the equivalent circuit given in Fig. 2, the base current of transistor 1 is given by
𝑉𝐹𝐵 − 𝑉𝑅𝐸𝐹
𝐼𝐵1 =
𝑅𝑇𝐻
For the transistor ‘Q1’ the collector current is
𝐼𝐶1 = 𝛽1 𝐼𝐵1

Figure 2-2: Biasing circuit and reference generation

Considering the 𝑉𝐵𝐸 as one drop and as well as transistor base-emitter drop the bias current
through ‘Q2’ can be written as
 𝑉𝐵𝐸
𝐼𝐵𝐼𝐴𝑆 ≃
𝑅2
Therefore the base current of the main transistor can be obtained as
𝐼𝐵3 = 𝐼𝐵𝐼𝐴𝑆 − 𝐼𝐶1
Finally the output current and voltage are respectively
𝐼𝑂𝑈𝑇 ≃ 𝛽3 𝐼𝐵3
𝑉𝑂𝑈𝑇 = 𝐼𝑂𝑈𝑇 𝑅5
The bias current gets diverted when the drop in RS is more than one diode drop. The current
limit is imposed by 𝑅𝑆 as follows:
𝑉𝐵𝐸
𝐼𝐿𝐼𝑀𝐼𝑇 =
𝑅𝑆
Questions:
 Evaluate the steady state voltages of every node in the circuit and the current in every
branch of the circuit for an input voltage of 25V and a load resistance of 50 Ω.
 Verify the same in the assembled circuit.
 Evaluate the power dissipation in Q1, Q2, and Q3.

2.3 Bill of Materials

Table 2-1: Bill of Material
SL
NO REFERENCE DESCRIPTION VALUE QTY
1 C1 ELECTRLYTIC 10uF/63V 1
2 C2 ELECTRLYTIC 47uF/63V 1
3 C3 CAP SMEB 0.1uF/63V BOX 1
4 R2,R5 RESISTOR 47E, 1/2W(CFR) 2
5 R1,R3 RESISTOR 1K(MFR) 2
6 R4 RESISTOR 560E(MFR) 1
7 R6,R7 RESISTOR 3.3K(MFR) 2
8 RS RESISTOR 1E, 2.5W(RMC) 1
9 P1 POT 100E, SINGLE TURN 1
10 D1 Zener 5.1V,1/2W 1
11 D2,D3,D4,D5 DIODE 1N4148 4
12 F1 FUSE 0.5A,250V 1
13 FUSE HOLDER FUSE HOLDER PBF-4 1
14 Q1 TRANSISTOR 2N2222 1
15 Q2 TRANSISTOR 2N2905 1
16 Q2 TRANSISTOR BASE TO -5 1
TRANSISTOR HEAT
17 Q2 SINK PI-06(ROUND) 1
18 Q3 TRANSISTOR MJE13007,2A,100V,25W 1
19 LD1,LD2 LED 3mm(RED)High bright 2
20 J1,J2 CONNECTOR 3 WAY PSC 2
21 HS1 HEAT SINK PI51(25mm) 1
22 JMP1 Bergstick 2 PIN BERG 1
23 TP3,TP9 TEST POINTS TURRETS TT 52 2
24 TP1,TP2,TP4,TP5,TP6,TP7,TP8 TEST POINTS 1 PIN BERG 7
25 WIRES,Green(2),Red,Orange WIRE,CRIMPING WIRES 1FT 4
26 SCREWS SCREWS (NICKLE)M3/8 3
27 PLAIN WASHER PLAIN WASHER (NICKLE)M3 4
28 FIBER WASHER FIBER WASHER M3 2
29 STARE WASHER STAR WASHER (NICKLE ) M3 1
30 NUT NUT (NICKLE) M3 1
31 SHORTING LINKS SHORTING LINKS SHORTING LINKS 1
32 PCB 7.5W CV-CL PCB SIZE 9.0X6.0cm 1
 Experiment 3

3 7.5W Constant Current Constant

Voltage Regulator

3.1 Circuit Diagram

Figure 3-1: Linear Constant Current Constant Voltage Load

3.2 Circuit Description

The circuit shown in Fig. 1 is a CCCV regulator. It works from source voltage of 20V to 35V.
It provides constant current (settable below 500 mA) and constant voltage output (settable
below 15V). The CC value is settable by the POT 𝑃2 . The CV value is settable by the POT 𝑃1 .
The main power device 𝑀1 is a P channel MOSFET. The current feedback is through 𝑅17 . The
voltage feedback is through 𝑅21 and 𝑅22 . The power supply for the control circuit is obtained
from power is from zener diode 𝐷1 (biased with the resistor 𝑅1 ). Current signal is amplified
with Opamp ‘U1A’ (with a gain of nearly 10). On the other hand, ‘U1B’ is the current
controller working as a PI amplifier. ‘U1C’ is the voltage controller working as a PI amplifier.
𝑃1 sets the voltage reference (Full POT setting 15V). The voltage controller output is
attenuated through 𝑅9 and 𝑅13 and serves as the current reference. 𝑃2 sets the current limit
(Full POT setting 0.5A).

The current feedback can be expressed as

 𝑅20
𝐼𝑓𝑒𝑒𝑑𝑏𝑎𝑐𝑘 = 2.2𝑖 = 10.34𝑖
𝑅19
Current reference is variable from 0 to 4.75V (Saturation level of ‘U1C’ through 𝑅9 , 𝑅13 and
𝑃2 . The corresponding current limit is variable between 0 and 650 mA).
Similarly, the voltage feedback can be expressed as:
𝑅22 𝑉𝑜𝑢𝑡
𝑉𝑓𝑒𝑒𝑑𝑏𝑎𝑐𝑘 = 𝑉𝑜𝑢𝑡 =
𝑅21 + 𝑅22 3
Voltage reference is variable from 0 to 5 V (Zener diode 𝐷1 voltage through 𝑅2 , 𝑃1 and 𝑅4 . The
corresponding set voltage is variable between 0 and 15 V).

15V from Zenor D1

To Q1

Figure 3-2: Voltage controller with inner current controller

Questions and Assignments:
 Determine the transfer function of the system (current loop and voltage loop)
 Find the respective Bode plots
 Evaluate the steady state voltages at various points.

3.3 Bill of Materials

Table 3-1: Bill of Material
SL
NO REFERENCE DESCRIPTION VALUE QTY
1 C1 CAP SMEB 10nF,63V BOX 1
2 C2,C4,C6 CAP SMEB 0.1uF,63V BOX 3
3 C3 ELECTRLYTIC 10uF/63V 1
4 C5,C7 ELECTRLYTIC 47uF/63V 2
5 R1 RESISTOR 470E,1W(CFR) 1
6 R2 RESISTOR 15K(MFR) 1
7 R4,R8,R13,R14 RESISTOR 10K(MFR) 4
8 R5 RESISTOR 220K(MFR) 1
9 R6 RESISTOR 2.2K(MFR) 1
10 R7 RESISTOR 100K(MFR) 1
11 R9 RESISTOR 18K(MFR) 1
12 R23,R24,R10 RESISTOR 3.3K(MFR) 3
13 R11 RESISTOR 1.2K(MFR) 1
16 R15,R20 RESISTOR(MFR) 4.7K(MFR) 2
17 R16,R18,R19,R21, RESISTOR(MFR) 1K(MFR) 4
18 R17 RESISTOR 1E,2.5W(RMC) 1
19 R22 RESISTOR(MFR) 470E(MFR) 1
20 P1,P2 RESISTOR(POT) 50K SINGLE TURN 2
21 F1 FUSE 0.5A,250V 1
22 FUSE HOLDER FUSE HOLDER PBF-4 1
23 LD1,LD2 LED 3mm(RED)High bright 2
TRANSISTOR
24 Q1 Base TO-18 1
25 Q1 TRANSISTOR 2N2222 1
26 J1,J2 CONNECTOR 3 WAY PSC 2
IRF9540
27 M1 MOSFET 1
P CHANNEL,2A,50V
28 D1 ZENER DIODE 15V,1/2W 1
29 D2,D3,D4,D5 DIODE 1N4148 4
30 U1 OP-AMP LM324 1
14 PIN IC BASE
31 U1 base IC BASE ROUND 1
32 HS1 HEAT SINK PI51(30mm) 1
33 TP9,TP13 TEST POINTS TURRETS TT 52 2

34 TP1,TP2,TP3,TP4,TP5,TP6,TP7,TP8,TP10,TP11,TP12 TEST POINTS 1 PIN BERG 11

35 WIRES, Green(2), Red, Orange WIRE,CRIMPING WIRES 1FT 4

36 SCREWS SCREWS M3/8 3
37 NUT NUT M3 1
38 STAR WASHER STAR WASHER M3 1
39 PLAIN WASHER PLAIN WASHER M3 4
40 FIBER WASHER FIBER WASHER M3 2
CP3:7.5W CC CV
41 PCB REGULATOR PCB SIZE 9 X 6.5 1
V4.0
 Experiment 4

4 7.5W Non-Isolated Boost Converter

4.1 Circuit Specification

This section covers a simple closed loop controlled boost converter with the following
specifications.
• Input: 9V to 12V
• Output: 15V, 0.05A to 0.5A
• Topology: Non-isolated Boost followed by 3 pin Linear regulator
• Controller: UC494C(UC494C)
• Switching Frequency: 100 kHz
• Protection: None
Figure below shows the full circuit diagram of the non-isolated boost converter operating from
12V battery (8V to 12V) providing regulated output power at 15V (0.5 A). The controller used
is UC494 of Unitrode make.

4.2 Circuit Description

1. Starting Power Supply:
The starting power supply is obtained from D1 (1N4148) and C1 (10 µF).

2. Oscillator Section:
𝑅8 (4.7 kΩ) and 𝐶2 (2.2 nF) determine the switching frequency. The switching frequency is
given by
1.11
𝐹𝑠 = = 100 𝑘𝐻𝑧
𝑅𝑡 𝐶𝑡
 D1 Tp2
Vcc
IN4148 {Pin no.12}

R1
10K
C1
Vg + 10uF Dead Time
− 25V Control
Tp3 {Pin no.4}

R2
200E

Figure 4-1: Startup and Dead Time Control Circuit

The selected switching frequency is approximately 100 kHz.

3. Minimum Pulse-Width:
The minimum ON time is decided by the dead time control circuit 𝑅1 (10k Ω) and 𝑅2 (200 Ω).
On a ramp voltage of 3V, and an internal additional bias voltage of 0.1 V, this is selected to be
15%.

4. Reference Voltage:
The internal reference is 5 V. The circuit uses a reference voltage of 2.5 V through the potential
divider 𝑅10 (10 k Ω) and 𝑅11 (10 k Ω).

5. Biasing-out the unused amplifier:

The controller has two internal amplifiers ‘a’ and ‘b’. The amplifier outputs are wired such that
the higher of the two outputs will prevail (wired OR). The amplifier b is not used and hence it
is biased (non-inverting input to ground and inverting input to 2.5 V) such that its output is
low.

6. Maximum Pulse-width limit:

The amplifier output (Compensation pin) is compared with the internal ramp to generate the
duty ratio. The amplifier output requires to be clamped below the peak of the ramp in order
that the maximum duty ratio is well below 3V, which is the peak of the ramp. For this purpose,
the amplifier output is provided with a clamp circuit consisting of 𝑄1 (2N2222), 𝑅6 (10k Ω),
𝑅7 (10k Ω), and 𝑄2 (2N2907). The clamp level is obtained from a biased diode network
consisting of 𝐷2 , 𝐷3 , 𝐷4 (1N4148) and 𝑅5 (1.5k Ω). The clamp level is 4 diode drops including
the base emitter drop of 𝑄1.

D1 Cathode Vcc
{TP2} R7 {Pin no.12}
R5
1.5K 10K
Q2 feedback
R6 2N2907
1K
TP5
{Pin no.2}
Inverting Pin
Q1
2N2222 Error Amplifier Output
{Pin no.3}

D2
Clamping the Error Amplifier
D3
Output to = (4*0.5)+0.7
IN4148
D4 = 2.7V

D5

Figure 4-2: Maximum Pulse Width Circuit

7. Duty ratio:
The input voltage is in the range of 9 to 12 V. The output of the boost converter is designed
for 18V. The range of duty ratio is from 0.29 to 0.53.

8. Main Inductor:
The rated current is 0.3 A. The ripple current is chosen as 0.1 A. With maximum on time of
5.3 µs, at input voltage of 8V, this gives an inductor value of approximately 400 µH.

9. The power MOSFET has to carry about 1A and block about 20V. The device chosen is
IRFZ44.

10. The diode carries about 0.5 A average current and blocks about 20 V and suitable for 100
kHz switching. The reverse recovery time has to be better than 50ns. MUR110 is selected.
11. The output capacitor required has to limit the voltage ripple to about 1% (0.17V). This
capacitor is selected to be 220 µF (an order of magnitude
 Figure 4-3: Controller Circuit
higher than the desired value).
12. The natural frequency of the converter is
1−𝑑
𝑁𝑎𝑡𝑢𝑟𝑎𝑙 𝐹𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 =
√𝐿𝐶
which is ranging from 1584 rad/sec to 2393 rad/sec. The higher frequency is at higher voltage.
13. The dc gain from duty ratio to output voltage consists of modulator gain and converter
gain. The modulator gain is the reciprocal of the ramp peak in the modulator. In UC494, it is
1/3.5. The converter dc gain is
𝑉𝑔
𝐷𝐶 𝐺𝑎𝑖𝑛 =
[1 − 𝑑]2
 Figure 4-4: Power Circuit of Boost Converter

Figure 4.5: Feedback Circuit

This gain varies from 36 to 24. The overall gain is therefore 10.28 to 6.827 for the converter.
The lower gain is at higher voltage.
14. The closed loop control used is a PI controller with lead/lag compensator. The PI corner
frequency [1/(𝑅16 𝐶8 )] is chosen at 1000 rad/sec. The lead/lag compensator frequencies are
chosen as [1/(𝑅15 𝐶7 )] 1269 rad/sec and [1/(𝐶7 (𝑅3 ||𝑅4 ||𝑅15 )] 44000 rad/sec.

15. The loop gain band-width on unity feedback will be 5310 to 6710 rad/sec.

16. 𝑅13 serves as a bleeder load.

17. The output consists of a 3 pin regulator 7815 (U1). 𝐶5 and 𝐶6 are the input and output
capacitors of the 3 pin regulator.
18. The MOSFET drive is through the pull up resistor 𝑅9 (680 Ω) and the gate shunt resistor
𝑅12 (10 k Ω).

19. 𝑅14 is the on-board load 30%. Additional 70% load may be connected off-board.

Questions:
 What is the small signal model of the converter?
 Carry out the controller design and make suitable Bode plot for the system.
 Simulate the system in MATLAB with similar features as in power and control circuit
described above.
 Compare your simulation observation with simulation findings.
 Find the effect of load variation and input voltage variation on output voltage
mathematically and justify your answer with simulation and with experiment.

4.3 Practical Waveform of the Boost Converter

(a) Gate Voltage (b) Switch Voltage

(c) Output voltage and Input Current of (d) Ramp Voltage
Boost Converter

(e) Diode Current (f) Switch Current

4.4 Bill of Materials

Table 4.1: Bill of Material Table

Sl.No. Item Symbol Specification Quantity

1 Resistor R1, R7, R10, R11, R12 10k Ω 5
2 Resistor R2 200 Ω 1
3 Resistor R3 5.6k Ω 1
4 Resistor R4,R6 1k Ω 2
5 Resistor R5 1.5k Ω 1
6 Resistor R8 4.7k Ω 1
7 Resistor R9 680 Ω 1
8 Resistor R13 3.3k Ω 1
9 Resistor R14 100 Ω,3W 1
10 Resistor R15 6.8K Ω 1
11 Resistor R16 15K Ω 1
12 Capacitor C1 10 µF,25V 1
13 Capacitor C2 0.0022 µF,63V 1
14 Capacitor C3,C5, C6,C10 0.1 µF,50V 4
15 Capacitor C4 220 µF,25V 1
16 Capacitor C7,C8 0.022 µF,50V 2
17 Capacitor C12 0.047 µF,50V 1
18 Capacitor C9 0.001 µF,50V 1
19 Capacitor C11 0.01 µF, 1
20 Fuse F1 1A,230V 1
21 Mosfet M1 IRFZ44N 1
22 Inductor L1 400 µH 1
23 Transistor Q1 2N2222 1
24 Transistor Q2 2N2907 1
25 Diode D1,D2,D3, D4,D5 IN4148 5
26 Diode D6 MUR110 1
27 Linear IC U1 UC494 1
28 Linear IC U2 LM7815C 1
29 Test Points T1 Berg Stick 18
28 Jumpers NMJ,GJ 2

30 16 Pin IC Base U1b 1

31 Terminal T1,T2 2
Connector
32 Heat Sink HS1,HS2 P149 2
33 PCB 7.5W HKPS V3.0 Size-8.35*6.44cm 1
 Experiment 5

5 7.5W Non-Isolated Fly-back Converter

5.1 Circuit Specification

This section covers a simple closed loop controlled fly-back converter with the following
specifications.
• Input: 15V to 25V
• Output: 15V, 0.5A, 7.5W
• Topology: Non-isolated Boost followed by 3 pin Linear regulator
• Controller: UC494C(UC494C)
• Switching Frequency: 100 kHz
• Protection: None
Figures below shows the full circuit diagram of the non-isolated fly-back converter operating
from 25V battery (15V to 25V) providing regulated output power at 15V (0.5 A). The
controller used is UC494 of Unitrode make.

5.2 Circuit Description

1. Starting Power Supply:
The starting power supply is obtained from D1 (1N4148) and C1 (10 µF).

2. Oscillator Section:
𝑅8 (4.7k Ω) and 𝐶2 (2.2 nF) determine the switching frequency. The switching frequency is
given by
1.11
𝐹𝑠 = = 100 𝑘𝐻𝑧
𝑅𝑡 𝐶𝑡

IIT Bhubaneswar SMPC Lab P a g e | 26

 D1 Tp2
Vcc
IN4148 {Pin no.12}

R1
10K
C1
Vg + 10uF Dead Time
− 25V Control
Tp3 {Pin no.4}

R2
200E

Figure 5.1: Startup Circuit

The selected switching frequency is approximately 100 kHz.

3. Minimum Pulse-Width:
The minimum ON time is decided by the dead time control circuit 𝑅1 (10k Ω) and 𝑅2 (200 Ω).
On a ramp voltage of 3V, and an internal additional bias voltage of 0.1 V, this is selected to be
15%.

4. Reference Voltage:
The internal reference is 5 V. The circuit uses a reference voltage of 2.5 V through the potential
divider 𝑅10 (10 k Ω) and 𝑅11 (10 k Ω).

5. Biasing-out the unused amplifier:

The controller has two internal amplifiers ‘a’ and ‘b’. The amplifier outputs are wired such that
the higher of the two outputs will prevail (wired OR). The amplifier b is not used and hence it
is biased (non-inverting input to ground and inverting input to 2.5 V) such that its output is
low.

IIT Bhubaneswar SMPC Lab P a g e | 27

 D1 Cathode Vcc
{TP2} R7 {Pin no.12}
R5
1.5K 10K
Q2
R6 2N2907
1K
TP5
{Pin no.2}
Inverting Pin
Q1
2N2222 Error Amplifier Output
{Pin no.3}

D2
Clamping the Error Amplifier
D3
Output to = (4*0.5)+0.7
IN4148
D4 = 2.7V

D5

Figure 5.2: Maximum Pulse Width Circuit

6. Maximum Pulse-width limit:

The amplifier output (Compensation pin) is compared with the internal ramp to generate the
duty ratio. The amplifier output requires to be clamped below the peak of the ramp in order
that the maximum duty ratio is well below 3V, which is the peak of the ramp. For this purpose,
the amplifier output is provided with a clamp circuit consisting of 𝑄1 (2N2222), 𝑅6 (10k Ω),
𝑅7 (10k Ω), and 𝑄2 (2N2907). The clamp level is obtained from a biased diode network
consisting of 𝐷2 , 𝐷3 , 𝐷4 (1N4148) and 𝑅5 (1.5k Ω). The clamp level is 4 diode drops including
the base emitter drop of 𝑄1.

7. Duty ratio:
The input voltage is in the range of 15 to 25. The output of the boost converter is designed for
18V. The range of duty ratio is from 0.49 to 0.62.

8. Main Inductor:
The rated current is 1.11 A. The ripple current is chosen as 0.22 A. With maximum on time of
6 µs, at input voltage of 15V, this gives an inductor value of approximately 400 µH with turns
ratio of 0.691, the primary is 48 turns and secondary is 33 turns.
IIT Bhubaneswar SMPC Lab P a g e | 28
9. The power MOSFET has to carry about 1A and block about 20V. The device chosen is
IRFZ44.(IRFZ44)

10. The diode carries about 0.5 A average current and blocks about 20V and suitable for 100
kHz switching. The reverse recovery time has to be better than 50ns. MUR110 is
selected.(MUR110)

11. The output capacitor required has to limit the voltage ripple to about 1% (0.17V). This
capacitor is selected to be 220 µF (an order of magnitude higher than the desired value).
12. The natural frequency of the converter is
1−𝑑
𝑁𝑎𝑡𝑢𝑟𝑎𝑙 𝐹𝑟𝑒𝑞𝑢𝑒𝑛𝑐𝑦 =
√𝐿𝐶
which is ranging from 1265 rad/sec to 1698 rad/sec. The higher frequency is at higher voltage.
13. The dc gain from duty ratio to output voltage consists of modulator gain and converter
gain. The modulator gain is the reciprocal of the ramp peak in the modulator. In UC494, it is
1/3.5. The converter dc gain is
𝑛𝑉𝑔
𝐷𝐶 𝐺𝑎𝑖𝑛 =
[1 − 𝑑]2

IIT Bhubaneswar SMPC Lab P a g e | 29

 Figure 5.3: Controller Circuit

Figure 5.4: Power Circuit of Fly-back Converter

IIT Bhubaneswar SMPC Lab P a g e | 30

 Figure 5.5: Feedback Circuit

This gain varies from 72 to 66. The overall gain is therefore 20.47 to 18.87 for the converter.
The lower gain is at higher voltage. The closed loop control used is a PI controller with lead/lag
compensator. The PI corner frequency [1/(𝑅16 𝐶8 )] is chosen at 3030 rad/sec. The lead/lag
compensator frequencies [1/(𝑅15 𝐶7 )] are chosen as 2220 rad/sec and [1/(𝐶7 𝑅3 ||𝑅4 ||𝑅15 )]
22000 rad/sec.
14. The loop gain band-width on unity feedback will be 5900 to 7610 rad/sec.
15. 𝑅13 serves as a bleeder load.

16. The output consists of a 3 pin regulator 7815 (U1). 𝐶5 and 𝐶6 are the input and output
capacitors of the 3 pin regulator.
17. The MOSFET drive is through the pull up resistor 𝑅9 (680 Ω) and the gate shunt resistor
𝑅12 (10 k Ω)

18. 𝑅14 is the on-board load 30%. Additional 70% load may be connected off-board.

IIT Bhubaneswar SMPC Lab P a g e | 31

Questions:
 What is the small signal model of the converter?
 Carry out the controller design and make suitable Bode plot for the system.
 Simulate the system in MATLAB with similar features as in power and control circuit
described above.
 Compare your simulation observation with simulation findings.
 Find the effect of load variation and input voltage variation on output voltage
mathematically and justify your answer with simulation and with experiment.

5.3 Practical Waveform of the Fly-back Converter

(a) Gate Voltage (b) Ramp Voltage

(c) Primary Inductor Voltage (d) Secondary Inductor Voltage

IIT Bhubaneswar SMPC Lab P a g e | 32

 (e) Primacy Current (f) Output voltage and Output Current

5.4 Bill of Materials

Table 5.1: Bill of Material Table
Sl.No. Item Symbol Specification Quantity
1 Resistor R1,R7,R10, 10k Ω 5
R11,R12
2 Resistor R2 200 Ω 1
3 Resistor R3 5.6k Ω 1
4 Resistor R4,R6 1k Ω 2
5 Resistor R5 1.5k Ω 1
6 Resistor R8 4.7k Ω 1
7 Resistor R9 680 Ω 1
8 Resistor R13 3.3k Ω 1
9 Resistor R14 100 Ω,3W 1
10 Resistor R15 6.8k Ω 1
11 Resistor R16 15k Ω 1
11 Capacitor C1 10 µF,25V 1
13 Capacitor C2 0.0022 µF,63V 1
14 Capacitor C3,C5, C6,C10 0.1 µF,50V 4
15 Capacitor C4 220 µF,25V 1
16 Capacitor C12,C8 0.022 µF,50V 2
17 Capacitor C7 0.047 µF,50V 1
18 Capacitor C9 0.001 µF,50V 1
19 Capacitor C11 0.01 µF, 1
20 Fuse F1 1A,230V 1
21 Mosfet M1 IRFZ44N 1
22 Inductor L1 410 µH 1A,48/33 1
Turns

IIT Bhubaneswar SMPC Lab P a g e | 33

 23 Transistor Q1 2N2222 1
24 Transistor Q2 2N2907 1
25 Diode D1,D2,D3, D4,D5 IN4148 5
26 Diode D6 MUR110 1
27 Linear IC U1 UC494 1
28 Linear IC U2 LM7815C 1
29 Test Points T1 Berg Stick 20
30 16 Pin IC Base U1b 1

31 Terminal Connector T1,T2 2

32 Heat Sink HS1,HS2 P149 2

33 PCB 7.5W Flyback V3.0 Size-8.35*6.44cm 1
34 Jumper J1,J2 Jumpers 2

IIT Bhubaneswar SMPC Lab P a g e | 34

 Experiment 6

6 7.5W Non-Isolated Forward

Converter

6.1 Circuit Specification

This section covers a simple closed loop controlled forward converter with the following
specifications.
• Input: 10V to 15V
• Output: 17V, 0.5A, 7.5W
• Topology: Non-isolated Forward Converter
• Controller: UC494C(UC494C)
• Switching Frequency: 100 kHz
• Protection: None
Figures below shows the full circuit diagram of the non-isolated forward converter operating
from 15V battery (10V to 15V) providing regulated output power at 17V (0.45 A). The
controller used is UC494 of Unitrode make.

6.2 Circuit Description

1. Starting Power Supply:
The starting power supply is obtained from 𝐷1 (1N4148) and 𝐶1 (10 µF).

2. Oscillator Section:
𝑅8 (4.7k Ω) and 𝐶2 (2.2 nF) determine the switching frequency. The switching frequency is
given by
1.11
𝐹𝑠 = = 100 𝑘𝐻𝑧
𝑅𝑡 𝐶𝑡

IIT Bhubaneswar SMPC Lab P a g e | 35

 D1 Tp2
Vcc
IN4148 {Pin no.12}

R1
10K
C1
Vg + 10uF Dead Time
− 25V Control
Tp3 {Pin no.4}

R2
200E

Figure 6.1: Startup Circuit

The selected switching frequency is approximately 100 kHz.

3. Minimum Pulse-Width:
The minimum ON time is decided by the dead time control circuit 𝑅1 (10k Ω) and 𝑅2 (200 Ω).
On a ramp voltage of 3V, and an internal additional bias voltage of 0.1 V, this is selected to be
15%.

4. Reference Voltage:
The internal reference is 5 V. The circuit uses a reference voltage of 2.5 V through the potential
divider 𝑅10 (10k Ω) and 𝑅11 (10k Ω).

5. Biasing-out the unused amplifier:

The controller has two internal amplifiers ‘a’ and ‘b’. The amplifier outputs are wired such that
the higher of the two outputs will prevail (wired OR). The amplifier b is not used and hence it
is biased (non-inverting input to ground and inverting input to 2.5 V) such that its output is
low.

6. Maximum Pulse-width limit:

The amplifier output (Compensation pin) is compared with the internal ramp to generate the
duty ratio. The amplifier output requires to be clamped below the peak of the ramp in order
that the maximum duty ratio is well below 3 V, which is the peak of the ramp. For this purpose,
the amplifier output is provided with a clamp circuit consisting of 𝑄1 (2N2222), 𝑅6 (10k Ω),
𝑅7 (10k Ω), and 𝑄2 (2N2907). The clamp level is obtained from a biased diode network
IIT Bhubaneswar SMPC Lab P a g e | 36
consisting of 𝐷2 , 𝐷3 , 𝐷4 (1N4148) and 𝑅5 (1.5k Ω). The clamp level is 4 diode drops including
the base emitter drop of 𝑄1.
D1 Cathode Vcc
{TP2} R7 {Pin no.12}
R5
1.5K 10K
Q2
R6 2N2907
1K
TP5
{Pin no.2}
Inverting Pin
Q1
2N2222 Error Amplifier Output
{Pin no.3}

D2
Clamping the Error Amplifier
D3
Output to = (4*0.5)+0.7
IN4148
D4 = 2.7V

D5

Figure 6.2: Maximum Pulse Width Circuit

7. Duty ratio:
The input voltage is in the range of 10 to 15. The output of the boost converter is designed for
18V. The range of duty ratio is from 0.56 to 0.37.
8. Main Inductor:
The rated current is 0.5A. The ripple current is chosen as 0.05A. With maximum on time of
3.33 µs, at input voltage of 15V, this gives an inductor value of approximately 2000 µH with
turns ratio of 3, the primary is 15 turns and secondary is 45 turns.

9. The power MOSFET has to carry about 1A and block about 20V. The device chosen is
IRFZ44.(IRFZ44)

10. The diode carries about 0.5 A average current and blocks about 20V and suitable for 100
kHz switching. The reverse recovery time has to be better than 50ns. MUR110 is selected.

11. The output capacitor required has to limit the voltage ripple to about
IIT Bhubaneswar SMPC Lab P a g e | 37
 Figure 6.3: Controller Circuit

1% (0.17V). This capacitor is selected to be 220 µF (an order of magnitude higher than the
desired value).

12. The natural frequency of the converter is

1
𝑁𝑎𝑡𝑢𝑟𝑎𝑙 𝐹𝑟𝑒𝑞𝑖𝑢𝑒𝑛𝑐𝑦 =
√𝐿𝐶
which is 1507.5 rad/sec. The higher frequency is at higher voltage.

13. The dc gain from duty ratio to output voltage consists of modulator gain and converter
gain. The modulator gain is the reciprocal of the ramp peak in the modulator. In UC494, it is
1/3.5. The converter dc gain is

𝐷𝐶 𝐺𝑎𝑖𝑛 = 𝑛𝑉𝑔
IIT Bhubaneswar SMPC Lab P a g e | 38
 Figure 6.4: Power Circuit of Forward Converter

This gain varies from 30 to 45. The overall gain is therefore 8.75 to 12.85 for the converter.
The higher gain is at higher voltage.
14. The closed loop control used is a PI controller with lead/lag compensator. The PI corner
frequency [1/(𝑅16 𝐶8 )] is chosen at 1820 rad/sec. The lead/lag compensator frequencies
[1/(𝑅15 𝐶7 )] are chosen as 1587 rad/sec and [1/(𝐶7 𝑅3 ||𝑅4 ||𝑅15 )] 15000 rad/sec .

15. The loop gain band-width on unity feedback will be 5900 to 7610 rad/sec.
16. 𝑅13 serves as a bleeder load.

17. The MOSFET drive is through the pull up resistor 𝑅9 (680 Ω) and the gate shunt resistor
𝑅12 (10 k Ω)

18. 𝑅14 is the on-board load 30%. Additional 70% load may be connected off-board.

IIT Bhubaneswar SMPC Lab P a g e | 39

 From Vox

R3
5.6K TP6
R15 10K

TP4 C7 47nF Inverting Pin

{Pin no.2}

R4 C8
C12 22nF
1K 47nF
C9
R16 1nF,50V
15K

Compensator Output {Pin no.3}

Figure 6.5: Feedback Circuit

Questions:
 What is the small signal model of the converter?
 Carry out the controller design and make suitable Bode plot for the system.
 Simulate the system in MATLAB with similar features as in power and control circuit
described above.
 Compare your simulation observation with simulation findings.
 Find the effect of load variation and input voltage variation on output voltage
mathematically and justify your answer with simulation and with experiment.

IIT Bhubaneswar SMPC Lab P a g e | 40

6.3 Practical Waveform of the Forward Converter

(a) Gate Voltage (b) Ramp Voltage

(c) Primary Transformer Voltage (d) Secondary Transformer Voltage

IIT Bhubaneswar SMPC Lab P a g e | 41

 (e) Inductor Voltage (f) Inductor Current

(g) Switch Voltage (h) Primary Current

Figure 6.6: Output Voltage for Forward Converter

IIT Bhubaneswar SMPC Lab P a g e | 42

6.4 Bill of Materials
Table 6.1: Bill of Material Table
Sl. Item Symbol Specification Quantity
No.
1 Resistor R1,R7,R10, 10k Ω 6
R11,R12,R16
2 Resistor R2 200 Ω 1
3 Resistor R3 5.6k Ω 1
4 Resistor R4,R6 1k Ω 2
5 Resistor R5 1.5k Ω 1
6 Resistor R8 4.7k Ω 1
7 Resistor R9 680 Ω 1
8 Resistor R13 3.3k Ω 1
9 Resistor R14 100 Ω,3W 1
10 Resistor R15 47K Ω 1
11 Capacitor C1 10 µF,25V 1
12 Capacitor C2 0.0022 µF,63V 1
13 Capacitor C3,C10 0.1 µF,50V 2
14 Capacitor C4 220 µF,25V 1
15 Capacitor C7,C8 10 µF,50V 2
16 Capacitor C13 0.047 µF,50V 1
17 Capacitor C9 0.001 µF,50V 1
18 Capacitor C11 0.01 µF, 1
19 Fuse F1 1A,230V 1
20 Mosfet M1 IRFZ44N 1
21 Transformer T1 1A,15/45 Turns 1
22 Transisor Q1 2N2222 1
23 Transisor Q2 2N2907 1
23 Diode D1,D2,D3,D4, IN4148 7
D5,D6,D9
24 Diode D8,D21 MUR110 2
25 Linear IC U1 UC494 1
26 Inductor L1 2mH 1
27 Test Points T1 Berg Stick 20
28 16 Pin IC Base U1b 1

29 Terminal Connector T1,T2 2

30 Heat Sink HS1 P149 1

IIT Bhubaneswar SMPC Lab P a g e | 43

 31 PCB 7.5W Forward V3.0 1

32 Jumper J1,J2 Jumpers 2

33 Diode ZD10 15V, Zener 1

IIT Bhubaneswar SMPC Lab P a g e | 44

 Experiment 7

7 7.5W Current Mode Control of Boost

Converter

7.1 Circuit Specification

This section covers a simple closed loop current mode controlled boost converter with the
following specifications.
• Input: 12V to 20V
• Output: 30V, 0.25A, 7.5W
• Topology: Non-isolated Boost Converter
• Controller: UC3843(UC3843)
• Switching Frequency: 50 kHz
• Protection: None
Figure 7.1 and 7.2 shows the full circuit diagram of the non-isolated boost converter operating
from 20V battery (12V to 20V) providing regulated output power at 30V (0.25 A). The
controller used is UC3843 of Unitrode make.

7.2 Circuit Description

The Circuit consists of a power circuit and a control circuit.

7.2.1 Control Circuit:

1. Controller: The controller used here is UC3843. It is 8 pin IC with maximum supply
voltage is 40V.

2. 𝐶2 , 𝐶𝑠ℎ are all used for filtering.

3. Reference voltage: IC has a internal reference Voltage of 5V.
IIT Bhubaneswar SMPC Lab P a g e | 45
4. Oscillator Section: Switching Frequency is determined by 𝑅𝑡 and 𝐶𝑡 .
1.72
𝐹𝑠 = = 50 𝑘𝐻𝑧
𝑅𝑡 𝐶𝑡
5. Slope Compensation: Transistor 𝑄4 and 𝑅𝑣 forms the Slope Compensation Circuit. The
Slope Compensation circuit is required when the circuit is operating with a duty ratio more
than 0.5.
6. Controller: Resistor 𝑅𝑓 and Capacitor 𝐶𝑓 forms the PI controller circuit.

7. Current Sense: UC3843 IC Pin 3 is the Current Sense Pin, it senses the rectified switch
current from the Current Transformer. This rectified Current gets added with the slope
compensation voltage and this the Current Sensed by the IC.
8. 𝑅4 is the Bleeder resistance used, based on the value of 𝑅4 , we decide the current to be
sensed such that the peak voltage at pin no. 3 less than 1V threshold.

7.2.2 Power Circuit:

1. It Consists of the Boost Converter with include- Inductor, Switch, Diode, Capacitor and
Load.
2. Duty Ratio: The input voltage is in the range of 12 to 20 V. The output of the boost
converter is designed for 30V. The range of duty ratio is from 0.6 to 0.33.
3. Main Inductor: The rated current is 0.25 A. The ripple current is chosen as 0.5 A. With
maximum on time of 12 µs, at input voltage of 12V, this gives an inductor value of
approximately 200 µH. Inductor is 200 µH with 29 Turns of 22 SWG.
4. The power MOSFET has to carry about 1A and block about 20V. The device chosen is
IRFZ44. MOSFET drive is through 𝑅𝑔 and 𝑅𝑑 .
5. The Diode Carries about 0.5A Average Current and Blocks about 20V and suitable for 50
KHz switching. The recovery time has to be better than 50ns. Therefore MUR110 is selected.
6. The capacitor 𝐶1 has to limit the voltage ripple to about 1%. This Capacitor is selected to
be 220 µF.
7. Current Transformer: The CT is used to sense the switch current. The Core used is E 16/8/5
of SWG 28 with 1:200 Turns.
8. The Load Resistor used is 120E. [7.5W]

IIT Bhubaneswar SMPC Lab P a g e | 46

 Figure 7.1: Control Circuit for Current Mode Control of Boost Converter

IIT Bhubaneswar SMPC Lab P a g e | 47

 Figure 7.2: Power Circuit for Current Mode Control of Boost Converter
Questions:
1. Derive the open loop and closed loop voltage transfer function.
2. Determine the minimum compensating ramp required for the converter
3. Measure the inductor voltage and current experimentally and compare the same with
the simulation results
4. Comment on selection of current sensor transformer turns ratio selection.

IIT Bhubaneswar SMPC Lab P a g e | 48

7.3 Practical Waveform of the CMC-Boost Converter

(a) Gate Voltage (b) Ramp Voltage

(c) Compensated current and Voltage (d) Current Sensed

(e) Inductor Voltage (f) Output voltage

IIT Bhubaneswar SMPC Lab P a g e | 49

7.4 Bill of Materials
Table 7.1: Bill of Material Table
Sl.No. Item Symbol Specification Quantity
1 Resistor Rg,Rf,Ri,Rb 10k Ω 4
2 Resistor Rt 6.8k Ω 1
3 Resistor Rv 8.2k Ω 1
4 Resistor R4 150 Ω 1
5 Resistor Rd 47 Ω 1
6 Resistor Risen 3.3k Ω 1
7 Resistor Ra 1k Ω 1
8 Resistor R1 120 Ω 1
9 Capacitor Csh 560pF 1
10 Capacitor C2, C3 0.22 µF,63V 1
11 Capacitor C1 220 µF,25V 1
12 Capacitor Cf 0.022 µF,50V 2
13 Capacitor Ct 0.0047 µF,50V 1
15 Current Transformer T2 1:200 1
16 Mosfet M1 IRFZ44N 1
17 Inductor L1 200 µH 1
18 Transisor Q1 2N2222 1
19 Diode D3 IN4148 1
20 Diode D2 MUR110 1
21 Linear IC U1 UC3843 1
22 Test Points T1-T10 Berg Stick 20
23 Jumpers NMJ,GJ,IS, 6
SCJ,PSJ,ISG
24 8 Pin IC Base U1b 1

25 Terminal Connector T1,T2 2

26 Heat Sink HS1 P149 2

27 PCB 7.5W CMC BOOST 1

IIT Bhubaneswar SMPC Lab P a g e | 50

IIT Bhubaneswar SMPC Lab P a g e | 51
 Experiment 8

8 7.5W Current Mode Control of

Forward Converter

8.1 Circuit Specification

This section covers a simple closed loop current mode controlled forward converter with the
following specifications.
• Input: 10V to 15V
• Output: 5V, 1.5A, 7.5W
• Topology: Non-isolated Forward Converter
• Controller: UC3843(UC3843)
• Switching Frequency: 100 kHz
• Protection: None
Figure 1 shows the full circuit diagram of the non-isolated forward converter operating from
15V battery (10V to 15V) providing regulated output power at 5V (1.5 A). The controller used
is UC3843 of Unitrode make.

8.2 Circuit Description

The Circuit consists of a power circuit and a control circuit.

8.2.1 Control Circuit:

1. Controller: The controller used here is UC3843. It is 8 pin IC with maximum supply
voltage is 40V.

2. 𝐶2 , 𝐶𝑠ℎ are all used for filtering.

3. Reference voltage: IC has a internal reference Voltage of 5V.

4. Oscillator Section: Switching Frequency is determined by 𝑅𝑡 and 𝐶𝑡 as follows:

 1.72
𝐹𝑠 = = 100 𝑘𝐻𝑧
𝑅𝑡 𝐶𝑡
5. Slope Compensation: The Slope Compensation circuit is not required since we are
operating less than 50% duty cycle.

6. Controller: Resistor 𝑅𝑓 and capacitor 𝐶𝑓 forms the PI controller circuit.

7. Current Sense: UC3843 IC Pin 3 is the Current Sense Pin, it sense the rectified switch
current from the Current Transformer. This rectified Current gets added with the slope
compensation voltage and this the Current Sensed by the IC.

8. 𝑅𝑏 is the Bleeder resistance used, based on the value of 𝑅𝑏 we decide the current to be
sensed such that the voltage at pin no. 3 should be less than 1V threshold.

8.2.2 Power Circuit:

1. It Consists of the Forward Converter with include a Inductor, Switch, Diode, Capacitor and
Load.

2. Duty Ratio: The input voltage is in the range of 10 to 15 V. The output of the boost
converter is designed for 30V. The range of duty ratio is from 0.5 to 0.33.

3. Main Inductor: The rated current is 1.5 A. The ripple current is chosen as 0.3 A. With
maximum on time of 5 µs, at input voltage of 10V, this gives an inductor value of
approximately 110 µH. Inductor is 110 µH with 29 Turns of 22 SWG.

4. Current Transformer: The CT is used to sense the switch current. The Core used is E 16/8/5
of SWG 28 with 1:200 Turns.

5. Transformer: The Transformer has a turns ratio of 1. With SWG 22 used for the primary
winding and SWG 23 used for the secondary winding. Core used is EE 16/8/5.The primary
turns is 12 and secondary turns is 12.

6. The power MOSFET has to carry about 1A and block about 20V. The device chosen is
IRFZ44. MOSFET drive is through the 𝑅𝑔 and 𝑅𝑑 .(IRFZ44)

7. The Diode Carries about 1.5A Average Current and Blocks about 20V and suitable for 100
KHz switching. The recovery time has to be better than 50ns. Therefore MUR110 is selected.

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 Figure 8.1: Control Circuit for Current Mode Control of Forward Converter

8. The capacitor 𝐶1 has to limit the voltage ripple to about 1%. This Capacitor is selected to
be 47 µF.
9. The Load Resistor used is 3.33E.[7.5W]

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Figure 8.2: Power Circuit for Current Mode Control of Forward Converter

Questions:
1. Derive the open loop and closed loop voltage transfer function.
2. Determine the minimum compensating ramp required for the converter
3. Measure the inductor voltage and current experimentally and compare the same with
the simulation results
4. Comment on selection of current sensor transformer turns ratio selection.

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8.3 Practical Waveform of the CMC-Forward Converter

(a) Gate Voltage (b) Ramp Voltage

(c) Output Voltage (d) Current Sensed

(e) Primary Transformer Voltage (f) Secondary Transformer voltage

IIT Bhubaneswar SMPC Lab P a g e | 56
8.4 Bill of Materials
Table 8.1: Bill of Material Table
Sl.No. Item Symbol Specification Quantity
1 Resistor Rg,Rf,Ri 10k Ω 3
2 Resistor Rt 8.2 Ω 1
3 Resistor R9 100 Ω 1
4 Resistor Rb 150 Ω 1
5 Resistor Rd 47 Ω 1
6 Resistor Risense 3.3k Ω 1
7 Resistor R5,R4 1k Ω 2
8 Resistor Rload 3.3 Ω 1
9 Capacitor Csh 560pF 1
10 Capacitor Cin 0.22 µF,63V 1
11 Capacitor Co 220 µF,25V 1
12 Capacitor Cf 0.022 µF,50V 2
13 Capacitor Ct 0.002 µF,50V 1
15 Current Transformer T2 1:200 1
16 Mosfet M1 IRFZ44N 1
17 Inductor L1 110 µH 1
18 Transfomer T1 E 16/8/5,1:1 1
19 Diode D3,D6 IN4148 2
20 Diode D1,D2 MUR110 2
21 Linear IC U1 UC3843 1
22 Test Points T1-T10 Berg Stick 20
23 Jumpers NMJ,GJ,IS, 6
SCJ,PSJ,ISG
24 8 Pin IC Base U1b 1

25 Terminal Connector T1,T2 2

26 Heat Sink HS1 P149 2

27 Diode D6,D4 Zener Diode (15V) 2
28 PCB CMC Forward V1.0 1

IIT Bhubaneswar SMPC Lab P a g e | 57

IIT Bhubaneswar SMPC Lab P a g e | 58
 Experiment 9

9 7.5W Quasi-Resonant Converter ZVS

- Boost Converter

9.1 Circuit Specification

This section covers a simple closed loop controlled boost converter with the following
specifications.
• Input: 10V to 13V
• Output: 15V, 0.5A, 7.5W
• Topology: Non-isolated Boost Converter
• Controller: 555 Timer (555 Timer)
• Switching Frequency: 80 to 120 kHz
• Protection: None
Fig. 2 and Fig. 3 show the full circuit diagram of the ZVS boost converter operating from 12V
input source (10V to 13V) providing regulated output power at 15V (0.5 A). The controller
used is 555 Timer.

9.2 Principle of Operation

1. The Major advantage of ZCS and ZVS quasi-resonant converters is that the power switch
is turned on and off at zero voltage and zero current, respectively. In ZCS topologies the
rectifying diode has ZVS, whereas ZVS topologies the rectifying diode has ZCS. The Second
advantage is that both ZVS and ZCS converter utilize Transformer leakage inductors and diode
junction capacitor and the output parasitic capacitor of the power switch.
2. The major disadvantage of ZCS and ZVS techniques is that they require variable frequency
control to regulate the output. This is undesirable since it complicates the control circuit and
generate unwanted EMI harmonics especially under wide load variation. In ZCS the power
switch turns off at zero current, but at turn on converter still suffers from the capacitor turn on
loss caused by the output capacitor of power switch.
IIT Bhubaneswar SMPC Lab P a g e | 59
 8

ON State
6
Soft Switching Trajectories
Current

Turn on trajectory

Turn off trajectory OFF State

0

0 2 4 6 8 10 12
Voltage
Figure 9.1: Switching Loci

3. Most regulator converters switches need to turn on or turn off the full load current at high
voltage, resulting in what is known as hard switching. Fig. 1 shows the typical switching loci
for a hard switching converter without and with snubber circuit.
4. In soft switching topologies, an LC resonant network is added to shape the switching
devices voltage or current waveform into a quasi-sinewave in such a way that a zero voltage
or zero current condition is created. This technique eliminates the turn on or turn off losses
associated with the charging or discharging of the energy stored in MOSFET’s parasitic
junction capacitors.

9.3 Circuit Description

1. The Controller used is 555 Timer.
2. For the Zero Voltage Switching Operation, the OFF time is fixed and the Frequency
variation is done by varying the ON time only.

IIT Bhubaneswar SMPC Lab P a g e | 60

 Figure 9.2: Control Circuit of ZVS-Boost Converter

3. The Frequency varied from 80 to 120 KHz.

4. The ON Time and OFF time equation for the 555 Timer can be written as:
𝑇𝑜𝑛 = 0693[𝑅1 + 𝑅2 ]𝐶1
𝑉𝑜𝑓𝑓 = 0.693𝑅2 𝐶1
5. The Frequency variation is done by keeping 𝑅2 fixed and by changing Trim pot 𝑅1 ⇒ the
ON time is varied.
6. The OFF time is fixed to be 2.3 µsec. The parameters for 𝐶1 , 𝑅1 and 𝑅2 are calculated from
the above equation.

IIT Bhubaneswar SMPC Lab P a g e | 61

 TP8 TP2 D2 TP4

JP6 L1=2mH MUR110

Fuse
2A L2 = 56.8uH

JP3
JP4
R6= 220E TP7

JP1 C4/C5
JP2 D5 R5
+ MUR110 47uF
Vg 30E
− JP5
JMP2 TP9 Q3A IRFZ44

R4 = 47E C3
11nF
R7 =10k

1 2 3

1 = Vcc
2 = Ground
3 = Gate Pulse

Figure 9.3: Power Circuit of ZVS-Boost Converter

7. For Zero voltage switching,

𝐿𝑟
𝑉𝑜 = 𝐼𝑔 √
𝐶𝑟
8. The Resonant Frequency is selected to be 120 kHz and then from above equation Lr = 56.84
µH and Cr=0.01 µF values are obtained.
9. Here in Zero Voltage Switching, when the switch voltage reaches zero then the switch is

IIT Bhubaneswar SMPC Lab P a g e | 62

turned on.
10. Jumper Settings: One of the possible setting of the jumpers are as follows:
Connect: JP6, JmP2, JP4, JP1, JP5
Do not connect: JP3, JP2
Questions:
1. Find the various operating modes for the circuit.
2. Determine the dynamic equations for the inductor current and capacitor voltage in each
mode.
3. Evaluate the gain of the converter with frequency variation as the input.
4. Determine the variation required for variable pot to achieve the regulation.
5. Is it possible to switch from half bridge operation to full bridge operation or vice versa
in this circuit and what are the relative merit/demerits?

9.4 Practical Waveform of the ZVS-Boost Converter

Figure 9.4: Resonant Inductor Current and Capacitor Voltage-Full Wave

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 Figure 9.5: Resonant Inductor Current and Capacitor Voltage-Half Wave

Figure 9.6: Gate Pulse form Control Circuit

IIT Bhubaneswar SMPC Lab P a g e | 64

 Figure 9.7: Output Voltage

9.5 Bill of Materials

Table 9.1: Bill of Material Table
Sl.No. Item Symbol Specification Quantity
1 Resistor R1 5k Ω pot 1
2 Resistor R2 3.3k Ω 1
3 Resistor R3 100 Ω 1
4 Resistor R4 22 Ω 1
5 Resistor R5 30 Ω,5W 1
6 Resistor R6 560 Ω 1
7 Resistor R7 10k Ω 1
9 Capacitor C1 1nF 1
10 Capacitor C2,C3 0.01 µF, 63V 2
11 Capacitor C4,C5 10 µF, 25V 2
12 Filter Inductor L1 2000 µH 1
13 MOSFET M1 IRFZ44N 1
14 Resonant Inductor L2 56.8 µH 1
15 Transistor Q1,Q2 2N2222, 2N2907 2
16 Diode D2,D5 MUR110 2
17 Linear IC U1 555 TIMER 1
18 Test Points T1-T10 Berg Stick 20

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 19 Jumpers JP1-JP6 6

20 8 Pin IC Base U1b 1

21 Terminal Connector T1,T2 2

22 Heat Sink HS1 P149 2

23 Diode D3 Zener Diode (10V) 1
24 PCB ZVS-BOOST 1

IIT Bhubaneswar SMPC Lab P a g e | 66

 Experiment 10

10 7.5W Quasi-Resonant Converter

ZCS - Buck Converter

10.1 Circuit Specification

This section covers a simple ZCS buck converter with the following specifications.
• Input: 10V to 13V
• Output: 7V, 1.0A, 7.5W
• Topology: Isolated Buck Converter
• Controller: 555 Timer (555 Timer)
• Switching Frequency: 100 to 67 kHz
• Protection: None
Fig. 2 and Fig. 3 shows the full circuit diagram of the ZCS buck converter operating from 15V
source (10V to 15V) providing regulated output power at 5V (1.5 A). The controller used is
555 Timer (open loop).

10.2 Principle of Operation

1. The Major advantage of ZCS and ZVS quasi-resonant converters is that the power switch
is turned on and off at zero voltage and zero current, respectively. In ZCS topologies the
rectifying diode has ZVS, whereas ZVS topologies the rectifying diode has ZCS. The Second
advantage is that both ZVS and ZCS converter utilize Transformer leakage inductors and diode
junction capacitor and the output parasitic capacitor of the power switch.
2. The major disadvantage of ZCS and ZVS techniques is that they require variable frequency
control to regulate the output. This is undesirable since it complicates the control circuit and
generate unwanted EMI harmonics especially under wide load variation. In ZCS the power
switch turns off at zero current, but at turn on converter still suffers from the capacitor turn on
loss caused by the output capacitor of power switch.

IIT Bhubaneswar SMPC Lab P a g e | 67

 8

ON State
6
Soft Switching Trajectories
Current

Turn on trajectory

Turn off trajectory OFF State

0

0 2 4 6 8 10 12
Voltage
Figure 10.1: Switching Loci

3. Most regulator converters switches need to turn on or turn off the full load current at high
voltage, resulting in what is known as hard switching. Fig. 1 shows the typical switching loci
for a hard switching converter without and with snubber circuit.
4. In soft switching topologies, an LC resonant network is added to shape the switching
devices voltage or current waveform into a quasi-sine wave in such a way that a zero voltage
or zero current condition is created. This technique eliminates the turn on or turn off losses
associated with the charging or discharging of the energy stored in MOSFET’s parasitic
junction capacitors.

10.3 Circuit Description

1. The Controller used is 555 Timer.
2. For the Zero Current Switching Operation, the ON time is fixed and the Frequency
variation is done by varying the OFF time only.

IIT Bhubaneswar SMPC Lab P a g e | 68

 1 2 3
TP5 TP9
TP2

R1
3.3K

8 4 TP4
7
10V 2
TP8
Zener D3
555 6
R2 D1
3 5 20K IN4148

JP1 1

C2 C1
0.01uF 1nF

1 = Vcc
2 = Ground
3 = Gate Pulse

Figure 10.2: Control Circuit of ZCS-Buck Converter

3. The Frequency varied from 67 to 100 KHz.

4. The ON Time and OFF time equation for the 555 Timer is given by
𝑇𝑜𝑛 = 0693[𝑅1 + 𝑅2 ]𝐶1
𝑉𝑜𝑓𝑓 = 0.693𝑅2 𝐶1
5. The Frequency variation is done by keeping a Trim pot for 𝑅2 and a diode in parallel across
𝑅2 to bypass the resistor during the ON time.
6. The ON time is fixed to be 2.3 µsec. The parameters for 𝐶1 , 𝑅1 and 𝑅2 are calculated from
the above equation.
7. The condition for Zero Current Switching is given by

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 𝐶𝑟
𝐼𝑜 = 𝑉𝑔 √
𝐿𝑟

Figure 10.3: Power Circuit of ZCS-Buck Converter

8. The Resonant Frequency is selected to be 100 kHz and then from above equation, the value
for the resonant circuit can be evaluated as Lr = 2 µH and Cr=0.47 µF.
9. Here in Zero Current Switching, when the Resonant Inductor Current reaches zero then the
switch is turned OFF.
10. Jumper Settings: One of the possible setting of the jumpers are as follows:
Connect: JP1, JP2, JP6,
Do not connect: JP5, JP3, JP4

Questions:
1. Find the various operating modes for the circuit.
2. Determine the dynamic equations for the inductor current and capacitor voltage in each
mode.

IIT Bhubaneswar SMPC Lab P a g e | 70

 3. Evaluate the gain of the converter with frequency variation as the input.
4. Determine the variation required for variable pot to achieve the regulation.
5. Is it possible to switch from half bridge operation to full bridge operation or vice versa
in this circuit and what are the relative merit/demerits?

10.4 Practical Waveform of the ZCS-Buck Converter

Figure 10.4: Resonant Inductor Current and Capacitor Voltage

Figure 10.5: Gate Pulse form Control Circuit

IIT Bhubaneswar SMPC Lab P a g e | 71

 Figure 10.6: Inductor Current

Figure 10.7: Output Voltage

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10.5 Bill of Materials
Table 10.1: Bill of Material Table
Sl.No. Item Symbol Specification Quantity
1 Resistor R2 20k Ω pot 1
2 Resistor R1 3.3k Ω 1
3 Resistor Ro 3.33Ω 1
4 Resistor R10 10k Ω 1
5 Capacitor Co 47 µF 1
6 Capacitor C1 1nF 1
7 Capacitor C2 0.01 µF,63V 2
8 Capacitor Cr,Cr1 0.47 µF,25V 2
9 Filter Inductor Lo 110 µH 1
10 MOSFET M1 IRFZ44N 1
11 Resonant Inductor Lr 2 µH 1
12 Diode D2,D4 MUR110 2
13 Linear IC U1 555 TIMER 1
14 Test Points T1-T10 Berg Stick 20
15 Jumpers JP1-JP6 6

16 8 Pin IC Base U1b 1

17 Terminal Connector T1,T2 2

18 Heat Sink HS1 P149 2

19 Diode D3 Zener Diode (10V) 1
20 PCB ZCS-BUCK 1

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IIT Bhubaneswar SMPC Lab P a g e | 74