PWM for HHO Electrolysis Water

TL 494 15 Amp DC Motor Speed Control

12V Dimmer

A dimmer is quite unusual in a caravan or on a boat. Here we describe how you can make one. So if you would like to be able to adjust the mood when you’re entertaining friends and acquaintances, then this circuit enables you to do so. Designing a dimmer for 12 V is tricky business. The dimmers you find in your home are designed to operate from an AC voltage and use this AC voltage as a fundamental characteristic for their operation. Because we now have to start with 12 V DC, we have to generate the AC voltage ourselves.

 

We also have to keep in mind that we’re dealing with battery-powered equipment and have to be frugal with energy. The circuit that we finally arrived at can easily drive 6 lamps of 10 W each. Fewer are also possible, of course. In any case, the total current has to be smaller than 10 A. L1 and S1 can be adapted to suit a smaller current, if required. Note that the whole circuit will also work from 6 V.

Discrete PWM Generator Circuit

PWM waveforms are commonly used to control the speed of DC motors. The mark/space ratio of the digital wave-form can be defined either by using an adjustable analogue voltage level (in the case of a NE555 based PWM generator) or digitally using binary values. Digitally derived PWM waveforms are most often produced by the timer/counter modules in microcontrollers but if you do not want to include a microcontroller in your circuit it’s also quite simple to generate the signals using discrete logic components.

An extension of the circuit shown can produce two PWM wave-forms from an 8-bit digital input word. Each signal has 15 values. The 8-bit word can be produced for example from an expansion board fitted in a PC or from an 8-bit port of a processor which does not have built-in PWM capability or from a laptop’s printer port. The mark/space ratio is only programmable up to 15/16 rather than 16/16; a binary input of 0000 produces a continuous low on both outputs turning both motors off.

Similar circuits often employ a dedicated ‘enable’ input to turn the motors off but it is not necessary in this design. The diagram shows the circuitry required to produce just one waveform. For the full two channel circuit it is necessary to use an additional 74HC193. The clock signal produced by the HCF4060 generator can be used to drive both channels and the free flip flop in the 74HC74 package can be used for the second channel (the corresponding pin numbers are shown in brackets). Altogether the entire two channel circuit can be built using just four ICs.

Bipolar Stepper Motor Control

First, we want to explain how such a controller works and what’s involved. A bipolar motor has two windings, and thus four leads. Each winding can carry a positive current, a negative current or no current. This is indicated in Table 1 by a ‘+’, a ‘–‘ or a blank. A binary counter (IC1) receives clock pulses, in response to which it counts up or down (corresponding to the motor turning to the left or the right). The counter increments on the positive edge of the pulse applied to the clock input if the up/down input is at the supply level, and it decrements if the up/down input is at earth level.

The state of the counter is decoded to produce the conditions listed in Table 2. Since it must be possible to reverse the direction of the current in the winding, each winding must be wired into a bridge circuit. This means that four transistors must be driven for each winding. Only diagonally opposed transistors may be switched on at any given time, since otherwise short circuits would occur. At first glance, Table 2 appears incorrect, since there seem to always be four active intervals. However, you should consider that a current flows only when a and c are both active. The proper signals are generated by the logic circuitry, and each winding can be driven by a bridge circuit consisting of four BC517 transistors.

Two bridge circuits are needed, one for each winding. The disadvantage of this arrangement is that there is a large voltage drop across the upper transistors in particular (which are Darlingtons in this case). This means that there is not much voltage left for the winding, especially with a 5-V supply. It is thus better to use a different type of bridge circuit, with PNP transistors in the upper arms. This of course means that the drive signals for the upper transistors must be reversed. We thus need an inverted signal in place of 1a. Fortunately, this is available in the form of 1d.

The same situation applies to 1b (1c), 2a (2d) and 2b (2c). In this case, IC4 is not necessary. Stepper motors are often made to work with 12V. The logic ICs can handle voltages up to 15 to 18 V, so that using a supply voltage of 12 V or a bit higher will not cause any problems. With a supply voltage at this level, the losses in the bridge circuits are also not as significant. However, you should increase the resistor values (to 22 kΩ, for example). You should preferably use the same power supply for the motor and the controller logic. This is because all branches of the bridge circuit will conduct at the same time in the absence of control signals, which yields short-circuits.

PWM Dimmer/Motor Speed Controller

This is yet another project born of necessity. It's a simple circuit, but does exactly what it's designed to do - dim LED lights or control the speed of 12V DC motors. The circuit uses PWM to regulate the effective or average current through the LED array, 12V incandescent lamp (such as a car headlight bulb) or DC motor. The only difference between the two modes of operation is the addition of a power diode for motor speed control, although a small diode should be used for dimmers too, in case long leads are used which will create an inductive back EMF when the MOSFET switches off.

The photo shows what a completed board looks like. Dimensions are 53 x 37mm, so it's possible to install it into quite small spaces. The parts used are readily available, and many subsitiutions are available for both the MOSFET and power diode (the latter is only needed for motor speed control). The opamps should not be substituted, because the ones used were chosen for low power and their ability to swing the output to the negative supply rail.

Note that if used as a motor speed controller, there is no feedback, so motor speed will change with load. For many applications where DC motors are used, constant speed regardless of load is not needed or desirable, but it is up to you to decide if this will suit your needs.

Description

First, a description of PWM is warranted. As the pot is rotated clockwise, the input voltage changes linearly with rotation. At first, the voltage is such that the comparator output is just narrow spikes, which turn the MOSFET on for a very short period. Average current is low, so connected LEDs will be quite dim, or a motor will run (relatively) slowly. As the input voltage coming from the pot increases, the MOSFET is on for longer and longer, so increasing power to the load.

Figure 1 - PWM Waveform Generation

Figure 1 shows how the PWM principle works. The red trace is the triangle wave reference voltage, and the green trace is the voltage from the pot. When the input voltage is greater than the reference voltage, the MOSFET turns on, and current flows in the load. Because the frequency is relatively high (about 600Hz), we don't see any flicker from the LEDs, but the tone is audible from a motor that's PWM controlled. The PWM signal is shown in blue. The average current through the load is determined by the ratio of on-time to off-time, and when both are equal, the average current is exactly half of that which would be drawn with DC.

The circuit is shown in Figure 2. U1 is the oscillator, and generates a triangular waveform. R4 and R5 simply set a half voltage reference, so the opamps can function around a 6V centre voltage. U2A is an amplifier, and its output is a 10V peak to peak triangle wave that is used by the comparator based on U2B. This circuit compares the voltage from the pot with the triangle wave. If the input voltage is at zero, the comparator's output remains low, and the MOSFET is off. This is the zero setting.

In reality, the reference triangle waveform is from a minimum of about 1.5V to a maximum of 9.5V, so there is a small section at each end of the pot's rotation where nothing happens. This is normal and practical, since we want a well defined off and maximum setting. Because of this range, for lighting applications, an industry standard 0-10V DC control signal can be used to set the light level. C-BUS (as well as many other home automation systems) can provide 0-10V modules that can control the dimmer.

While a 1N4004 diode is shown for D2, this is only suitable if the unit is used as a dimmer. For motor speed control, a high-current fast recovery diode is needed, such as a HFA15TB60PBF ultra-fast HEXFRED diode. There are many possibilities for the diode, so you can use whatever is readily available that has suitable ratings. The diode should be rated for at least half the full load current of the motor, and the HFA15TB60PBF suggested is good for 15A continuous, so is fine with motors drawing up to 30A.

Construction

While it's certainly possible to build the dimmer on veroboard or similar, it's rather fiddly to make and mistakes are easily made. Also, be aware that because of the current the circuit can handle, you will need to use thick wires to reinforce some of the thin tracks. This is even necessary for the PCB version. Naturally, I recommend the PCB, and this is available from ESP. The board is small - 53 x 37mm, and it carries everything, including the screw terminals. The PCB is double-sided with plated-through holes, and has solder masks on both sides.

The MOSFET will need a heatsink unless you are using the dimmer for light loads only. It is necessary to insulate the MOSFET from the heatsink in most cases, since the case of the transistor is the drain (PWM output). For use at high current and possible high temperatures, the heatsink may need to be larger than expected. Although the MOSFET should normally only dissipate about 2W or so at 10A, it will dissipate a lot more if it's allowed to get hot. Switching MOSFETs will cheerfully go into thermal runaway and self destruct if they have inadequate heatsinking. You may also use an IGBT (insulated gate bipolar transistor) - most should have the same pinouts, and they do not suffer from the same thermal runaway problem as MOSFETs.

As noted above, there are many different MOSFETs (or IGBTs) and fast diodes that are usable. The IRF540 MOSFET is a good choice, and being rated 27A it has a generous safety margin. There are many others that are equally suitable - in fact any switching MOSFET rated at 10A or more, and with a maximum voltage of more than 20V is quite ok.

Testing

Connect to a suitable 12V power supply. When powering up for the first time, use a 100 ohm "safety" resisor in series with the positive supply to limit the current if you have made a mistake in the wiring. The total current drain is about 2.5mA with the pot fully off, rising to 12.5mA when fully on. Most of this current is in the LED, which is also fed from the PWM supply so you can see that everything is working without having to connect a load.

Make sure that the pot is fully anti-clockwise (minimum), and apply power. You should measure no more than 0.25V across the safety resistor, rising to 1.25V with the pot at maximum. If satisfactory, remove the safety resistor and install a load. High intensity LED strip lights can draw up to ~1.5A each, and this dimmer should be able to drive up to 10 of them, depending on the capabilities of the power supply and the size of the heatsink for the MOSFET.

10 to 1000 MHz Oscillator

Nowadays, it is no longer necessary to use discrete components to build oscillators. Instead, many manufacturers provide ready-made voltage-controlled oscillator (VCO) ICs that need only a few frequency-determining external components. One example is the RF Micro Devices RF2506. This IC operates with a supply voltage between 2.7 and 3.6 V (3.3V nominal) and provides a low-noise oscillator transistor with integrated DC bias setting. In addition, it has an isolating buffer amplifier that strongly reduces the effects of load variations (load pulling) on the oscillator. If a voltage less than 0.7V is applied to the power-down input (pin 8), the oscillator is shut down and the current consumption drops from 9mA to less than 1µA. The VCO is enabled when the voltage on pin 8 is at least +3V.

Connecting the feedback capacitors C1 and C2 to pins 3 (FDBK) and 4 (VTUNE) transforms the internal transistor into a Colpitts oscillator. A resonator is also needed; here this consists of C4 and L1, and it is coupled via C3. Keep the Q factor of the coil as high as possible (by using an air-core coil, for example), to ensure a low level of phase noise. Since most applications require a tuneable oscillator, the varicap diode D1 (BBY40, BBY51, BB804 etc) can be used to adjust the resonant frequency. The tuning voltage UTune is applied via a high resistance. The value of the tuning voltage naturally depends on the desired frequency range and the variable-capacitance diode (D1) that is used. The table shows a number of suggestions for selecting the frequency-determining components. If the frequency range is narrow, a parallel-resonant circuit should be connected between the output pin and +Vcc, to form the collector load for the output transistor.

This can be built using the same components as the oscillator resonator. With a broadband VCO, use a HF choke instead, with a value of a few microhenries to a few nanohenries, depending on the frequency band. In this case C6 is not needed. The output level of this circuit is –3dBm with an LC load and –7 dBm with a choke load. The table that accompanies the schematic diagram provides rough indications of component values for various frequencies. It is intended to provide a starting point for experimentation. The coupling between the variable-capacitance diode and C5 determines the tuning range of the VCO. The manufacturer maintains an Internet site at www.rfmd.com, where you can find more information about this interesting oscillator IC.

12V Speed Controller/Dimmer

This handy circuit can be used as a speed controller for a 12V motor rated up to 5A (continuous) or as a dimmer for a 12V halogen or standard incandescent lamp rated up to 50W. It varies the power to the load (motor or lamp) using pulse width modulation (PWM) at a pulse frequency of around 220Hz. SILICON CHIP has produced a number of DC speed controllers over the years, the most recent being our high-power 24V 40A design featured in the March & April 2008 issues. Another very popular design is our 12V/24V 20A design featured in the June 1997 issue and we have also featured a number of reversible 12V designs.

Circuit looks like:

For many applications though, most of these designs are over-kill and a much simpler circuit will suffice. Which is why we are presenting this basic design which uses a 7555 timer IC, a Mosfet and not much else. Being a simple design, it does not monitor motor back-EMF to provide improved speed regulation and nor does it have any fancy overload protection apart from a fuse. However, it is a very efficient circuit and the kit cost is quite low.

Parts layout:

There are many applications for this circuit which will all be based on 12V motors, fans or lamps. You can use it in cars, boats, and recreational vehicles, in model boats and model railways and so on. Want to control a 12V fan in a car, caravan or computer? This circuit will do it for you.

Circuit diagram:

The circuit uses a 7555 timer (IC1) to generate variable width pulses at about 210Hz. This drives Mosfet Q3 (via transistors Q1 & Q2) to control the speed of a motor or to dim an incandescent lamp.
Halogen lamps: 

 
While the circuit can dim 12V halogen lamps, we should point out that dimming halogen lamps is very wasteful. In situations where you need dimmable 12V lamps, you will be much better off substituting 12V LED lamps which are now readily available in standard bayonet, miniature Edison screw (MES) and MR16 halogen bases. Not only are these LED replacement lamps much more efficient than halogen lamps, they do not get anywhere near as hot and will also last a great deal longer.

Small DC Motor Control Using PWM

Small DC motors are efficiently controlled using pulse-width modulation (PWM) method. The circuit described here is built around an LM324 low-power quad-operational amplifier. Of the four op-amps (operational amplifiers) available in this IC, two are used for triangular wave generator and one for comparator. Op-amp N2 generates a 1.6kHz square wave, while op-amp N1 is configured as an integrator. The square wave output of N2 at its pin 14 is fed to the inverting input (pin 2) of N1 through resistor R1. As N1 is configured as an integrator, it outputs a triangular wave of the same frequency as the square wave. The triangular wave is fed to pin 5 of op-amp N3, which is configured as a comparator.

Small DC Motor Control Circuit Diagram :

The reference voltage at pin 6 of the comparator is fixed through the potential divider arrangement formed by potmeter VR1 and resistors R4 and R5. It can be set from –6V (lowermost position of VR1) to +6V (uppermost position of VR1). 

  

The triangular wave applied at pin 5 of N3 is compared with the reference voltage at its pin 6. The output at pin 7 is about +12V when the voltage at pin 5 is greater than the voltage at pin 6. Similarly, the output at pin 7 is about -12V when the voltage at pin 5 is lower than the voltage at pin 6.

The output from comparator N3 is the gate voltage for n-channel MOSFET (T1). T1 switches on when the gate voltage is positive and switches off when the gate voltage is negative. Setting of the reference voltage therefore controls the pulse-width of the motor. When T1 is switched on for a longer period, the pulse width will be wider, which means more average DC component and faster speed of the motor. Speed will be low when the pulse width is small. Thus potmeter VR1 controls the speed of the motor.

Assemble the circuit on a general-purpose PCB and enclose in a suitable cabinet. The circuit requires ±12V power supply for its working. It can also be modified to control the speed of a 6V or 24V DC motor.

Low Frequency Sinewave Generators

The two circuits below illustrate generating low frequency sinewaves by shifting the phase of the signal through an RC network so that oscillation occurs where the total phase shift is 360 degrees. The transistor circuit on the right produces a reasonable sinewave at the collector of the 3904 which is buffered by the JFET to yield a low impedance output. The circuit gain is critical for low distortion and you may need to adjust the 500 ohm resistor to achieve a stable waveform with minimum distortion. The transistor circuit is not recommended for practical applications due to the critical adjustments needed. 

The op-amp based phase shift oscillator is much more stable than the single transistor version since the gain can be set higher than needed to sustain oscillation and the output is taken from the RC network which filters out most of the harmonic distortion. The sinewave output from the RC network is buffered and the amplitude restored by the second (top) op-amp which has gain of around 28dB. Frequency is around 600 Hz for RC values shown (7.5K and 0.1uF) and can be reduced by proportionally increasing the network resistors (7.5K). The 7.5K value at pin 2 of the op-amp controls the oscillator circuit gain and is selected so that the output at pin 1 is slightly clipped at the positive and negative peaks. The sinewave output at pin 7 is about 5 volts p-p using a 12 volt supply and appears very clean on a scope since the RC network filters out most all distortion occurring at pin 1.

Generating Long Time Delays

Generating long delays of several hours can be accomplished by using a low frequency oscillator and a binary counter as shown below. A single Schmitt Trigger inverter stage (1/6 of 74HC14) is used as a squarewave oscillator to produce a low frequency of about 0.5 Hertz. The 10K resistor in series with the input (pin 1) reduces the capacitor discharge current through the inverter input internal protection diodes if the circuit is suddenly disconnected from the supply. This resistor may not be needed but is a good idea to use. The frequency is divided by two at each successive stage of the 12 stage binary counter (CD4040) which yields about 1 hour of time before the final stage (Q12) switches to a high state. Longer or shorter times can be obtained by adjusting the oscillator frequency or using different RC values. Each successive stage changes state when the preceding stage switches to a low state (0 volts), thus the frequency at each stage is one half the frequency of the stage before. Waveform diagrams are shown for the last 3 stages. To begin the delay cycle, the counter can be reset to zero by momentarily connecting the reset line (pin 11) to the positive supply. Timing accuracy will not be as good as with a crystal oscillator and may only be around 1 or 2% depending on the stability of the oscillator capacitor.

Ignition Coil Buzz Box

Here's a circuit to create a buzzcoil using a standard automotive ignition coil. A 556 dual timer is used to establish the frequency and duty cycle of the coil current. One of the timers is used as an oscillator to generate the 200 Hz rectangular waveform needed to control the (IRF740 MOSFET) while the second timer switches the oscillator on and off as the breaker points open and close (closed = on). The result is a steady stream of sparks from the ignition coil spaced about 5 milliseconds apart while the breaker points are closed. 

Operation:
Pin 8 and 12 are the threshold and trigger inputs of one timer which are driven by the breaker points and produce an inverted signal at the timer output (pin 9). When the points are closed to ground, pin 9 will be high and visa versa. The signal at pin 9 controls the reset line (pin 4) of the second timer and holds the output at pin 5 low while pin 4 is low and pins 8 and 12 are high (points open). The 15K and 4.7K resistors and 0.33uF capacitor are the timing components that establish the frequecy and duty cycle of the second timer which is about 4 milliseconds for the positive interval and 2 milliseconds for the negative. During the positive time interval, the MOSFET gates are held high which causes the ignition coil current to rise to about 4 amps. This equates to about 80 millijoules of energy in the coil which is released into the spark plug when the timer output (pin 5) moves to ground, turning off the MOSFET. A 12 volt zener diode is placed at the junction of the 10 and 27 ohm resistors to insure the MOSFET gate input never goes above 12 volts or lower than -0.7 volts. A 200 volt/5 watt zener is used at the MOSFET drain to limit the voltage to +200 and lengthen the spark duration. The circuit should operate reliably with a shorted plug, however operating the circuit with no load connected (plug wires fallen off, etc.) may cause a failure due to most of the power being absorbed by the zener. You can also use a transient voltage suppressor (TVS) such as the 1.5KE200A or 1.5KE300A in place of the zener. It's probably a better part, but hard to obtain.

Monostable Flip Flop

The monostable flip flop, sometimes called a 'one shot' is used to produce a single pulse each time it is triggered. It can be used to debounce a mechanical switch so that only one rising and one falling edge occurs for each switch closure, or to produce a delay for timing applications. In the discrete circuit, the left transistor normally conducts while the right side is turned off. Pressing the switch grounds the base of the conducting transistor causing it to turn off which causes the collector voltage to rise. As the collector voltage rises, the capacitor begins to charge through the base of the opposite transistor, causing it to switch on and produce a low state at the output. The low output state holds the left transistor off until the capacitor current falls below what is needed to keep the output stage saturated. When the output side begins to turn off, the rising voltage causes the left transistor to return to it's conducting state which lowers the voltage at it's collector and causes the capacitor to discharge through the 10K resistor (emitter to base). The circuit then remains in a stable state until the next input. The one shot circuit on the right employs two logic inverters which are connected by the timing capacitor. When the switch is closed or the input goes negative, the capacitor will charge through the resistor generating an initial high level at the input to the second inverter which produces a low output state. The low output state is connected back to the input through a diode which maintains a low input after the switch has opened until the voltage falls below 1/2 Vcc at pin 3 at which time the output and input return to a high state. The capacitor then discharges through the resistor (R) and the circuit remains in a stable state until the next input arrives. The 10K resistor in series with the inverter input (pin 3) reduces the discharge current through the input protection diodes. This resistor may not be needed with smaller capacitor values.

Note: These circuits are not re-triggerable and the output duration will be shorter than normal if the circuit is triggered before the timing capacitors have discharged which requires about the same amount of time as the output. For re-triggerable circuits, the 555 timer, or the 74123 (TTL), or the 74HC123 (CMOS) circuits can be used.

Bistable Flip Flop

Here are two examples of bistable flip flops which can be toggled between states with a single push button. When the button is pressed, the capacitor connected to the base of the conducting transistor will charge to a slightly higher voltage. When the button is released, the same capacitor will discharge back to the previous voltage causing the transistor to turn off. The rising voltage at the collector of the transistor that is turning off causes the opposite transistor to turn on and the circuit remains in a stable state until the next time the button is pressed and released. Note that in the LED circuit, the base current from the conducting transistor flows through the LED that should be off, causing it to illuminate dimly. The base current is around 1 mA and adding a 1K resistor in parallel with the LED will reduce the voltage to about 1 volt which should be low enough to ensure the LED turns completely off.

Triangle and Squarewave Generator

Here is a simple triangle/squarewave generator using a common 1458 dual op-amp that can be used from very low frequencies to about 10 Khz. The time interval for one half cycle is about R*C and the outputs will supply about 10 milliamps of current. Triangle amplitude can be altered by adjusting the 47K resistor, and waveform offset can be removed by adding a capacitor in series with the output.

Astable Multivibrator

Low Frequency Wien Bridge RC Sinewave Oscillators

32.768 KHz oscillator using a watch crystal

Below are a couple circuits you can use to produce a 32.768 KHz square wave from a common watch crystal. The output can be fed to a 15 stage binary counter to obtain a 1 second square wave. The circuit on the left using the 4069 inverter is recommended over the transistor circuit and produces a better waveform. The single transistor circuit produces more of a ramping waveform but the output swings the full supply voltage range so it will easily drive the input to a CMOS binary counter.

Universal Signal Generator

Three-Phase Square Wave Oscillator