David E.

Sharpe
March 27, 2004
Solid-State Variac 01 (SSVAC01)

Circuit: An AC switch in series with power path to transformer consists of AC line
connected in series to (~) of an AC/DC bridge rectifer, and a suitably sized IGBT connected
across DC output of bridge (+ to C, - to E). Isolated single ended control 555 (1-99%) used
provide fixed frequency gate drive (gate drive: + to G, - to E, gate level ~ 13 V). A low pass filter
is connected between AC switch output and HV transformer load to reduce HF commutation
components of chopping operation, so the HV transformer (load) only
"sees" the 60Hz LF components. See sketch below:


















The above circuit is functionally the same as a small AC Variac. At low DC (small output voltage)
HFAC distortion can be seen in output, but at high output DC, there is virtually
no distortion.
EMI/RFI
FILTER
DIODE
BRIDGE
+ -
LOW
PASS
FILTER
IGBT
555 PWM
OPEN LOOP
CONTROLLER
LV DC PS
HV
TRF
RC SNBR
120
VAC
60Hz
to E, gate level ~ 13 V). A low pass filter
The above circuit is functionally the same as a small AC Variac. At low DC (small output voltage)
David E. Sharpe
March 27, 2004
Solid-State Variac 01 (SSVAC01)

Circuit: The below is a block diagram of actual circuit with pictures and short video. LV transformers bracketing
the AC PWM controller is to limit currrent in event of a short circuit, and allow probing of all circuit parameters safely at
low power. Also in present circuit, line side EMI/RFI as shown is not installed.



















EMI
/
RFI
DIODE
BRIDGE
+ -
LOW
PASS
FILTER
IGBT
555 PWM
OPEN LOOP
CONTROLLER
LV DC PS
RC SNBR
120
VAC
60Hz
LV
TRF
LV = 120
HV = 480
300VA
A
LV
TRF
LV = 36
HV = 120
300VA

Circuit: The below is a block diagram of actual circuit with pictures and short video. LV transformers bracketing
the AC PWM controller is to limit currrent in event of a short circuit, and allow probing of all circuit parameters safely at
HV
TRF
A
LV1 TRF
Vin 120 VAC
Vout 34 VAC
555 PWM Controller
DC Rectifier Vout 32 VDC
IDC to load 10 ADC
DC power throughput 320 W
IGBT V
drop
1.5 VDC
Bridge Rect. V
drop
1.4 VDC FORCE AIR COOL POWER ELECTRONICS
Power cell Pdis 29 W
(at full power)
Vin step up TRF2 32 VAC
Vout step TRF2 110 VAC
Videal 128 VAC
I line to NST 2.4 AAC 307.2
PVA to NST 264 VA
TRF2 loss 24 VA
(115 x 460, loss is
excessive IR, I
2
R loss)
Changes made since pictures were taken:
1. Changed 555 timing resistors to increase PWM carrier frequency from 1.2kHz to 12.6kHz.
Results: - Significantly reduced output distortion, especially at lower duty cycle settings.
- Reduced heating (Saturation?) in LP Filter inductor.
2. Increased IGBT gate drive resistor from 68 ohm to 1000 ohms.
Results: - Dramatically reduced dVdT, DI/dt switching noise, only very minor increase in
IGBT heating.
3. Added RC snubbber across C E connections of IGBT (20 ohm, 10W, 20nF, 600VDC)
Results: - Reduced noise (meaured 5X reduction in noise peak amplitude across IGBT).