EEK 471 LAB 8

Universiti Sains Malaysia Electrical Engineering Department Advanced Power Electronic Laboratory EEK471

The MOSFET Buck Chopper

INTRODUCTION The buck chopper Transformers are of great importance in electric circuits because they allow voltage and current levels to be converted. However, transformers operate only with ac power. When dc voltage and current levels must be converted, choppers can be used. For example, a step-down transformer is normally used to convert an ac voltage into a lower ac voltage. With dc power, a similar conversion can be performed using a buck chopper. Choppers uses very fast semiconductor switches to convert dc voltages and currents from higher to lower levels and vice versa. The semiconductor switches can be designed with bipolar transistors, metal oxide semiconductor field-effect transistors (MOSFETs), diodes, thyristors, etc. Figure 1 shows a buck chopper built with a MOSFET (Q) and a diode (D), and some waveforms related to this circuit.

Figure 1: Operation of a buck chopper.

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When MOSFET Q switches on, the dc power supply voltage, (V) is applied to the load, diode D automatically switches off, and the current flowing in the load (lo) starts to increase. When MOSFETQ switches off, the dc power supply voltage is no longer applied to the load, diode D automatically switches on, and the current continues flowing in the load through diode D, but it starts to decrease. Diode D is usually referred to as a free-wheeling diode since it provides an alternative path for the load current, which continues to flow when MOSFET Q is off. The dc voltage at the buck chopper output (VO) is proportional to the dc voltage at the buck chopper input (VI) and the time MOSFET Q is on during each cycle. This time, which is referred to as the on-time (ton), is in turn proportional to the duty cycle (ton/T) of the switching control signal applied to the gate of MOSFET Q. The equation relating voltages VO and VI s given by the expression: VO = VI x Thus, voltage VO can be varied by varying the duty cycle . Since the duty cycle can vary between 0 and 1, voltage VO cannot exceed voltage V. Varying the frequency of the switching control signal while maintaining the duty cycle constant does not vary the voltage VO and the dc current at the buck chopper output (lo), However, the ripple on the current lo decreases as the frequency of the switching control signal increases. The power which the buck chopper delivers at its output (PO) is equal to the power it receives at its input (PI) minus the power dissipated in the semiconductor switch. The power dissipated in the semiconductor switch is usually small compared to the power PO. The power efficiency of buck choppers, thus, often exceeds 90% and can even approach 100%. Notice that the power efficiency is the ratio of the output power on the input power times 100%, as stated in the following equation: Power Efficiency = (PO / PI) x 100% EQUIPMENTS EMS 8821 Enclosure Power Supply EMS 8840-0A PE Power Supply EMS 8837-0A Power Mosfets Module EMS 9029-00 Chopper/Inverter Control Unit EMS 8412-05 Lab-Volt DC Voltmeter/Ammeter EMS 8311 Variable Resistance EMS 8325 Smoothing Inductor EMS 9056-15 and EMS 9056-05 Voltage/Current Isolator 24V AC Power Switch Textronic Oscilloscope Connection Leads BNC-connector cable

WARNINGS The voltages and currents that are used during this lab are larger and rated at 240VDC Line-toNeutral with current as high as 20 amps (or higher if circuits are improperly connected). Please take the proper precautions and use your head before touching any circuitry. NEVER change any circuit connections while the power supply is turned on. Ask the demonstrator to check your connections before turning on the switches. And follow the rating of voltmeters and ammeters given to prevent equipments from damaged.

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Experiment: Part I Operation of the MOSFET buck chopper 1. In this part, you will use the circuit shown in Figure 1a to observe the operation of a MOSFET buck chopper. In this circuit, the output of the MOSFET buck chopper is connected to a current-type load consisting of resistor R and inductor L. A voltage isolator and a current isolator will allow you to observe the waveforms of the voltage and current at the MOSFET buck chopper output. Connect the modules as shown in Figure 1a. 2. Note that diode D4 is the power diode connected in parallel with MOSFET Q4. Diode D1, which is connected in parallel with MOSFET Q1 and MOSFET Q4 are not shown in Figure 1a because they are useless in this circuit. MOSFET Q4 is forced to the off state by connecting SWITCHING CONTROL INPUT 4 of the Power MOSFETS module to the common point.

Figure 1a: Circuit of the MOSFET buck chopper

Figure 1b: Load R = 343 and L = 3.2H

Line Voltage (VAC) 0 - 240

Table 1a: Parameters setting e1 (V) E1(V) i1 (A) I1 (A) 600 300 5 1.5

R () 343

L(H) 3.2

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3. Make the following settings on the Chopper/Inverter Control Unit DC SOURCE 1 Minimum DC SOURCE 2 Mid position MODE CHOP. PWM 4. Make sure that the main power switch of the Power Supply is set to the 0 (OFF) position. Set the voltage control knob to 0. 5. Set the 24V ac power switch to the 1 (ON) position. The POWER ON LED on the Power MOSFETS module should light up to indicate that the module is correctly powered. 6. Set the main power switch to 1 (ON) and slowly set the voltage control knob to 50(%). This supplies dc power to the MOSFET buck chopper. On the oscilloscope, make the appropriate settings to position the traces of channels 1 and 2 in the upper and lower halves of the screen, respectively. The trace of channel 1 represents the waveform of the voltage across the load connected to the MOSFET buck chopper output. The trace of channel 2 represents the switching control signal applied to MOSFET Q1. 7. On the Chopper/Inverter Control Units, set the DC SOURCE 2 control knob so that the period of the switching control signal to approximately 5 ms. Consequently the operating frequency of the MOSFET buck chopper is approximately 200 Hz. Sketch the waveforms displayed on the oscilloscope screen in Figure 1c.

Figure 1c: The switching control signal applied to MOSFET Q1 and the waveform of the voltage across the load connected to the MOSFET buck chopper output. From the waveforms sketched in Figure 1c, explain why a low dc voltage appears across the load, as indicated by the DC Voltmeter/Ammeter. 8. On the Chopper/Inverter Control Unit, slowly set the DC SOURCE 1 control knob to the MAX position while observing the voltage indicated by the DC Voltmeter/Ammeter and the waveforms on the oscilloscope screen. Describe how the dc voltage at the MOSFET buck chopper output varies when the duty cycle of the switching control signal is increased. Explain why this circuit is referred to as a buck chopper, knowing that the duty cycle of the switching control signal is now set to maximum. 9. On the Chopper/inverter Control Unit, set the DC SOURCE 1 control knob back to the MIN position, then slowly set this control knob to the MAX position while observing the current indicated by the DC Voltmeter/Ammeter. Does the polarity of the dc current flowing in the load change as the duty cycle of the switching control signal varies? In which direction does the power flow?

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10. On the Chopper/Inverter Control Unit, set the DC SOURCE 1 control knob so that the duty cycle of the switching control signal is equal to 50%. Measure and note the output voltage of the variable-voltage dc power supply (VI). It is indicated by the meter on the Power supply. VI = ________ V dc Calculate the dc voltage which should appear at the output of the MOSFET buck chopper using the following equation: VO = x VI VO = ________ V dc On the DC Voltmeter/Ammeter, measure and note the output voltage of the MOSFET buck chopper. VO (measured) = ________ V dc Does the measured output voltage correspond to the calculated output voltage? 11. On the Chopper/Inverter Control Unit, slowly turn the DC SOURCE 2 control knob in both directions to vary the frequency of the switching control signal, while observing the voltage and current indicated by the DC Voltmeter/Ammeter. Does the frequency of the switching control signal have a significant effect on the dc voltage and current the MOSFET buck chopper provides? If so, describe this effect. Does the frequency of the switching control signal have a significant effect on the ripple on the current flowing in the load? If so, describe this effect.

12. Turn OFF all power supplies connected to the circuit but do not remove any connections because in Part II you will use it once again.

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Experiment: Part II Output power versus input power 1. Make sure that the main power switch of the Power Supply is set to the 0 (OFF) position. Set the voltage control knob to 0. In this part, you will use the similar circuit as in Figure 1a but this time you will add a dc ammeter at the input of the MOSFET buck. This circuit will allow you to determine the power at the input and output of the MOSFET buck chopper, the voltage of the variable dc power supply being known. You will then compare the output power to the input power and determine the power efficiency of the chopper. 2. Set up the circuit using parameters in Table 2a. Connect the second dc ammeter I2 of the DC Voltmeter/Ammeter in series with MOSFET Q1. Line Voltage (V) 0 - 240 I1 dc (A) 1.5 I2 dc (mA) 300 Table 2a: Parameters setting i1 (A) E1 dc (V) e1 (V) 5 300 600 R() 343 L(H) 3.2

3. Make the following settings on the Chopper/Inverter Control Unit DC SOURCE 1 Minimum DC SOURCE 2 Maximum MODE CHOP. PWM 4. Set the main power switch of the Power Supply to the 1 (ON) position. Then slowly set the voltage control knob of the power supply to 50%. 5. On the Chopper/Inverter Control Unit set the DC SOURCE 1 control knob so that the variable-voltage power supply provides current I2 approximately 200mA. 6. On the Power Supply and the DC Voltmeter/Ammeter, measure and note the dc voltage and current which the variable-voltage dc power supply supplies to the MOSFET buck chopper and to the load. Use these results to calculate the power which is supplied to the MOSFET buck chopper PI and PO. Note the resulting power in the space below. PI = ________ W PO = ________ W Calculate the power efficiency of the MOSFET buck chopper using the following equation:

Power efficiency = (PO / PI) x 100% Power efficiency = ________ % Is the power at the output of the MOSFET buck chopper nearly equal to the power at its input? 7. On the Power Supply, set the voltage control knob to the 0 position then set the main power switch and the 24 V ac power switch to the 0 position. Set the rocker switch on the Enclosure/ Power Supply to the 0 position. Remove all leads, cables and probes.

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REVIEW QUESTIONS 1. A MOSFET buck chopper is powered by a 300V dc power supply. What is the output voltage range of this chopper if the duty cycle can vary between 5% and 95%? 2. Briefly describe the operation of the MOSFET buck chopper. 3. Explain why a diode is connected across the output terminals of a MOSFET buck chopper. 4. Describe the effects the switching control signal frequency has on the output voltage and current of a MOSFET buck chopper. Explain. 5. Name the component operating with ac power which best compares to the MOSFET buck chopper.