Universal Driver 2.7 Rev C
loneoceans, Wed Sept 10 2014, 06:11AM[Update - Third UD27C batch (blue) all sold out! - Also see
for updates on 24VDC input if you're using a UD2.7A/B board!Hi everyone,
I wanted to make a few universal drivers for myself but there were a couple of things I wanted to change on the existing designs, so I made a bunch of changes and I've named it UD2.7. Thought you guys might be interested since the changes may be useful. Original design credit goes all to Steve Ward! Also many thanks to the work of Bart Anderson, Philip Slawinski and Eric Goodchild for previous revisions of the board.
With permission from Steve Ward, I'll be posting a link to all the schematics, .brd .sch and gerber files, BOM, along with a write up to document it a bit more in detail which might be useful as a reference.
see the UD2.7 page here:
Some of the things I wanted to change included added a under voltage lockout, removing all the hot linear regulators, as well as making it easier to solder by hand and to use. The main logic and drive circuits are unchanged from the previous UD2.5 and therefore should be a tested and proven design.
Here is a small list of improvements:
- Heat-smearing 9V regulator replaced with a switching regulator (but still TO-220 compatible if you really want, with space for heatsink)
- All other regulators replaced with SMD ones, reducing overall height of the board and increasing robustness
- Added on-board blue LED for power indication!
- Under-voltage Lockout added, a feature I really wanted and circuit suggested by Hydron
- Flattened ground plane and some re-worked traces and component placing
- Added new 24VDC input jack for use with small SMPS DC power supply instead of heavy transformer
- Increased solder pads for hard-to-solder components such as the dual MOSFETs
- Added series capacitor with 15R resistor in parallel with 2uF GDT output capacitor to prevent burning out resistor in event of malfunction
- Improved silkscreen for easier use (e.g. LED breakout jack now labeled on top)
- All through-hole resistors are now flat instead of standing up for increased robustness
- Some components changed to further reduce height of board
- Board is now even slightly smaller to fit in smaller boxes
- Main component reference IDs (e.g. C33) maintained for easy discussion on forums
- .. along with all the previous improvements from previous versions
[new improvements for Rev B]
- Improved silkscreen
- Additional optional gate-drive capacitor
- Added UVLO adjustment potentiometer for lock-out adjustment (or you can use a resistor instead for a fixed one)
[new improvements for Rev C]
- Even more improved silkscreen for less confusion
- Fixed error in UD2.7A/B
- Daisy chained 9V regulator back to original for maximum 28VAC input (19-26.5V nominal)
- Improved regulator placement for better heat sinking
- Other cosmetic improvements
[Update: New photos of completed boards] Here's how the boards look like. I also have a lot of boards, looks great in red.
Oh where did the voltage regulators go?
I've hidden them at the bottom-side of the board :) I'll be posting much more information in the coming days, so be sure to check this thread for updates.
Thanks everyone.
Re: Universal Driver 2.7 Rev C
Graham Armitage, Wed Sept 10 2014, 02:09PM
That looks really neat - nice job. I am currently building a UD2.5 board, but like the modifications you have made. Especially the 24v power supply to replace the bulky transformer. Thanks for offering to share the files. Planning on selling drivers/boards in the future?
Graham Armitage, Wed Sept 10 2014, 02:09PM
That looks really neat - nice job. I am currently building a UD2.5 board, but like the modifications you have made. Especially the 24v power supply to replace the bulky transformer. Thanks for offering to share the files. Planning on selling drivers/boards in the future?
Re: Universal Driver 2.7 Rev C
Vitalii, Wed Sept 10 2014, 02:33PM
Hey, can I use it with half bridge from Steve's DRSSTC3?
Vitalii, Wed Sept 10 2014, 02:33PM
Hey, can I use it with half bridge from Steve's DRSSTC3?
Re: Universal Driver 2.7 Rev C
loneoceans, Thu Sept 11 2014, 06:19PM
Yes I have more boards than I need so I'd be happy to sell them for cheap, but before that I'll be testing this extensively to make sure everything works as expected. So far it's looking pretty good. Documentation takes a bit of time but I'll try to get it up within a week or two along with testing the board. And yes this board will for sure be able to run half bridges to full bridges as well as for use in QCW (the normal buck converter kind not the phase shifted ones) with little or no modification.
loneoceans, Thu Sept 11 2014, 06:19PM
Graham Armitage wrote ...
That looks really neat - nice job. I am currently building a UD2.5 board, but like the modifications you have made. Especially the 24v power supply to replace the bulky transformer. Thanks for offering to share the files. Planning on selling drivers/boards in the future?
That looks really neat - nice job. I am currently building a UD2.5 board, but like the modifications you have made. Especially the 24v power supply to replace the bulky transformer. Thanks for offering to share the files. Planning on selling drivers/boards in the future?
Yes I have more boards than I need so I'd be happy to sell them for cheap, but before that I'll be testing this extensively to make sure everything works as expected. So far it's looking pretty good. Documentation takes a bit of time but I'll try to get it up within a week or two along with testing the board. And yes this board will for sure be able to run half bridges to full bridges as well as for use in QCW (the normal buck converter kind not the phase shifted ones) with little or no modification.
Re: Universal Driver 2.7 Rev C
loneoceans, Fri Sept 19 2014, 06:16PM
A little more updates. Did some preliminary testing of the new board and so far everything works exactly as expected. Here's the UD2.7 with basic testing, alongside an older UD2.1 in green. Hopefully this will give an idea of how it looks like in practice :) Seems to work great so far from 35kHz to 550kHz.
More to come soon with testing together with a real bridge. It runs a lot cooler than the previous linear regulator UDs which will hopefully bode well for long term enclosed reliability. To test them, I set them running continuously with a signal generator input charging and discharging a capacitor at various frequencies. This board runs significantly cooler than the previous versions :)
loneoceans, Fri Sept 19 2014, 06:16PM
A little more updates. Did some preliminary testing of the new board and so far everything works exactly as expected. Here's the UD2.7 with basic testing, alongside an older UD2.1 in green. Hopefully this will give an idea of how it looks like in practice :) Seems to work great so far from 35kHz to 550kHz.
More to come soon with testing together with a real bridge. It runs a lot cooler than the previous linear regulator UDs which will hopefully bode well for long term enclosed reliability. To test them, I set them running continuously with a signal generator input charging and discharging a capacitor at various frequencies. This board runs significantly cooler than the previous versions :)
Re: Universal Driver 2.7 Rev C
Intra, Mon Oct 06 2014, 12:29PM
So, I'll be glad if that happens.
Beside that, according to Legal Information page, publishing anything on this forum, except where otherwise noted, is licensed under a Creative Commons Attribution-ShareAlike 2.5 License.
And, according Steve's 7/3/2011 12:36 PM,
> On 7/3/2011 12:36 PM, Steve Ward wrote:
>> After seeing Finn's "Prediktor" controller use the lead compensator so
>> nicely, i developed my own, though have yet to publish it in any formal way:
>>
>>
>>
>> And now the switch timing can be controlled much better, allowing the IGBT
>> turn on to happen really at zero current, which keeps the wheeling diode
>> recovery from causing big voltage transients.
>>
>> Steve
nothing was noted otherwise.
Don't seems it like, you can post this design by your will only?
Seems to be Eric did like that.
Intra, Mon Oct 06 2014, 12:29PM
loneoceans wrote ...
With permission from Steve Ward, I'll be posting a link to all the schematics, .brd .sch and gerber files, BOM, along with a write up to document it a bit more in detail which might be useful as a reference.
With permission from Steve Ward, I'll be posting a link to all the schematics, .brd .sch and gerber files, BOM, along with a write up to document it a bit more in detail which might be useful as a reference.
So, I'll be glad if that happens.
Beside that, according to Legal Information page, publishing anything on this forum, except where otherwise noted, is licensed under a Creative Commons Attribution-ShareAlike 2.5 License.
And, according Steve's 7/3/2011 12:36 PM,
> On 7/3/2011 12:36 PM, Steve Ward wrote:
>> After seeing Finn's "Prediktor" controller use the lead compensator so
>> nicely, i developed my own, though have yet to publish it in any formal way:
>>
>>
>>
>> And now the switch timing can be controlled much better, allowing the IGBT
>> turn on to happen really at zero current, which keeps the wheeling diode
>> recovery from causing big voltage transients.
>>
>> Steve
nothing was noted otherwise.
Don't seems it like, you can post this design by your will only?
Seems to be Eric did like that.
Re: Universal Driver 2.7 Rev C
loneoceans, Mon Oct 06 2014, 04:28PM
Yep I've talked to Steve and he was ok with the publication of the board and documentation. I'm sure Eric had also asked Steve beforehand. I just want to make sure to acknowledge that the series of UD2s so far is due to all the hard work that people like Eric and Bart who had helped improved on the design, and of course the original designer Steve Ward, so the rights belong to him. Want to show our appreciation to them for giving back to the community :)
I've got a quick documentation page written up here with wiring diagrams etc, and will be continually updated:
Hopefully this will also be helpful for folks looking to use the UD2, and to understand a bit more about DRSSTC driving.
I've successfully tested all the functions including AC / DC inputs, UVLO, gate drive, OCD, phase lead, and it all seems to be in working order. I've even tested it recently on my QCW tesla coil and it seems to work great as well. The board also runs very much cooler than the original ones with the linear regulators and I'm very happy with how this turned out.
I had a bunch of unpopulated red boards for sale at $12 each + shipping. Please drop me a PM if you want one.
loneoceans, Mon Oct 06 2014, 04:28PM
Intra wrote ...
So, I'll be glad if that happens.
Beside that, according to Legal Information page, publishing anything on this forum, except where otherwise noted, is licensed under a Creative Commons Attribution-ShareAlike 2.5 License.
...
So, I'll be glad if that happens.
Beside that, according to Legal Information page, publishing anything on this forum, except where otherwise noted, is licensed under a Creative Commons Attribution-ShareAlike 2.5 License.
...
Yep I've talked to Steve and he was ok with the publication of the board and documentation. I'm sure Eric had also asked Steve beforehand. I just want to make sure to acknowledge that the series of UD2s so far is due to all the hard work that people like Eric and Bart who had helped improved on the design, and of course the original designer Steve Ward, so the rights belong to him. Want to show our appreciation to them for giving back to the community :)
I've got a quick documentation page written up here with wiring diagrams etc, and will be continually updated:
Hopefully this will also be helpful for folks looking to use the UD2, and to understand a bit more about DRSSTC driving.
I've successfully tested all the functions including AC / DC inputs, UVLO, gate drive, OCD, phase lead, and it all seems to be in working order. I've even tested it recently on my QCW tesla coil and it seems to work great as well. The board also runs very much cooler than the original ones with the linear regulators and I'm very happy with how this turned out.
I had a bunch of unpopulated red boards for sale at $12 each + shipping. Please drop me a PM if you want one.
Re: Universal Driver 2.7 Rev C
bomber315, Mon Oct 06 2014, 05:38PM
This is awesome! With winter coming i am getting back into all of my electronics stuff again. This will surely make building a coil bigger and better than my onetesla a heck of a lot easier.
That being said i think im going to hold off for the time being. Once i gather more parts and resources im sure there will be new development of the board. Surely this is a work in progress right? I skimmed the documentation in your link and im loving it. Now off to read more documentation.
bomber315, Mon Oct 06 2014, 05:38PM
This is awesome! With winter coming i am getting back into all of my electronics stuff again. This will surely make building a coil bigger and better than my onetesla a heck of a lot easier.
That being said i think im going to hold off for the time being. Once i gather more parts and resources im sure there will be new development of the board. Surely this is a work in progress right? I skimmed the documentation in your link and im loving it. Now off to read more documentation.
Re: Universal Driver 2.7 Rev C
Thomas W, Mon Oct 06 2014, 05:46PM
How much are the populated boards? if you are providing them, that is.
I would be very interested in getting on.
Thomas W, Mon Oct 06 2014, 05:46PM
How much are the populated boards? if you are providing them, that is.
I would be very interested in getting on.
Re: Universal Driver 2.7 Rev C
jay, Thu Oct 09 2014, 06:18PM
Do you have any of these boards left? I am interested in acquiring one.
Alternativly, are you planning on uploading the Gerber files with the documentation on your site?
jay, Thu Oct 09 2014, 06:18PM
Do you have any of these boards left? I am interested in acquiring one.
Alternativly, are you planning on uploading the Gerber files with the documentation on your site?
Re: Universal Driver 2.7 Rev C
loneoceans, Tue Oct 21 2014, 12:09AM
Just a quick update - the boards have since been sold out. Who would have thought 25 would go so fast? I also posted all the files and gerbers on my website for you all to make your own! I've also included a direct link to a mouser cart with all the components so you can just buy all the parts with one simple click. :)
As always, let me know of anything you might want to be added to the next revision since this will probably be an ongoing project.
loneoceans, Tue Oct 21 2014, 12:09AM
jay wrote ...
Do you have any of these boards left? I am interested in acquiring one.
Alternativly, are you planning on uploading the Gerber files with the documentation on your site?
Do you have any of these boards left? I am interested in acquiring one.
Alternativly, are you planning on uploading the Gerber files with the documentation on your site?
Just a quick update - the boards have since been sold out. Who would have thought 25 would go so fast? I also posted all the files and gerbers on my website for you all to make your own! I've also included a direct link to a mouser cart with all the components so you can just buy all the parts with one simple click. :)
As always, let me know of anything you might want to be added to the next revision since this will probably be an ongoing project.
Re: Universal Driver 2.7 Rev C
Thomas W, Thu Oct 30 2014, 03:01PM
Im very interested, PM Sent. :)
Thomas W, Thu Oct 30 2014, 03:01PM
Im very interested, PM Sent. :)
Re: Universal Driver 2.7 Rev C
Graham Armitage, Thu Oct 30 2014, 03:23PM
Sent a PM last time and no response. Missed out on the board. So please put me down for 2 (green is fine). Will send PM with details too. Thanks.
Graham Armitage, Thu Oct 30 2014, 03:23PM
Sent a PM last time and no response. Missed out on the board. So please put me down for 2 (green is fine). Will send PM with details too. Thanks.
Re: Universal Driver 2.7 Rev C
loneoceans, Thu Oct 30 2014, 04:54PM
Sending another batch out :) and looks like green is popular. Apologies for the last time but the previous batch ran out really quickly and were out before I got your message. You're on for this one :) There are a small number of tiny changes I wanted to make as well, mostly physical changes, such as:
- Jumper for UVLO to enable/disable it, or Increase solder-pad size for UVLO voltage reference adjustment (or add a SMD potentiometer)
- Add additional space for extra and optional gate drive rail capacitor of your choice (I found more capacitance was useful for long-pulse operation such as in QCWs when the 24V rail would drop too much especially when using a 18VAC input, but not required for normal DRSSTC operation)
I found them to be useful for example if you wanted to run at a lower gate drive voltage such as 20V instead of 24V (could be useful for long pulse runs like in QCW mode to reduce gate drive power), and will also slightly improve silkscreen labeling.
[Edit]
I also had several requests for a kit / assembled board, and I just wanted to point out that it is unlikely for me to do a parts kit or assembly, mostly becuase it would end up a bit too expensive and take too long for me to assemble the boards since I'll have to do it by hand. In addition, I asked several people and it looks like folks would already need to make orders for parts anyway, and many people already have extra items on hand such as expensive fiber transmitters etc. I also didn't think this would be appropriate as a money-making thing since the rights do belong to Steve Ward as well as the hard work done by other folks like Bart and Eric in previous revisions. I've tried to make the board easy to hand-assemble with many parts clearly labeled and hard-to-solder pads improved, so hopefully this helps :)
UD2.7 Rev B Render:
Here's the very slightly revised board with no electrical revisions except for added UVLO header, UVLO voltage set point pot and an extra spot for more capacitance (can use for example a large 8x20mm 680uF 35V cap or whatever you want, which can be mounted sideways on the board, top or bottom). The new UD2.7B board will look like this if you're interested. Batch to be sent out this weekend and shouldn't take more than 2 - 3 weeks to arrive.
loneoceans, Thu Oct 30 2014, 04:54PM
Graham Armitage wrote ...
Sent a PM last time and no response. Missed out on the board. So please put me down for 2 (green is fine). Will send PM with details too. Thanks.
Sent a PM last time and no response. Missed out on the board. So please put me down for 2 (green is fine). Will send PM with details too. Thanks.
Sending another batch out :) and looks like green is popular. Apologies for the last time but the previous batch ran out really quickly and were out before I got your message. You're on for this one :) There are a small number of tiny changes I wanted to make as well, mostly physical changes, such as:
- Jumper for UVLO to enable/disable it, or Increase solder-pad size for UVLO voltage reference adjustment (or add a SMD potentiometer)
- Add additional space for extra and optional gate drive rail capacitor of your choice (I found more capacitance was useful for long-pulse operation such as in QCWs when the 24V rail would drop too much especially when using a 18VAC input, but not required for normal DRSSTC operation)
I found them to be useful for example if you wanted to run at a lower gate drive voltage such as 20V instead of 24V (could be useful for long pulse runs like in QCW mode to reduce gate drive power), and will also slightly improve silkscreen labeling.
[Edit]
I also had several requests for a kit / assembled board, and I just wanted to point out that it is unlikely for me to do a parts kit or assembly, mostly becuase it would end up a bit too expensive and take too long for me to assemble the boards since I'll have to do it by hand. In addition, I asked several people and it looks like folks would already need to make orders for parts anyway, and many people already have extra items on hand such as expensive fiber transmitters etc. I also didn't think this would be appropriate as a money-making thing since the rights do belong to Steve Ward as well as the hard work done by other folks like Bart and Eric in previous revisions. I've tried to make the board easy to hand-assemble with many parts clearly labeled and hard-to-solder pads improved, so hopefully this helps :)
UD2.7 Rev B Render:
Here's the very slightly revised board with no electrical revisions except for added UVLO header, UVLO voltage set point pot and an extra spot for more capacitance (can use for example a large 8x20mm 680uF 35V cap or whatever you want, which can be mounted sideways on the board, top or bottom). The new UD2.7B board will look like this if you're interested. Batch to be sent out this weekend and shouldn't take more than 2 - 3 weeks to arrive.
Re: Universal Driver 2.7 Rev C
twist2b, Sun Nov 02 2014, 01:48AM
I am extremely interested. Let me know how I can contribute to buying. I would like a populated one though.
twist2b, Sun Nov 02 2014, 01:48AM
I am extremely interested. Let me know how I can contribute to buying. I would like a populated one though.
Re: Universal Driver 2.7 Rev C
omegalabs, Sun Nov 02 2014, 11:56AM
Sent a PM, I'm interested in 5 boards.
omegalabs, Sun Nov 02 2014, 11:56AM
Sent a PM, I'm interested in 5 boards.
Re: Universal Driver 2.7 Rev C
Gigavolt, Sun Nov 09 2014, 04:13AM
I would also would be interested in a couple of the new UD 2.7 boards, have emailed you.
Gigavolt, Sun Nov 09 2014, 04:13AM
I would also would be interested in a couple of the new UD 2.7 boards, have emailed you.
Re: Universal Driver 2.7 Rev C
bomber315, Mon Nov 10 2014, 01:32PM
i am certainly in no hurry, but i am wondering if there is any kind of time frame on the arrival of these boards?
are we talking a couple weeks or a couple months? I know once i have it im going to want to build something with it and i have a lot of stuff to learn/ parts to collect.
bomber315, Mon Nov 10 2014, 01:32PM
i am certainly in no hurry, but i am wondering if there is any kind of time frame on the arrival of these boards?
are we talking a couple weeks or a couple months? I know once i have it im going to want to build something with it and i have a lot of stuff to learn/ parts to collect.
Re: Universal Driver 2.7 Rev C
loneoceans, Mon Nov 17 2014, 02:48AM
UD2.7B Boards arrived, soldered them up and it checks out as expected and tested the frequency range up to 800kHz. Drop me a note if interested. Note that the big capacitor (C4C) is *optional* and I normally wouldn't populate it.
Note that I added about 1200uF of extra capacitance on the 24V rail for long pulse operation, but this is not required in normal DRSSTC operation. Remember to adjust C33 to suit your needs.
So far I'm quite happy with the board and am unlikely to make further changes in the near future. Instead, will be making a simpler but more powerful programmable driver. But that's a story for a another time~!
loneoceans, Mon Nov 17 2014, 02:48AM
bomber315 wrote ...
i am certainly in no hurry, but i am wondering if there is any kind of time frame on the arrival of these boards?
are we talking a couple weeks or a couple months? I know once i have it im going to want to build something with it and i have a lot of stuff to learn/ parts to collect.
i am certainly in no hurry, but i am wondering if there is any kind of time frame on the arrival of these boards?
are we talking a couple weeks or a couple months? I know once i have it im going to want to build something with it and i have a lot of stuff to learn/ parts to collect.
UD2.7B Boards arrived, soldered them up and it checks out as expected and tested the frequency range up to 800kHz. Drop me a note if interested. Note that the big capacitor (C4C) is *optional* and I normally wouldn't populate it.
Note that I added about 1200uF of extra capacitance on the 24V rail for long pulse operation, but this is not required in normal DRSSTC operation. Remember to adjust C33 to suit your needs.
So far I'm quite happy with the board and am unlikely to make further changes in the near future. Instead, will be making a simpler but more powerful programmable driver. But that's a story for a another time~!
Re: Universal Driver 2.7 Rev C
Gunboat, Thu Nov 20 2014, 12:20PM
I am also interested in a2 boards.PM me and we can go from there,thanks.
Gunboat, Thu Nov 20 2014, 12:20PM
I am also interested in a2 boards.PM me and we can go from there,thanks.
Re: Universal Driver 2.7 Rev C
Polonium210, Mon Nov 24 2014, 11:01PM
Do you also sell your buck controller and easy bridge boards? I would be interested in those as well.
Polonium210, Mon Nov 24 2014, 11:01PM
Do you also sell your buck controller and easy bridge boards? I would be interested in those as well.
Re: Universal Driver 2.7 Rev C
CiscoOPA, Tue Nov 25 2014, 10:08PM
If there's interest in either/both and he doesn't mind sharing the files we could put together a group order perhaps...
CiscoOPA, Tue Nov 25 2014, 10:08PM
If there's interest in either/both and he doesn't mind sharing the files we could put together a group order perhaps...
Re: Universal Driver 2.7 Rev C
bomber315, Wed Nov 26 2014, 12:18AM
im interested in this "easy bridge board" im not even sure what is exactly. Just when i think i have read most of what he has done i find more...
bomber315, Wed Nov 26 2014, 12:18AM
im interested in this "easy bridge board" im not even sure what is exactly. Just when i think i have read most of what he has done i find more...
Re: Universal Driver 2.7 Rev C
loneoceans, Fri Dec 05 2014, 08:10PM
[edit]
Yes I do, and I have a new batch just in :) Still working on it, but lets not get side-tracked for the UD27 topic and I'll post those in my QCW thread when I'm worked on them a bit more since they are very much a work in progress and I have no immediate plans for documentation, so you'll have to be able to figure out things by yourself. Drop me a PM otherwise.
Hopefully the updated 2.7 design is working for everyone. So far I've also got it working on a conventional 100kHz DRSSTC with great results making 4 to 5 ft of spark with a foot long secondary.
loneoceans, Fri Dec 05 2014, 08:10PM
Polonium210 wrote ...
Do you also sell your buck controller and easy bridge boards? I would be interested in those as well.
Do you also sell your buck controller and easy bridge boards? I would be interested in those as well.
[edit]
Yes I do, and I have a new batch just in :) Still working on it, but lets not get side-tracked for the UD27 topic and I'll post those in my QCW thread when I'm worked on them a bit more since they are very much a work in progress and I have no immediate plans for documentation, so you'll have to be able to figure out things by yourself. Drop me a PM otherwise.
Hopefully the updated 2.7 design is working for everyone. So far I've also got it working on a conventional 100kHz DRSSTC with great results making 4 to 5 ft of spark with a foot long secondary.
Re: Universal Driver 2.7 Rev C
Polonium210, Sat Dec 06 2014, 04:11AM
Awesome! Keep me posted!
Polonium210, Sat Dec 06 2014, 04:11AM
loneoceans wrote ...
Yes I do, and I have a new batch just in :) Still working on it, but lets not get side-tracked for the UD27 topic and I'll post those in my QCW thread when I'm worked on them a bit more.
Hopefully the updated 2.7 design is working for everyone. So far I've also got it working on a conventional 100kHz DRSSTC with great results.
Polonium210 wrote ...
Do you also sell your buck controller and easy bridge boards? I would be interested in those as well.
Do you also sell your buck controller and easy bridge boards? I would be interested in those as well.
Yes I do, and I have a new batch just in :) Still working on it, but lets not get side-tracked for the UD27 topic and I'll post those in my QCW thread when I'm worked on them a bit more.
Hopefully the updated 2.7 design is working for everyone. So far I've also got it working on a conventional 100kHz DRSSTC with great results.
Awesome! Keep me posted!
Re: Universal Driver 2.7 Rev C
loneoceans, Thu Dec 11 2014, 06:08PM
Some updates - found an error on the PCB (both Rev A and B w.r.t. the 24VDC input) thanks to Daniel, but with a simple fix so no worries!
Problem:
This happens when the 24VDC jack is used instead of the AC input. The 24VDC jack goes directly to the 24V rail. However, the 9V switching regulator's input is not connected to the 24V rail but rather the rectified AC rail. I originally wired it this way to reduce added load on the 24V regulator since the 9V switching regulator accepts up to 34V input but it looks like I got ahead of myself! You would think that this meant that the 9V and 5V rails would not be powered, but it turns out that inside the 24V regulator, there is a diode in series with about 28k from the output to the input, hence allowing the regulator to 'conduct backwards'. This also explains why the board still checked out ok on the voltage rails and still works in driving coils, probably helped by the generous amount of logic bus capacitance and the fact that the logic doesn't draw too much power.
Fix:
If you're using AC input, there is no problem. If you are using DC input, you can supply 26.5VDC into the AC jack instead - the diode bridge drops about 0.5V and the 7824 drops about 2V for 24V on the 24V rail.
If you're using the DC input, the problem can be solved by a simple fix: - simply solder on a diode from the output to the input of the 7824 regulator (i.e. classic reverse protection diode). So when the 24V rail is powered via DC input, current flows across the regulator. The diode I used for D14 (GSD2004W-E3-08) as a reverse protection diode across the 9V switching regulator can be used, or any other general purpose diode like a 1N4001 will be fine. This can be soldered directly across the legs of the 7824 regulator and fits perfectly. Make sure the diode is from the output to the input, as shown in the attached diagram.
I will also be updating the schematics etc to reflect this error, but in the future I think it makes more sense to go back to the 9V regulator input powered from the 24V rail for the next revision.
loneoceans, Thu Dec 11 2014, 06:08PM
Some updates - found an error on the PCB (both Rev A and B w.r.t. the 24VDC input) thanks to Daniel, but with a simple fix so no worries!
Problem:
This happens when the 24VDC jack is used instead of the AC input. The 24VDC jack goes directly to the 24V rail. However, the 9V switching regulator's input is not connected to the 24V rail but rather the rectified AC rail. I originally wired it this way to reduce added load on the 24V regulator since the 9V switching regulator accepts up to 34V input but it looks like I got ahead of myself! You would think that this meant that the 9V and 5V rails would not be powered, but it turns out that inside the 24V regulator, there is a diode in series with about 28k from the output to the input, hence allowing the regulator to 'conduct backwards'. This also explains why the board still checked out ok on the voltage rails and still works in driving coils, probably helped by the generous amount of logic bus capacitance and the fact that the logic doesn't draw too much power.
Fix:
If you're using AC input, there is no problem. If you are using DC input, you can supply 26.5VDC into the AC jack instead - the diode bridge drops about 0.5V and the 7824 drops about 2V for 24V on the 24V rail.
If you're using the DC input, the problem can be solved by a simple fix: - simply solder on a diode from the output to the input of the 7824 regulator (i.e. classic reverse protection diode). So when the 24V rail is powered via DC input, current flows across the regulator. The diode I used for D14 (GSD2004W-E3-08) as a reverse protection diode across the 9V switching regulator can be used, or any other general purpose diode like a 1N4001 will be fine. This can be soldered directly across the legs of the 7824 regulator and fits perfectly. Make sure the diode is from the output to the input, as shown in the attached diagram.
I will also be updating the schematics etc to reflect this error, but in the future I think it makes more sense to go back to the 9V regulator input powered from the 24V rail for the next revision.
Re: Universal Driver 2.7 Rev C
loneoceans, Fri Jan 16 2015, 10:59PM
For those interested, I've got a new Rev C board order (and probably last batch) which I will place this weekend. It doesn't have many changes, but I ran out of Rev B boards so here's the next order:
- Improved silkscreen for less confusion
- Fixed error in UD2.7A/B boards
- Daisy chained 9V regulator back to original for maximum 28VAC input (19 - 26.5VAC nominal)
- Improved regulator thermal pads for better heat performance
- Other cosmetic improvements
If you're interested, drop me a PM so I can estimate a good order size. Otherwise I probably won't order too many. Price should be in the ballpark of $10 to $8 depending on order size, same green HASL finish. :)
Have a good weekend!
loneoceans, Fri Jan 16 2015, 10:59PM
Gunboat wrote ...
I am also interested in a2 boards.
I am also interested in a2 boards.
For those interested, I've got a new Rev C board order (and probably last batch) which I will place this weekend. It doesn't have many changes, but I ran out of Rev B boards so here's the next order:
- Improved silkscreen for less confusion
- Fixed error in UD2.7A/B boards
- Daisy chained 9V regulator back to original for maximum 28VAC input (19 - 26.5VAC nominal)
- Improved regulator thermal pads for better heat performance
- Other cosmetic improvements
If you're interested, drop me a PM so I can estimate a good order size. Otherwise I probably won't order too many. Price should be in the ballpark of $10 to $8 depending on order size, same green HASL finish. :)
Have a good weekend!
Re: Universal Driver 2.7 Rev C
Kolas, Sat Jan 17 2015, 02:10AM
I have always wondered about this in PCB design: do sharp edges and pockets from pads (where components interface with the board) cause any kind of losses? Or are they just nit picky pet peeves that bother me aesthetically and end up being something i should get over?
Kolas, Sat Jan 17 2015, 02:10AM
I have always wondered about this in PCB design: do sharp edges and pockets from pads (where components interface with the board) cause any kind of losses? Or are they just nit picky pet peeves that bother me aesthetically and end up being something i should get over?
Re: Universal Driver 2.7 Rev C
loneoceans, Thu Jan 22 2015, 06:42PM
What do you mean by sharp edges and pads and what sort of losses are you referring to? Are you talking about solder pads? If there are no solder pads how do you solder components on the board? At the frequencies we are working at, pcb layout is generally not too big of a deal, but once you get into RF stuff and high speed signalling, traces and layout matter a lot - you can use them to make antennas, capacitors, inductors, and all sort of RF magic things. :)
Anyway boards have been ordered, hope I have enough since it's a smaller order this time.
loneoceans, Thu Jan 22 2015, 06:42PM
Kolas wrote ...
I have always wondered about this in PCB design: do sharp edges and pockets from pads (where components interface with the board) cause any kind of losses? Or are they just nit picky pet peeves that bother me aesthetically and end up being something i should get over?
I have always wondered about this in PCB design: do sharp edges and pockets from pads (where components interface with the board) cause any kind of losses? Or are they just nit picky pet peeves that bother me aesthetically and end up being something i should get over?
What do you mean by sharp edges and pads and what sort of losses are you referring to? Are you talking about solder pads? If there are no solder pads how do you solder components on the board? At the frequencies we are working at, pcb layout is generally not too big of a deal, but once you get into RF stuff and high speed signalling, traces and layout matter a lot - you can use them to make antennas, capacitors, inductors, and all sort of RF magic things. :)
Anyway boards have been ordered, hope I have enough since it's a smaller order this time.
Re: Universal Driver 2.7 Rev C
Vitalii, Mon Feb 09 2015, 10:37AM
Hey guys. This board looks really cool with UVLO!
I hope to be in US next month and buy it (or just buy components).
But can you kindly take look on my last question about UD-2.5 (on UD-2.5 thread)? When I power it on from 24V DC I burn U3. Why???
Vitalii, Mon Feb 09 2015, 10:37AM
Hey guys. This board looks really cool with UVLO!
I hope to be in US next month and buy it (or just buy components).
But can you kindly take look on my last question about UD-2.5 (on UD-2.5 thread)? When I power it on from 24V DC I burn U3. Why???
Re: Universal Driver 2.7 Rev C
loneoceans, Wed Feb 18 2015, 10:53PM
Looks like you figured out the problem already :).
Anyway quick update - I've received the latest UD2.7C boards and while populating them I realized I had a few ICs short! Have parts on order and they should arrive very soon, and I'll be able to get the latest revision tested and sent out to any folks who were interested. You will get a message/email once they are ready.
As for the previous 2.7 boards, I've had some feedback from a few folks that it's working great in their coils, so I'm happy to hear that. Have I think 5 or more boards left after all those who were interested.
loneoceans, Wed Feb 18 2015, 10:53PM
Vitalii wrote ...
Hey guys. This board looks really cool with UVLO!
I hope to be in US next month and buy it (or just buy components).
But can you kindly take look on my last question about UD-2.5 (on UD-2.5 thread)? When I power it on from 24V DC I burn U3. Why???
Hey guys. This board looks really cool with UVLO!
I hope to be in US next month and buy it (or just buy components).
But can you kindly take look on my last question about UD-2.5 (on UD-2.5 thread)? When I power it on from 24V DC I burn U3. Why???
Looks like you figured out the problem already :).
Anyway quick update - I've received the latest UD2.7C boards and while populating them I realized I had a few ICs short! Have parts on order and they should arrive very soon, and I'll be able to get the latest revision tested and sent out to any folks who were interested. You will get a message/email once they are ready.
As for the previous 2.7 boards, I've had some feedback from a few folks that it's working great in their coils, so I'm happy to hear that. Have I think 5 or more boards left after all those who were interested.
Re: Universal Driver 2.7 Rev C
RateReducer, Sat Feb 21 2015, 12:08PM
Hi!
I just ordered the parts for the board with the "Populated Mouser Project Order" I noticed that the Slot-7 Inductors need to be ordered at Coilcraft... Wich values shall i buy? I want to run big bricks similar to CM300 so i guess the 29-49uH inductors will fit ^^
Which value is good for small IGBTs e.g. for 200kHz or QCW operation?
Are there any other parts missing in the Populated Mouser Project Order?
Regards, Daniel
RateReducer, Sat Feb 21 2015, 12:08PM
Hi!
I just ordered the parts for the board with the "Populated Mouser Project Order" I noticed that the Slot-7 Inductors need to be ordered at Coilcraft... Wich values shall i buy? I want to run big bricks similar to CM300 so i guess the 29-49uH inductors will fit ^^
Which value is good for small IGBTs e.g. for 200kHz or QCW operation?
Are there any other parts missing in the Populated Mouser Project Order?
Regards, Daniel
Re: Universal Driver 2.7 Rev C
Goodchild, Wed Feb 25 2015, 03:17PM
Just a note.
The zip folder with the eagle files on your website for Rev C is empty. I downloaded it and the zip folder doesn't have any files in it.
Maybe it's just me? Thought I would mention it.
Goodchild, Wed Feb 25 2015, 03:17PM
Just a note.
The zip folder with the eagle files on your website for Rev C is empty. I downloaded it and the zip folder doesn't have any files in it.
Maybe it's just me? Thought I would mention it.
Re: Universal Driver 2.7 Rev C
loneoceans, Wed Feb 25 2015, 09:21PM
The actual value depends very much on the parameters of your circuit and transistors used / operating frequency etc, but if I recall right, I think 7M3-123 is good for TO247 transistors, and the 393 good for larger CM200/300 transistors. Mouser also doesn't stock the plastic fiber receivers, which you need to get from Digikey (but this is optional). I was thinking of switching to a different inductor but it turns out that tunable inductors are really not common! The mouser order is just from what I ordered - you should check it yourself to make sure all the parts are there.
Replying Eric - thanks for help pointing that out! I'll re-upload the file. I've had some problems with files getting messed up and images not loading properly, so I'll get to re-uploading a bunch of stuff. Maybe I'll put it up on another more reliable fileshare or dropbox. Also a shout-out to Eric who worked on lots of improvements for the UD2.5. Hopefully people can continue working to improve it, just like the work of Bart and Eric previously.
Also, here's the Rev C version:
I have it soldered up and tested from about 12kHz to 1Mhz along with the associated features such as UVLO and it performs as expected. Working on getting my page updated with more details as well.
For those folks who ordered, I've sent out a mail to you. Please let me know if you want them, otherwise if I do not get a reply, I'll send them out to other people who are on the wait list (ordered too few again -.-). Thanks!
loneoceans, Wed Feb 25 2015, 09:21PM
RateReducer wrote ...
Hi!
I just ordered the parts for the board with the "Populated Mouser Project Order" I noticed that the Slot-7 Inductors need to be ordered at Coilcraft... Wich values shall i buy? I want to run big bricks similar to CM300 so i guess the 29-49uH inductors will fit ^^
Which value is good for small IGBTs e.g. for 200kHz or QCW operation?
Are there any other parts missing in the Populated Mouser Project Order?
Regards, Daniel
Hi!
I just ordered the parts for the board with the "Populated Mouser Project Order" I noticed that the Slot-7 Inductors need to be ordered at Coilcraft... Wich values shall i buy? I want to run big bricks similar to CM300 so i guess the 29-49uH inductors will fit ^^
Which value is good for small IGBTs e.g. for 200kHz or QCW operation?
Are there any other parts missing in the Populated Mouser Project Order?
Regards, Daniel
The actual value depends very much on the parameters of your circuit and transistors used / operating frequency etc, but if I recall right, I think 7M3-123 is good for TO247 transistors, and the 393 good for larger CM200/300 transistors. Mouser also doesn't stock the plastic fiber receivers, which you need to get from Digikey (but this is optional). I was thinking of switching to a different inductor but it turns out that tunable inductors are really not common! The mouser order is just from what I ordered - you should check it yourself to make sure all the parts are there.
Replying Eric - thanks for help pointing that out! I'll re-upload the file. I've had some problems with files getting messed up and images not loading properly, so I'll get to re-uploading a bunch of stuff. Maybe I'll put it up on another more reliable fileshare or dropbox. Also a shout-out to Eric who worked on lots of improvements for the UD2.5. Hopefully people can continue working to improve it, just like the work of Bart and Eric previously.
Also, here's the Rev C version:
I have it soldered up and tested from about 12kHz to 1Mhz along with the associated features such as UVLO and it performs as expected. Working on getting my page updated with more details as well.
For those folks who ordered, I've sent out a mail to you. Please let me know if you want them, otherwise if I do not get a reply, I'll send them out to other people who are on the wait list (ordered too few again -.-). Thanks!
Re: Universal Driver 2.7 Rev C
loneoceans, Mon May 25 2015, 10:06PM
[Update - all sold out]
I recently made another small run of blue PCBs, drop me a PM if anyone is interested!
Also some questions I've had that I wanted to clarify:
- The UVLO can be replaced any other similar UVLO of a different cut-off voltage. E.g. you can use a 4.5V UVLO and change the resistors.
- UD2.7C fixes the bug in the 24V rail - for revision A and B, a simple diode fixes the problem.
- The large capacitor in slot C4C is not required for normal operation.
So far I've used the version 2.7C board in my twin Semikron Coils and more recently my QCW 1.5, so they should be pretty reliable and field tested. Always appreciate any comments or suggestions anyone might have.
loneoceans, Mon May 25 2015, 10:06PM
[Update - all sold out]
I recently made another small run of blue PCBs, drop me a PM if anyone is interested!
Also some questions I've had that I wanted to clarify:
- The UVLO can be replaced any other similar UVLO of a different cut-off voltage. E.g. you can use a 4.5V UVLO and change the resistors.
- UD2.7C fixes the bug in the 24V rail - for revision A and B, a simple diode fixes the problem.
- The large capacitor in slot C4C is not required for normal operation.
So far I've used the version 2.7C board in my twin Semikron Coils and more recently my QCW 1.5, so they should be pretty reliable and field tested. Always appreciate any comments or suggestions anyone might have.
Re: Universal Driver 2.7 Rev C
nzoomed, Sun Nov 22 2015, 08:10PM
Ive just finished construction of my UD 2.7 and there are a few parts missing from it as it turns out!
The weird thing is there are some components that had more than what was needed, but perhaps there was a minimum buy with some of these parts?
For future reference to those that are building:
IC11 is missing (LM8365BALMF27)
No molex pins are included (08-52-0123)
JMP1 is missing (69190-402)
There is supposed to be 4 capacitors (C0805C105K4RACTU) but the order contains only 3.
Yet there was an extra (C1206C105K5RACTU) in the 1206 package that i was able to just solder onto C25
I probably can get the IC and molex pins from RS, but the jumper pins can easily be removed from an old motherboard or hard drive etc.
Im pretty sure thats everything, but at least it should help prevent those from making the same mistake as me!
I should have checked the order, but with so many parts on the list, i assumed it was all good.
Hopefully Loneoceans will revise the order, or i may be able to post a revised link here later :)
nzoomed, Sun Nov 22 2015, 08:10PM
RateReducer wrote ...
Are there any other parts missing in the Populated Mouser Project Order?
Regards, Daniel
Are there any other parts missing in the Populated Mouser Project Order?
Regards, Daniel
Ive just finished construction of my UD 2.7 and there are a few parts missing from it as it turns out!
The weird thing is there are some components that had more than what was needed, but perhaps there was a minimum buy with some of these parts?
For future reference to those that are building:
IC11 is missing (LM8365BALMF27)
No molex pins are included (08-52-0123)
JMP1 is missing (69190-402)
There is supposed to be 4 capacitors (C0805C105K4RACTU) but the order contains only 3.
Yet there was an extra (C1206C105K5RACTU) in the 1206 package that i was able to just solder onto C25
I probably can get the IC and molex pins from RS, but the jumper pins can easily be removed from an old motherboard or hard drive etc.
Im pretty sure thats everything, but at least it should help prevent those from making the same mistake as me!
I should have checked the order, but with so many parts on the list, i assumed it was all good.
Hopefully Loneoceans will revise the order, or i may be able to post a revised link here later :)
Re: Universal Driver 2.7 Rev C
loneoceans, Tue Nov 24 2015, 01:15AM
Thanks for looking through. I'll try to get the list updated. The mouser cart was just what I had ordered at the time and I had a lot of spare components on hand; you should be easily able to populate the cart from the BOM list though.
Also, I have a bunch of extra boards. Drop me a mail (loneoceans at g mail d0t com) if you're interested. :)
loneoceans, Tue Nov 24 2015, 01:15AM
nzoomed wrote ...
Ive just finished construction of my UD 2.7 and there are a few parts missing from it as it turns out!
The weird thing is there are some components that had more than what was needed, but perhaps there was a minimum buy with some of these parts?
For future reference to those that are building:
IC11 is missing (LM8365BALMF27)
No molex pins are included (08-52-0123)
JMP1 is missing (69190-402)
There is supposed to be 4 capacitors (C0805C105K4RACTU) but the order contains only 3.
Yet there was an extra (C1206C105K5RACTU) in the 1206 package that i was able to just solder onto C25
I probably can get the IC and molex pins from RS, but the jumper pins can easily be removed from an old motherboard or hard drive etc.
Im pretty sure thats everything, but at least it should help prevent those from making the same mistake as me!
I should have checked the order, but with so many parts on the list, i assumed it was all good.
Hopefully Loneoceans will revise the order, or i may be able to post a revised link here later :)
RateReducer wrote ...
Are there any other parts missing in the Populated Mouser Project Order?
Regards, Daniel
Are there any other parts missing in the Populated Mouser Project Order?
Regards, Daniel
Ive just finished construction of my UD 2.7 and there are a few parts missing from it as it turns out!
The weird thing is there are some components that had more than what was needed, but perhaps there was a minimum buy with some of these parts?
For future reference to those that are building:
IC11 is missing (LM8365BALMF27)
No molex pins are included (08-52-0123)
JMP1 is missing (69190-402)
There is supposed to be 4 capacitors (C0805C105K4RACTU) but the order contains only 3.
Yet there was an extra (C1206C105K5RACTU) in the 1206 package that i was able to just solder onto C25
I probably can get the IC and molex pins from RS, but the jumper pins can easily be removed from an old motherboard or hard drive etc.
Im pretty sure thats everything, but at least it should help prevent those from making the same mistake as me!
I should have checked the order, but with so many parts on the list, i assumed it was all good.
Hopefully Loneoceans will revise the order, or i may be able to post a revised link here later :)
Thanks for looking through. I'll try to get the list updated. The mouser cart was just what I had ordered at the time and I had a lot of spare components on hand; you should be easily able to populate the cart from the BOM list though.
Also, I have a bunch of extra boards. Drop me a mail (loneoceans at g mail d0t com) if you're interested. :)
Re: Universal Driver 2.7 Rev C
nzoomed, Tue Nov 24 2015, 04:42AM
I may be interested in another board or two after this project perhaps.
At least i know you still have spare boards.
Im interested to learn more about the new driver board you are designing :)
nzoomed, Tue Nov 24 2015, 04:42AM
loneoceans wrote ...
Thanks for looking through. I'll try to get the list updated. The mouser cart was just what I had ordered at the time and I had a lot of spare components on hand; you should be easily able to populate the cart from the BOM list though.
Also, I have a bunch of extra boards. Drop me a mail (loneoceans at g mail d0t com) if you're interested. :)
Its all good :)Thanks for looking through. I'll try to get the list updated. The mouser cart was just what I had ordered at the time and I had a lot of spare components on hand; you should be easily able to populate the cart from the BOM list though.
Also, I have a bunch of extra boards. Drop me a mail (loneoceans at g mail d0t com) if you're interested. :)
I may be interested in another board or two after this project perhaps.
At least i know you still have spare boards.
Im interested to learn more about the new driver board you are designing :)
Re: Universal Driver 2.7 Rev C
nzoomed, Sun Dec 06 2015, 10:21AM
I just finished assembly and everything seems all sweet - for now anyways.
Except i think i did one stupid thing... :(
After switching on my UD board (had it on for about 30 seconds) i noticed smoke coming from one of the GDT MOSFETS (pretty sure it was U3)
Anyway, i quickly switched it off and then realised that i had not connected the phase jumpers to the board!
I expect this was the cause, as i suspect this prevents any negative bias when idle causing them to take off and oscillate heavily?
It has been fine after connecting them and nothing is hot to touch.
Question is, will it be OK, or have i cooked it?
It doesnt look burnt and nothing has melted that i can see, it did not even smell from the smoke.
I wont be able to fully test it until i get my MIDI controller (next week hopefully)
But if anyone can point out to me what components are likely to be damaged, that would be great, as i will order some spares.
I have two outputs if the first one doesn't work anyway, so not all is lost.
nzoomed, Sun Dec 06 2015, 10:21AM
I just finished assembly and everything seems all sweet - for now anyways.
Except i think i did one stupid thing... :(
After switching on my UD board (had it on for about 30 seconds) i noticed smoke coming from one of the GDT MOSFETS (pretty sure it was U3)
Anyway, i quickly switched it off and then realised that i had not connected the phase jumpers to the board!
I expect this was the cause, as i suspect this prevents any negative bias when idle causing them to take off and oscillate heavily?
It has been fine after connecting them and nothing is hot to touch.
Question is, will it be OK, or have i cooked it?
It doesnt look burnt and nothing has melted that i can see, it did not even smell from the smoke.
I wont be able to fully test it until i get my MIDI controller (next week hopefully)
But if anyone can point out to me what components are likely to be damaged, that would be great, as i will order some spares.
I have two outputs if the first one doesn't work anyway, so not all is lost.
Re: Universal Driver 2.7 Rev C
Justin, Sun Dec 06 2015, 11:28AM
If the magic smoke escapes, all hope is lost.
Justin, Sun Dec 06 2015, 11:28AM
nzoomed wrote ...
I just finished assembly and everything seems all sweet - for now anyways.
Except i think i did one stupid thing... :(
After switching on my UD board (had it on for about 30 seconds) i noticed smoke coming from one of the GDT MOSFETS (pretty sure it was U3)
Anyway, i quickly switched it off and then realised that i had not connected the phase jumpers to the board!
I expect this was the cause, as i suspect this prevents any negative bias when idle causing them to take off and oscillate heavily?
It has been fine after connecting them and nothing is hot to touch.
Question is, will it be OK, or have i cooked it?
It doesnt look burnt and nothing has melted that i can see, it did not even smell from the smoke.
I wont be able to fully test it until i get my MIDI controller (next week hopefully)
But if anyone can point out to me what components are likely to be damaged, that would be great, as i will order some spares.
I have two outputs if the first one doesn't work anyway, so not all is lost.
I just finished assembly and everything seems all sweet - for now anyways.
Except i think i did one stupid thing... :(
After switching on my UD board (had it on for about 30 seconds) i noticed smoke coming from one of the GDT MOSFETS (pretty sure it was U3)
Anyway, i quickly switched it off and then realised that i had not connected the phase jumpers to the board!
I expect this was the cause, as i suspect this prevents any negative bias when idle causing them to take off and oscillate heavily?
It has been fine after connecting them and nothing is hot to touch.
Question is, will it be OK, or have i cooked it?
It doesnt look burnt and nothing has melted that i can see, it did not even smell from the smoke.
I wont be able to fully test it until i get my MIDI controller (next week hopefully)
But if anyone can point out to me what components are likely to be damaged, that would be great, as i will order some spares.
I have two outputs if the first one doesn't work anyway, so not all is lost.
If the magic smoke escapes, all hope is lost.
Re: Universal Driver 2.7 Rev C
nzoomed, Sun Dec 06 2015, 08:06PM
Only one of the MOSFETS smoked and was the only one that felt hot.
There are two outputs on the board itself and the other pair should still work hopefully.
I think the smoke was more from solder flux on the MOSFET's joints, rather than the MOSFET itself anyway.
nzoomed, Sun Dec 06 2015, 08:06PM
Justin wrote ...
If the magic smoke escapes, all hope is lost.
nzoomed wrote ...
I just finished assembly and everything seems all sweet - for now anyways.
Except i think i did one stupid thing... :(
After switching on my UD board (had it on for about 30 seconds) i noticed smoke coming from one of the GDT MOSFETS (pretty sure it was U3)
Anyway, i quickly switched it off and then realised that i had not connected the phase jumpers to the board!
I expect this was the cause, as i suspect this prevents any negative bias when idle causing them to take off and oscillate heavily?
It has been fine after connecting them and nothing is hot to touch.
Question is, will it be OK, or have i cooked it?
It doesnt look burnt and nothing has melted that i can see, it did not even smell from the smoke.
I wont be able to fully test it until i get my MIDI controller (next week hopefully)
But if anyone can point out to me what components are likely to be damaged, that would be great, as i will order some spares.
I have two outputs if the first one doesn't work anyway, so not all is lost.
I just finished assembly and everything seems all sweet - for now anyways.
Except i think i did one stupid thing... :(
After switching on my UD board (had it on for about 30 seconds) i noticed smoke coming from one of the GDT MOSFETS (pretty sure it was U3)
Anyway, i quickly switched it off and then realised that i had not connected the phase jumpers to the board!
I expect this was the cause, as i suspect this prevents any negative bias when idle causing them to take off and oscillate heavily?
It has been fine after connecting them and nothing is hot to touch.
Question is, will it be OK, or have i cooked it?
It doesnt look burnt and nothing has melted that i can see, it did not even smell from the smoke.
I wont be able to fully test it until i get my MIDI controller (next week hopefully)
But if anyone can point out to me what components are likely to be damaged, that would be great, as i will order some spares.
I have two outputs if the first one doesn't work anyway, so not all is lost.
If the magic smoke escapes, all hope is lost.
Only one of the MOSFETS smoked and was the only one that felt hot.
There are two outputs on the board itself and the other pair should still work hopefully.
I think the smoke was more from solder flux on the MOSFET's joints, rather than the MOSFET itself anyway.
Re: Universal Driver 2.7 Rev C
Dr Hankenstein, Sun Dec 13 2015, 04:15AM
Do you have any complete and tested boards available? I am interested.
Kind regards,
Hank
Dr Hankenstein, Sun Dec 13 2015, 04:15AM
Do you have any complete and tested boards available? I am interested.
Kind regards,
Hank
Re: Universal Driver 2.7 Rev C
Graham Armitage, Mon Dec 14 2015, 09:43PM
Just noticed that 74HC14DR2G is obsolete. Is 771-74HC14D-T a good alternative?
Graham Armitage, Mon Dec 14 2015, 09:43PM
Just noticed that 74HC14DR2G is obsolete. Is 771-74HC14D-T a good alternative?
Re: Universal Driver 2.7 Rev C
nzoomed, Mon Dec 14 2015, 10:07PM
nzoomed, Mon Dec 14 2015, 10:07PM
Graham Armitage wrote ...
Just noticed that 74HC14DR2G is obsolete. Is 771-74HC14D-T a good alternative?
I used SN74HC14DG4 from mouser.Just noticed that 74HC14DR2G is obsolete. Is 771-74HC14D-T a good alternative?
Re: Universal Driver 2.7 Rev C
Vitalii, Tue Jan 05 2016, 10:27PM
I'd like to buy a board but by some reason can't send you PM. pls, contact me.
Vitalii, Tue Jan 05 2016, 10:27PM
I'd like to buy a board but by some reason can't send you PM. pls, contact me.
Re: Universal Driver 2.7 Rev C
loneoceans, Fri Apr 22 2016, 12:28AM
Not too long ago I made a add-on board for the UD2 boards and a bunch of people were asking me about it so I thought I'll post something.
Most solid state coils which use the UD2 driver invariably require the use of a large bus capacitor. This capacitor (usually several thousands of uF) looks like a short across the mains at first turn on, which can cause fuse blows / breaker trips. The solution was usually to use a large heavy variable transformer or a separate pre-charge circuit such as a phase angle controller to limit in-rush current.
I wanted a simple, reliable solution to this problem, and this led to the development of the pre-charge board. This board pre-charges the bus cap via a power resistor for an adjustable time (couple of seconds), and then bypasses it once the capacitor is charged, preventing in-rush current. I also added a few other features such as safe and automatic bus-cap discharge once power is turned off. Also, the board allows a standard IEC input jack, basic EMI filtering and also adds a thermal-cut-off capability via an external thermistor and plugs into the UD2.7's UVLO trip allowing the driver to be turned off in such a fault condition. The result is a nice little companion to the UD2 board.
Some people were asking for it so I've some leftover ones which I thought I'll offer here:
Finally, I was going to do another final round of assembled UD2 boards so if you happened to be interested in any boards, do drop me an email at loneoceans [at] gmail [dot] com since I'll be doing a round of component orders soon.
loneoceans, Fri Apr 22 2016, 12:28AM
Not too long ago I made a add-on board for the UD2 boards and a bunch of people were asking me about it so I thought I'll post something.
Most solid state coils which use the UD2 driver invariably require the use of a large bus capacitor. This capacitor (usually several thousands of uF) looks like a short across the mains at first turn on, which can cause fuse blows / breaker trips. The solution was usually to use a large heavy variable transformer or a separate pre-charge circuit such as a phase angle controller to limit in-rush current.
I wanted a simple, reliable solution to this problem, and this led to the development of the pre-charge board. This board pre-charges the bus cap via a power resistor for an adjustable time (couple of seconds), and then bypasses it once the capacitor is charged, preventing in-rush current. I also added a few other features such as safe and automatic bus-cap discharge once power is turned off. Also, the board allows a standard IEC input jack, basic EMI filtering and also adds a thermal-cut-off capability via an external thermistor and plugs into the UD2.7's UVLO trip allowing the driver to be turned off in such a fault condition. The result is a nice little companion to the UD2 board.
Some people were asking for it so I've some leftover ones which I thought I'll offer here:
Finally, I was going to do another final round of assembled UD2 boards so if you happened to be interested in any boards, do drop me an email at loneoceans [at] gmail [dot] com since I'll be doing a round of component orders soon.
Re: Universal Driver 2.7 Rev C
profdc9, Fri Apr 22 2016, 12:50AM
How about using a current inrush limiting resistor? I have used
EPCOS/TDK B57127P509M301
I suppose if required you could use several smaller resistance larger current versions if necessary.
Dan
profdc9, Fri Apr 22 2016, 12:50AM
How about using a current inrush limiting resistor? I have used
EPCOS/TDK B57127P509M301
I suppose if required you could use several smaller resistance larger current versions if necessary.
Dan
Re: Universal Driver 2.7 Rev C
loneoceans, Fri Apr 22 2016, 02:23AM
That is correct, a simple way is to use a NTC which I've done so in the past and it can work just fine within some limitations
But they do have a few drawbacks including the fact that they do not work if for some reason power is turned off, the cap bank is discharged and the coil turned on while the NTC Is still hot, among other reasons. Likewise, another simple way is to use a variac, but that's big and heavy to lug around, so I made the board to address this and to add a bunch of other features too. It seemed like just using a resistor was a simple and reliable way to get this to work :)
loneoceans, Fri Apr 22 2016, 02:23AM
profdc9 wrote ...
How about using a current inrush limiting resistor? I have used
EPCOS/TDK B57127P509M301
I suppose if required you could use several smaller resistance larger current versions if necessary.
Dan
How about using a current inrush limiting resistor? I have used
EPCOS/TDK B57127P509M301
I suppose if required you could use several smaller resistance larger current versions if necessary.
Dan
That is correct, a simple way is to use a NTC which I've done so in the past and it can work just fine within some limitations
But they do have a few drawbacks including the fact that they do not work if for some reason power is turned off, the cap bank is discharged and the coil turned on while the NTC Is still hot, among other reasons. Likewise, another simple way is to use a variac, but that's big and heavy to lug around, so I made the board to address this and to add a bunch of other features too. It seemed like just using a resistor was a simple and reliable way to get this to work :)
Re: Universal Driver 2.7 Rev C
nzoomed, Sat Jun 11 2016, 10:30PM
Hi Loneoceans.
I was thinking about gate voltages when i was working on my coil and was wondering if this may be a good feature to add to a future driver (i know you said you will look at designing a completley new driver rather than updating UD 2.7)
You will probably say its a waste of time, and it could very well cause other problems, but what i propose is a variable gate voltage (VGV) feature that will run the gate voltages at a minimum of say 20V (or user preset), but slowly increase the gate voltages as the current increases on the primary up to a maximum limit of either 24V, or again user preset.
I know this is not really an issue with CM300 bricks which are pretty robust, but different IGBT's could potentially benefit from this and could perhaps give more reliability.
For example, you should get away with 20V on the gates if you are running up to around 800A or so on a CM300, but ideally for better switching, this is increased to 24V, which the driver could automatically increase when it detects higher current over a preset threshold.
Perhaps rather than a variable gate voltage, it would probably make a more simple design to just switch the gate voltage up to 24V or so once the driver detects higher current.
Im interested to know if such a design would be a good addition to a driver, or would it cause more issues with phase lead and ringing etc when the voltage switches?
nzoomed, Sat Jun 11 2016, 10:30PM
Hi Loneoceans.
I was thinking about gate voltages when i was working on my coil and was wondering if this may be a good feature to add to a future driver (i know you said you will look at designing a completley new driver rather than updating UD 2.7)
You will probably say its a waste of time, and it could very well cause other problems, but what i propose is a variable gate voltage (VGV) feature that will run the gate voltages at a minimum of say 20V (or user preset), but slowly increase the gate voltages as the current increases on the primary up to a maximum limit of either 24V, or again user preset.
I know this is not really an issue with CM300 bricks which are pretty robust, but different IGBT's could potentially benefit from this and could perhaps give more reliability.
For example, you should get away with 20V on the gates if you are running up to around 800A or so on a CM300, but ideally for better switching, this is increased to 24V, which the driver could automatically increase when it detects higher current over a preset threshold.
Perhaps rather than a variable gate voltage, it would probably make a more simple design to just switch the gate voltage up to 24V or so once the driver detects higher current.
Im interested to know if such a design would be a good addition to a driver, or would it cause more issues with phase lead and ringing etc when the voltage switches?
Re: Universal Driver 2.7 Rev C
Justin, Wed Jul 06 2016, 09:03AM
So I found out the hard way that if the UVLO pot (R29) is turned too far in the wrong direction(like say if you soldered it in that way) it feeds up to 16.4V into the LM8365 and kills it.
Justin, Wed Jul 06 2016, 09:03AM
So I found out the hard way that if the UVLO pot (R29) is turned too far in the wrong direction(like say if you soldered it in that way) it feeds up to 16.4V into the LM8365 and kills it.
Re: Universal Driver 2.7 Rev C
Hydron, Thu Jul 07 2016, 07:55AM
Hydron, Thu Jul 07 2016, 07:55AM
Justin wrote ...
So I found out the hard way that if the UVLO pot (R29) is turned too far in the wrong direction(like say if you soldered it in that way) it feeds up to 16.4V into the LM8365 and kills it.
I'd suggest a 13k (E24) or better yet, a 13.3k (E48) resistor in series with the pot in the next revision to eliminate this issue - with 24Vin this should keep the ULVO input just below the absolute max of 6.5V even with the pot at 0 ohms.So I found out the hard way that if the UVLO pot (R29) is turned too far in the wrong direction(like say if you soldered it in that way) it feeds up to 16.4V into the LM8365 and kills it.
Re: Universal Driver 2.7 Rev C
DerStrom8, Thu Jul 21 2016, 04:09PM
Hi loneoceans, I have just a couple of comments (corrections) to your schematic:
1) Your 7809 regulator does not seem to be annotated properly in the Rev C schematic? It's labeled "ICx" (
2) The output from your UVLO chip is correct (it's labeled "To IC6A Pin 1 (CLR) via Jumper") but the corresponding comment on IC6A says "To OCD (IC11) Pin 1". This should read "To UVLO (IC11) Pin 1".
Regards,
Matt
DerStrom8, Thu Jul 21 2016, 04:09PM
Hi loneoceans, I have just a couple of comments (corrections) to your schematic:
1) Your 7809 regulator does not seem to be annotated properly in the Rev C schematic? It's labeled "ICx" (
 "Link2")
2) The output from your UVLO chip is correct (it's labeled "To IC6A Pin 1 (CLR) via Jumper") but the corresponding comment on IC6A says "To OCD (IC11) Pin 1". This should read "To UVLO (IC11) Pin 1".
Regards,
Matt
Re: Universal Driver 2.7 Rev C
loneoceans, Sat Aug 06 2016, 09:59PM
Thanks everyone for helping to point out the errors in the documentation and for the suggestions! Will be updating the pages etc. For the trimmer resistor, thanks for pointing that out! Typically though this isn't a problem since the trimmer pot comes set at its default value directly from the manufacturer in a good range for soldering directly and adjusting, but definitely something to take note of!
As a side note, for those interested, I have a bunch of UD2.7C PCBs in stock for $10/board or $25 for 3. See here:
Finally, I also just assembled a new bunch of my MIDI 2 controllers due to very popular demand: available if anyone is interested.
loneoceans, Sat Aug 06 2016, 09:59PM
DerStrom8 wrote ...
Hi loneoceans, I have just a couple of comments (corrections) to your schematic:
1) Your 7809 regulator does not seem to be annotated properly in the Rev C schematic? It's labeled "ICx" (
2) The output from your UVLO chip is correct (it's labeled "To IC6A Pin 1 (CLR) via Jumper") but the corresponding comment on IC6A says "To OCD (IC11) Pin 1". This should read "To UVLO (IC11) Pin 1".
Regards,
Matt
Hi loneoceans, I have just a couple of comments (corrections) to your schematic:
1) Your 7809 regulator does not seem to be annotated properly in the Rev C schematic? It's labeled "ICx" (
2) The output from your UVLO chip is correct (it's labeled "To IC6A Pin 1 (CLR) via Jumper") but the corresponding comment on IC6A says "To OCD (IC11) Pin 1". This should read "To UVLO (IC11) Pin 1".
Regards,
Matt
Thanks everyone for helping to point out the errors in the documentation and for the suggestions! Will be updating the pages etc. For the trimmer resistor, thanks for pointing that out! Typically though this isn't a problem since the trimmer pot comes set at its default value directly from the manufacturer in a good range for soldering directly and adjusting, but definitely something to take note of!
As a side note, for those interested, I have a bunch of UD2.7C PCBs in stock for $10/board or $25 for 3. See here:
Finally, I also just assembled a new bunch of my MIDI 2 controllers due to very popular demand:
available if anyone is interested.Re: Universal Driver 2.7 Rev C
Nestade, Tue Jul 18 2017, 06:18PM
Hi,
Does anyone have a updated version of the mouser project ( as some things are not available anymore and some aren't available before 2018.
However I'm not very experienced yet and I don't want to replace the parts with incompatible ones which may cause problems with the driver.
Regards,
Nestade
EDIT: Just replaced the missing compounds - will it work with this parts?
Replaced:
863-74HC08DR2G >> 863-MC74HC08ADR2G
71-CRCW0805-470-E3 >> 71-CRCW0805470RFKEB
71-CRCW0805-1.0K-E3 >> 71-CRCW0805-1.0K
71-CRCW0805-4.7K-E3 >> 71-CRCW0805-4.7-E3
81-GRM31CR71H475KA2L >> 80-C1206C475K5R
810-C3225X7R1H225K >> 810-C3225X7R1H225K-9
71-CRCW080510K0FKEB >> 71-CRCW0805-10K
71-CRCW0805-100K-E3 >> 71-CRCW0805-100K
71-CRCW121015R0JNEAH >> 71-CRCW121015R0FKEAH
652-TC33X-2-503E >> 652-TC42X-2-503E
Nestade, Tue Jul 18 2017, 06:18PM
Hi,
Does anyone have a updated version of the mouser project (
as some things are not available anymore and some aren't available before 2018.However I'm not very experienced yet and I don't want to replace the parts with incompatible ones which may cause problems with the driver.
Regards,
Nestade
EDIT: Just replaced the missing compounds - will it work with this parts?
Replaced:
863-74HC08DR2G >> 863-MC74HC08ADR2G
71-CRCW0805-470-E3 >> 71-CRCW0805470RFKEB
71-CRCW0805-1.0K-E3 >> 71-CRCW0805-1.0K
71-CRCW0805-4.7K-E3 >> 71-CRCW0805-4.7-E3
81-GRM31CR71H475KA2L >> 80-C1206C475K5R
810-C3225X7R1H225K >> 810-C3225X7R1H225K-9
71-CRCW080510K0FKEB >> 71-CRCW0805-10K
71-CRCW0805-100K-E3 >> 71-CRCW0805-100K
71-CRCW121015R0JNEAH >> 71-CRCW121015R0FKEAH
652-TC33X-2-503E >> 652-TC42X-2-503E
Re: Universal Driver 2.7 Rev C
nzoomed, Wed Jul 19 2017, 12:46AM
I think somewhere i posted a revised order list as there were a few things I found missing at the time that I build my coil also.
Ill try and find it.
nzoomed, Wed Jul 19 2017, 12:46AM
I think somewhere i posted a revised order list as there were a few things I found missing at the time that I build my coil also.
Ill try and find it.
Re: Universal Driver 2.7 Rev C
Nestade, Wed Jul 19 2017, 10:46PM
Hi,
Okay - thanks :)
Do you think my changes will work? (I listed the things I changed as this parts weren't available at the moment - would be nice if you could have a look if you have time as I'm a noob yet)
Regrads,
Nestade
Nestade, Wed Jul 19 2017, 10:46PM
nzoomed wrote ...
I think somewhere i posted a revised order list as there were a few things I found missing at the time that I build my coil also.
Ill try and find it.
I think somewhere i posted a revised order list as there were a few things I found missing at the time that I build my coil also.
Ill try and find it.
Hi,
Okay - thanks :)
Do you think my changes will work? (I listed the things I changed as this parts weren't available at the moment - would be nice if you could have a look if you have time as I'm a noob yet)
Regrads,
Nestade
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