Velleman K8004 Dc To Pulse Width Modulator Instruction Manual (+ PDF)

Contents hide

K8004 DC to Pulse Width Modulator

Product Information

Product Name: Dc to Pulse Width Modulator (K8004)
Total Solder Points: 82
Difficulty Level: Beginner
Features:
– PWM range: 0 to 100%
– PWM frequency: 100 to 5000Hz adjustable
– Minimum PWM offset: 0 to 20% adjustable
– Adjustable sensitivity: 2.5 to 35VDC
– Short circuit protection
– Overload protection: 6.5A
Specifications:
– Power Supply: 8 to 35VDC unregulated
– Supply current (No load): 35mA typ
– Efficiency: better than 90% at full load
– Dimensions (wxdxh): 85 x 48 x 45mm

Product Usage Instructions

1. Make sure you have the right tools for assembly,
including:
– A good quality soldering iron (25-40W) with a small tip. Keep it
clean by wiping it on a wet sponge or cloth and apply solder to the
tip for a wet look.
– Thin raisin-core solder. Do not use any flux or grease.
– Diagonal cutter to trim excess wires.
– Needle nose pliers for bending leads or holding components in
place.
– Small blade and Phillips screwdrivers.
– Optionally, a basic multi-meter may be required for some
projects.

2. Follow the assembly hints carefully to ensure a successful
project:
– Mount the components against the PCB surface and carefully solder
the leads.
– Make sure the solder joints are cone-shaped and shiny.
– Trim excess leads as close as possible to the solder joint.
– Remove components from the tape one at a time and always check
their value on the parts list to avoid mistakes.

3. Pay attention to the polarity of diodes and electrolytic
capacitors. Make sure to place them correctly.

4. Construction:
– Diodes: D1: 1N4148, D2: 1N4148, D3: 1N4007
– Resistors: R1: 220, R2: 220, R3: 2K2, R4: 2K2, R5: 10K, R6: 100K,
R7: 220K
– IC socket: IC1: 16P
– Trim potentiometer: RV1: 10K, RV2: 10K, RV3: 250K
– Ceramic Capacitors: C1: 100nF (104), C2: 100nF (104), C3: 100nF
(104), C4: 100nF (104)
– Transistor: T1: BC547
– Screw connectors: J1: 2p, J2: 2p, J3: 2p
– Electrolytic capacitor: C… (polarity must be observed)
– 5W Resistors: R8: 0.22 (R22), R9: 0.22 (R22), R10: 0.22
(R22)
– Transistor: T2: BUK9535-55 or equivalent
– IC: IC1: SG3525 (position of the notch must be checked)

5. Test:
– Connect the supplied 4k7 resistor between the + and – points of
the load.
– Connect the Vref point to the DC input.
– Set preset RV3 to the middle of its adjustment range.
– Connect a DC voltage between 8 and 35V with the points +V and
GND.
– Measure between the + and – points of LOAD with a voltmeter (set
to read DC voltage).
– If everything goes well, adjust the voltage on the output with
RV2.

View Fullscreen

Total solder points: 82 Difficulty level: beginner 1 2 3 4 5 advanced
Dc to Pulse Width Modulator

ILLUSTRATED ASSEMBLY MANUAL

K8004
Allowms ovteorrys,ehffeicaietenrtscoornltirgohl tosf. DC
H8004IP-2

Features & Specifications
Features:
PWM range: 0 to 100%. PWM frequency: 100 to 5000Hz adjustable. Minimum PWM offset: 0 to 20% adjustable. Adjustable sensitivity: 2.5 to 35VDC Short circuit protection. Overload protection: 6.5A
Specifications:
Power Supply: 8 to 35VDC unregulated Supply current (No load): 35mA typ Efficiency: better than 90% at full load Dimensions (wxdxh): 85 x 48 x 45mm
2

Assembly hints
1. Assembly (Skipping this can lead to troubles ! ) Ok, so we have your attention. These hints will help you to make this project successful. Read them carefully.
1.1 Make sure you have the right tools:
A good quality soldering iron (25-40W) with a small tip. Wipe it often on a wet sponge or cloth, to keep it clean; then apply solder to the tip, to give it a wet look. This is called `thinning’ and will
protect the tip, and enables you to make good connections. When solder rolls off the tip, it needs cleaning. Thin raisin-core solder. Do not use any flux or grease. A diagonal cutter to trim excess wires. To avoid injury when cutting excess leads, hold the lead so they
cannot fly towards the eyes. Needle nose pliers, for bending leads, or to hold components in place. Small blade and Phillips screwdrivers. A basic range is fine.
0.000
For some projects, a basic multi-meter is required, or might be handy
1.2 Assembly Hints :
Make sure the skill level matches your experience, to avoid disappointments. Follow the instructions carefully. Read and understand the entire step before you perform each operation. Perform the assembly in the correct order as stated in this manual Position all parts on the PCB (Printed Circuit Board) as shown on the drawings. Values on the circuit diagram are subject to changes. Values in this assembly guide are correct* Use the check-boxes to mark your progress. Please read the included information on safety and customer service
* Typographical inaccuracies excluded. Always look for possible last minute manual updates, indicated as `NOTE’ on a separate leaflet.
3

Assembly hints
1.3 Soldering Hints : 1- Mount the component against the PCB surface and carefully solder the leads
2- Make sure the solder joints are cone-shaped and shiny 3- Trim excess leads as close as possible to the solder joint
REMOVE THEM FROM THE TAPE ONE AT A TIME !
DO NOT BLINDLY FOLLOW THE ORDER OF THE COMPONENTS ONTO THE TAPE. ALWAYS CHECK
THEIR VALUE ON THE PARTS LIST!
4

1. Diodes. Watch the polarity ! 3. IC socket. Watch the posi- 5. PCB pins tion of the notch!
D…
CATHODE

Construction

D1 : 1N4148 D2 : 1N4148 D3 : 1N4007
2. Resistors
R…

R1 : 220 R2 : 220 R3 : 2K2 R4 : 2K2 R5 : 10K R6 : 100K R7 : 220K

(2-2-1-B) (2-2-1-B) (2-2-2-B) (2-2-2-B) (1-0-3-B) (1-0-4-B) (2-2-4-B)

IC1 : 16P
4. Trim potentiometer
RV…
RV1 : 10K RV2 : 10K RV3 : 250K

Vref 6. Ceramic Capacitors
C…
C1 : 100nF (104) C2 : 100nF (104) C3 : 100nF (104) C4 : 100nF (104)

Construction
7. Transistor
T1 : BC547

10. Screw connectors
J1 : 2p

8. Electrolytic capacitor. Watch the polarity !

J2 : 2p J3 : 2p

C5 : 10µF C6 : 10µF C7 : 100µF (40Vmin)

C…
11. 5W Resistors

R…

R8 : 0,22 (R22)

9. Diode, check the polarity

2mm

D4 : 6A2 / 6A6

D…

R9 : 0,22 (R22)

CATHODE

R10 : 0,22 (R22)

R…

12. Transistor

10mm M3 BOLT

LOCK WASHER

M3 NUT
T2 : BUK9535-55 or eq.
13. IC, Check the position of
the notch !

IC1: SG3525

Test
14. Test
Connect the supplied 4k7 resistor between the + and – points of the load. Connect the Vref point to the DC input. Set preset RV3 to the middle of its adjustment range. Connect a DC voltage between 8 and 35V with the points +V and GND. Measure between the + and – points of LOAD with a voltmeter (set to read DC voltage). If everything goes well then the voltage on the output can be adjusted with RV2.
Fig 1.0
7

Different configurations

15. Different configurations

Figure A :
Standard configuration, use a separate control voltage.

K8004 GND DCIN

+V
+
– LOAD
GND

DC LOAD

POWER

SUPPLY

(8…35VDC)
—

-+
DC CONTROL VOLTAGE (max. 35V)

Figure B :
Connection to one of the analogue outputs of the K8000 interface card. If DAC1 is used then the circuit can be controlled with the demo program, “dimmer”. The circuit can also be tested with the test program of the K8000.

Figure C :
Internal reference voltage used as control voltage.

VREF K8004 GND DCIN

+V
+
– LOAD
GND

K8004 GND DCIN

+V
+
– LOAD
GND

GND DAx DACx
K8000

DC LOAD

+
POWER SUPPLY (8…35VDC)
–

DC LOAD

+
POWER SUPPLY (8…35VDC)
–

Setting up
16. Setting up
RV1: setting the minimum output voltage.
Set the control voltage to zero (perhaps by disconnecting it). An initial pre-voltage can then be adjusted using preset RV1. This is especially useful with motors (in order to overcome mechanical resistance) and with halogen lamps (in order to pre-heat the filament).
RV2: setting the maximum output voltage.
Set the control voltage to the maximum voltage that you are going to use. The maximum output voltage can be adjusted with the preset, RV2 (useful for limiting motor speed or light intensity).
RV3: setting the output frequency.
If an irritating noise can be heard in the load, then it can be resolved by adjusting the output frequency. The normal position of this preset is the middle of its range.
9

PCB
17. PCB
10

P8004’2

18. Schematic diagram.

Schematic diagram
D2 D1
T1
11

VELLEMAN NV Legen Heirweg 33, B-9890 GAVERE
Belgium (Europe)

5 410329 292096