Constant Current PWM (Pulse Width Modulator)

This PMW is layed out specifically to fit in a Velleman G106 sealed

die cast aluminum enclosure measuring 4.5" L x 2.5" W x 1.25" H.

Circuit description:

U1 is a LM324N quad op-amp. U1A and U1B form a triangle wave

generator. The output voltage swing is approx 1/3-2/3 Vcc. The
output is fed to comparator U1C which turns it to square wave based
on the threshold voltage at pin 10. The duty cycle threshold is set by
VR1. R6 and R7 are calibrated to give full range duty cycle
adjustment of VR1. The voltage reference for R7 is normally held at
Vcc by the output of current limiting error amp U1D. Gain is set at
1000 (subject to change depending on how stiff you want the current
to limit).

Any time the source of Q1 draws current a voltage drop occurs

across R12. 40 amps will give 120mV, the max setting on VR3. If the
voltage drop across R12 exceeds the preset value of VR3, the
comparator drops the PWM duty cycle until the average is just less
than the preset value. C4 ensures that the current limiting is average
not peak.

R12 is a 4.5" piece of 16ga stranded speaker wire or appliance power

cord. One end is shorted together. The two leads at the other end are
connected to the Source of the MOSFET, AT THE SOURCE
TERMINAL, and to the common ground, AT THE COMMON
GROUNDING POINT. Also, the PC board terminal at the junction of
C4/VR3 connects directly to the common ground and the PC board
terminal for R10 connects directly to the MOSFET Source terminal.
These steps are very important to observe as unwanted oscillations
and instability can occurr.

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 Schematic for variable frequency PWM with
average value current limiting using LM324N

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 Constant current PWM PC board layout for
Velleman G106 sealed diecast aluminum
enclosure.

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 Photo

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 PWM Parts List

Unless noted, all resistors are in ohms, 1/4W, 5% tolerance. All capacitors are in uF, 16V minimum

Designation P/N Qty Description Mouser Digi-Key

512-LM324N LM324NFS-ND
U1 LM324 1 Quad Op-Amp
$0.33 ea $0.42 ea
511-L78010CV 296-11109-5-ND
U2 7810 1 10V Regulator
$0.28 ea $0.81 ea
512-HUF75344G3 IRFP064NPBF-ND
Q1 IRFP064N 1 Power MOSFET
$2.17 ea $6.00 ea
755-1N4004AT-82 1N4004RLG
D1, D2 1N4004 2 Rectifier
$0.49 ea $2.27 for 10
R1, R7 1.8k 2 Resistor
R2 22k 1 Resistor
R3, R4, R5 10K 1 Resistor
R6 3.9k 1 Resistor
R8 100k 1 Resistor
R9 100 1 Resistor
R11 1M 1 Resistor
R12 (note 1) 0.003 1 Resistor
R10, R13 1k 1 Resistor
R14 10 / 0.5W 1 Resistor
C1 0.022uF 1 Disk ceramic cap
C2, C4 47uF 2 Electrolytic cap
C3 0.047uF 1 Disk ceramic cap
VR1 10k 1 Linear taper pot
VR2 20K 1 Linear taper pot
VR3 1K 1 Linear taper pot
3 Knobs
Perf board,
1 0.1"x0.1"
hole pattern
1 14 pin IC socket
1 Heat Sink
1 Project box
Misc: Perf board terminals, ground lugs, binding posts, stand-offs, hookup wire.

Note 1: R12 is a 4.5" length of 16ga two conductor appliance cord. See schematic description for
details.

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