Delta Sinewave Converter Overview

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Delta Energy SystemsAC to AC Sine Wave Converter

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Basic Requirements from Customers

Supply AC Load in range from 0-230Vrms (AC current!) Adjustable AC output voltage via signal interface Temperature characteristic of load is extremely non-linear (very low cold resistance)p y ( y ) no galvanic separation between input / output required Meet EN61000-3-2 (Harmonics) Meet EN61000 3 3 (Flicker) Meet EN61000-3-3 (Flicker) no hold up time High efficiency Vmains VLoad

Compact design Light weight Cost efficient design

© 11-02-08 Delta Energy Systems 2

Cost efficient design

control

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Resistance [Ohm]

Load Type: Fuser Lamp

25.00

30.00

Resistance [Ohm]Temperature Characteristic: extremely non-linear temperature

characteristic

2150W @ 230V fuser lamp

20.00

2 @ 0Vrms 24 @ 230Vrms

1R10.00

15.00

121

230

0

V

V

RR

0.00

5.00

12230VR


0V 50V 100V 150V 200V 250V

Voltage2150W @ 230V fuser lamp

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Basic requirements for useful solution

Features

Output voltage / current must have same form and function for resistive load like input voltage (sinusoidal)voltage (sinusoidal) no harmonics generated (EN61000-3-2)

Amplitude of output voltage / current must be regulated according control interface 0 100% continuos mode 0-100% continuos mode

Continuously flowing input / output current in all operating points, no periodic or aperiodic interrupts in static operating point no flicker generated (EN61000-3-3)

Soft transition between operating points increases load dynamic range while still meeting flicker requirements


y g g q

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AC/AC Converter: Line Synchronization

T4 L1

T3

VLine

Vout1

Buck ConverterPWM control T1 250kHz 1,2


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AC/AC Converter: Line Synchronization

VLine

Advantages: polarity detection of line voltage is very fast

7-15s after zero-crossing

T3

g

no overlapping of Gate signals for T3, T4

demagnetizing of choke is guaranteed

T4

safe operation during dead time becauseof low voltage / low energy

15-30s 15-30s


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Sinewave Converter: test results

Step responseVout = 20V 200VPout = 7.5% 75%VLine = 230V

Vout 100V/DIV/10ms internal control signal


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Sinewave Converter: test results

Step responseVout = 200V 20VPout = 75% 7.5%VLine = 230V

Vout 100V/DIV/10ms internal control signal


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Sinewave Converter: ideal solution

Advantages Sinewave Converter does not create any harmonics

easy to meet EN61000-3-2 (Harmonics)y ( )

To meet Flicker requirements does not depend on control mechanism any more. It only depends on load dynamics which can be maximized by use of the Sinewave Converter. Soft transition between operation points enlarges dynamic range while still in line withSoft transition between operation points enlarges dynamic range while still in line with flicker requirements. easy to meet EN61000-3-3 (Flicker)

All ki d f t l i t f b i l t d f t t lt / t/ t l All kind of control interfaces can be implemented for output voltage/current/power control digital (serial, parallel), analog, PWM, others

Peak current limitation


tolerant for overload conditions

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Sinewave Converter: ideal solution

Advantages Sinewave Converter offers linear and continuous control characteristic

complete range between 0-100% programmable Vout

Efficiency 98% simple thermal handling, high power density

p g p g

75%

100%

Si l d li ht d i50%

Simple and light design easy to integrate into end-user application

Programmable limitation of output voltage range

25% 50% 75% 100% controlsignal

25%(0-90Vrms) offers use all over the world with only one type of load / module simplifies logistics


signal

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Use of Sinewave Converter

Applications copy machines (fuser lamps)

IR lamps IR lamps

printing machines, laser printers

heaters for process control (medical, biological, physical, chemical)

temperature regulating systems (technical applications)

Dryers

illumination

motor drives, motor control

steam generation


steam generation

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Sinewave Converter = Electronic Variac

Comparison traditional variac:

4kW, 230V, 50Hz265x405x415mm, 1.47W / inch3

44kg, 91W / kg

Sinewave Converter:Sinewave Converter:4kW, 230V, 50Hz105x95x315mm, 20.9W/inch3

2.1kg, 1.9kW/kg

V2V1

Sinewave Converter:


Equivalent Circuit Diagram

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Applications: 3x900W for copy machineC N h l d Customer: Netherlands

Application: high speed copy machine Heater: infrared fuser lamp (900W) Modules: 3 modules used per copy machine (3x900W) Cooling: convection cooling Size: 130x70x195mm / 1kg

Vin: 190Vac - 264Vac

Size: 130x70x195mm / 1kg

Vout: 0-230Vac Pout: 0-900W (0-4Aac) Control: digital, 6 Bit parallel for output


g , p pvoltage control

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Applications: 2400W for copy machineC USA Customer: USA

Application: high speed copy machine Heater: infrared fuser lamp (2400W) Modules: 2 modules used per copy machine Cooling: fan cooled Vin: 190Vac - 264Vac Vin: 190Vac 264Vac Vout: 0-230Vac Pout: 0-2400W (0-10.5Aac) Size: 77x90x305mm / 2.0kg Control: PWM, 500Hz, 0-100% duty cycle

for output voltage control


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Applications: 4000W for printing machineC USA Customer: USA

Application: high speed printing machine (fuser lamp) Heater: infrared heating tube (4000W) for toner fixing Modules: 2 modules used per copy machine Cooling: fan cooled Vin: 190Vac - 264Vac Vin: 190Vac 264Vac Vout: 0-230Vac Pout: 0-4000W (0-18.5Aac) Size: 105x95x315mm / 2.1kg Control: PWM, 500Hz,

0-100% duty cycle for outputvoltage control


voltage control

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Applications: 540W / 750W for diagnosticsC G Customer: Germany

Application: PCR analysis (Polymerize Chain Reaction) Heater: linear resistor for process control Modules: 1 module combined with power supply Cooling: fan cooled Vin: 90Vac - 264Vac Vin: 90Vac 264Vac Vout: 0-90V Pout: 0-540W / 750W (0-6A / 8.5A)

(2 versions)(2 versions) Control: serial, 12 Bit high speed for

output voltage control Accuracy: accuracy for temperature control


Accuracy: accuracy for temperature control< 0.5°C required

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Applications: 800W for blood dialysisC G Customer: Germany

Application: blood dialysis Heater: thick film resistor for process control Modules: 1 module combined with power supply Cooling: fan cooled Vin: 90Vac - 264Vac Vin: 90Vac 264Vac Vout: 0-90V Pout: 0-800W (0-10A) Control: PWM, 500Hz,

0-100% duty cycle for outputvoltage control


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Patent StatusUS P d US 932 934 US Patent granted: US 5,932,934

German Patent granted: DE 197 10 161 C2 European Patent pending: EP 0 865 150 A3


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Questions

Contact

Don Nasca

Delta Energy SystemsDelta Energy Systems

503-703-0208

[email protected]


Delta Sinewave Converter Overview

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