Delta\'s patented AC to AC Sine Wave Converter for applications requiring clean programmable AC power.

1. Energy Systems
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Delta Energy Systems
AC to AC Sine Wave Converter

2. Energy Systems
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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)
EN61000 3 3
 no hold up time
 High efficiency Vmains VLoad
 Compact design
 Light weight
 Cost efficient design
control
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Load Type: Fuser Lamp
Resistance [Ohm]
Temperature Characteristic: 2150W @ 230V fuser lamp
30.00
 extremely non-linear temperature
characteristic 25.00
 2 @ 0Vrms
 24 @ 230Vrms 20.00
R 0V 1 15.00
 10.00
R 230V 12
230V
5.00
0.00
0V 50V 100V 150V 200V 250V
2150W @ 230V fuser lamp
Voltage
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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)
 no harmonics generated (EN61000-3-2)
Amplitude of output voltage / current must be regulated according control interface
 0 100% continuos mode
0-100%
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
1 T4
L
1 T3 Vout
VLine
Buck Converter
PWM control T1 2
1,2
50kHz
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AC/AC Converter: Line Synchronization
Advantages:
 polarity detection of line voltage is very fast VLine
 7-15s after zero-crossing
 g
 no overlapping of Gate signals for T3, T4
 demagnetizing of choke is guaranteed T3
 safe operation during dead time because
of low voltage / low energy T4
15-30s 15-30s
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Sinewave Converter: test results
 Step response
Vout = 20V 200V
Pout = 7.5%  75%
VLine = 230V
 Vout 100V/DIV/10ms
 internal control signal
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Sinewave Converter: test results
 Step response
Vout = 200V 20V
Pout = 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 with
flicker requirements.
 easy to meet EN61000-3-3 (Flicker)
 All kind of control interfaces can be implemented f output voltage/current/power control
ki d f t li t f b i l t d for t t lt / t/ t l
 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
p g p g Vout
100%
 Efficiency 98%
 simple thermal handling, high power density
75%
 Si l and light d i
Simple d li ht design
 easy to integrate into end-user application 50%
 Programmable limitation of output voltage range
(0-90Vrms) offers use all over the world with only 25%
one type of load / module
 simplifies logistics control
25% 50% 75% 100%
signal
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Use of Sinewave Converter
Applications
 copy machines (fuser 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
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Sinewave Converter = Electronic Variac
Comparison
 traditional variac:
4kW, 230V, 50Hz
265x405x415mm, 1.47W / inch3
44kg, 91W / kg
 Sinewave Converter:
4kW, 230V, 50Hz
105x95x315mm, 20.9W/inch3
2.1kg, 1.9kW/kg
V1
Sinewave Converter: V2
Equivalent Circuit Diagram
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Applications: 3x900W for copy machine
 C
Customer: N h l d
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
 Vout: 0-230Vac
 Pout: 0-900W (0-4Aac)
 Control: digital, 6 Bit parallel for output
g , p p
voltage control
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Applications: 2400W for copy machine
 C
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
 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 machine
 C
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
 Vout: 0-230Vac
 Pout: 0-4000W (0-18.5Aac)
 Size: 105x95x315mm / 2.1kg
 Control: PWM, 500Hz,
0-100% duty cycle for output
voltage control
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Applications: 540W / 750W for diagnostics
 C
Customer: G
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
 Vout: 0-90V
 Pout: 0-540W / 750W (0-6A / 8.5A)
(2 versions)
 Control: serial, 12 Bit high speed for
output voltage control
 Accuracy: accuracy for temperature control
< 0.5°C required
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Applications: 800W for blood dialysis
 C
Customer: G
Germany
 Application: blood dialysis
 Heater: thick film resistor for process control
 Modules: 1 module combined with power supply
 Cooling: fan cooled
 Vin: 90Vac - 264Vac
 Vout: 0-90V
 Pout: 0-800W (0-10A)
 Control: PWM, 500Hz,
0-100% duty cycle for output
voltage control
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Patent Status
 US P
Patent granted: US 5,932,934
d 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 Systems
503-703-0208
dnasca@delta-corp.com
© 11-02-08 Delta Energy Systems 19