This is a power-saving pulse-width modulator (PWM) controller for solenoids with an internal supply regulator. The board is based on the DRV110 IC which is a PWM current controller which is specifically designed for solenoid and relay applications. The project regulates the current with a well-controlled waveform to reduce power dissipation on the load. The solenoid current is ramped up fast to ensure the opening of the valve or relay. After initial ramping, the solenoid current is kept at a peak value to ensure correct operation, after which the current is reduced to a lower hold level to avoid thermal problems and reduce power dissipation.
This is a power-saving pulse-width modulator (PWM) controller for solenoids with an internal supply regulator. The board is based on the DRV110 IC which is a PWM current controller which is specifically designed for solenoid and relay applications. The project regulates the current with a well-controlled waveform to reduce power dissipation on the load. The solenoid current is ramped up fast to ensure the opening of the valve or relay. After initial ramping, the solenoid current is kept at a peak value to ensure correct operation, after which the current is reduced to a lower hold level to avoid thermal problems and reduce power dissipation.
The peak current duration is set with an external capacitor C2. The peak and hold levels of the current ramp can be adjusted using trimmer potentiometer PR2 and PR1, as well as the PWM frequency, which can independently be set with external resistor R6. External setting resistors can also be omitted if the default values for the corresponding parameters are suitable for the application. The DRV110 device has an internal Zener diode that limits the supply at VIN to VZENER for applications that require a higher supply voltage. High DC voltages such as 48V can also be accommodated this way.
Enable and disable the switch is controlled by the EN pin. The EN pin contains an internal resistor network to set the pin to logic HIGH when the EN pin is floating. This feature can be used for situations where a control signal is not required and the solenoid is only energized when a supply voltage is present. Such applications could be valves or contactors. By pulling down Enable pin disable the output.
IPEAK and IHOLD depend on PR1 and PR2 trimmer pot resistance values RPEAK-PR1 and RHOLD-PR2 as shown in the circuit. If the PEAK pin or HOLD pin is connected to the ground or RPEAK or RHOLD is less than 43.33 kΩ (typical), then IPEAK is at its default value of 300 mA for IPEAK and 50 mA for IHOLD.
The IPEAK value can alternatively be set using trimmer pot PR1. For example, if a PR1 60-kΩ (= RPEAK) is connected between PEAK and GND, and RSENSE = 1 Ω, then the externally set IPEAK level will be 900 mA. If RPEAK -PR1 = 200 kΩ and RSENSE = 1 Ω, then the externally set IPEAK level will be 300 mA. It is not recommended to use a resistor between 30 kΩ and 55 kΩ to avoid the IPEAK or IHOLD current slipping from the maximum current setting to the default setting. In case RSENSE = 2 Ω instead of 1 Ω, then IPEAK = 450 mA (when RPEAK-PR1 = 55 kΩ) and IPEAK = 150 mA (when RPEAK-PR1 = 200 kΩ
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