ZeroFossilFuel CCPWM v2.x Assembled PC Board

Assembled PC Board for Zero Fossil Fuel's Constant Current PWM v2.x

Includes Alt Fuel Systems Revision 3 Updates

This assembled PC board is for those who wish to build ZeroFossilFuel's version 2 constant current PWM, including version 2.1 and heavy duty design.   Buy this assembled circuit board and save time building Zero's CCPWM.  Alt Fuel Systems modifications for duty cycle stabilization and improved MOSFET drive capability are included.  The modifications reduce MOSFET heating and improve longevity.

The PCB is a durable high quality product designed to fit in the G106 enclosure. The board can be used with other enclosures, or in "open air" for bench top testing. 

Features and upgrades.

• The board is grounded through the mounting screws eliminating the need for an internal ground wire in a metal enclosure.
• Additional solder pads for direct connection of 12VDC cooling fan power leads.
• FET driver helps MOSFETs run cooler, and to allows connecting several MOSFETs for high current systems.
  
• Wire connection solder pads accept wire up to #18 wire size.
• R14 replaced with inductor L1 to help protect against high frequency supply transients.
• Capacitor added to stabilize output duty cycle when current limiting is active.
• PC board is shaped to fit in the G106 enclosure without requiring modification to the enclosure.
• Precision potentiometers allow accurate setting of frequency, static duty cycle, and current limit.
• Hand assembled using lead free, silver bearing solder.
• Every board is tested and packaged in static protective packaging to ensure you receive a functional unit.

The PC boards are tested with several different settings of frequency, duty cycle and current limit, and are shipped with the following final test settings. Frequency is set at 2KHz. Static duty cycle is set at 95%. Current limit is set to maximum setting (high current). Be sure to take these settings into consideration when powering your PWM for the first time. Depending on the design of your system, it may be necessary to reduce the current limit setting before powering the PWM to prevent an over current condition. If in doubt, turning the current limit adjustment pot screw "I" at least 20 turns Counter-Clockwise will reduce the current limit setting and provide a zero or low current starting point.

For additional images, click on the product image above.

Circuit design credits go to ZeroFossilFuel.  He created the original PWM design and released it under a general public license so everyone can all benefit from its use.  Additional circuit information is available at ZeroFossilFuel's website alt-nrg.org.

The Benefits of Using a FET Driver?

Most of the heat generated by the MOSFETs occurs during the time the MOSFET is changing between its on and off states.  The gate of the MOSFET (the control pin, or "switch") is essentially a capacitor that must be charged and discharged to turn the device on and off. A FET driver switches the MOSFET much faster by eliminating resistance in the supply pathway to the gate (essentially connecting the gate pin directly to power or ground to switch it on or off). This speeds up charging of the gate capacitance and reduces the amount of time the MOSFET spends in transition, and, therefore, the amount of time it can produce heat. This effect is greatly amplified when using multiple MOSFETs. In simpler terms, cooler MOSFETs.

Board dimensions: 2.300 in. x 1.325 in.
Mounting holes accept 1/8 in. screws.
(PC board dimensions are the same as the revision 2 boards.)

Assembled PC board only, does NOT include additional components required to build a complete PWM or documentation. This PC board was designed as part of a complete PWM assembly as designed by ZeroFossilFuel. His design includes additional components which provide power supply noise filtration which protects the PWM from damage. Use of this PC board in other designs that do not include adequate supply noise filtration is not recommended. Visit Zero Fossil Fuel's website for more information on building a complete PWM. PC board appearance may vary from that shown as equivalent or better components may be substituted during assembly.