Electronics > Projects, Designs, and Technical Stuff

5VDC project, 110VDC overvoltage protection

(1/4) > >>

Bouteille:
Hello all,

I spent some time programming a PIC microcontroller and I would appreciate some help to design a circuit for it.

My first concern is overvoltage protection. In normal usage, the circuit expects regulated 5V.
However, this project will be used on ebikes and I know that sometimes people (like me) mix cables and put battery voltage (24V to 120V DC depending on the battery) where 5V DC is expected... oops !
I would like the circuit to survive to this kind of event (function not required in this condition).

My electronics skills are very limited so I searched a bit online and found some suggestions incuding zener diodes, polyswitch, crowbar circuit, or dedicated chips.

Easiest solution seems to be a Zener diode in parallel to circuit input, downstream to a polyswitch.
Knowing the following characteristics of the circuit (basically just a microcontroller), I would like to know how relevant this is.
I would also appreciate some help for selecting appropriate components.

Circuit characteristics:

Operating input voltage: 5V (2.5V to 5.5V, absolute max 6.5V)
Typical consumption : 50-200mA (never above 250mA)

Max input voltage protection (survival required, no operation): 26S li-ion battery (110V max, several amps capable)

For the polyswitch, I selected this part: PolySwitch TRF600 Series, 150 mA, 300 mA, 250 VDC
Datasheet: http://www.farnell.com/datasheets/2282572.pdf

Questions:

1. The polyswitch looks big but I guess specifications must be over the maximum protection (and not operation) voltage, correct ?

2. If I understand correctly the Zener diode must handle the short-circuit current until the polyswitch 'trips'.
But how to estimate the correct 'trip-time' from polyswitch datasheet, and then select an appropriate Zener to use in this application ?

Must I use the polyswitch 'Typical Resistance' (datasheet page 238, ie. 8.0Ω), and 'Typical Time-to-Trip Curves at 20°C' (datasheet page 245) ?

3. I assume that the regulated 5V from ebike controller will not be super-stable. Assuming a 5V Zener, is it a problem if the input voltage fluctuates between 4V and 5.5V ?

4. From EEVBLOG Zener diodes video, their use is not recommended for voltage regulation because of varying characteristics with temperature, current, etc...
Would you recommend another protection strategy for this project (crowbar, tps2400) ?


Any other suggestion appreciated, thank you very much for your help !

Mazo:
I don't think clamping the voltage is needed here(It is harder to clamp than to just switch off and "hide" from the overvoltage)
Here is a fast and dirty circuit.It is dependent on the Vbe of Q3 so not exactly the best accuracy.A TL431 used as a comparator can fix that if it's a problem.

Zero999:
You could just use a series resistor to limit the current to a level safe for the MCU input and add a zener to the 5V rail to prevent it from exceeding a safe level.

james_s:
Also select connectors wherever possible that mechanically prevent this sort of oops. A connector carrying high voltage should be quite different than one carrying 5V.

Yansi:
Here you have, eat that!  >:D

http://www.ti.com/lit/an/snva717/snva717.pdf

Navigation

[0] Message Index

[#] Next page

There was an error while thanking
Thanking...
Go to full version
Powered by SMFPacks Advanced Attachments Uploader Mod