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Constructional Project
180-230V DC Moto
Controls 180-230V DC motors rated from 1A
to 10A (¼HP to 2.5HP)
Controlled by four common op amp ICs
with one opto-coupler and three linear
regulators
Zero to full speed control
Safe startup procedure
Emergency cut-out switch facility
Automatic over-current switch-off
Optional reversing switch capability
PWM, Live and Power indicator LEDs
Rugged diecast aluminium enclosure
Current and back-EMF monitoring for speed regulation under load
Initial setup adjustments can be made with a low-voltage supply
DC
motors from 180-230V DC power
various pieces of equipment; they
are particularly common
in treadmills. Often, these motors are
removed from the treadmill, possibly because the speed controller has
failed.
Such motors can be reused for other
purposes, such as adding computer control to a lathe. Many of these motors
are sold via the internet on sites such
as eBay, often inexpensively.
The type of DC motor we are referring to here typically has permanent
magnets in the stator and field coils for
the rotor. The electrical connection to
the field coils is made via a commutator and brushes.
These motors can be powered from
the mains using a full-wave bridge
rectifier to convert the 230 AC voltage
from the mains to a pulsating DC voltage, where the voltage rises and falls
in a sinewave shape over each half of
the mains waveform. The resulting
average voltage is close to 230V DC.
Warning: Mains Voltage
This Speed Controller operates
directly from the 230V AC mains
supply; contact with any live component is potentially lethal. Do not
build it unless you are experienced
working with mains voltages.
34
Scope 1 shows the resulting ‘DC’
waveform that is applied to the motor
for it to run at full speed. If you want
to slow the motor down, you need a
speed controller.
Our DC Motor Speed Controller provides the same 100Hz pulsating DC
mains rectified voltage as a full-wave
rectifier, but it adds speed control by
switching this waveform on and off
more rapidly, at around 900Hz. The
averaged DC voltage is thus multiplied by the proportion of time it is
switched on.
This type of drive is called pulsewidth modulation (PWM), where voltage is applied to the load in a series of
pulses with a duty cycle (0-100%) that
can be adjusted to control the average
voltage applied to the motor.
With the duty cycle set at 100%, the
motor is driven with the full 100Hz
full-wave rectified mains voltage. As
the duty cycle reduces, so does the average voltage applied to the motor. A
50% duty cycle reduces the average
voltage by one-half.
Scope 2 shows the PWM-chopped
full-wave rectified mains with it on
about 60% of the time (a 60% duty
cycle). The resulting averaged voltage should be about 60% of the full
waveform shown in Scope 1. The mean
measured value of 113V is 58% of the
195V reading from Scope 1.
Note that some mains motor speed
controllers designed to work with universal motors will be able to control
the speed of DC motors, especially if
they rectify the incoming mains immediately. However, such controllers
are usually optimised for use with AC
motors, so they lack some features that
are desirable for use with DC motors.
Our new design
By designing a controller purely
for DC motors, we can provide the
best control of this type of motor. For
example, a typical universal motor
speed controller might have feedback
to maintain motor speed under load,
but only by monitoring the motor current. That type of feedback control does
not monitor motor speed and relies on
the motor current being indicative of
motor speed and load.
One problem with that is that, under
load, the motor speed drops and it
draws more current. This extra current causes the controller to increase
the PWM duty cycle to increase the
motor speed. That increases the current further, so the controller increases the duty cycle further. The process
can quickly become unstable, possibly producing bursts of voltage to
the motor. That is especially likely to
happen if too much motor speed correction is applied.
Practical Electronics | July | 2025
180-230V DC Motor Speed Controller
or Speed Controller
High-voltage DC motors are
commonly used in lathes,
consumer-grade treadmills,
industrial conveyor belts and
similar equipment. This Speed
Controller can control such
a motor over a wide range
of speeds, from very slow
to full speed. A constant
speed is maintained even with
a varying load due to motor-generator voltage
(back-EMF) sensing and current feedback circuitry.
Part 1 by John Clarke
In this new design, we also monitor
the motor speed using back-EMF (electromotive force). The motor generates
this back-EMF from its rotation and
it directly indicates the motor speed
– see Scope 3. The generated voltage
will drop when the motor is loaded,
since it will slow down.
Increasing the duty cycle of voltage
applied to the motor can compensate
for this reduction in motor speed. This
is a negative feedback control, so it is
far more stable than feedback based
purely on motor current.
Compare Scope 3, with the motor
driven by switched PWM, to Scope 2.
You can see that in Scope 3, the motor
load also generates a voltage (backEMF) during the PWM off-times. This
is seen as the spikes below the baseline indicated by the small arrow and
“1” on the left. The motor is generating spikes of around -85V.
Applying a combination of both current and back-EMF feedback control,
with a measured amount of each, provides excellent speed control without
the risk of speed instability.
Incidentally, we don’t use backEMF speed control for a universal
motor controller because that voltage is essentially non-existent. The
Scope 1: this is the pulsating ‘DC’
waveform that is applied to the motor
for it to run at full speed, created by
rectifying the 230V AC mains. Note
that the mean (average) voltage is
lower than the RMS. This waveform
(like the others) was captured using
an isolated differential probe.
Scope 2: the full-wave rectified mains
being switched on and off with a duty
cycle of about 60% (60% on, 40% off).
As expected, the resulting average
voltage is about 60% of the full
waveform in Scope 1.
Practical Electronics | July | 2025
generated voltage relies on having a
magnetised core. Since the universal
motor has windings for both the armature and stator, there is little remnant magnetism when the windings
are not powered. Hence, little to no
voltage is produced.
However, with a DC motor, the stator
can comprise permanent magnets or
powered windings, so a voltage is induced in the rotor as it spins.
Design inspiration
We based our new controller on
the features of a small lathe controller (the Sieg C1 micro lathe) that was
Scope 3: the motor voltage when
driven by the switched PWM version
of the full-wave rectified mains
waveform. You can see how the motor
load generates negative voltage spikes
of about -85V (back-EMF) during the
PWM off periods while the motor is
not being driven.
35
Constructional Project
extensively documented by Dr Hugo
Holden. He provides considerable
detail on the operation of that circuit,
as well as a description of how it uses
op amps, in a PDF on his website at
https://pemag.au/link/abmn
While the Sieg controller is for small
motors rated up to 1A, we have designed ours to handle any high-voltage
DC motor from 1A to 10A.
The Sieg motor controller includes
several safety features we also incorporated into our new design. One such
feature is the facility for a safety/emergency stop switch, where the motor
does not start when the switch is open
and will shut off if it opens during operation. This feature does not need to
be used; it can be bypassed with a wire
loop if not required.
However, it’s a great idea to include such a switch for a lathe or
any other piece of industrial equipment. A lathe can be set up so it will
not run unless a safety shield is in
place to protect against flying debris.
In other cases, the safety switch can
be a large, red emergency stop button
(available from Farnell). You could
even have both simply by wiring them
in series. Whenever one opens, the
motor will stop.
There are other conditions under
which the motor won’t run for safety.
For example, when the controller is
initially powered up or if the motor
becomes overloaded during operation.
The motor cannot start or be restarted
unless the speed control is brought
back to the full anti-clockwise position before being advanced to start
the motor running. That assumes the
safety switch is closed and there is no
motor overload.
The Sieg controller does this with
a switch incorporated within the
speed potentiometer. That is not terribly unusual as many vintage radios
and some music instrument amplifiers have a power switch within the
volume potentiometer, where rotating the potentiometer fully anti-
clockwise opens the switch to disconnect the power.
However, in the Sieg controller and
our design, the switch must be closed
when the potentiometer is fully anticlockwise and open when it is advanced clockwise. That is the reverse
of a radio/amplifier potentiometer,
making it a rather unique and difficult
part to obtain.
Even if we decided to use that style
of potentiometer, with (say) a relay to
reverse the switching sense, it still
would not be ideal. That’s because
volume control potentiometers have
a logarithmic resistance change over
their rotation, while we need a linear
response.
Therefore, we use a standard potentiometer that does not have a switch
incorporated and instead provide the
switching feature using a comparator and relay. That avoids having to
source a special type of potentiometer.
The comparator monitors the potentiometer’s wiper voltage and switches a
relay according to the potentiometer
position.
How it works
The basic block diagram is shown
in Fig.1. The circuitry is based around
a full-wave bridge rectifier that provides the 100Hz half-sinewave ‘DC’
voltage from the mains. The IGBT
that switches power on and off to the
motor is connected in series with the
motor, between the DC terminals of
the bridge rectifier.
The IGBT’s gate is driven by PWM
circuitry that controls the motor speed.
The duty cycle of the PWM signal depends on the position of the speed potentiometer (VR1), the motor current
(detected by sense resistors) and the
motor with both back-EMF from its
negative terminal.
The PWM signal is generated by
comparing voltage Vo (derived from
the speed potentiometer voltage and
the current and voltage feedback) to
a sawtooth waveform. Vo comes from
the output of op amp IC2c, while
Fig.1: the voltage from speed control pot VR1 (at left) is buffered and mixed with
the motor current and speed feedback signals, then fed to comparator IC4a.
Comparing that DC voltage to a sawtooth waveform produces a PWM output
with a duty cycle proportional to the control voltage. That goes to the IGBT,
which switches voltage to the motor. The other components are associated with
the over-current shutdown, safety switch and power-up inhibit functions.
36
Practical Electronics | July | 2025
180-230V DC Motor Speed Controller
the sawtooth waveform is from the
oscillator based on IC4b. IC4a compares the sawtooth waveform to Vo
and generates the variable duty-cycle
PWM output.
The manual speed control voltage
from potentiometer VR1 is buffered
via IC2a, which applies a DC voltage
to the N1 node, at the input to IC2b.
Voltages from the feedback loop outputs, from IC3b and IC2d, are also applied to N1. These provide the speed
(Vs) and torque (Vt) signals, which are
derived from the motor back-EMF and
the motor current, respectively.
For torque feedback, the motor current is determined by the voltage across
the current sense resistance in series
with the motor’s positive terminal.
The resulting voltage is amplified by
IC1b, which has its gain set by trimpot
VR2. The gain is adjusted according to
the motor current rating; more gain is
used for low-current motors and less
for higher-current motors.
The resulting voltage is applied to
op amp IC2d, with an offset voltage
set via trimpot VR3.
The motor’s back-EMF voltage is
amplified by IC3c and is offset using
trimpot VR7 before being applied to
op amp IC3b. IC3c provides a low-pass
filter with a roll-off point of 1.6Hz to
remove the 100Hz ripple.
The torque voltage from IC2d (Vt)
and the speed signal from IC3b (Vs) are
summed with the speed control signal
at N1, while a separate torque signal
is applied to the N2 junction of the
main servo amplifiers, IC2b and IC2c,
via VR4. This provides feedback adjustment, allowing for the best speed
control as the motor is loaded.
For current overload detection, the
motor current is amplified by op amp
IC3d and compared against a threshold
by comparator IC3a (it’s actually an
op amp but used in open-loop mode,
so it acts as a comparator). If the current limit is exceeded, the motor is
switched off by the shutdown relay,
RLY2, which switches off RLY3. That
disconnects power from the motor.
These relays return to their normal
positions when the overload is cleared
and the speed control is rotated fully
anti-clockwise.
IC1a detects when the speed control pot is set at zero. It compares the
buffered speed control voltage from
IC2a against a 119mV reference. The
Relay (RLY1) is powered, opening the
connected contacts, when the voltage
Practical Electronics | July | 2025
This is the motor we used for testing, You can find lots of similar second-hand
and new motors on eBay.
from the speed control is higher than
119mV. The open relay contacts prevent the motor from starting, although
it will continue to run if it is already
running.
Other relays are connected in series
with the coil of the one that powers the
motor, so if any of them open, that will
stop the motor from spinning. That
includes if an overload is detected or
the emergency/safety switch is open.
For the motor to run, the speed potentiometer must be set almost fully
anti-clockwise (switching RLY1 off),
then rotated more clockwise to start
the motor.
The circuit has three main supply
rails: a ±12V split supply and a +15V
supply. The +12V supply connects to
the positive output of the full-wave
bridge rectifier, so the whole circuit
operates at mains potential. Level
shifting between IC4a’s output and the
gate of IGBT Q1 is via an opto-coupled
Mosfet/IGBT gate driver (IC5).
Circuit details
The full circuit is shown in Fig.2.
It comprises five ICs, an IGBT, several diodes, two transistors, three
relays plus numerous capacitors and
resistors.
A significant component for PWM
drive generation is op amp IC4b, wired
as a sawtooth oscillator (near the
bottom of the diagram). This is the
second amplifier in dual LM833 op
amp IC4. It is powered from the ±12V
supply.
A bias voltage is generated using two
100kW resistors connected in series
across the ±12V supply. The centre connection of this voltage divider is con-
nected to the non-inverting input, pin
5 of IC4b. The voltage at pin 5 would
be 0V, except for the fact that there is
also a 47kW resistor between pin 5 and
the op amp output, pin 7.
To calculate the voltage at pin 5, the
two 100kW resistors connected across
the ±12V supply can be considered a
50kW resistor between pin 5 and 0V.
That leaves a 47kW/50kW voltage divider, with the voltage at the end of the
47kW resistor shifting between about
10.9V when pin 7 is high and -10.9V
when it is low.
So when the op amp output is high,
the 47kW resistor pulls pin 5 to around
5.6V, and when the op amp output is
low, it is around -5.6V. The output
oscillates between the high and low
states due to the 10nF capacitor at the
inverting input (pin 6) and the charge
and discharge resistances between
pins 6 and 7.
When power is first applied, the
10nF capacitor is discharged, so pin 6
is near -10.9V. Pin 5 is at a higher voltage than that, so pin 7 goes high. Pin
5 then sits at around 5.6V. The 10nF
capacitor charges via the 1kW resistor
and diode D4. As soon as the capacitor
at pin 6 charges just beyond the pin 5
voltage, pin 7 goes low, to -10.9V, since
the inverting input voltage is above the
non-inverting input.
Pin 5 is then at -5.6V, and the capacitor discharges via the 91kW resistor.
Diode D4 is reverse-biased and does not
take part in the discharge cycle. Once
the capacitor voltage exceeds -5.6V,
the pin 7 output goes high again, and
the process repeats.
So the 10nF capacitor is charged
quickly via the 1kW resistor and
37
Constructional Project
diode D4, then discharged much
more slowly via the 91kW resistor. The
resulting waveform is described as a
sawtooth shape, rising quickly and
falling more slowly. The waveform
ranges from about +5.6V to -5.6V at
about 900Hz.
38
The sawtooth waveform at pin 6 of
IC4b goes to the inverting (pin 2) input
of IC4a, which compares it against
the Vo voltage from IC2c (at its non-
inverting pin 3 input). The output of
IC4a goes high (to around 10.9V) when
the voltage from the IC4a oscillator is
lower than the feedback voltage; its
output is low (-10.9V) otherwise.
IC4a’s output is therefore a rectangular waveform with a higher duty
cycle (higher for longer) when the Vo
voltage is higher. IC4a’s output drives
optically-coupled Mosfet/IGBT driver
Practical Electronics | July | 2025
180-230V DC Motor Speed Controller
Fig.2: virtually all the op amp based control circuitry is on the left half of the diagram; 12 op amp stages are used, inside
four ICs, two of which operate as comparators. The IGBT and its driving circuitry are at lower middle, with the current
measurement shunts and relays that switch power to the motor above that. The linear power supply is at upper right.
IC5. It level-shifts IC4a’s square-wave
output to a voltage suitable for driving the gate of Q1.
Scopes 4 & 5 show the sawtooth
waveform and Q1’s PWM gate-drive
signal at duty cycles of about 10%
and 90%. The top trace (yellow) is
the PWM signal, while the lower cyan
trace is the sawtooth waveform, which
oscillates between ±5.6V. The yellow
horizontal dotted line (representing
Vo) shows how the PWM output is
high when the sawtooth waveform is
below that level.
Scope 6 shows the PWM drive to
Q1’s gate. The rise and fall times of
the waveform are 1.37μs and 1.2μs, respectively, with the gate voltage reachPractical Electronics | July | 2025
ing 14.8V. We want the switching time
to be short to minimise heating in Q1
during partial conduction periods, and
the gate drive needs to be within its
±25V rating while being high enough
to fully switch it on, which occurs at
around 15V.
The 15V supply for driving the gate
comes from the positive output of the
bridge rectifier via diode D2 and four
series/parallel 22kW 1W resistors. This
provides an average of 5mA to IC5 and
the 15V zener diode (ZD2). That supply
is smoothed to a DC voltage by a 100μF
capacitor with parallel 1μF and 100nF
ceramic capacitors so that IC5 can receive bursts of current for driving Q1’s
gate when needed.
LED1 is also driven by this 15V
supply, so it indicates when power
is being fed to the circuit from the
positive side of the bridge rectifier.
When lit, the entire circuit is at mains
potential.
IC5 has an internal LED between
pins 1 and 3, and its output goes high
when that LED is powered via the
620W resistor from the output of IC4a
and diode D3.
That diode prevents a negative voltage from being applied to IC5’s internal LED when IC4a’s output goes negative. The 620W series resistor limits
the LED current to around 10mA. Q1’s
gate is driven via a 75W rate-limiting
gate resistor.
39
Constructional Project
The IGBT is protected from overvoltage at switch-off by transient voltage
suppressor TVS1, which conducts if
Q1’s collector goes above 400V, causing the gate to be pulled high. That
switches on Q1 to shunt the excess
voltage. The 10W series resistor limits
the current into protective 15V zener
diode ZD1, which prevents the gate
voltage from going beyond Q1’s maximum limits.
Apart from TVS1, any high voltage spikes are also coupled via diode
D1 into the 47nF capacitor connected
across the + and – terminals of BR1.
The capacitor absorbs some voltage
transients.
A snubber between the IGBT’s collector and emitter terminals prevents
switch-off oscillations. It comprises
a 47nF capacitor and two paralleled
470W 5W resistors.
Inductor L1, in series with the
motor, limits the current rise rate
when the motor is switched on to
protect the IGBT from excessive surge
current. It also helps to filter the
900Hz switching drive for the motor,
reducing electromagnetic interference (EMI).
The motor current is monitored via a
set of 0.022W shunt resistors. The four
0.022W 3W resistors are connected in
series/parallel, yielding a 0.022W 12W
resistance. They connect between the
bridge rectifier positive terminal and
L1. This shunt produces a voltage at
the lower end that is below the +12V
supply, in proportion to the current
flow.
The motor voltage is monitored via
a 220W 1W resistor from the motor’s
negative terminal. This voltage is also
negative with respect to the +12V
supply and becomes more negative
with increased back-EMF voltage. The
circuitry for monitoring these feedback
voltages will be described separately.
Current feedback
IC1b amplifies the voltage across
the current measurement shunt resistors. Its gain can be adjusted between 1.5 times (with trimpot VR2 at
minimum resistance) and 13.1 times,
when the resistance between pins 6
and 7 of IC1b is 5.22kW. This allows
the circuit to work with motors rated
between 1A and 10A with the correct
overload threshold.
Note how IC1 has a 15V positive
supply rather than 12V. This means
the positive supply for IC1 is 3V above
the 12V that the shunt resistor is referenced to. That way, the op amp output
can reach 12V when there is no voltage across the shunt.
Even though the op amp is a rail-torail type, where the input and output
voltages can be up to the supply rails,
there will be some differences due to
the input offset voltage of the op amp
and the fact that the output can only
reach within a few millivolts of its
supply rails. So, with IC1’s positive
supply above 12V, the op amp has the
headroom to handle 12V signals.
The output voltage from IC1b is amplified and inverted by op amp IC2d,
which has a gain of -6.8, determined
by the 10kW input resistor and the
68kW feedback resistor. This amplifier
also acts as an integrator, filtering out
the PWM signal and the pulsating DC
due to the 220nF capacitor connected
across the 68kW resistor.
The resulting low-pass filter has a
roll-off point at about 10.6Hz, well
below the 100Hz of the rectified mains
and the 900Hz PWM signal. IC2d’s
output is applied to the N1 node via
a 33kW resistor.
Scope 4 & 5: these captures show the sawtooth waveform and the Q1’s PWM
gate drive signal for duty cycles of about 10% and 90%. The top trace (yellow)
is the PWM voltage, while the lower cyan trace is the sawtooth waveform with
a range of ±5.6V. The dotted yellow horizontal line represents Vo; when the
sawtooth waveform is below it, the PWM output is high.
40
By the way, all inverting amplifiers
in the motor controller circuit include
a resistor from the non-inverting input
of the op amp to the 0V rail. These are
to equalise the two input impedances
so that any input currents will balance
out. This minimises offset voltages due
to the parasitic input currents.
Note how op amp IC2d also connects to the -12V supply via an 8.2kW
resistor and trimpot VR3. This preset
trimpot adjusts the voltage offset at
the Vt test point (IC2d’s output). It is
adjusted to provide the correct operation of the PWM by keeping voltage
within range of the voltage swing from
the sawtooth oscillator, IC4b.
The output voltage of IC1b is also
applied to the current overload circuitry that comprises IC3d and IC3a;
more on that later.
Motor speed feedback
The motor back-EMF voltage is monitored via a 220kW 1W resistor from the
motor’s negative terminal. This voltage is attenuated and offset toward the
+12V rail by the connected 8.2kW resistor. The resulting voltage is applied
to an inverting and integrating buffer,
IC3c, via a 100kW resistor to its inverting input, pin 9.
Speed trimpot VR7, in series with a
100kW resistor, provides level-shifting
of the voltage from IC3c. As mentioned
earlier, IC3c provides low-pass filtering with a corner frequency of around
16Hz due to the 1μF capacitor in parallel with the 100kW feedback resistor.
IC3b provides voltage inversion with
a gain of -2 before applying the speed
feedback voltage to the N1 node via a
10kW resistor.
Motor speed adjustment
VR1 is used to adjust the motor
Scope 6: a zoomed-in view of the
PWM drive waveform at Q1’s gate.
The rise and fall times are 1.37µs
and 1.2µs, respectively, with the gate
voltage ranging from 0V when the
IGBT is off to 14.8V when on.
Practical Electronics | July | 2025
180-230V DC Motor Speed Controller
speed manually. It is connected in
series with a 620W resistor across the
12V supply. The 620W resistor is included so that the voltage from the potentiometer’s wiper ranges from 0V to
10.6V. That provides a suitable range
to feed to op amp IC2a, which is not
a rail-to-rail type.
The potentiometer wiper charges
and discharges a 100μF capacitor via
one of two separate paths. When rotated clockwise to increase the voltage,
the capacitor is charged via the 10kW
resistor, so it takes about one second
for the capacitor to fully charge and
signal full motor speed.
When the potentiometer is wound
anti-clockwise to reduce the speed,
the voltage is more quickly decreased
by discharging the capacitor via diode
D5 and its series 100W resistor. This
allows the motor to be stopped quickly if necessary. IC2a’s output feeds the
N1 node via a 6.8kW resistor.
The current and voltage feedback
signals, plus the speed control potentiometer signals, are all summed
at the N1 node. This results in a
summed output from the IC2b mixer
of the three sets of voltages for the
current and voltage feedback signals, plus the speed control potentiometer.
A second node (N2) mixes the
IC2b output (via a 10kW resistor)
and the torque from the IC2d output
(via trimpot VR4 and its series 10kW
resistor). The final summation is
performed by IC2c, producing the
Vo output signal that’s applied to the
PWM comparator, IC4a.
The IC4a comparator has a small
amount of hysteresis so it does not oscillate when the non-inverting input
voltage is close to the sawtooth oscillator waveform voltage. The 100W
and 1MW resistors at pin 3 cause the
pin 3 voltage to shift slightly when
IC4a’s output state changes, preventing the two voltages at pins 2 and
3 from remaining at the same level
for long.
A voltage clamp comprising zener
diode ZD3 and diode D10 at the pin
3 input to IC4a limits the voltage to
one diode drop below -8.2V. This
clamping prevents the input from
going below the op amp’s input voltage range. Without the clamp, if the
voltage went below -9V, the op amp
output would swing high instead of
staying low due to a phase reversal
internal to the op amp.
Practical Electronics | July | 2025
The Speed Controller fits neatly into an aluminium enclosure. The black ‘wires’
are actually fibre-optic light pipes for the LEDs.
The full adjustment range of VR1
suits 230V DC motors. For motors
rated to a lower voltage, like 180V,
you can simply operate VR1 over the
lower 80% of its range. If you need to
prevent more than an average of 180V
from being applied to the motor, you
can increase the 620W resistor in series
with VR1 to 1.6kW.
Current overload detection
The motor-current-derived voltage
from IC1b is applied to the current
overload circuitry comprising op amp
IC3d and comparator IC3a (another
op amp used as a comparator). IC3d
amplifies the voltage from IC1b with
a gain of -4.68 times (220kW/47kW),
with its output voltage level-shifted
by trimpot VR5 that’s connected to
the -12V supply by way of a 24kW
resistor.
IC3a compares the output voltage
from IC3d against a reference voltage
set by VR6.
VR6 is connected as an adjustable
divider across the ±12V rails with a
12kW padder resistor and sets the current overload trip level.
If the motor current is high enough
to produce a voltage from IC3d’s output
above the overload level, the comparator output will go high, switching on
transistor Q3 and consequently, relay
RLY2.
A 100μF capacitor holds this pin
2 input at -12V for a few seconds at
power-up. The initial low voltage ensures the comparator output at pin 1
of IC3a is high at power up, so RLY2
switches on and opens its NC contact.
That ensures RLY3 is not on during
power-up, so the motor cannot run
immediately.
41
Constructional Project
When transistor Q3 is switched on,
we ensure it’s on long enough to activate RLY2 due to the 100μF capacitor
that’s initially charged via diode D9
from IC3a’s output.
When there is an overcurrent condition and RLY2 is powered, it disconnects power to RLY3’s coil. RLY3 is
the high-current relay that connects
power to the motor by joining the M+
terminal to inductor L1.
If an overcurrent condition triggers
the relays, that will quickly cease as
the motor will no longer be powered.
RLY2’s contacts will close again, so
RLY3 can be powered once more, and
the motor can be restarted.
However, power for RLY3’s coil
comes via RLY1’s contacts, and RLY1’s
contacts are open unless the speed potentiometer is fully anti-clockwise. So,
the speed potentiometer must be returned to the fully-off position before
RLY1’s contacts close. RLY3 is then
powered to provide voltage to the
motor once the speed potentiometer
is rotated clockwise.
Restart switch
We described earlier how IC1a and
RLY1 provide the ‘switched potentiometer’ action we need from a regular
potentiometer, but here are more details on how that section works.
IC1a acts as a Schmitt-trigger comparator, monitoring the speed potentiometer voltage after buffer IC2a. It
compares that voltage to a 119mV
reference from a 100kW/1kW voltage
divider across the 12V supply. When
IC2a’s output is below this 119mV
reference, the output of IC1a is low,
so RLY1 is not powered. When IC2a’s
output is above 119mV, IC1a’s output
goes high and drives transistor Q2 via
its 1kW base resistor.
IC1a includes hysteresis so the
output does not oscillate at the 119mV
threshold. IC1a is powered from the
15V supply, with a 1MW feedback
resistor, so this hysteresis is around
15mV.
In more detail, when IC1a’s output is
low, its pin 3 input is pulled lower than
IC2a’s output due to the 1MW/1kW voltage divider. When IC1a’s output goes,
pin 3 is pulled about 15mV higher, so
the output from IC2a needs to drop a
further 15mV before IC1a’s output will
go low again.
When Q2 is on and RLY1 is powered, its normally closed contacts open,
disconnecting RLY3’s 12V coil power
42
Parts List – 180-230V DC Motor Speed Controller
1 double-sided plated-through PCB coded 11104241, 201 × 134mm
1 Gainta G124 or BS11MF diecast aluminium enclosure, 222 × 146 × 55mm
[both available from TME]
2 SRM-1C-SL-12VDC, NT73 -2 or equivalent 10A, 12V DC coil SPDT PCBmounting relays (RLY1, RLY2) [Farnell 1094019]
1 T92P11D22-24, HF92F-024D-2C21S or FRA8PC-S2 30A, 24V DC coil DPDT
panel-mount relay (RLY3) [Farnell 270350]
1 Myrra 44237 PCB-mounting 12V + 12V 5VA mains transformer (T1)
[Farnell 1214601]
2 30 × 20 × 12.5mm powdered iron toroidal cores (L1) [Farnell 4167313]
1 8-way 300V 15A 8.25mm-pitch PCB-mount barrier terminals (CON1)
[Farnell 4476943]
1 vertical-mount 300V 15A 3-way pluggable header with screw terminals,
5.08mm spacing (CON2) [Farnell 2452499 + 3797901]
1 vertical-mount 300V 15A 2-way pluggable header with screw terminals,
5.08mm spacing (CON3) [Farnell 2468397 + 3399493]
3 PCB-mount 5mm pitch 6.3mm male spade connectors (CON5-CON7)
3 6.3mm fully-insulated female crimp spade connectors
1 IEC C14 panel-mount mains connector with integral fuse (CON10)
[Farnell 9521615]
1 M205 230VAC fast-blow fuse (F1) (with a current rating to suit the motor)
1 13A mains IEC lead
1 13A chassis-mount mains socket [eg, RS 500-0459]
1 24mm 5kW single-gang linear potentiometer, 500V rating (VR1)
[Farnell 1436327]
3 5kW top adjust trimpots (VR2-VR4)
3 50kW top adjust trimpots (VR5-VR7
1 knob to suit VR1
2 14-pin DIL IC sockets (optional)
2 8-pin DIL IC sockets (optional)
3 100mm-long 3mm LED fibre-optic light transporters (optional)
[Mouser 749-FLP25V4.0-SBC]
4 yellow 5mm inner diameter crimp eyelets for 4-6mm diameter wire
4 M3 × 6mm tapped standoffs (not required for G124 case)
8 M3 × 6mm panhead machine screws (not required for G124 case)
Hardware & cables
2 M4 × 10 panhead machine screws (for Earth-to-chassis connections)
2 4mm inner diameter star washers
2 M4 hex nuts
2 M3.5 × 6mm panhead machine screws (PCB to Altronics enclosure)
1 M3 × 12mm panhead machine screw (for Q1)
4 M3 × 10mm panhead machine screws (for BR1, D1 & RLY3)
2 M3 × 10mm countersunk head machine screws (for IEC connector)
3 M3 × 6mm panhead machine screws (for REG1-REG3)
3 3mm inner diameter washers (for D1 and RLY3)
8 M3 hex nuts
1 TOP3 insulating washer
1 500mm length of 1.25mm diameter enamelled copper wire
1 500mm length of 10A green/yellow striped (for Earth) mains-rated wire
1 500mm length of 10A brown (for Active) mains-rated wire
1 500mm length of 10A blue (for Neutral) mains-rated wire
1 450mm x 8mm plastic cable tie (for T1)
1 250mm x 4.8mm plastic cable tie (for L1)
12 100mm x 3.6mm plastic cable ties
1 120mm length of black 5mm diameter heatshrink tubing
1 60mm length of red 5mm diameter heatshrink tubing
1 15mm length of blue 5mm diameter heatshrink tubing
1 15mm length of yellow 5mm diameter heatshrink tubing
Practical Electronics | July | 2025
180-230V DC Motor Speed Controller
Semiconductors
1 LMC6482AIN dual CMOS op amp, DIP-8 (IC1) [Farnell 3117147]
2 LM324AN quad op amps, DIP-14 (IC2, IC3)
1 LM833 dual op amp, DIP-8 (IC4)
1 TLP5701 optically-isolated Mosfet driver, SMD-6 (IC5)
[Farnell 3872508 or 2768341]
1 7812 +12V 1A linear regulator, TO-220 (REG1)
1 7815 +15V 1A linear regulator, TO-220 (REG2)
1 7912 -12V 1A linear regulator, TO-220 (REG3)
1 STGW40M-120DF3 1.2kV 80A IGBT, TO-247 (Q1) [Farnell 2470028]
2 BC337 NPN transistors, TO-92 (Q2, Q3)
4 3mm or 5mm high brightness red LEDs (LED1, LED3-LED5)
1 3mm or 5mm high-brightness green LED (LED2)
1 PB5006 600V 45A SIL bridge rectifier (BR1) [Farnell 3774973]
1 W04 1A 400V bridge rectifier (BR2)
1 RURG3060 600V 30A fast diode (D1) [Farnell 2495903]
4 1N4004 400V 1A diodes (D2, D6-D8)
5 1N4148 75V 200mA signal diodes (D3-D5, D9, D10)
2 15V 1W zener diodes (ZD1, ZD2) [1N4744A]
1 8.2V 1W zener diode (ZD3) [1N4738A]
1 P4KE400CA bi-directional TVS diode (TVS1) [Mouser 576-P4KE400CA]
3mm diameter required if light transporters are used
🔹
🔹
🔹
Capacitors
1 100μF 25V PC electrolytic
2 470μF 25V PC electrolytic
4 10μF 25V PC electrolytic
4 100μF 16V PC electrolytic
1 1μF 63V or 100V MKT polyester
1 1μF 50V multi-layer or monolithic ceramic
1 220nF 63V or 100V MKT polyester
7 100nF 63V or 100V MKT polyester
1 100nF X7R multi-layer or monolithic ceramic
2 47nF 630V pulse double-metallised polypropylene (Kemet R76PI24705050J)
[Farnell 3649826]
1 10nF 63V or 100V MKT polyester
Resistors (all axial ¼W 1% unless noted)
2 20kW
4 1kW
2 1MW
1 12kW
2 620W
1 220kW
8 10kW
2 470W 5W (5% OK)
1 220kW 1W (5% OK)
1 10kW (SMD 1206-size) 1 430W
8 100kW
2 8.2kW
1 220W
1 91kW
2 6.8kW
4 100W
1 68kW
4 4.7kW
1 75W
2 47kW
1 4.3kW
1 10W
3 33kW
1 3.3kW
1 24kW
2 2.2kW
4 22kW 1W (5% OK)
2-4 0.022W 3W 1% SMD M6332/2512-size
(TE Connectivity TLRP3A30CR022FTE) [Farnell 3828731] ●
0-2 0.05W 3W 1% SMD M6332/2512-size
(TE Connectivity TLRP3A30CR050FTE) [Farnell 3828740] ●
● see Table 1 next month for quantities (4 × 0.22W is sufficient for all motors)
unless RLY3 is already on and its contacts are closed. This is because a set
of RLY3’s contacts are in parallel with
RLY1’s contacts (the points labelled ‘a’
and ‘b’ in Fig.2).
The only way to restore power to
the motor via the RLY3 contacts is to
return speed potentiometer VR1 to its
fully anti-clockwise position. In this
case, RLY1’s contacts close and +12V
is reconnected to RLY3’s coil.
The safety switch connection between pins 7 and 8 of CON1 can also
stop the motor and prevent it from
restarting until the speed potentiometer is returned to the anti-clockwise
position.
An open safety switch disconnects
power to RLY3’s coil, immediately removing power to the motor.
Setting it up safely
You might be wondering about the
purpose of the CON5 & CON7 terminals near CON1 on the circuit diagram,
shown joined by a wire bridge. This
allows you to disconnect the +12V
supply from the positive terminal of
the bridge rectifier when making adjustments.
Also, because the mains supply to
the active side of the bridge rectifier
(BR1) and transformer T1 are via separate terminals on CON1, BR1 can be
left disconnected during initial setup
and testing.
With BR1 disconnected, the motor
can’t run, and much of the circuit is
essentially isolated from the mains
Active. This allows you to adjust some
of the trimpots and monitor the voltages in the circuit more safely. The circuit is still connected to mains Neutral via the bridge rectifier, though. So,
during setup, it is essential to check
that the mains Neutral is close to the
Earth voltage.
Even though some adjustments can
be made with the mains Active isolated, some trimpots must be adjusted
while the circuit is at mains potential.
We will describe how to do this safely
in the setup and testing section of the
article next month. It involves using
a high-voltage-insulated screwdriver
with a multimeter and probes rated
for use at mains voltages.
Next month
Construction, testing and setup details for the 180-230V DC Motor Speed
Controller will be in a follow-up article next month.
PE
Practical Electronics | July | 2025
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