Hi,
We have been using Hi link Module (HLK-5M05) in the motor controller application for AC to DC conversion.
Input voltage is taken from the contactor parallelly.
Whenever the contactor is driven, Spike is observed on the output voltage of the HLK-5M05 module which is causing the microcontroller to malfunction (Halt). System will be start working once the controller goes to power on reset
Input Voltage (AC): 90V ~ 264V
Output Voltage (DC): 5V
Output Current: 1A

We have replaced the Hi-Link (HLK-5M05) module with LS05-26B05R3 having phase to phase input voltage with a 4kV isolation and facing the same issue
Input Voltage (AC): 90V ~ 528V
Output Voltage (DC): 5V
Output Current: 1mA
Isolation Voltage: 4kV
Below is the attached datasheet link for LS05-26B05R3 module
https://www.mornsun-power.com/html/pdf/LS05-26B05R3.html
Kindly suggest the possible solutions and debugging tips
Thanks in advance.

 

I am not familiar with that "power converter", nor any of it's specifications. The output current, " Output Current: 1mA" makes no sense either. unless it is a digital signal and not a power supply.
In addition, I do not see the connections of the contactor mentioned nor the "microcontroller" referenced.
I do see two connections showing the "VCC5VO tied to the "GND PWR symbol, via "PWR_FLAG, and that really makes no sense to me at all.
Besides all of those issues, in a system with a sensitive microcontroller it makes no sense at all to tie the digital logic portion common to any "ground" as any portion of a power connection loop.
So there is both some advice and a request for a bit more detail. It could easily be that the problem is in the parts that we are not shown.

 

Hi MisterBill,

Thank you for your reply

Sorry, Output current of the LS05-26B05R3 module is 1A

Attached is the block diagram for your reference

 

We have had similar problems in the past due to layout of the wiring. You need to keep the controller wiring short and as far away from the mains as you can. Also, a metal box for the controller is a good idea. This sort of thing can be caused by induced currents, not just the power supply dropping out.
On that side of things, maybe add a 2200uF electro and a 100nF cap across C5. And a Tranzorb on the 5V supply too. More bypassing is always a good idea.
All the I/O used needs to be opto isolated and do not share a GND between the 5V and mains if you can have then isolated often helps.
Can you post the circuit of the opto/Triac part? More detail often helps.

 

Hi
add inductor in series with fuse F1. Rated to 10mH 0.2A

 

We have replaced the Hi-Link (HLK-5M05) module with LS05-26B05R3 having phase to phase input voltage with a 4kV isolation and facing the same issue
Input Voltage (AC): 90V ~ 528V
Output Voltage (DC): 5V
Output Current: 1mA <<------ where I got the one milliamp information.
Isolation Voltage: 4kV

And also where I see various connections made to the frame ground of the whole assembly.
As Dendad mentioned, the proximity of power wires to signal wires is also a probable source of interference. Also, Connecting the "AC to DC converter module in parallel with the operating coil of a power contactor can couple power disturbances to that power converter, which may then momentarily disrupt the output. Does the power contactor change states from on to off during the operation of the system (or is it a machine of some kind??) Normally all of the digital logic control system and all of the analog portions, are powered separately so that they will be fully stable and ready to control all of the machine motions before motion poser is switched on.
With the digital system power being switched on at the same time as that 5_phase motor it is quite possible for power disturbances to travel into the logic at it's startup interval.
I am quite aware of motor starting disturbances, even with high quality components operating correctly and well within their ratings. That is why I have always taken the precautions at the system design stage, which is to avoid having to solve problems later.

 

We have had similar problems in the past due to layout of the wiring. You need to keep the controller wiring short and as far away from the mains as you can. Also, a metal box for the controller is a good idea. This sort of thing can be caused by induced currents, not just the power supply dropping out.
On that side of things, maybe add a 2200uF electro and a 100nF cap across C5. And a Tranzorb on the 5V supply too. More bypassing is always a good idea.
All the I/O used needs to be opto isolated and do not share a GND between the 5V and mains if you can have then isolated often helps.
Can you post the circuit of the opto/Triac part? More detail often helps.

Hi Dendad,

Thank you for your suggestions and we are checking on the same. We are using similar kind of TRIAC circuit

 

And also where I see various connections made to the frame ground of the whole assembly.
As Dendad mentioned, the proximity of power wires to signal wires is also a probable source of interference. Also, Connecting the "AC to DC converter module in parallel with the operating coil of a power contactor can couple power disturbances to that power converter, which may then momentarily disrupt the output. Does the power contactor change states from on to off during the operation of the system (or is it a machine of some kind??) Normally all of the digital logic control system and all of the analog portions, are powered separately so that they will be fully stable and ready to control all of the machine motions before motion poser is switched on.
With the digital system power being switched on at the same time as that 5_phase motor it is quite possible for power disturbances to travel into the logic at it's startup interval.
I am quite aware of motor starting disturbances, even with high quality components operating correctly and well within their ratings. That is why I have always taken the precautions at the system design stage, which is to avoid having to solve problems later.
[/QUOTE]

Hi MisterBill,

Thank you for your suggestions. We are looking into the same