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5 V to 6 kV DC-DC Converter Using Switching Regulator with Cockcroft-

Walton Voltage Multiplier for High Voltage Power Supply Module

Article  in  Recent Advances in Electrical & Electronic Engineering · June 2018

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Recent Advances in Electrical & Electronic Engineering, 2017, Volume 10 1

5 V to 6 kV DC-DC Converter Using Switching Regulator with Cockcroft-

Walton Voltage Multiplier for High Voltage Power Supply Module

Nor Afiqah Azmia, Sohiful Anuar Zainol Murad*b, Azizi Harun1, and Rizalafande Che Ismail2a

ab
School of Microelectronic, Universiti Malaysia Perlis, Arau Perlis, Malaysia

Abstract: This paper describes the design of 5 V to 6 kV DC-DC converter by using a switching regulator with Cockroft-
Walton (C-W) voltage multiplier for a high voltage power supply module. The proposed design consists of Pulse Width
Modulation (PWM) controller circuit, voltage multiplier, and feedback signal. A single unit of 5 V input triggers LT1618
controller circuit to generate 20 V which then produces 300 V from LT8331 output that is connected to diode-capacitor
multiplier circuit to achieve final 6 kV. A negative feedback signal is required to stabilize an output voltage. With the
implementation of C-W voltage multiplier technique, the output is boosted up as required from the input signal voltage 5
V DC. The LTspice simulation results indicate that the proposed DC converter can generate 6.20 kV. Line regulation of
17 % and the load regulation of 14 % are obtained based on the proposed design. The proposed design is suitable for high
voltage power supply module.

Keywords: DC-DC Converter, High voltage, Power supply, Switching Regulator, Voltage multiplier

1. INTRODUCTION Due to several developments of the transformer circuit

Nowadays, our society is administered by computers and
other electronic appliances. A high voltage generating is
widely used in industrial applications, such as plasma
generating, DC backup system, Scanning Electron
Microscopy (SEM), Photomultiplier Tube (PMT),
capacitance microphones, ultrasonic transducer and many
more [1]–[4]. In electronic appliances, a high voltage DC
power supply is a critical element and must perform
consistently. Based on a conventional method of DC high
voltage power supply, a transformer is implemented in the
design as shown in Figure 1 [5]. The output of a secondary
step up transformer will increase the voltage and
consequently the design circuit involving Cockcroft-Walton
(C-W) voltage multiplier will increase the voltage for each
stage.
The C-W voltage multiplier is very prevalent among high
voltage DC application due to the benefits of low voltage
stress on the diodes and capacitors, the circuit compactness
and cost efficiency. A conventional design of C-W voltage
multiplier is constructed by connecting a diode-capacitor
ladder stage where each stage constitutes of two capacitors
and two diodes [6]. A voltage-fed modified C-W topologies
applied in [7]–[9] are discussed where the usage of high turn
ratio transformer leads to large winding capacitance and
leakage inductance, which leads to high current and voltage
stresses and higher switching losses on the switches.
*School of Microelectronic, Universiti Malaysia Perlis, Kampus Pauh Putra,
02600 Arau Perlis,Malaysia; Tel/Fax: +60 4-988 5509/5515, +604-9885510;
E-mails: sohifulanuar@unimap.edu,my
design, the voltage multiplier has been divided into several
sections and splitting sources as proposed in [10]. As a
power loss in a capacitor which is caused by increasing
frequency will affect the high voltage DC power supply, it is
necessary to retain the produced noise lower than 5% [11].
With an implemented of same values of capacitance, it is
believed that the voltage has dropped, the ripple voltage and
noise are reduced and the designs presented in [4], [12]–[14]
are the way to improve half-wave C-W voltage multiplier.
Besides, there are other criteria influencing the high voltage
management and several methods have been proposed in [1]
to achieve the high voltage. However regarding to the
conservative method which covers multiplier circuit and
transformer where utilizes AC source, the transformer will
lead to the cost inefficiency and the ripple problem still
unsolved [15].
Pursuant to the above problems, step-up transformer is
replaced with boost type structure for carrying out the step-
up process. Instead of that, boost converter types provides
high voltage ratio compare to previous C-W voltage
multiplier based converter design [16]–[19]. Besides,
regarding to another aspects, it is compactable series with
compactness design. However, the low frequency applied
(50-60 Hz) to the converter can caused high ripple voltage
appears at the output [19]. The output voltage value also
gives an impact that produces the value lesser than
theoretical due to the non-ideal characteristic of the circuit
elements.
By applying step-up converter and voltage multiplier
method in one design to generates high voltage output, there
are several technique applied. Among of the method

© 2017 Bentham Science Publishers

2 Recent Advances in Electrical & Electronic Engineering, 2017, Vol. 10, No. 2
concerned is the flyback converter with switching circuit is
proposed in [18] by keeping an increase to a much higher
voltage value. Referring to the other converter aspect, a C-W
voltage multiplier with a step up converter by using an
interleaved PWM controller which employs two independent
frequencies is presented in [20], [21]. It is suitable for a high
step up application using a boost inductor but it suffers in
switching losses of switch and diodes due to the different
switches implemented in [22]. Other authors implement an
inverter in [19] with various frequencies thus stimulating an
effect to the capacitor. Besides, the design of the DC-DC
converter which consist a stage of diode-capacitor-inductor
at input and voltage multiplier at output to produce low
voltage stress is proposed in [22], [23]. Switched capacitor
technique applied in [24], [25] is widely used to achieve high
voltage gain but the conduction losses increase caused by
high charging current which flow through the main switch.
Moreover, many of the design implemented non-isolated
step-up DC-DC converter as in [12] for a renewable energy
application with a low DC input voltage. A system based on
a combination of switched-coupled-inductor boost converter
is presented by using a cascaded C-W voltage multiplier in
[25] and diode-capacitor voltage multiplier in [26], [27] as a
turn ratio of inductor which easily boosts the low input to a
very high output.
Besides of introduced design on literatures, most of the
switching regulator step-up converter has been design and
integrate in one chip to control voltage and current sense.
Because of the switching loss, low voltage stress and low
efficiency in conventional converter, built-in switching
regulator design which constitutes of control circuitry design
is implemented. Most of the commercial control ICs, where
the simplicity of the design are introduced instead of having
high performance, affordable price and other advantage in
terms of dc-dc conversion application [28]. Other than that,
there are several advantages by operating this method which
involves programmable switching frequency by setting with
an external resistor [29]. This step-up DC-DC switching
regulator operates with minimum input voltage or battery-
powered system [30] and use controlled mode Pulse Width
Modulation (PWM) method to provide precise output
regulation and low noise [31]. Therefore, this paper
contribution includes:
 Propose transformer less dc-dc converter for high
voltage and low current power supply module.
 Propose simple circuitry of dc-dc converter
employed boost converter and less number of voltage
multiplier stages.
Section 2 presents the operating principle of the proposed
circuit and the selection of the components for the circuit
design. Section 3 presents the simulations results and
discussions for the proposed circuit design and final
conclusion is given in the final section.
N. A. Azmi, et al.
2. OPERATING PRINCIPLE OF PROPOSED
CIRCUIT
A block diagram of the proposed C-W voltage multiplier
design is shown in Figure 2. In order to obtain DC high
voltage 6 kV, step-up converter is needed by applying a
voltage multiplier at the end of proposed model scheme. The
purpose of using DC-DC converter is to boost up the output
voltage. By applying this type of switching regulator, the
number of diode-capacitor multiplier stages is reduced and
thus improved the previous design which had applied 32
stages [32].
Regarding to the 5V DC input supply that provides a
square wave signal with a switching frequency, the input
pulse transfers into PWM step-up converter to drive the
MOSFET switch. The main purpose of using PWM step-up
converter is to control the pulse width of the input signal and
is used to drive MOSFET switches. Besides, the circuit
which making a loop in this design is negative feedback
function as to regulate an output voltage in the development
circuit.
The output produced from the first MOSFET driver is 20
V DC with a 1.4 MHz switching frequency. Then, this value
will become as an input signal to another controller circuit
and drives another switch. Based on this second output
switch which is 300 V DC with 200 kHz and 600 V DC will
amplify by using a voltage multiplier circuit. This multiplier
circuit consists of twice capacitor-diode combination for
each stage where each of them can generate 300 V DC as in
a block diagram in Error! Reference source not found.. At
the end of this improvement circuit, negative feedback signal
which constitutes of voltage or current controlled sense is
connected at the output voltage terminal and linked into
PWM converter circuit. The input supply and negative
feedback signal are compared until they reach the same value
before obtaining the required output voltage as in Figure 3.
By referring to the proposed design, switching regulator
DC-DC boost converter are implemented on both Linear
Technology Integrated Circuit. Common controlled method
is divided into voltage-controlled mode and current-
controlled mode. Current-controlled method is implemented
on this design with the operation in block diagram Figure 3
to accomplish a project demand. Power stage consists of
diode, inductor and an output capacitor. The input voltage,
Vin deliver into this building block and converted into the
output voltage, Vout. Control section is conquering around
this block with the involvement of voltage divider, error
amplifier and PWM comparator in the comparator in the
modulator and voltage loop compensator subsection.
In this method, it regulates the output current with an
infinite loop gain and the output is a high impedance source.
5 V to 6 kV DC-DC Converter Using Switching Regulator with Cockcroft-
Walton Voltage Multiplier for High Voltage Power Supply Module
Regarding to this method, the current loop is nested with a
slower voltage response because the inductor current
increases with a slopes are determining by the difference
input and output voltage and responds to the line and load
changes, The Vout is subtracted from a reference voltage, Vref
to create an error signal, Verror. Then Verror commands an
output current rather than voltage which compared with the
ramp that generated by the slope of the inductor current and
applied to the PWM comparator. PWM ramp is generated by
a signal derived from the output inductor current. Therefore
when the output voltage drops, current-controlled mode
supplies more current to the load.
2.1 Circuit Design and Component Selection
Figure 4 shows an illustration of LT1618 connection
boost converter model schemes which operates as a current-
controlled mode with a 1.4 MHz constant frequency to
provide an excellent line and load regulator. The power
switch MOSFET that is connected with switch (SW) pin will
turn the oscillator cycle and start to operate. The input
voltage which is connected from SW pin flows through the
comparator inside known as a Vramp due to the summation of
the smallest voltage drop together with the oscillator ramp as
illustrates in the block diagram in Figure 3. Besides, as the
feedback voltage, Vfeedback from divider circuit will be
generated at the feedback (FB) pin is then being compared to
reference voltage Vref and based on the comparison, the error
voltage, Verror is obtained. When the Vramp achieves greater
than Verror, an internal SR latch will reset in which makes the
power switch in off condition. If Verror increased, more
output current is delivered to the output.
Based on this connection, the two inverting inputs are
from the Vfeedback loop which are connected with the voltage
divider circuit and current feedback loop from current sense
at negative (ISN) and positive (ISP) pin that are attached
with the sense resistor, Rsense. As either one of them
generates high input, it will force a converter in a constant-
current mode or constant-voltage mode. Moreover, current
sense amplifier acts as a sense voltage between ISP and ISN
pin and provide level-shifted version to the error amplifier.
In this situation, current sense voltage is regulated to 50 mV
between ISP and ISN pin, then the output of the current
sense amplifier provides 1.263 V to the non-inverting input
of Verror. The converter is in constant-current mode as the FB
pin value is not more than 1.263 V. This circuitry IC design
operates with a wide input voltage range and high switching
frequency 1.4MHz which allows the use of low profile
components used.
Regarding to this performance, an output voltage is
connecting with Vin pin for another LT8331 converter
topology as illustrate in Figure 5. At the beginning of each
clock cycle, an oscillator works as a turning on the internal
power switch. The voltage on the feedback pin (FBX) then is
compared with the internal reference voltage which is 1.6 V
by using an internal error amplifier. As a load current
increases, it will cause reduction in FBX voltage as the
OUT2 connecting each other. Therefore, the error amplifier
will increase a voltage with specific load current. In order to
keep output in regulation, the error amplifier is connected
with the FBX thus, establishing the correct peak switch
current level. LT8331 is able to generate positive or negative
output voltage with a single FBX pin. It can be increased
permittedly to generate positive output voltage. With voltage
Recent Advances in Electrical &
Electronic Engineering, 2017, Vol. 10 No. 2 3
divider connection, the FBX pin is capable to pull up to 1.6V
internal bias voltage. LT8331 will stop switching if the
Shutdown and Under voltage Detect Pin (EN/UVLO) pin
obtained is lower than 1.6 V. The BIAS connection is used
to improve efficiency across load. Concerning to the
reference voltage at LT1618 and LT8331, the output value
can be determined through specific resistor value on
feedback divider according to the equations (1) and (2). By
using a simple boost converter, a high voltage application
can easily achieve. It is believed that based on this
application, an output voltage is acquired by applying
straight boost configuration and it double the value as a two
stage boost with a few additional components.
 Vout 
R1  R2   1 (1)
 1.263 
R7  R8 
 Vout  1 
 (2)
 1.6 
In the proposed design, a voltage multiplier circuit
consists of coupled diode-capacitor combination which is
declared as one stage. This voltage multiplier circuit
constitutes cascading clamping and half-wave rectifier
circuit to generate the highest value. Therefore, for this
purpose, 20 stages are required with 40 ceramic capacitors
with 0.1 µF value and 1N4007 type of diode as shown in
Figure 6. The Peak Inverse Voltage (PIV) for the diode and
voltage rating for a capacitor is 1000 V. Working voltage in
each component must be larger than the input supply in order
to prevent damage to the circuit. The voltage in the
component needs to be considered as the number of stages
increases to generate greater output voltage. Every stage will
produce a 300 V DC, so that the output can easily be
measured at any points depending on the voltage value
needed. Besides, the voltage drop and ripple voltage need to
take apart in circuit design as number of stages increase. The
equations are shown on (3) and (4) where f is the 200 kHz
frequency; C is 0.1 µF ceramic capacitor and n as the
number of stages applied;
I  2 3 n2 n 
V   n    (3)
fc  3 2 6 
I  n ( n 1) 
V    (4)
rip fc  2 
Before obtaining the required voltage value, an output
voltage is connected to a voltage divider and is declared as a
negative feedback signal. The resistor values involved in this
divider network are 1 MΩ and 2.7 kΩ. The output voltage
for the LT1618 feedback circuit is directly connected to the
output in which is linked into LT8331 input voltage. As the
voltage divider circuit is connected, the output voltage
actually can be varied from 48 V to the required voltage with
a modifying circuit. An input supplied with a variable value
in the range of 10 V to 48 V for the second converter and 5
V from the input supply into Vin pin for the first topology.
This voltage values also acts as a reference to the input
signal from the feedback signal. The PWM controller will
constantly operate the square pulse if the reference voltage
value is larger than the feedback voltage obtained. On the
4 Recent Advances in Electrical & Electronic Engineering, 2017, Vol. 10, No. 2
other side, when the voltage for both reference and feedback
are produced at the same value, the PWM controller is not
generating the PWM signal into MOSFET switches. The
pulse will stop amplifying and the voltage value remains
constant after gaining the voltage difference between them.
By adjusting the resistor value in the divider network, the
output voltage changes as required value.
3. RESULTS AND DISCUSSIONS
Based on the components summarized on Table I
respectively, LTspice is applied to simulate the proposed
converter. The systems specification for the simulation
design as in Table II and the waveform are explained in
details the operation of the suggested DC-DC boost
converter with incorporation of C-W Voltage Multiplier.
Figure 7 shows an output performance for both PWM
controller units. The output voltage of 20.35 V is generated
from LT1618 controller with the input supply of 5 V DC at
1.4 MHz built-in frequency. Error! Reference source not
found. shows the 5 V DC to 600 V simulation output
performances for the boost converter and a stage of
multiplier circuit. The resulting output voltage value from
cascading of LT1618 and LT8331 is 296.43 V. At Vout2
connection, 591.88 V is generated from a stage of voltage
multiplier which connects through Vout1 point.
As both converters have been simulated, the load current
and output power are measured and the waveform is shown
in Figure 9a)–b). The load resistance is varied and the
current value is measured. At resistor value RL = 250 Ω,
ILoad = 79.9 mA and the power output produced Pout = 1.59 W
with an output voltage, Vout = 20 V for the initial DC-DC
converter. While for the forward boost regulator integrated
circuit, when a resistor value RL = 20 kΩ applied, ILoad =
14.3 mA and Pout = 4.06 W are generated at output voltage,
Vout = 300 V. In cascaded converter obtain Pout = 0.74W
value and ILoad = 2.72 mA at the resistive load value RL =
100 kΩ when 300 V output produces from 5 V input voltage
as appear in Figure 10.
Then, the output from the second controller will be the
input for the voltage multiplier circuit that consists of 20
stages cascaded diode and capacitor. As each stage obtains
300 V DC produced by LT8331 as shown in Figure 8, the
final output at the end of multiplier circuit has successfully
generated 6 kV DC. In the designing of a high voltage power
supply, the output current is low with the value 0.038 mA
and the power generated is 0.2 W. High voltage power
supply can gain variable output performances as the
reference voltage in PWM controller unit is varied.
As mentioned earlier, the 6 kV DC is obtained when 20
stages of voltage multiplier with collaboration of PWM
controller circuit is used. Figure 11 configurations states how
the final output of 6.20 kV is obtained. Error! Reference
source not found. presents the comparison of the
performances of the previously reported transformer less dc-
N. A. Azmi, et al.
dc converter and this work. Based on the summary of the
results in Error! Reference source not found., the proposed
design generates low output power and low current as
compared to others. The proposed design is suitable for high
voltage low current power supply module applications.
The voltage drop occurs as the associated power loss
through the technique of multiplier stages. The ripple voltage
value is about 0.42 V and there is no voltage drop yet but the
voltage increase by 3.33%. If voltage drop occurs, it is
considered low as compared to the largest number of stages
multiplier applied. The voltage drop on output and ripple
voltage will increase as the load current and the number of
stage is increased.
By comparing between different types of the power
supplies, there are two aspects that need to be considered in
terms of voltage regulation and minimum load resistance. In
the voltage regulation, the change of output voltage due to
the variation of load current based on the resistance value
from 5 kΩ to 300 kΩ is known as load regulation. With a
proper design of power supply, the no-load voltage (VNL) is
larger than full-load voltage (VFL) as shown in Figure 12.
The voltage regulation obtained based on the configuration is
14 % when concern with 2.8 mA current value. For the line
regulation which is declared as variation in the output
voltage because of the change on input voltage in Figure 13
and Figure 14 with 2 V and 8 V values another type of
regulation. Between two different minimum input supplies,
the generated output is 5.17 kV and 6.20 kV with the 17 %
line regulation.
Therefore, according to the lower value achieved, the
differences between full load and no load voltage are lesser
and better in the power supply. There are some differences
with the presenting value due to the losses occurred during
the development process. Due to the different values in both
experimental and theoretical aspects, voltage drop problem
should be encountered even though the number of stages has
been reduced by using the dissimilar capacitance value in
every stage. Besides, ripple voltage can be minimized by
increase the frequency values and implements low equivalent
series resistance.
Figure 15 shows the efficiency of the proposed converter
and cascaded between then in a boost mode. The maximum
efficiency is around 87.7% at P out = 2.57 W and the full-load
efficiency is approximately 87.5% at Pout = 1.00 W for the
first integrated circuit converter on Figure 15 a). The peak
efficiency for the follows converter is 96.6% which is
achieve at Pout = 9.53 W while the efficiency at full load Pout
= 1.5 W is 89.5% on Figure 15 b). On the other side, the
maximum efficiency of the cascaded converter for an input
voltage 5 V with 300 V output is 91.8% at P out = 1.983 W
and 80.55% when Pout = 0.729W at full-load efficiency for
Figure 16.
The results for the proposed design achieves lower
efficiency at the lower value of input voltage due to the
5 V to 6 kV DC-DC Converter Using Switching Regulator with Cockcroft-
Walton Voltage Multiplier for High Voltage Power Supply Module
higher conducting loss attended by higher input current. For
the lower power applications, the peak efficiency is within
the range of 80% to 90%. The designers able to maximize
the efficiency for the system based on their application and
specific criteria. Otherwise, for the full-load or higher load
condition, the conducting loss of the diode and resistance
loss of capacitor occurred and caused the decrement
efficiency value.
CONCLUSION
A switching regulator with C-W voltage multiplier
design circuit of 6 kV DC high voltage power supply with
1.4 MHz and 200 kHz high frequency, step-up DC-DC
converter and voltage multiplier is proposed. The entire
equivalent circuit of high voltage power supply is established
by integrating individual stages. This design will offer lower
power dissipation 0.22 W and reduce the size of circuit by
reducing the components used. By minimizing the number of
stages in the conventional C-W voltage multiplier circuit
from 1200 into 20 stages, consequently will produce lower
voltage drop due to the lesser components used. Therefore,
this proposed technique is significant for a high voltage
output and low voltage drop. The circuit has been simulated
and verified with the selected experiment. The simulation as
well as the experiment results clearly shows that both output
voltages are agreed with each other. By implementing
surface mounted devices (SMD), the circuit can be fabricated
in a smaller size PCB and it is a suitable candidate for power
supply module.
CONFLICT OF INTEREST
The authors would like to acknowledge the financial
spport obtained from CREST under the project code P19C1-
14 and the continuous supports by USAINS Infotek and ICE.
ACKNOWLEDGEMENTS
We thank to the Dr. Sohiful Anuar and Dr. Azizi Harun
for their assistance with measurement and analyses, Dr.
Rizalafande for his supporting with study administration.
The authors’ responsibilities were as follows: design the
research and wrote the manuscript; analyzed data and
validated; edited and conducted the research manuscript with
a final content; and all the authors read and approved the
final manuscript
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Received: March 20, 2014 Revised: April 16, 2014 Accepted: April 20, 2014

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