1kW smps project (based on MicrosiM design)

Hyper2283

Hyper2283

New member
I tried to start the SMPS, I used a test transformer, without coupling 220 V~, and I put a low voltage from a transformer. The relay is coupling and the led from protection card is ON. On the scope I see no trace of switching on the transformer primary . What could it be? What are the critical steps by which to test the functionality of the source? Please help. Thanks.
 
MicrosiM

MicrosiM

Administrator
Staff member
Hyper2283 said:
I tried to start the SMPS, I used a test transformer, without coupling 220 V~, and I put a low voltage from a transformer. The relay is coupling and the led from protection card is ON. On the scope I see no trace of switching on the transformer primary . What could it be? What are the critical steps by which to test the functionality of the source? Please help. Thanks.
Click to expand...

Let me take a look at the PCB + your setup.

Provide Full informations also, if you can

Please
 
fabiodord

fabiodord

New member
My compliments Ludo,

very good work!

The tracks are very ordered and all the stages are very clear and distinct....

So really good work!
 
Corvett

Corvett

New member
Wth

Hyper2283 said:
I tried to start the SMPS, I used a test transformer, without coupling 220 V~, and I put a low voltage from a transformer. The relay is coupling and the led from protection card is ON. On the scope I see no trace of switching on the transformer primary . What could it be? What are the critical steps by which to test the functionality of the source? Please help. Thanks.
Click to expand...

How the hell you expect help from any one without telling any informations? ((@

Witch PCB you have made? :D
 
ludo3232

ludo3232

Member
luchni said:
Excellent job Ludo, it looks pretty good. I guess that the protection card uses the same layout? Could you make the pads on the small resistors capacitors and diodes bigger (like 2.1844) in the updated version, that would be great.
Keep up the good work :)
Click to expand...

Thanks luchni :)
No i have made a smaller protection card, but same schematic.. i post new layout soon

i make bigger pads, but later and i post updated file.
 
ludo3232

ludo3232

Member
Hyper2283 said:
I tried to start the SMPS, I used a test transformer, without coupling 220 V~, and I put a low voltage from a transformer. The relay is coupling and the led from protection card is ON. On the scope I see no trace of switching on the transformer primary . What could it be? What are the critical steps by which to test the functionality of the source? Please help. Thanks.
Click to expand...

Post pictures of your smps... and details your step to powering up the smps and your measurements
 
Hyper2283

Hyper2283

New member
So here is my smps based on 2.1 Ver. First of all, the only difference from this version is that I put the protection card on the main board , I calculated the RC snubber, and on the protection i can't find 330 pf capacitors and I uesd 430 pf. I hesitated to used 220 volt directly and I used a 40 volt transformer. As a main ferrite transformer was used to monitor switching on the tranformer primary. It seems that the oscillator does not start since the protection is active. What might be the problem? Thanks for your understanding.
 

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MicrosiM

MicrosiM

Administrator
Staff member
As a start.

Disconnect the output of the protection circuit. to the SG3525 Pin10.

Free PIN 10 of the SG3525, dont connect any thing to that pin.

NEVER apply Power 220VAC, until I tel you further.

Check if you have waves. Post Waves at:-

1- S&G of each MOSFET
2- Output Of SG3525, PIN11 and PIN14 referenced to GND
3- Remove Current sense transformer
4- You may not need Snubbers if your transformer built correctly!

I think there is some mistake in the protection, thats why its triggered.

Check your solder, Parts direction
 
Hyper2283

Hyper2283

New member
MicrosiM

It seems that SG does not work. Now I try to replace the SG and try again. I checked all the circuit, there nothing wrong. Thanks.
 
J

Julio25

New member
@ erhan,sir did you build the 1kw smps by microsim?how is it?coz im planning to it too,and use it in my power amp..what are your experience sir about smps?
 
L

lorylaci

New member
Dear Microsim,
It's an amazing project!
I made a dozen of resonant SMPSs, but as is said to MicrosiM, I always had a much greater voltage drop. As I seeked through this tread, I've seen you transformer winding instruction. I always use transformer leakege inductance as resonant inductance, and I always made it higher, because I use it, and didodes parallel with resonant capacitors for overload protection. In your transformer winding instructions I can see you have a transfomer with much smaller leakage inductance. This helps voltage drops so much? But as I see it will remove the overload protection, so I must use some other method. Am I correct?
 
MicrosiM

MicrosiM

Administrator
Staff member
Voltage Drop

lorylaci said:
Dear Microsim,
It's an amazing project!
I made a dozen of resonant SMPSs, but as is said to MicrosiM, I always had a much greater voltage drop. As I seeked through this tread, I've seen you transformer winding instruction. I always use transformer leakege inductance as resonant inductance, and I always made it higher, because I use it, and didodes parallel with resonant capacitors for overload protection. In your transformer winding instructions I can see you have a transformer with much smaller leakage inductance. This helps voltage drops so much? But as I see it will remove the overload protection, so I must use some other method. Am I correct?
Click to expand...

lorylaci


Thanks for joining.

It will be very difficult to know the exact reason for voltage drop. As per my first SMPS years ago I had 40V drop, while I had no idea why!

If you can show schematic or picture of your project, Give me more information about it, Transformer winding details, Bulk Capacitors value, SMPS Topology, it will be easy to give you some hints and tips.

I also use same method into my SMPS, I Use transformer leakage inductance, around 2 ~3 uH.

Please, if you can give more informations, I will be glade to help you out.


Kindly give me more details about what you wrote above, RED TEXT


:)


Thanks
 
L

lorylaci

New member
Here is a layout of one of my plans (i know the creepage distances are not sufficient! - so nobody should build this without redesign, in my new designs i corrected creepages). This is kinda straightforward, so I hope you will see the schematic from it (I rarely do schematics, just plan straight on PCB).
The voltage at the resonant capacitors is proportional to the current passing and their capacitance. So when it reaches the supply voltage the parralel diodes will start conducting. Since their (caps) voltage cannot pass through a limit (due to diodes), the current cannot pass through a certain limit, this way it is short-circuit proof. My leakage inuctance for this design is about 50-60uH (transformer is not-gapped, so magnetising inductance is about 3mH), so power limit is set about 400W. No-load to almost-full-load voltage drop can exceed 20%, too much.
 

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MicrosiM

MicrosiM

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lorylaci said:
Here is a layout of one of my plans (i know the creepage distances are not sufficient! - so nobody should build this without redesign, in my new designs i corrected creepages). This is kinda straightforward, so I hope you will see the schematic from it (I rarely do schematics, just plan straight on PCB).
The voltage at the resonant capacitors is proportional to the current passing and their capacitance. So when it reaches the supply voltage the parralel diodes will start conducting. Since their (caps) voltage cannot pass through a limit (due to diodes), the current cannot pass through a certain limit, this way it is short-circuit proof. My leakage inuctance for this design is about 50-60uH (transformer is not-gapped, so magnetising inductance is about 3mH), so power limit is set about 400W. No-load to almost-full-load voltage drop can exceed 20%, too much.
Click to expand...

That leakage inductance is so huge.

What is the frequency of that SMPS?

Transformer you are using?
 
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