1kW smps project (based on MicrosiM design)
- Thread starter ludo3232
- Start date
niss_man
New member
Found this litz on the ebay. 130 x AWG 36
This would work right?
Would 1 meter of the wire be enough?
http://www.ebay.com.au/itm/LITZ-WIR...494?pt=LH_DefaultDomain_0&hash=item2c5daf38f6
Regards
Simon
This would work right?
Would 1 meter of the wire be enough?
http://www.ebay.com.au/itm/LITZ-WIR...494?pt=LH_DefaultDomain_0&hash=item2c5daf38f6
Regards
Simon
Thats a robust litz wire for SMPS, get at least 10 Meters. and keep the rest for further tests
For this project you will need at least 4 ~ 6 meters
Thats a 2 Amps diode, not more 200W of power. 100V
I advice to find a higher rating diode
niss_man
New member
I am just waiting for my parts to arrive from various sources. In the mean time could someone please help me understand how to wind the main transformer? I have read microsims pdf and also all of this thread but it would help if there were more detailed pictures of how to wind the transformer in a step by step fasion.
Reading the pdf was a bit confusing. Pdf says winding order is half primary," all" secondary, half primary. Then later on it says wind the bobbin using half primary, half secondary, half secondary, half primary?
Also I am not sure what pads to start at and finish at when winding.
I am guessing to starrt winding as follows .:- 1/2 primary:- Start at pad 1-finish-pad 5? When the turns are finished the end of the coil, the wire will be on the opposite end of the transformer. Does this mean the wire has to loop over the whole transformer and then get soldered onto PAD5?
Does this wire then get cut at PAD 5 and a new 1/2 primary get turned from pad 6-finish at pad 10?
Any help to make it easier when starting to wind the transformer would be greatly appreciated as I want to build the transformer properly.
Regards
Simon
Reading the pdf was a bit confusing. Pdf says winding order is half primary," all" secondary, half primary. Then later on it says wind the bobbin using half primary, half secondary, half secondary, half primary?
Also I am not sure what pads to start at and finish at when winding.
I am guessing to starrt winding as follows .:- 1/2 primary:- Start at pad 1-finish-pad 5? When the turns are finished the end of the coil, the wire will be on the opposite end of the transformer. Does this mean the wire has to loop over the whole transformer and then get soldered onto PAD5?
Does this wire then get cut at PAD 5 and a new 1/2 primary get turned from pad 6-finish at pad 10?
Any help to make it easier when starting to wind the transformer would be greatly appreciated as I want to build the transformer properly.
Regards
Simon
zeus_threat
Member
This is how you do it sorry i didn't go through the details of how this smps was built but basically say you have 30 turns primary(pin 1 2 3) and 10 turns secondary (pin 4 5 6 7)and decide a turn direction clockwise or anti-clockwise. I did anti-clockwise for my transformer so all turns are wound anti-clockwise
1) Start with primary and connect your litz wire to pin 1
2) Start coiling anti-clockwise and make 15 turns. Make sure you spread the turns as evenly as possible along the core. Connect the end to pin 2
3) Tape the coil
4) Connect the scondary wire1 to pin 4 coil and secondary wire 2 to pin 6
5) Coil both wire simultaneously anti clockwise to get 10 turns spread evenly along the bobin
6) Connect the ends of secondary wire 1 to pin 5 and end of secondary wire 2 to pin 7
7) Tape the secondary winding
8) Connect another wire for primary to pin 2 and coil anti clockwise to get 15 turns spread evenly
9) Connect the last end of primary wire to pin 3
So you get Primary input pin1 and pin2 secondary ouput pin 4 5 6 and 7
Then connect pin 5 and 6 to become your secondary output ground and pin 4 and 7 go to your bridge rectifier
Hope this helps
1) Start with primary and connect your litz wire to pin 1
2) Start coiling anti-clockwise and make 15 turns. Make sure you spread the turns as evenly as possible along the core. Connect the end to pin 2
3) Tape the coil
4) Connect the scondary wire1 to pin 4 coil and secondary wire 2 to pin 6
5) Coil both wire simultaneously anti clockwise to get 10 turns spread evenly along the bobin
6) Connect the ends of secondary wire 1 to pin 5 and end of secondary wire 2 to pin 7
7) Tape the secondary winding
8) Connect another wire for primary to pin 2 and coil anti clockwise to get 15 turns spread evenly
9) Connect the last end of primary wire to pin 3
So you get Primary input pin1 and pin2 secondary ouput pin 4 5 6 and 7
Then connect pin 5 and 6 to become your secondary output ground and pin 4 and 7 go to your bridge rectifier
Hope this helps
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niss_man
New member
Would the first coil be made like this. Seems bad that the wire crosses existing coils to get back to it's second connection point. Anyone have a photo of how this is done?
Also if there were lets say only 3 turns for the primary, would they be spaced to fill the whole width of the bobbin.?(there would be alot of space between the windings- is this ok or do the windings touch each other and and placed centrally on the bobbin so the space is to the left and right of the coil and not between wires???)
Regards
Simon
Also if there were lets say only 3 turns for the primary, would they be spaced to fill the whole width of the bobbin.?(there would be alot of space between the windings- is this ok or do the windings touch each other and and placed centrally on the bobbin so the space is to the left and right of the coil and not between wires???)
Regards
Simon
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niss_man
New member
a: So what your saying is that it is ok to have a wire crossing ontop of the others to get back to the second conection point 2 in my diagram?
b: Your also saying that it is "better to have no gap between the turns" and place turns centrally on the core? (zeus said to spread turns across bobin?)
c: Any pictures of this?
Regards
Simon
b: Your also saying that it is "better to have no gap between the turns" and place turns centrally on the core? (zeus said to spread turns across bobin?)
c: Any pictures of this?
Regards
Simon
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a: So what your saying is that it is ok to have a wire crossing ontop of the others to get back to the second conection point 2 in my diagram?
Yes this is NORMAL
b: Your also saying that it is "better to have no gap between the turns" and place turns centrally on the core? (zeus said to spread turns across bobin?)
NO GAP for primary turns/ secondary turns, ONLY 2~3mm tape on both sides of bobbin
c: Any pictures of this?
Will try to make pictures
Yes this is NORMAL
b: Your also saying that it is "better to have no gap between the turns" and place turns centrally on the core? (zeus said to spread turns across bobin?)
NO GAP for primary turns/ secondary turns, ONLY 2~3mm tape on both sides of bobbin
c: Any pictures of this?
Will try to make pictures
niss_man
New member
Have just used your turns calculator. I will want 60v x 2 output. I have 240v AC 50hz supply here.
Is this correct or will I need to change the Vin to something different? At the moment it shows primary turns is 17 and secondary per 60v = 6 turns. So winding this would be
1/2 primary 8.5 turns
1/2 secondary 6 turns
1/2 secondary 6 turns
1/2 primary 8.5 turns.
Would that be correct microsim?
Regards
Simon
Is this correct or will I need to change the Vin to something different? At the moment it shows primary turns is 17 and secondary per 60v = 6 turns. So winding this would be
1/2 primary 8.5 turns
1/2 secondary 6 turns
1/2 secondary 6 turns
1/2 primary 8.5 turns.
Would that be correct microsim?
Regards
Simon
Attachments
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Turns.jpg
I think its easier for you to make a new one your self, it will take you 30 minutes in eagle!
luchni
New member
There are several tutorials for creating new libraries in eagle on the internet, for technical data find the datasheet for the desired core/part, everything you need is there. Even if you are totaly new to eagle, it will take 30 minutes to create a new part. Google is your friend
giololucas
New member
Hello Microsim.
I just started some experimetations based in your 1kW smps. The circuit is the very same and the transformer it´s quite near to a ETD49 (mine´s central post is square instead of round).
When I connect a load (200W) to secondary the transformer it starts to make a little noise inside like bzzzzzzzz, do you know what this could be?
When I finish the tests in veroboard I will draw a PCB and post here.
Thank you!