1kW smps project (based on MicrosiM design)
- Thread starter ludo3232
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NiltonCyber
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MicroSim god natt som skriver jeg et bilde her av mine SMPS
NiltonCyber
New member
NiltonCyber
New member
V orezKy04 here in the forum has the schema
vorezky04
New member
Dear mr.microsim. I want buil smps 1000 watt with schematic ludo first. But i don't see the layout final use ir2153 with protection card.
Can you guide me step by step?
Because hard to find ic SG and IR in my town. So my solution use IR2153 with under voltage protection and short circuit.
Thank you
Can you guide me step by step?
Because hard to find ic SG and IR in my town. So my solution use IR2153 with under voltage protection and short circuit.
Thank you
Hi All,
I am new in this great forum, thanks for the valuable knowledge you guys are sharing. I am willing to build a SMPS for my CNC machine (still under construction), the spec are:
I- 3 Stepper motors 6 Amps each (18 Amps) + 2 Amps for the controle board to work and a litle room for safty which makes a total of 25 Amps -
II- The voltage will be 70VDC (the output power is 1750W)
I will be using a Half bridge to drive the transformer, I already have some IR2110, IR2111, IR2153 and all other necessary components except the transformer!!!
I am searching in old TV to find a big one to use, So guys any suggestions are welcome, I have read alot about trafo re-winding, could someone post a procedure with pictures on how to do it, this will be great?
Thnaks in advance,
Regards.
I am new in this great forum, thanks for the valuable knowledge you guys are sharing. I am willing to build a SMPS for my CNC machine (still under construction), the spec are:
I- 3 Stepper motors 6 Amps each (18 Amps) + 2 Amps for the controle board to work and a litle room for safty which makes a total of 25 Amps -
II- The voltage will be 70VDC (the output power is 1750W)
I will be using a Half bridge to drive the transformer, I already have some IR2110, IR2111, IR2153 and all other necessary components except the transformer!!!
I am searching in old TV to find a big one to use, So guys any suggestions are welcome, I have read alot about trafo re-winding, could someone post a procedure with pictures on how to do it, this will be great?
Thnaks in advance,
Regards.
Welcome, and thanks for Joining.
I would recommend that you get an ETD49 Core, or ETD59, while that application will use power in constant mode.
You can refere to this circuit, and its regulated :- http://www.diysmps.com/forums/showthread.php?250-IR2153-smps-with-short-circuit-protection./page6 POST#60
Let us know if you need any further help
Thank You
I would recommend that you get an ETD49 Core, or ETD59, while that application will use power in constant mode.
You can refere to this circuit, and its regulated :- http://www.diysmps.com/forums/showthread.php?250-IR2153-smps-with-short-circuit-protection./page6 POST#60
Let us know if you need any further help
Thank You
Hi All,
Since the most cretical part of my project is the transformer, I decided to not start any activities untill I find one! And I've found a trafo that I believe is big enough to deliver more than 1700W ( happy me )!
I used ExcellentIT-EN (thanks to the guys who post it in this forum), but the results were a bit confusing; just to let you know that I entred the dimentions of the trafo to the SW, but I randomly set "Effective Permeability" to 1700 and "Current Dencity, A/mm^2" to 7!!
the confusing points are:
1- Primary current = 38.4A, this higher that the output current!!
2- (most confusing) Wire diameter of primary winding is 11 turns of 425 strands * 0.1mm; is this a correct value?
3- Secondary winding is using deffirent strands diametr 0.63, am I right?
According to point 1, the transistors of the half bridge have to be able to handle more current, any ref?
how to insert images???
Thanks for yor help.
RABSMPS.
Since the most cretical part of my project is the transformer, I decided to not start any activities untill I find one! And I've found a trafo that I believe is big enough to deliver more than 1700W ( happy me
)!I used ExcellentIT-EN (thanks to the guys who post it in this forum), but the results were a bit confusing; just to let you know that I entred the dimentions of the trafo to the SW, but I randomly set "Effective Permeability" to 1700 and "Current Dencity, A/mm^2" to 7!!
the confusing points are:
1- Primary current = 38.4A, this higher that the output current!!
2- (most confusing) Wire diameter of primary winding is 11 turns of 425 strands * 0.1mm; is this a correct value?
3- Secondary winding is using deffirent strands diametr 0.63, am I right?
According to point 1, the transistors of the half bridge have to be able to handle more current, any ref?
how to insert images???
Thanks for yor help.
RABSMPS.
Its just you cannot change duty cycle into the IR2153D, while it has nothing to do with adjusting the output voltage, while its only going to regulate the voltage into a Regulated SMPS.
As far as I Know
Hi MicrosiM
I believe that changing the duty cycle will change the output voltage as well, under heavy loads, the voltage Vo tends to go down, the output current Io will go down also => power Po goes down!
the feedback circuit acts at this moment, it measures Vo against some V ref and via an opto coupler it sends this information the PWM circuit to adjust duty cycle accordingly.
After AC line is rectifyed and filtred, we get a DC voltage to feed the trafo via chopping circuit (half / full bridge; push-pull or whatever used topology), the longer the switches are closed, more energy is stored in the trafo coil, the higher the Vo will be and vice versa.
The trick is to determine 3 duty cycle values: 1) when VDC chopper is at minimum Duty Cyle is at maximum, 2) VDC nominal Duty Cycle Nominal and VDC chopper maximum Duty Cycle minimum; we have to permanently monitor the VDC chopper with an error amplifier , this can be done either by putting a sence resistor in series with primary trafo winding or by monitoring Vo; Vo and VDC chopper are related to each other by the Duty Cycle, trafo winding ratio, the losses in the trafo and the chpper.
For my projet, I have bought IR2153, SG3525, IR2110, resistors, capacitors, optocoupler, TL431, 0.1 and 0.6 wire and many more; I want to design a fixed output volatge PSU, 70V up to 30Amps ander any load with short cecuit, over load (which is similar to short cercuit) pertection, under volatge protection and low EMI for this any suggestions or advices are welcome (spetial thanks to you and Dimonis).
Regards,
RABSMPS
I believe that changing the duty cycle will change the output voltage as well, under heavy loads, the voltage Vo tends to go down, the output current Io will go down also => power Po goes down!
the feedback circuit acts at this moment, it measures Vo against some V ref and via an opto coupler it sends this information the PWM circuit to adjust duty cycle accordingly.
After AC line is rectifyed and filtred, we get a DC voltage to feed the trafo via chopping circuit (half / full bridge; push-pull or whatever used topology), the longer the switches are closed, more energy is stored in the trafo coil, the higher the Vo will be and vice versa.
The trick is to determine 3 duty cycle values: 1) when VDC chopper is at minimum Duty Cyle is at maximum, 2) VDC nominal Duty Cycle Nominal and VDC chopper maximum Duty Cycle minimum; we have to permanently monitor the VDC chopper with an error amplifier , this can be done either by putting a sence resistor in series with primary trafo winding or by monitoring Vo; Vo and VDC chopper are related to each other by the Duty Cycle, trafo winding ratio, the losses in the trafo and the chpper.
For my projet, I have bought IR2153, SG3525, IR2110, resistors, capacitors, optocoupler, TL431, 0.1 and 0.6 wire and many more; I want to design a fixed output volatge PSU, 70V up to 30Amps ander any load with short cecuit, over load (which is similar to short cercuit) pertection, under volatge protection and low EMI
for this any suggestions or advices are welcome (spetial thanks to you and Dimonis).Regards,
RABSMPS
Thats completely true, but this is regulation of the voltage
changing Duty in here (PWM) will do the regulation, and duty will increase when voltage goes down. but you will not get more than the set voltage. if you set SMPS for 70V, even at full Load 30A will still 70V
Regards
changing Duty in here (PWM) will do the regulation, and duty will increase when voltage goes down. but you will not get more than the set voltage. if you set SMPS for 70V, even at full Load 30A will still 70V
Regards
Hi MicrosiM,
Right, that is my aim; A fixed Vo over a wide range of Io (from 0Amps to full load)
with SG3525 the duty cycle can vary from 0% to max 49%, in this case I have to set D nominal to 35% and calculate the 2 other duty cycles for VDC chopper min and max as well as figuring out what should be the feedback voltage swing to satisfy these conditions it is not easy for me to do all this math (I am degital electronic engineer all I know are 0s and 1s).
BTW, The Freq of SG3525 is devided by 2 and distributed to both output A and B, this means we will have F/2 for the trafo in case of half bridge and F for full bridge right?
the same applys for VDC chopper, it would be VDC/2 for half bridge and VDC for full bridge?
your advice are very helpful, thanks in advance.
Regards,
RABSMPS.
Right, that is my aim; A fixed Vo over a wide range of Io (from 0Amps to full load
)with SG3525 the duty cycle can vary from 0% to max 49%, in this case I have to set D nominal to 35% and calculate the 2 other duty cycles for VDC chopper min and max as well as figuring out what should be the feedback voltage swing to satisfy these conditions
it is not easy for me to do all this math (I am degital electronic engineer all I know are 0s and 1s).BTW, The Freq of SG3525 is devided by 2 and distributed to both output A and B, this means we will have F/2 for the trafo in case of half bridge and F for full bridge right?
the same applys for VDC chopper, it would be VDC/2 for half bridge and VDC for full bridge?
your advice are very helpful, thanks in advance.
Regards,
RABSMPS.
Hi Microsim!
Hope you remember me, few months ago I tried to build this SMPS, but I didn't succeeded. The signals were OK and there was voltage on the secondary when I connected a 60V transformer (I don't have isolation transformer) to the input. But when I left the transformer and connected directly, the IRFP460 transistors died, and also the ir2110 and sg3525 died. I don't know exactly why this happened. Now I give it another shot, I hope I'll have better luck this time.
Can I use SG2525 instead SG3525? It's easier to get in my place.
I saw on pictures and videos that everybody tested the power supply loaded with something. Could that be the problem that I started it with no load? And I put only 1000uF capacitors on the output.
Thank you for your help!
Regards,
Attila
Hope you remember me, few months ago I tried to build this SMPS, but I didn't succeeded. The signals were OK and there was voltage on the secondary when I connected a 60V transformer (I don't have isolation transformer) to the input. But when I left the transformer and connected directly, the IRFP460 transistors died, and also the ir2110 and sg3525 died. I don't know exactly why this happened. Now I give it another shot, I hope I'll have better luck this time.
Can I use SG2525 instead SG3525? It's easier to get in my place.
I saw on pictures and videos that everybody tested the power supply loaded with something. Could that be the problem that I started it with no load? And I put only 1000uF capacitors on the output.
Thank you for your help!
Regards,
Attila
Yes I do remember,
In order to give you proper help, Please post pictures of your setup of the SMPS + the schematic you are using.
It will be impossible to know the reason for this problem, also you CAN use SG2525.
Regards