1kW smps project (based on MicrosiM design)

ludo3232

Member
The load is 4 x 750W (at 220V..) Lamp in parallel.

The temp of mos is 41°C during the test with 800W load (788W)

The voltage on output is 100V with no load (+/- 50V) And 86V with 9Amps load..

The transformer is ETD49, wound with 0.4 mm X 5 wire. Primary have 22 Turns and secondary 2 X 7 turns.

Frequency is 77Khz

The gates of mosfet is drive directly by the ir2153 with 10Ω resistor and 1n4148 diode

I have make some changes and i make a new pcb soon.. Protection card not tested yet !

I will winding a new transformer soon with 0.1mm Wires
 

IGBT

Switching Fanatic!
IR2153D design

The load is 4 x 750W (at 220V..) Lamp in parallel.

The temp of mos is 41°C during the test with 800W load (788W)

The voltage on output is 100V with no load (+/- 50V) And 86V with 9Amps load..

The transformer is ETD49, wound with 0.4 mm X 5 wire. Primary have 22 Turns and secondary 2 X 7 turns.

Frequency is 77Khz

The gates of mosfet is drive directly by the ir2153 with 10Ω resistor and 1n4148 diode

I have make some changes and i make a new pcb soon.. Protection card not tested yet !

I will winding a new transformer soon with 0.1mm Wires


I see you have good results ledo32

Is this Hard Switching SMPS? while 800W and 41C, its very nice indeed

can you show me some oscilliscope waves of smps at others points, that will help us learn.

If you will make a new PCB, Please keep in mind I need to make one also!

Thank u :)
 

ludo3232

Member
hello..

Smps is loaded now with 1200W and i have 80V at secondary , Mos 50°C with no fan...

I will post more things later and pictures of waves for "IGBT"

Now i start drawing the new PCB and i will test new current protection before make it definitive..

When pcb is finished AND tested i share it with diysmps users..

Pictures coming soon.. no stress please wait..

Thanks
 

meanman64

Member
hello..

Smps is loaded now with 1200W and i have 80V at secondary , Mos 50°C with no fan...

I will post more things later and pictures of waves for "IGBT"

Now i start drawing the new PCB and i will test new current protection before make it definitive..

When pcb is finished AND tested i share it with diysmps users..

Pictures coming soon.. no stress please wait..

Thanks

Hi Ludo,
That's good news can't wait anymore.
Thanks for all
 

ludo3232

Member
Hi all..

Smps is stable with 1200W load.. for 45 minutes tested..

- Mos 52°C without fan
- Tranformer 55°C without fan
- Out diodes 61°C with fan (but small heatsink..)

On 1200w load i have 20V drop.. is due to transformer, now is winded with 5 x 0.4 wires.. my new transformer is winded with 0.1mm wire and have less voltage drop..

Now i start to test protection card and finalize schematics for making a good final pcb..

I post pictures of measurements.
 

Attachments

  • primary transfo no load.JPG
    primary transfo no load.JPG
    96.3 KB · Views: 311
  • Gate High.JPG
    Gate High.JPG
    85.6 KB · Views: 232
  • Gate low.JPG
    Gate low.JPG
    86.3 KB · Views: 217
  • D+S Highmos.JPG
    D+S Highmos.JPG
    90.7 KB · Views: 207
  • D+S Lowmos.JPG
    D+S Lowmos.JPG
    85.1 KB · Views: 185
  • Transformer Sec no load.JPG
    Transformer Sec no load.JPG
    86.5 KB · Views: 189
  • 1uF capacitor loaded.JPG
    1uF capacitor loaded.JPG
    91.7 KB · Views: 220
  • primary transfo loaded.JPG
    primary transfo loaded.JPG
    96.2 KB · Views: 210

ludo3232

Member
Hi all!

This project is no longer interested?

...

Now i have finish the test of new protection circuit.. i have short-circuited many times (20 -30 times..) the output and mos survives !

Its based on current transformer, comparator, and ne555 latch.. 0.55 uS rise time

[video=youtube;I5LwLU71YWo]http://www.youtube.com/watch?v=I5LwLU71YWo[/video]
 

ravs

Member
hi ludo3232

thanks for scope pics.

who says we are not interested in this.iam following the whole story.just waiting from your end
to be completed and post details and pcb files.

thanks

ravs

be a vegeterian......
 

IGBT

Switching Fanatic!
Smps

Hi all!

This project is no longer interested?

...

Now i have finish the test of new protection circuit.. i have short-circuited many times (20 -30 times..) the output and mos survives !

Its based on current transformer, comparator, and ne555 latch.. 0.55 uS rise time

[video=youtube;I5LwLU71YWo]http://www.youtube.com/watch?v=I5LwLU71YWo[/video]


Let me be clear, from your results, You have one amazing SMPS witch cannot be found on the web.
So you must be proud of it, it ROCKS!!

I am surprized of the protection circuit, IR2153D has several issues with transformer primary startup current, does your smps activate protection circuit at startup?


Keep the good work, I need one also, when you can post the files?

Can we adjust voltages at output?

Keep going
 
Last edited:

ludo3232

Member
Let me be clear, from your results, You have one amazing SMPS witch cannot be found on the web.
So you must be proud of it, it ROCKS!!

I am surprized of the protection circuit, IR2153D has several issues with transformer primary startup current, does your smps activate protection circuit at startup?


Keep the good work, I need one also, when you can post the files?

Can we adjust voltages at output?

Keep going


i have solved the problem of startup current, is no elegants solution but work good...

I have added a softstart resistor (50Ohm) before the primary rectifier and slow charging the main cap for 1s and and a relay short circuit this resistor..

when 220vac it's removed, an another relay discharge the main cap to a 100Ohm R..

if i no use this, the protection circuit activate at startup. i have tested somes other solution, and its not work..

the files are ready soon.. wait please, i want test new board for i no mistakes..

No we can no adjust the output voltage. it's fixed by transformer turn ratio.
 

MicrosiM

Administrator
Staff member
SMPS Delay

Hi all


Personally I appreciate the hard work done by ludo for making this SMPS from scratch.

Ludo will come back soon to complete it, we are sorry for the delay.

I wish that he will recover soon.

Thanks for all
 

fabiodord

New member
Hi Microsim,

I'm working at the preliminary board based on your schematic/board about this SMPS.
Just a question about your post in one of the first message in this thread, I see your schematic but I can't understand where is connected the coil of SW1.

Thanks in advance

Fabio
 

MicrosiM

Administrator
Staff member
Hi Microsim,

I'm working at the preliminary board based on your schematic/board about this SMPS.
Just a question about your post in one of the first message in this thread, I see your schematic but I can't understand where is connected the coil of SW1.

Thanks in advance

Fabio


Hello


I cant understand witch coil, Please show that on schematic

i will be glad to help you out ;)
 

fabiodord

New member
Hello,

in the schematic is signed the component.
Has been called RELAY 12V but I can't see the coil of relay.

Thanks a lot

-)
 

Attachments

  • IR 21531 with note.pdf
    35.1 KB · Views: 1,918

MicrosiM

Administrator
Staff member
Hello,

in the schematic is signed the component.
Has been called RELAY 12V but I can't see the coil of relay.

Thanks a lot

-)


Thats correct

That design was the start of SMPS, and some missing details are there.

That coil is connected to th output of SMPS, AUX winding, when SMPS starts it will short the NTC.

Ludo made the final design, with all modifications


We have to wait some time, because he made the final PCBs and the final working proto type
 

ludo3232

Member
Hi all!

I'm back after a long health problem .. now i am fine.

Sorry for the long waiting

I'll post in the next day complete and final PCB and schematics after finishing to tests.

Ludo
 
Top