1kW smps project (based on MicrosiM design)

[sanumar001]

Why do not use a transformer instead of the GDT IR2110? .GDT Works more reliably and more easily customized.https://www.youtube.com/watch?v=EAVYDca-Hkk
This is my smps 48v battery charger from the wind turbine.

 

[zoky2]

Hallo,
my SMPS finally work ,but without protection.If i connect protection card .smps won't start.The protection led is flashing and I have no voltage on output. When connect the light bulb serial with 230 AC ,then everything work well .protection don' t 'kick at start up,but if I increase load at output, then it kick like it should. I thing the protection is too sensitive at startup and I wanna now how to fix this problem.The current trafo is yellow toroid from old computer PSU with 50 turn of wire,the rest is like Ludo' shematic.

regards
zoky2

 

[MicrosiM]

Hallo,
my SMPS finally work ,but without protection.If i connect protection card .smps won't start.The protection led is flashing and I have no voltage on output. When connect the light bulb serial with 230 AC ,then everything work well .protection don' t 'kick at start up,but if I increase load at output, then it kick like it should. I thing the protection is too sensitive at startup and I wanna now how to fix this problem.The current trafo is yellow toroid from old computer PSU with 50 turn of wire,the rest is like Ludo' shematic.

regards
zoky2

Do you have a resistor connected in parallel to the current sense transformer secondary side?

If not, start with 47R

Regards

 

[zoky2]

Hay
Hay
I put the 47R resistor parallel to secundary of current sense transformer ,but with no change.I tried with resistors from 47R to 330R with no luck,so I was changing the power resistor on AC input from 22R to 130R and now the protection not kick at startup.I was doing some testing and I can get about 550w from SMPS without too much heating. More testing will be done when I get big enought load like some owen heater or iron ...

Best regard
zoky2

 

[Weller]

Hi all,

I'm wondering about the fact that people often don't use a PFC in kW SMPS designs. A quick calculation shows that the conduction angle of the bridge rectifier is very small. When this angle is 45 degrees (which is very high), the peak mains supply current (repetitive) is more than 4 times higher than the RMS current. That means above 16A for an 1kW SMPS and 64A when you want to use 4 of them.

In practice it could be over 100A.

A PFC could be used to spread the current over the entire period.

Do they give any problems for normal use at full load?

 

[MicrosiM]

Hi all,

I'm wondering about the fact that people often don't use a PFC in kW SMPS designs. A quick calculation shows that the conduction angle of the bridge rectifier is very small. When this angle is 45 degrees (which is very high), the peak mains supply current (repetitive) is more than 4 times higher than the RMS current. That means above 16A for an 1kW SMPS and 64A when you want to use 4 of them.

In practice it could be over 100A.

A PFC could be used to spread the current over the entire period.

Do they give any problems for normal use at full load?

Hi Weller,

Thats true, but these SMPS units are used in audio amplifier while they will deliver 1/3 of the real power.

I totally agree with you that the PFC is needed., in order to fix that issue.

 

[syadad]

Hi Wally
greetings this is a 2.6kw smps made by hien i have not personally made it so i cant comment but its very similar to what i have made in #722 the first picture only my smps has no protection i
have made pcb for 3 pairs IRFP260 with EE65 CORE its tested and working so i am designing new pcb with protection for 15 volts dc supply i used VIPER22A but TOP244 15volts supply gave a better result
so maybe i have to make small trafo for top244 15 volts supply
warm regards
michelle

hii michelle,
please sent me pcb in pdf, i want to try your project

 

[ragaman]

Hi, I want to share some pics of my last smps proyect, is based Sg3525+ ir2110+totem poles for drive 2 pairs of Mosfet, the core is EE55, for Now Im using irfp22n50 Mosfet, the overcurrent protection is working perfectly.

Enjoy.

 

[MicrosiM]

Hi, I want to share some pics of my last smps proyect, is based Sg3525+ ir2110+totem poles for drive 2 pairs of Mosfet, the core is EE55, for Now Im using irfp22n50 Mosfet, the overcurrent protection is working perfectly.

Enjoy.

Nice work, Keep it up

 

[Marshall]

@MicrosiM

Please i need calculations ..i will make another one SMPS with IR and SG .. I want to use FDH44N50, ETD49/N27.. so how many turns i need for primary ? i need +/-110V in sec ..so how many Volts per turn ? and i want f to be 150 or above Khz ?..can a get 4Kva ?

 

[Marshall]

Please ! Can i get help here ?

 

[sweetperfume]

hello all,
i am new to smps thing but want to build one.. i got the pcb version 3.1 made by ludo. any one can gibe some guidance from where to startup.. i also dont have access to varistor thing.. any alternatives for that?
thanks in advance

 

[Weller]

For my first proto of SMPS I need to wind my ETD59 transformer.

The transformer_formula.xlsx made by MicrosiM says I need 8 turns (Vin = 190V) primary and secundary twice 4 turns (Vout =2x 90V).

freq 100kHz
BdMax 1600g
Ae 3.68cm2
Vin 190V (PFC = 385V)

4 turns are not much. This means also I got 24V with 1 turn. Is that a normal value?

 

[gapjg]

Dears,
I am planning to build V 2.1 can any one post the complete part list (BOM) with capacitor and resistor details for V 2.1?
Thanks in advance

 

[sweetperfume]

first image is of output core and second is of gate. tell me if anything here is incorrect. one more thing high out of ir2110 shows 50khz freq and Lo out shows double of high out. is this normal??
i have powered it directly with 116v dc supply using a trafo.

 

[sweetperfume]

i uploaded images of scope but unable to see it in my post.. how is it so?

 

[sweetperfume]

did some settings now and here is the output of mosfets

 

[MicrosiM]

Waves looks nice at the mosfets outputs

You can go a head with the 220VAC with the Precautions mentioned

Regards

 

[sweetperfume]

Waves looks nice at the mosfets outputs

You can go a head with the 220VAC with the Precautions mentioned

Regards

Thank you sir. But what about the freq difference at high and low output of ir2110?

 

[afton]

Greetings ...
First sorry for my bad english..
I am a new member on this forum, my name is afton, Iam come from East Java Indonesia .
I want to ask about a replacement transformer EI38-1 what? because here the transformer is difficult to get it

regards,