4kw smps

TBDz

New member
Thanks My Friend
You know if I can use the MicroSim formula for quasi-resonant switching power supplies?

Hugs
Cleber

The answer lies in what the transformer's primary sees during its operation. I am not a power supply expert and certainly is not experienced in designing a quasi-resonant SMPS. However, one thing is always true is that you want to consider the worse case circuit condition that the transformer primary sees. One of the worse case for the transformer primary, in determining the maximum operating flux density, is the frequency range. If you look at the equation, you will see that the lower the switching frequency, the higher the operating flux density of a given transformer with a fixed number of turns.
 

josa

New member
wow
nice , does it provide 4000Wats outputpower contineously ? in an 40°c environment ?
What is the effeciency Pout/Pin ?
Johan
 

MicrosiM

Administrator
Staff member
Constant Load

wow
nice , does it provide 4000Wats outputpower contineously ? in an 40°c environment ?
What is the effeciency Pout/Pin ?
Johan

Nope!

4200W Constant was drawn from this SMPS for 6 minutes only.

To give you some idea about Heat for some parts during that period:-

IGBTS Heatsink, 60C *with Fan
Output Diodes 65C *without Fan
Transformer 60C
Resonant Coil 64C
* Every thing gets HOT! and I really mean It *HOT*.

So this is to clear out whats going on at this level of power.

Also others who claim 8 hours test with there 4KW SMPS is totally crap. 4000W means high current, every thing will get hot. and such Power Suplies are designed for Audio mainly *as in my case* not for constant Load!

Thanks
 

Murilo

DIY ADICTED
Very nice design!!

The transformer was made by you too?
Which kind of capacitor did you use on resonant tank? polypropylene? polyester?
Red coil is the resonant one right? I didn't get why u used two color wiring, isnt't a simple inductor?
Did you reach ZVS and ZCS on this smps??

Again, very nice design!

Hugs
Murilo
 

MicrosiM

Administrator
Staff member
The transformer was made by you too?

Manufacturered at firm

Which kind of capacitor did you use on resonant tank? polypropylene? polyester?

MKP series capacitors, Special DC link capacitors.

Red coil is the resonant one right? I didn't get why u used two color wiring, isnt't a simple inductor?

Other coil is for currect sense :D

Did you reach ZVS and ZCS on this smps??

ZCS

Murilo,

I am glad you have joined diysmps. and thank you for joining.

It will interested for us, to see your FULL BRIDGE SMPS.

Thank you
 

Murilo

DIY ADICTED
Manufacturered at firm
You should thank for have this facility, in Brazil, i it's hard to find and costly a simple litz cable"!

MKP series capacitors, Special DC link capacitors.

Can you share the model of it, i didn't find small ones like you show on the videos and knowledge is always important. -)

Other coil is for currect sense :D

1:1 turns ratio or not? :eek: 22 Amps on primary and on R16? In a 0,2R resistor, this is arround 100w!! HEHEHE

ZCS

It's nice to see that has someone who cares about soft switching and power factor, in Brazil, everyone just want higher current output (99% want a 12~14.4v@200A 100% ready project to sell for those who has 10kW of amplifiers on car) and doesn't care about efficience, power factor, protections, soft-start.

I saw that you are tired of those who claim, i'm too, i heard more than 50 times that skin effect doesn't exist, that he got 50A on 18 AWG wire without get HOT, and other things, you are not alone!

Didn't used a inductor in output filter?? Can i ask why?

Murilo,
I am glad you have joined diysmps. and thank you for joining.
It will interested for us, to see your FULL BRIDGE SMPS.
Thank you


I hope i can help and learn with the community, my internet doesn't help, but i will try make a thread with my smps, maybe first in forum with synchronous rectification? :D Just to advance, i used UCC2895, in Brazil i didn't find UCC28950 in time to use it!

I didn't saw, where are you from?
 

MicrosiM

Administrator
Staff member
You should thank for have this facility, in Brazil, i it's hard to find and costly a simple litz cable"!

I manufactured them in USA


Can you share the model of it, i didn't find small ones like you show on the videos and knowledge is always important. -)

here some info:- http://uk.farnell.com/vishay-roederstein/mkp1848-510-094k2/capacitor-mkp-1100v-1uf/dp/1791629?Ntt=179-1629

1:1 turns ratio or not? :eek: 22 Amps on primary and on R16? In a 0,2R resistor, this is arround 100w!! HEHEHE

True. but for music use, its OK, constant power, things will BURN! ;ww:

It's nice to see that has someone who cares about soft switching and power factor, in Brazil, everyone just want higher current output (99% want a 12~14.4v@200A 100% ready project to sell for those who has 10kW of amplifiers on car) and doesn't care about efficience, power factor, protections, soft-start.

I agree, in my commercial version of the 1100W SMPS, I have implemented complex protection circuits into my design

I saw that you are tired of those who claim, i'm too, i heard more than 50 times that skin effect doesn't exist, that he got 50A on 18 AWG wire without get HOT, and other things, you are not alone!

I will give an example of, how people can be fooled very easily, check this thread by a big joke company called PWM. just check the parts and lets see if it will handle 2000W ((@

http://www.diyaudio.com/forums/power-supplies/166721-my-4kw-smps-finished.html

Didn't used a inductor in output filter?? Can i ask why?

I dont know why many people asked same question, since I never found any reason to use them in UNREGULATED power supplies, they do lower the stress on switching power devices. but many commercial amplifiers manufacturers dont use them!, they only use 6uh beads!



I hope i can help and learn with the community, my internet doesn't help, but i will try make a thread with my smps, maybe first in forum with synchronous rectification? Just to advance, i used UCC2895, in Brazil i didn't find UCC28950 in time to use it!

Thank you
 

Murilo

DIY ADICTED
I dont know why many people asked same question, since I never found any reason to use them in UNREGULATED power supplies, they do lower the stress on switching power devices. but many commercial amplifiers manufacturers dont use them!, they only use 6uh beads!

Sorry, i didnt't saw that is unregulated! :D

Thanks for your explanations!
 

mariano

New member
what will be the price to make this PS it will just what I need, i am wating for some mosfet to finish 10 channels 400wrms per channel amp. and i will need the power supply
 

MicrosiM

Administrator
Staff member
what will be the price to make this PS it will just what I need, i am wating for some mosfet to finish 10 channels 400wrms per channel amp. and i will need the power supply

Sorry for late replay :(

This SMPS is not that costly, but I don't advice you to make one SMPS for 4000W, and this was a prototype for 4KW SMPS.

I advice you to make 2KW units, and use them. you can modify other designs found at forums. Just use bigger core like ETD59


Thanks for interest :)
 

NiltonCyber

New member
yes, because I have a 80+80 Vcc 500W per channel amplifier and would like to use this font, excuse me for the English because I'm from Brazil.
 
Last edited:

giololucas

New member
yes, because I have a 500W per channel amplifier and would like to use this font, excuse me for the English because I'm from Brazil.

Hi Nilton!
I advice you to try something smaller, less than 1KW , because SMPS are complicated and tricky, then you can go further with hi power.

Olá Nilton.
Sugiro a você iniciar com uma fonte menor que 1KW (tem varios bons aqui no site para voce se basear), SMPS são complicadas e cheias de manha, que voce só pega o jeito montando uma.
Com certeza até voce conseguir fazer funcionar a primeira, alguns mosfets irão explodir. Então se vc usar peças para 4KW o prejuizo será enorme. Mas enfim fica a seu critério.
Boa sorte
Abraço.
 

MicrosiM

Administrator
Staff member
The schematic of that 4KW smps are no longer secret, But I dont advice you to start with 4KW SMPS.

I cancelled that design due many problems, and I dont like the 4000W into one module with one EE65 Transformer.

1- 125KHz is a tricky frequency, and require special parts like IGBTs

2- Using Isolated drive topology is tricky also, and require expensive parts.

4- 4000W is really hard target, specially if you are looking for constant loads, like in my case. But for audio applications my SMPS was perfect.

I am now in the final stages of producing my final 1200W SMPS, PCBs almost ready for assembly. after that I will make 500W SMPS with PFC.
then I will go with a high power SMPS around 3KW with dual ETD59 transformers

If you need any help, let me know
 

NiltonCyber

New member
ok montei ESSA de 1k Mais percebi Muita Queda de tesão parágrafo 80 65v Meu ampli de 80 e 80 usei quarto FiOS primarios e secundario 11 +11 11 +11 6 FiOS Por Que o ramo acontecendo ESTA?
 

giololucas

New member
ok montei ESSA de 1k Mais percebi Muita Queda de tesão parágrafo 80 65v Meu ampli de 80 e 80 usei quarto FiOS primarios e secundario 11 +11 11 +11 6 FiOS Por Que o ramo acontecendo ESTA?

Sorry I did not understand the configuration of transformer.
Desculpe, não entendi a configuração do transformador , pode explicar melhor.
 

NiltonCyber

New member
ok, I rewound 11 +11 2-wire Primary and secondary 11 +11 with 6 wires has a voltage of + - 82V with a load over 100w drops to 65V
 
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