My 2500Watts to 5000Watts Comercial SMPS for Audio Amplifiers

DjLeco

DjLeco

Moderator
Finally finising mine SMPS project for Audio Power Amplifiers, and not only audio, ready for selling.

Is an resonant LLC ZVS SMPS mode, soft switching.

This SMPS will be mage custom every client (output tensions and power for amplifier power supply) and will have power from 2500W to 5000W; even I had success of more than 6500Watts peak power on outputs (extracted 34 amps from 220Vac main supply).

It will offer 2 sets of simmetrical +/- outputs with common GND, FIRST,the power outputs ones, the big one until 4500Watts between +/- minimum 50Vdc and maximum +/- 190Vdc, unregulated.

The second one is a maximum 500watts power from +/-50Vdc until +/- 90Vdc, unregulated, power being calibrated by classic 3,15A fuses.

Also it offers some low tensions low current outputs, all regulated, and those are:

One simmetrical output of +/-15 volts,regulated, with common GND of +/- power rails, at max 0,8 amps, for preamplifiers, etc.

Two floating 15 volts,regulated at max 0,8 amps for classD drivers, or something else wich need FLOATING supply.

One 24 volts,regulated, at max 0,5-0,6 amps for fans relais, etc.

One variable output of 7-22 volts, max 0,3-0,5 amps for fan of main heatsink SMPS cooling




All unregulated outputs, power ones, can be made custom client, until maximum +/- 190 volts, rest ones will be classical as above described.

It have been used only high quality materials and components taken from Farnell, Mouser, Aavid Thermalloy,all brand new.

External dimensions of PCB are:



where on upper part the main heatsink exceedes 10mm above PCB, so must be taken 319mm / 220mm dimensions.

Price is between 200 and 300 EURO, depending of output power from 2500Watts and 5000Watts.

Contact me at claudiu971@yahoo.com mail or yahoo messenger, only if interested of buying, thank you.

Some little presentation movie, to the prototype of 5000Watts, custom made for a client wich demanded +/- 100Vdc at 4500watts, on power +/- rails for amplifiers:


http://www.youtube.com/watch?v=slSJ7fOOR8w&feature=youtu.be

More details and tests here:





[video=youtube;Worp-0qH-V4]http://www.youtube.com/watch?v=Worp-0qH-V4&feature=youtu.be[/video]

[video=youtube;uqsrQEEEJJE]http://www.youtube.com/watch?v=uqsrQEEEJJE&feature=youtu.be[/video]

[video=youtube;664wDHuKXYw]http://www.youtube.com/watch?v=664wDHuKXYw&feature=youtu.be[/video]
 
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DjLeco

DjLeco

Moderator
It was a small metalic object near blue EMI coils, with interrracts at magnetic field...

:02.47-tranquillity:
 
DjLeco

DjLeco

Moderator
Current transformer, even if is old school, regarding new developements.

It is SAFEST, and robust, and can be easy adjusted the tripping value.
 
K

Kanwar

Member
Very good work LECO

It is Fixed frequency or variable frequency and what is the size the transformer core?
 
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K

Kanwar

Member
Then its ZCS not ZVS, correct your post and neither its LLC.

Your SMPS is Zero Current Switching Series Resonant mode, a Robust design.:UP:

ZVS & LLC needs variable frequency to function properly in order to achieve resonance.:)
 
DjLeco

DjLeco

Moderator
Kanwar said:
Then its ZCS not ZVS, correct your post and neither its LLC.

Your SMPS is Zero Current Switching Series Resonant mode, a Robust design.:UP:

ZVS & LLC needs variable frequency to function properly in order to achieve resonance.:)
Click to expand...

Yes you are perfectly right, I thinked at other things (FAN7621 http://www.fairchildsemi.com/ds/FA/FAN7621.pdf ) when I write...

Yes ZCS is very robust design, also helping for minimising or even ommiting inductor between rectifier bridge and capacitor in secondary.
 
K

Kanwar

Member
If possible, kindly show waveforms of Transformer primary and main secondary, it will reveal the nature of good working SMPS. Also the waveform across resonant capacitor to show the current waveform.
 
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DjLeco

DjLeco

Moderator
I will put this week, when I will have some time.

But I asure you, primary waveform is rectangular, capacitor form is almost perfect sinusoidal when loading.

Secondary waveform, never checked...
 
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K

Kanwar

Member
Thanxz Leco,

Don't forget to post secondary waveforms, its the main thing which shows the behavior of good transformer under loaded and offloaded conditions.
 
DjLeco

DjLeco

Moderator
As I have promised, I put some scope images, SMPS is loaded with couple tenth of watts.

Resonant voltage:



Primary winding trafo:




Secondary winding trafo:




High Side IGBT between G and E:

 
DjLeco

DjLeco

Moderator
One custom made SMPS from initial project for this project, where that amp doesn't have main transformer:

http://www.forum.poweraudio.ro/viewtopic.php?f=8&t=16953

Is about Mach Audio M2400 (Romanian product), classH 2 step (cloned in some parts from QSC RMX2450), wich needs +/- 55Vdc Lo Rail and +/- 110Vdc Hi rail for amplifiers modules and 22Vdc unregulated for main fans and protection+delay coupling speakers relais offering 2x1200Watts/2 ohms, max output power.


Made one movie splitted in 3 parts where I prooved perfect working and very accurate protection acting.

SMPS was calibrated for 3200watts continuous, protection acting at more than 3600Watts peak.

Alot of smps's are not able to start in almost full max power regim without tripping protection, with more or less output storage capacitors, I have tested with 2x2000uF/rail and later adding another 2x 10000uF more.

Also, alot of smps's fails if trying to start under overload or short circuit on output, condition, not problem here.


Interestingly,in official project, trafo was one 2000Va toroid, a little undersized for 2x1200watts in 2 ohms, but maybe they calculate just the musical program is under 75% of a pure sinusoid, and accepted those purposes.


Now with 3200W continuous power, those amp will work freely

Enjoy videos!

Part 1 where at the end 10amps fuse fails:

[video=youtube;aI5kFyYW2u4]http://www.youtube.com/watch?v=aI5kFyYW2u4[/video]

Part 2 with fuse replaced by 16 A one:

[video=youtube;Q5tjbVgDge0]http://www.youtube.com/watch?v=Q5tjbVgDge0[/video]

Part 3, where I have added another 10000uF per rail (20000uf), for challenging heavier protection part at startul under almost full load:

[video=youtube;ALYTnEgWN5Q]http://www.youtube.com/watch?v=ALYTnEgWN5Q[/video]
 
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