Testing mine 2,5 Kw half bridge rezonant mode

DjLeco

DjLeco

Moderator
On air, spider montage testing:

Rezonant mode, half bridged IRG4PC50W IGBT's ETD59 core, 3C90 material, 600x0,071 litz for primary winding , 2x200x0,08 for secondary winding,maximum randament achieved ay 55 Khz (don't know why)...

Tried more or less spires for primary, in any case, maximum randament achieved @ 55 Khz...
Someone can explain that?
Why doesn't want to give maximum randament at 80-100-125 Khz, instead 54 Khz??

Movie during testing:


[video=youtube;ZRIuq4J7CrE]http://www.youtube.com/watch?v=ZRIuq4J7CrE[/video]
 
D

DEXTER

New member
Nice , that is almost 3.6kw , can you tell me more about the transformer windings , how many turns did you use , cross section area of primary wire , and for the control , those igbt are driven from IR2110? or u use a GDT?
I'm working at something like that , but at FS 100khz , and on etd59 , with cooper foil wound's .....
Keep on going !
 
C

chaudio

New member
I've never seen one of those wirewound resistors glow red before. Might be slightly over the max operating temperature! You are also obviously not scared about high voltages at all!!!

Very interested to find out more information about the design. I've repaired many similar switchmode power supplies and I'm slowly building up a stock of components to build my own. The transformer, resonant choke and getting the resonance right are the bits I'm not sure about yet.
 
DjLeco

DjLeco

Moderator
Primary (for testing only) 14 spires with 600x0.071 litz.

Opto gate drivers.

Maximum randament achieved around 54 Khz.

It follows primary winding with Cu foil 0,1x40 mm, I must experimentate the number of turns for primary...
 
IGBT

IGBT

Switching Fanatic!
cool

DjLeco


I am also in the process of making something close, can you share your schematic?

at least without part numbers. how did you calculate turns?
 
flyingpig

flyingpig

New member
36000w ??

DEXTER said:
Nice , that is almost 3.6kw , can you tell me more about the transformer windings , how many turns did you use , cross section area of primary wire , and for the control , those igbt are driven from IR2110? or u use a GDT?
I'm working at something like that , but at FS 100khz , and on etd59 , with cooper foil wound's .....
Keep on going !
Click to expand...

@ Dexter

Where did you get the 3.6KW from?

No idea how that SMPS is working in that way, long wires, random setup.

DjLeco..

You are using (Half Bridge) rectifier? how is that?
 
DjLeco

DjLeco

Moderator
Mine smps is classically SG3525 with opto drivers for IGBT drive.

Is Half Bridge and bialternance recrifier(secondary) with double diode.
I will never calculate turns, I have experimentate for maximum power output, with minimim dissipation(maximum randament).

No usually calculations formula is fitting on real life of smps!

Also I'm no good in calculation...
 
D

DEXTER

New member
for flyingpig
CHECK the movie , the two rezistors in pararel means 2 ohm , and a 85 V across them =>42.4A ....
POWER=U*I ....85*42.5=3612W ....i think peak power not for long durations ...but wery goood for that smps , wen it will be on pcb , and after he tunes up it ,that will rock !
 
DjLeco

DjLeco

Moderator
Last tests, trafo winded for +/- 95 VDC stabilised (@2.5 Kw for 2x800Watts AB Class Amplifier http://www.forum.poweraudio.ro/viewtopic.php?f=64&t=9276 ), primary filtrage capacity 3x470uF/450 Volts, bridge rectifier 35Amps/1000Volts, Main (220v fuse) 15 Amps (blew and replaced with 25 amps), secondary fuse (310VDC) 20 Amps, secondary storage 2x1200uF/200 Volts and parraleled with another 470uF/450 volts, for testing only, entire SMPS with NO PFC!!!
Rezonant mode @ approx 70 Khz.

Trafo primary winding litz 600x0,071, and secondary, 4 wires of 200x0.08 litz.

Tested on 2x4 ohms (low thermal derive) seried, resulting 8 ohms dummy load, and finally test, with another 8 ohms parralleled on one of 4 ohms, rezulting final resistor of 6,66 ohms.

Goerts (made in Germany) current shunt of 50Amps/100mV drop, means 50mV drop are 25 Amps current seried with it.

On 8 ohms (cold resistors) 179,5 volts and 41,80 mVolts on shunt (22,34 amps).

On 6,66 ohms, 174,5 volts and 48 mVolts on shunt (around 26 amps, including low thermal derive of incandescent resistors and error precision of shunt and multimeter) .

Comments, and I left to you, honor to calculate power obtained on ETD59 3C90 Material.

Movies during testing:

[video=youtube;TXu4udrkfOM]http://www.youtube.com/watch?v=TXu4udrkfOM[/video]

[video=youtube;e5VJW-QdEUo]http://www.youtube.com/watch?v=e5VJW-QdEUo[/video]

[video=youtube;0InvsWFqG3o]http://www.youtube.com/watch?v=0InvsWFqG3o[/video]

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

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Last edited:
DjLeco

DjLeco

Moderator
I finished schematics, i send it for pcb designing, and I wait.
When it's done, I'll post it, but without schematics..
 
tebci

tebci

New member
dear Djleco


I don't know if you can help me by transformer turns ratio and schematic of your SMPS, or any help you can provide.

Thank you
 
A

Acca

New member
DjLeco said:
On air, spider montage testing:

Rezonant mode, half bridged IRG4PC50W IGBT's ETD59 core, 3C90 material, 600x0,071 litz for primary winding , 2x200x0,08 for secondary winding,maximum randament achieved ay 55 Khz (don't know why)...

Tried more or less spires for primary, in any case, maximum randament achieved @ 55 Khz...
Someone can explain that?
Why doesn't want to give maximum randament at 80-100-125 Khz, instead 54 Khz??

Movie during testing:


[video=youtube;ZRIuq4J7CrE]http://www.youtube.com/watch?v=ZRIuq4J7CrE[/video]
Click to expand...

Transformer must calculated for desired frequency.This is explain.On different freq. number of turns must be changed.
 
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