"TO-247" First Project - 600W SMPS"

[TO-247]

Hi

i'm going to start my first audio smps.i want use it for my Nmos200 :

http://www.diysmps.com/forums/showthread.php?179-Quasi-s-Nmos200-2-Pair-Edition

+/-40v 5A 2X200W@2Ohm - 600W max power consumption = +/-40v 7.5A per rail

i was read this thread :

http://www.diysmps.com/forums/showthread.php?79-1kW-smps-project-(based-on-MicrosiM-design)


now i'm confused

i don't know which circuit is suitable for me !

IR2153 or IR2110+SG3525

it's because at first , ludo built the ir2153 based circuit but in newer version , he was build 3525+2110 based circuit and result was more reliable.

can anyone help me about this issues ?

there is the latest version of Ludo's IR2110+SG3525 based circuit , please tell me about it , it's OK ?

 

[MicrosiM]

Last version of ludo`s SMPS is working fine, and it will save you time

If you decided to make it, post every step here, to save your time later

Thanks

 

[TO-247]

My SMPS schematic is ready !
it's Ver.0

please download and tell me about it , what you think ? it's Good and reliable ?
it's like Ludo's last design , but somethings changed.

 

[MicrosiM]

Cool


It looks Good

Make sure to review it before making PCB. just to prevent any mistake.

Other wise, very nice schematic!

 

[TO-247]

Thanks MicrosiM

But i think that schematic have a lot of problems :

- the output voltage not adjustable , what you think ?

- the Snubber circuit behind the mosfets (5R6+330pf) , it's a copy from QSC PLX1802 Schematic ! it's ok for this circuit ? that circuit use IGBT and worked in resonant mode.

- what about current sense inductor ? 15uh is ok ? please tell me about winding and core specs.

- main transformer was calculated based on excel file and you can download 80V design on the attachment. i got minimum voltage of the 220v line around 200v , then 200v X 1.41= 282v/2 = 140v , you can see another parameters on excel file.

- on current limit circuit , how much is the P1 ?

- the output inductor maybe in wrong place , it's must be after the rectifier , also i don't know the good specs for that.

I'm sorry for asking too meny questions

 

[MicrosiM]

--------------------------
Thanks MicrosiM

But i think that schematic have a lot of problems :

- the output voltage not adjustable , what you think ?

For audio application, you dont need regulated SMPS.

- the Snubber circuit behind the mosfets (5R6+330pf) , it's a copy from QSC PLX1802 Schematic ! it's ok for this circuit ? that circuit use IGBT and worked in resonant mode.

Your snubbers are OK, whats the problem if you take info from other designs?

- what about current sense inductor ? 15uh is ok ? please tell me about winding and core specs.
Current sensor will be try and error at the first, that value is just OK as a start

- main transformer was calculated based on excel file and you can download 80V design on the attachment. i got minimum voltage of the 220v line around 200v , then 200v X 1.41= 282v/2 = 140v , you can see another parameters on excel file.

If you have followed the formula, your transformer will work.

- on current limit circuit , how much is the P1 ?

P1 value, start with 50K

- the output inductor maybe in wrong place , it's must be after the rectifier , also i don't know the good specs for that.

No need for those output inductors, since its not a REGULATED SMPS

I'm sorry for asking too meny questions
--------------------

* Calculations for transformer is OK

Dont forget

Making this SMPS from scratch, like in your case, will need things to be done right

I advice you to ask about every thing.

Good Luck!

 

[TO-247]

Thanks for quick replay

Your snubbers are OK, whats the problem if you take info from other designs?

i think that design may not work good in my design , but it's good choice for me.

If you have followed the formula, your transformer will work.

the value of paralleled wires are ok ? the current of secondary is about 7.5A at maximum , 15X0.1mm will be ok ?

Dont forget

Making this SMPS from scratch, like in your case, will need things to be done right

I advice you to ask about every thing.

don't worry it's not my first 220v smps , i have made 100w 18v smps about 1 years ago , but design based on pi-expert.

i'm also download very useful pdf files from this forum to learning about construction , winding , calculation and many other things , thank you for supporting "DIYSMPS"

what's your opinion about 16v 0.5A auxiliary smps ? i want to design and replace it for pcb transformer.

anyway , i think designing this PCB will be difficult

i'm also going to buy Rigol 100mhz Scope and X100 Probe , also isolation transformer ;ww:

- the schematic at version 0.1 also available , but i'm not grantee the operation of this circuit before testing it.

 

[MicrosiM]

1- The parallel wires are OK.

2- 16v 0.5A auxiliary transformer is OK

This circuit is already working, but SMPS needs a try before making the final design, ludo made 4 prototypes before the final version.

 

[TO-247]

How Can I Get +/-24v (For Eq,Protectors,Fans,Etc.) on this smps ?

if the voltage per turn = 7.78 , then for 24v = 3Turn + 16v = 2Turn = 40v 5Turn

is this schematic true ? can i use this method ?

 

[TO-247]

How Can I Get +/-24v (For Eq,Protectors,Fans,Etc.) on this smps ?

if the voltage per turn = 7.78 , then for 24v = 3Turn + 16v = 2Turn = 40v 5Turn

is this schematic true ? can i use this method ?

Can anyone help me ?

 

[MicrosiM]

Aux

Can anyone help me ?

I advice you to make additional winding fro AUX supply.

 

[TO-247]

Softstart and PWM circuit was tested successfully ! the value of the 2.7K resistor behind the 8.2K must be change to 180 Ohm for 80KHz output.

I advice you to make additional winding fro AUX supply.

please check the new version of transformer secondary and tell me about it. also help me for choosing correct wire diameter for 24v lines. Thanks MicrosiM

 

[MicrosiM]

Very Good!

Transformer is OK, and its better to do it that way.

 

[TO-247]

Rigol 1102E and Hameg X100 Probe were arrived.

pwm circuit also tested with the scope and pictures of test is available on attachments.

next step : working on 16v 0.5A smps and over current protection , also testing gate driver with 2110.

____________________


i have a question , if the 0.10mm wire not available , can i use the 0.2mm wire ?

for example : for primary using of 6x0.20mm and for secondary using of 9x0.2mm.

how can i calculate it ?

 

[MicrosiM]

Rigol 1102E and Hameg X100 Probe were arrived.

pwm circuit also tested with the scope and pictures of test is available on attachments.

next step : working on 16v 0.5A smps and over current protection , also testing gate driver with 2110.

____________________


i have a question , if the 0.10mm wire not available , can i use the 0.2mm wire ?

for example : for primary using of 6x0.20mm and for secondary using of 9x0.2mm.

how can i calculate it ?

Scope looks good!


Whats that SMPS 16V 0.5A ? are you going to use small SMPS for AUX supply?

for the wires, you can use 8 x 0.2mm for both primary and secondary.

Dont forget to twist wires all over each others, firmly


Dont forget ISOLATION TRANSFORMER

Good Luck :UP:

 

[TO-247]

Scope looks good!

thanks

Whats that SMPS 16V 0.5A ? are you going to use small SMPS for AUX supply?

yes , but it's under development.

for the wires, you can use 8 x 0.2mm for both primary and secondary.

Dont forget to twist wires all over each others, firmly

thanks

Dont forget ISOLATION TRANSFORMER

yes , sure ! what do you do for measurements of smpses ? don't connect the gnd of scope ? or using the isolating transformer ?

 

[TO-247]

are you going to use small SMPS for AUX supply?

actually i'm going to make a smps instead of 18v-0.25 PCB Transformer , not for aux (+/- 24v).

 

[MicrosiM]

I advice you to use Isolation transformer. !!!:

I use 220VAC Primary to 110VAC secondary. Transformer to power my oscilloscope.

Transformer I am using is normal transformer being used in old amplifier! and it does the job perfectly!

While My oscilloscope operates from 100VAC to 220VAC, I have no problems!

So try locating something close, around 300W 110VAC, if your oscilloscope operates at 110VAC

 

[TO-247]

Thanks MicrosiM , so you use the isolation transformer for power the scope.

when i search on the internet , i have seen the rigol 1102 or many digital scopes , using the smps for powering the circuits and that smps was isolated from main ac line.

look at the rigol smps on the attachment , the y caps behind the transformer , show the isolation between primary and secondary.

so what's the main reason for usage of isolation transformer ?

anyway , my scope power consumption is 50w , is the 100w isolation transformer ok ?

 

[MicrosiM]

Isolation Transformer

Thanks MicrosiM , so you use the isolation transformer for power the scope.

when i search on the internet , i have seen the rigol 1102 or many digital scopes , using the smps for powering the circuits and that smps was isolated from main ac line.

look at the rigol smps on the attachment , the y caps behind the transformer , show the isolation between primary and secondary.

so what's the main reason for usage of isolation transformer ?

Thats a very good question indeed.

At first, i never used isolation transformer, and only connected my oscilloscope to the mains line 220VAC without GND.

one day, I was measuring the signal at IGBT, and i started to hear a noise, like hssss. then.. ::SD

BLOOOOOM, huge spark came from my oscilloscope, and every thing WENT OFFLINE.

I was scared to death barbecue of my 1400US$ oscilloscope ;ww:

On later test, I thought it was a mistake from me, and I insisted to repeat same test!! x-(

then, BLOOOOOM

After that, I tried to investigate what the hell is going on, If you look carefully. in real life
You are connecting the live GND of your SMPS -320VDC to the Scope GND.

And for some reason, Varistor in oscilliscope blown two times.

For me, I cannot tell the exact reason for my scope varistor blow.

But its clear, connecting - or + 320VDC line to oscilloscope, WHILE oscilloscope itself is connected to the mains 220VAC line, I don't think its correct thing.

read this statement, found in service manual of SMPS amplifier

"This will result in about 320Vdc between ‘LIVE GND’ and +HT. ‘LIVE GND’ is named as such
because it is not isolated from mains but it is the reference point for the PSU. If you need to
stick a scope probe around the primary side with the unit plugged in you must connect mains
via an Isolation Transformer. Without this, at best you will only trip your RCD breaker, at
worst you or your scope may not live to regret it. Do not forget that 320Vdc is still pretty
shocking whether it is isolated or not."


100W ISOLATION TRANSFORMER IS GOOD