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Thread: 1kW smps project (based on MicrosiM design)

  1. #1331
    Attachment 6817
    thanks for your reply silvio,
    this is the circuit i have used ,1)the circuit is half bridge topology,2)the supply input volt is 230volt 50hz,3)transformer material is cf139cosmoferrites,
    4)2step means i have made 2 different voltage ,-+60and,-+120volt dc.
    5)i used igbt instead of mosfet to increase the watts. igbt no,30n60a4d
    6)i want to get maximum power from etd 49,
    7)so tell me what frequency should i keep to get 60volts and also the winding turns
    8)the above image is my final design the circuit and design is perfect only the the transformer iam not able to do it properly

    waiting for your reply
    thanks p.s.raju

  2. #1332
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    QUOTE=P.S.RAJU
    thanks for your reply silvio,
    this is the circuit i have used ,1)the circuit is half bridge topology,2)the supply input volt is 230volt 50hz,3)transformer material is cf139cosmoferrites,
    4)2step means i have made 2 different voltage ,-+60and,-+120volt dc.
    5)i used igbt instead of mosfet to increase the watts. igbt no,30n60a4d
    6)i want to get maximum power from etd 49,
    7)so tell me what frequency should i keep to get 60volts and also the winding turns
    8)the above image is my final design the circuit and design is perfect only the the transformer iam not able to do it properly

    waiting for your reply
    thanks p.s.raju[/QUOTE]

    Hi Rayu I have worked out the windings on the data you gave me. I have posted a couple of pictures for you to see if I understand you correctly about the 2 step windings.
    I have understood that the amplifier will be working most of the time on 60v and then when there is peak current draw on high volume setting a mosfet will switch the other half of the secondary to maintain the voltage. The first picture will show the winding configuration. The current in the second half of the winding will be somewhat lower due to the higher voltage. However I opted for a current draw of 8 amps for this winding and around 12 amps for the main 60v winding.

    The PDF file will show all the details of the windings including number of turns, number of wires 0.5mm for different current rating (9 wires of 0.5mm for main 60v and 6 wires for 120v. You need 12 wires (18 amps) for the primary

    Please note that the workout voltage on the software is written down at 50v but this is the loaded voltage with an inductor in the output included, however the peak voltage will be around 61v at the rated input voltage. You can see the real unloaded voltage peaks in the small box in the lower middle of the software. The amplifier will be working around the peak voltage most of time.

    I have also included +-15v for you and also output for fan motor

    If you have difficulty in understanding please ask and I will help you.

    Rayu.JPG
    Attached Files Attached Files
    Last edited by Silvio; 11-05-2018 at 10:32 PM.

  3. #1333
    thanks silvio i will try this calculation
    p.s.raju

  4. #1334
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    Quote Originally Posted by P.S.RAJU View Post
    thanks silvio i will try this calculation
    p.s.raju
    If you are using any auxiliary windings use also 0.5mm wire as in the data I forgot to change the wire diameter for these windings. However a single strand of 0.5mm is enough.

  5. #1335
    hi silvio thanks for your kind help i tried your winding data the voltage is coming perfectly with out load , but when i connect a load of amp of 1000watt the power supply
    igbt30n60a4d blows off and the supply becomes dead.

  6. #1336
    i also got the smps transformer winding tool (excellent(7100) from the forum ,and some one helped to how to use it ,
    in my calculation also the igbt blows off
    SMPS_Transformer_Winding.pdf
    the above pdf is a file found from the fourm this is etd49 winding detial out voltage is 50+-
    can you tell the frequency of this detial
    the above pdf data of transformer works perfectly with load also
    thanks
    Last edited by P.S.RAJU; 11-10-2018 at 07:38 PM. Reason: correction

  7. #1337
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    Quote Originally Posted by P.S.RAJU View Post
    i also got the smps transformer winding tool (excellent(7100) from the forum ,and some one helped to how to use it ,
    in my calculation also the igbt blows off
    SMPS_Transformer_Winding.pdf
    the above pdf is a file found from the fourm this is etd49 winding detial out voltage is 50+-
    can you tell the frequency of this detial
    the above pdf data of transformer works perfectly with load also
    thanks
    1) The switching frequency is 65Khz
    2) send some scope shots of the wave forms at the gates of the igbt. (measure one gate at a time and isolate the scope)
    3) load the smps gradually and use a lamp in series until you get things stable.
    4) post also schematic of the circuit you are using.
    5) Probably the IGBTs are blowing due to incorrect gate drive or because of noise entering the gates at high load.
    6) Post some pics of your pcb from top and bottom.

    Regards Silvio
    Last edited by Silvio; 11-12-2018 at 08:12 AM.

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