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Thread: 1000w smps based on LUDO3232

  1. #11
    .... Silvio's Avatar
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    Hi Lucas, I made my first test today though I did not receive the output caps and had only a couple of 470uf at 200v that I put on temporarily. I adjusted the ringing and fitted the snubbers on the drain source of the switching fets. I did some experimentation with different values and found the best combination with the smps loaded at around 400 watts. I managed to get around 1100watts out of it with resistive loads attached to the output. Load was 9 amp at 122 volts. However the output of the isolation trafo is rated at 200 volts and and not 220 as I first taught it is. I guess I have to add a few turns to it to get 220 at least. My set up was with and isolated oscilloscope and with the isolation power transformer. I still have to try it on mains. My output voltage is calculated at 78-0-78 with 230 volts input. getting within the ripple at load I guess it will sag to about 130-140 volts on full load. I also adjusted the over current protection and made it work on 10 amp load


    Schematic 1000w.pdf

  2. #12
    .... Silvio's Avatar
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    1000 watt SMPS based on LUDO 3232 Schematics but with a different arrangement

    This power supply works like a charm and pushed out over 1100 watts. The output voltage was designed for 80-0-80 at 225 volts AC however it will rise to 180 with 235 volts but keeping in mind that it will sag a bit on load thus keeping in the 80 volt region when loaded. I will post a video of the end result when I receive the output caps. The short circuit protection works like a charm and can be adjusted without a lot of hustle, 3 cheers for LUDO for this. The CPU heat sink does it job fine especially when on heavy load and the temperature stays rather cool at say 30-35 degrees C with the fan on. The heat sink was positioned so that it also cools the trafo as the current density of the copper wire is 6 amps per square mm. The efficiency was calculated at 96% when fully loaded. I am posting the full Schematics, PCB, Component layout etc. so one can replicate.

    I would like to thank MicrosiM , LUDO and especially Wally for the helpful advice given during this SMPS build


    All information is in the PDF file attached.

    1000W smps final.pdf
    Last edited by Silvio; 12-18-2016 at 12:35 AM.

  3. #13
    @ Silvio

    Very nice design, great results.
    www.diysmps.com & www.Micro-Audio.com

  4. #14
    .... Silvio's Avatar
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    Adding a few turns to rise the output of the isolation trafo

    IMG_0385.JPG

    Checking input and output voltages for comparison

    IMG_0387.jpg IMG_0389.JPG

  5. #15
    .... Silvio's Avatar
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    1000 watt SMPS based on LUDO 3232 Schematics LOAD TEST

    Here is the Load test of the 1000 watt SMPS


  6. #16
    Hi Silvio,

    Very nice project, congrat...
    How can I change the number of windings in the secondary for the main voltage +/- 28V 30Amps?
    Any help is welcomed :

  7. #17
    .... Silvio's Avatar
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    Hi Villenjak, yes you could change the winding to +/- 28v but you have to give me some details about the core used and the switching frequency and also the mains input voltage. You can also go to switching power supply informations on this site and there is an XL sheet which can calculate the number of turns needed.

    Regards,

    Silvio

  8. #18
    Hi Silvio,
    I would not change the core (ETD49) and freq. Mains input is 220VAC. Can I change your diagram as attached?

    change.bmp

  9. #19
    .... Silvio's Avatar
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    Quote Originally Posted by villenjak View Post
    Hi Silvio,
    I would not change the core (ETD49) and freq. Mains input is 220VAC. Can I change your diagram as attached?

    change.bmp
    Yes you can change the diagram as attached.
    1 what core material are you using? (N87, N27, 3c90, etc) Please specify
    2 what Power do you need on the main output?
    3 What power do you need on the 5v rail.
    4 Is the SMPS used for audio?
    5 What maximum voltage the amplifier can take? (Please note that the voltage will drop on load as my schematic is not regulated)
    6 Are you using my PCB layout with cpu heatsink?
    7 do you need aux power for fan and soft start delay?

    Please answer all the questions carefully and I will work out for you the number of turns/wire gauge etc for your transformer

    Regards

    Silvio

  10. #20
    Hi Silvio,
    I'll try to answer all questions:
    1. N87
    2. 900W max.
    3. 25W max.
    4. No. For UHF linear power amplifier (class AB) 200W SSB (to start, later 400W)
    5. 28V max.
    6. Yes
    7. Yes (maybe 12v)

    I hope you can help me

    Regards

    Villenjak

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