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Thread: diy 500W smps with voltage or current regulation

  1. #1

    diy 500W smps with voltage or current regulation

    Hi folks

    I need make smps for some heater 450W (500W) who need work sometimes several hours ( max 16 hours on day with that 450 - 500W ) .
    Input voltage 230 V
    Output voltage 16 - 24 V (need have voltage regulation for secondary side ) , secondary side not need have rectification .
    Output current 20 A
    Heating element have 1.3 Ohm resistance (power will change with voltage or current regulation on smps )
    Min working time on day 8 hours constant , max working time 16 hours on day .

    That can be maybe options like switch transformers for halogen lamp.

    Can you give me yours suggestion , or share some circuit diagram and data for diy it ?

    I need say that I m make only one smps before 3 years for some LED lamp , and my experience is very small with smps devices .

    Thanks all

  2. #2
    Hi

    Anyone have some suggestion ?

    For start will be fine if some one have any circuit diagram who will be start point .
    I am found on this forum one circuit diagram who look like nice start options .

    Mikro uni.GIF
    Last edited by mojalovaa; 03-27-2017 at 10:51 AM.

  3. #3
    No one have say something for start help ?

    If I wont use top circuit diagram , can I use for start this transistors : http://si.farnell.com/multicomp/bu42...247/dp/9294112 .
    All so for core for transformers , if I wont have 500W power , who dimension for core need be minimum , I m look something like this : http://www.ebay.com/itm/1ste-E4215-F...oAAOSwImRYfXNs

    Please if some one is make this smps , can share more information with me , like number of turn and similar ?

  4. #4
    diysmps Senior Member Silvio's Avatar
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    You got all the information you need in the schematic and parts list. you also got the number of turns for transformer and also for the output inductors

  5. #5
    Thanks Silvio

    I see that , but if you are look better that I m write with voltage or current regulation .

    On my case I need have options for regulation min and max voltage or current value on secondary wind .

    For sample , if max current on my smps is 21 A , then need options that can all so change that current for sample from 10 A min to 21A max , or if is not possible current then voltage for sample form 14 to 24 V .

  6. #6
    diysmps Senior Member Silvio's Avatar
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    You got all the information you need in the schematic and parts list. you also got the number of turns for transformer and also for the output inductors.

    With EE 42 core you can get 500 watts all day

    The transistors can handle 6 amps continuous so at 155vdc @ 6 amps = 930 watts. they can handle the power easy.

    I can help you with the number of turns but the data I have is for PC40 which is equivalent to CF139. It should more or less near.

    Regulation of the output voltage however is not available with the circuit shown as this is a self oscillation circuit with no regulation of frequency and neither output voltage.
    why don't you look for a circuit with sg3525 or TL494 chip. These will be more complicated but will better in the end for your need of application.
    If you want to build an smps you need to have an oscilloscope otherwise you cannot see what is happening in your circuit. You also need an isolation transformer so that you will be safe while tweeking your smps. High voltage is present and is lethal (320vdc)

    If you are a beginner like me I would suggest that you start with something simple as a lot of surprises await you until you learn.

    One last thing if you want a 24v supply you can always buy a ready made one which can handle the power you need continuous. Most of them will be regulated.

    Please read SMPS warnings in the menu bar as smps do not joke when they blow and are dangerous.

    Regards,

    Silvio

  7. #7
    Hi folks

    After few day searching who options will be the best for my SMPS with voltage or current regulation I have dilemma .

    First options that I m think make is with UC3842 , have you experience with that IC , and what is opinions for that options ?
    Second options is that I use TEA1507 , that IC have better efficiency but all so not see that people us it allot for diy version , what is opinions for that IC ?

    smps-fig3.gifUC3842 flaybuck.png

  8. #8
    diysmps Senior Member Silvio's Avatar
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    Quote Originally Posted by mojalovaa View Post
    Hi folks

    After few day searching who options will be the best for my SMPS with voltage or current regulation I have dilemma .

    First options that I m think make is with UC3842 , have you experience with that IC , and what is opinions for that options ?
    Second options is that I use TEA1507 , that IC have better efficiency but all so not see that people us it allot for diy version , what is opinions for that IC ?

    smps-fig3.gifUC3842 flaybuck.png
    Hello again. I was just wondering if you really need this smps for a heater, well If you come by an old microwave oven that has been discarded you can use the transformer in it and modify it to your needs. You will remove the secondary high voltage winding and re wind it with some insulated wire you will easily get 500 watts out of it. Try to keep things simple. You can make some tappings in the secondary windings to regulate the wattage drawn by the heater.

    Coming back to your suggestions regarding the chips you mentioned as you can see they are forward converters and using only one transistor to drive the winding. It is quite some load for a forward converter and if you opt for half bridge topology I guess you will get better results. I will post you a link where you can find a good power supply. It is from 320volt.com You can adopt to use your EE44 transformer instead of the one shown and as for transistors you can use irf 450 or irf 460 these are cheap to buy and can give you a lot of power. You can adopt the circuit with different zener diodes to get a switchable voltage selection hence the heating control.

    Link http://320volt.com/en/700w-800w-900w...sg3525-ir2110/

    Regards

  9. #9
    Hi

    Today I m make one transformers for my SMPS , but I m little confused because have very thick wire on primary and all so on secondary side .
    For primary side I m use 6x 0.425 mm2 wire and for secondary side need be used 27 x 0.425 mm2 wire , that is total confuse me because almost is impossible put that on ETD44 core .

    I wont use UC3842 for switch FET .

    This calculation for transformers is OK ?

    DSC_0187.JPG



    smps transformers calculation.jpgsmps transformers calculation.jpg

  10. #10
    diysmps Senior Member Silvio's Avatar
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    Hello, arrange your current density in the software to 4A/mm^2 for continuous use, and 6 to 7A/mm^2 for 50% duty cycle without cooling. If you use cooling fan on transformer you can use 7A/mm2 for continuous use.

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