1kW smps project (based on MicrosiM design)

M

maxente

New member
Thank you Microsim and wally7856
I will test the SMPS with a bigger load, so far i tested with 6A load and post some results later
The schematic i use is this with no reation and no SMD
 

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M

maxente

New member
I tested the SMPS, with no load i have 116v, with 6A load i have 102v and with 8,22A load voltage remains at 98v
 
R

renotrend

Member
hi Microsim ,long time not post , i am plane to make big SMPS like +80vdc ct -80vdc*20A . i have part ,chip sg3525 & ir2110,IGBT irg4pc50u and 30n60a4d ,etd59 pc40 material ,recitifier RBV2506 for primer and FMU36 for sekunder ,capasitor primer 1800uf/200volt i have 4 pcs , email choper strands 0,10 x100 strand i have 50 meter. do you have suggest design such as how turn for primer and how freq osc and etc ,

thanks for your support,

regards,
Renotrend
 
MicrosiM

MicrosiM

Administrator
Staff member
renotrend said:
hi Microsim ,long time not post , i am plane to make big SMPS like +80vdc ct -80vdc*20A . i have part ,chip sg3525 & ir2110,IGBT irg4pc50u and 30n60a4d ,etd59 pc40 material ,recitifier RBV2506 for primer and FMU36 for sekunder ,capasitor primer 1800uf/200volt i have 4 pcs , email choper strands 0,10 x100 strand i have 50 meter. do you have suggest design such as how turn for primer and how freq osc and etc ,

thanks for your support,

regards,
Renotrend
Click to expand...


You can refer to _kaip_ schematics.

And 80Khz switching frequency. let me know if you will use ETD59 to give you the number of turns


regards
 
MicrosiM

MicrosiM

Administrator
Staff member
renotrend said:
thanks Microsim ,i will use ETD59 PC40 material .how turns for primer ?

regards,
Renotrend
Click to expand...


ETD59 @ 80Khz you will need:-

12 Turns for primary (half bridge SMPS)

6 Turns for 80V, that means 6 + 6 Turns for secondary

1 Turn = 13.3


All information's above are 90% accurate, due the line voltage changes, but this is exactly what you will need.


Let me know if you need more help
 
R

renotrend

Member
ok ,thanks Microsim for your guide . i will post result later .
i will make unregulated version.
i thinks that good result noise audible for audio amplifier
 
A

akraj

New member
Hi All:

I am designing a DC to DC Converter using ETD49 but the problem is FET's are becoming too hot and cosuming over current.

Bellow the is the specification:

Primary : 2X2 turns (Copper foil)
Secondary : 100 turns (22 AWG)
Freq : 28KHz
Input Viltage : 12V
Driver IC : SG3525 (Direct drive to FET's 22ohm gate resistor)

After rectification it provides 290V DC, without load current consumption is approx 100ma but if give 200W then it takes 25A and 288V!! Even at 400W load 286V.

Looking for ward for your expert opinion to find out the problem.

Cordially,
Raj
 
W

wally7856

New member
akraj said:
Hi All:

I am designing a DC to DC Converter using ETD49 but the problem is FET's are becoming too hot and cosuming over current.

Bellow the is the specification:

Primary : 2X2 turns (Copper foil)
Secondary : 100 turns (22 AWG)
Freq : 28KHz
Input Viltage : 12V
Driver IC : SG3525 (Direct drive to FET's 22ohm gate resistor)

After rectification it provides 290V DC, without load current consumption is approx 100ma but if give 200W then it takes 25A and 288V!! Even at 400W load 286V.

Looking for ward for your expert opinion to find out the problem.

Cordially,
Raj
Click to expand...


I assume your 12vdc comes from a battery being charged.

14.7vdc, 4, 28khz, 1400G, Ae 2.114 = 4.434 Turns
14.7vdc, 4, 28khz, 1500G, Ae 2.114 = 4.14 Turns
14.7vdc, 4, 28khz, 1550G, Ae 2.114 = 4.005 Turns
14.7vdc, 4, 28khz, 1600G, Ae 2.114 = 3.88 Turns
14.7vdc, 4, 28khz, 2000G, Ae 2.114 = 3.1 Turns
14.7vdc, 4, 28khz, 2100G, Ae 2.114 = 2.956 Turns
14.7vdc, 4, 28khz, 2600G, Ae 2.114 = 2.38 Turns
14.7vdc, 4, 28khz, 3000G, Ae 2.114 = 2.07 Turns
14.7vdc, 4, 28khz, 3100G, Ae 2.114 = 2.003 Turns

With 2x2 turns you are running 3100G, that is way to high.
With 3x3 turns you would have 2100G, This is high but will probably work.
With 4x4 turns you would have 1550G, This is a good safe Gauss level.

Also a 22 ohm gate resistor is probably to high also. You may not be turning the fet on fast enough. You may want to give us a schematic.
 
K

kaip

New member
Finally the boards arrived from China.
Chinese newyear delayed them by weeks....

20130227_170731.jpg 20130227_170801.jpg 20130304_103930.jpg 20130304_103943.jpg 20130304_104002.jpg

I don't have all the components yet but to give you an idea....

Found a small error with one of the blue status LED's on the output. It was the wrong way around.

Here is the latest version of the schematic (and board) with minimal components needed to make it just as Ludo and Microsim designed it here in this thread.
View attachment smps02 - Minimal.pdf

I have some extra 8 boards available for you guys.
Please send me a message if you 'd like one.
They're 20 EURO
 
A

akraj

New member
wally7856 said:
I assume your 12vdc comes from a battery being charged.

14.7vdc, 4, 28khz, 1400G, Ae 2.114 = 4.434 Turns
14.7vdc, 4, 28khz, 1500G, Ae 2.114 = 4.14 Turns
14.7vdc, 4, 28khz, 1550G, Ae 2.114 = 4.005 Turns
14.7vdc, 4, 28khz, 1600G, Ae 2.114 = 3.88 Turns
14.7vdc, 4, 28khz, 2000G, Ae 2.114 = 3.1 Turns
14.7vdc, 4, 28khz, 2100G, Ae 2.114 = 2.956 Turns
14.7vdc, 4, 28khz, 2600G, Ae 2.114 = 2.38 Turns
14.7vdc, 4, 28khz, 3000G, Ae 2.114 = 2.07 Turns
14.7vdc, 4, 28khz, 3100G, Ae 2.114 = 2.003 Turns

With 2x2 turns you are running 3100G, that is way to high.
With 3x3 turns you would have 2100G, This is high but will probably work.
With 4x4 turns you would have 1550G, This is a good safe Gauss level.

Also a 22 ohm gate resistor is probably to high also. You may not be turning the fet on fast enough. You may want to give us a schematic.
Click to expand...

Hi Wally:

Thanks a lot for your reply.

So far I know ETD49 can handle 4000G. I changed freq to 56KHz still the result is same. I checked wave shape and saw that gate driving is okay. Also used totem pole driving, same result. What is noticed is that FET's drain is not going back to 12 volt when is off. Even the gate is off, drain remains at 7 volts. That is why the loss is occurring. On the other hand other side is gets on and both drain collides somewhere at 8 volt level.

Back kick voltages to around 60v and comes down to 8 volt with some ripples. But rise to 12v is not sharp.

Any suggestion?

I have not saved any image, sorry for that. I will try to capture them next time.

Thanks
Raj
 
W

wally7856

New member
akraj said:
Hi Wally:

Thanks a lot for your reply.

So far I know ETD49 can handle 4000G. I changed freq to 56KHz still the result is same. I checked wave shape and saw that gate driving is okay. Also used totem pole driving, same result. What is noticed is that FET's drain is not going back to 12 volt when is off. Even the gate is off, drain remains at 7 volts. That is why the loss is occurring. On the other hand other side is gets on and both drain collides somewhere at 8 volt level.

Back kick voltages to around 60v and comes down to 8 volt with some ripples. But rise to 12v is not sharp.

Any suggestion?

I have not saved any image, sorry for that. I will try to capture them next time.

Thanks
Raj
Click to expand...


1) Post a schematic.

2) With 3x3 turns you would have 2100G, do not exceed this.

3) With no schematic my best guess is that you have your topologies mixed up. I think you have a half bridge driving your push pull and that is why you measure 7 to 8 volts on drain. Your center tap on the primary must be connected to a capacitor center tap.
 
A

akraj

New member
wally7856 said:
1) Post a schematic.

2) With 3x3 turns you would have 2100G, do not exceed this.

3) With no schematic my best guess is that you have your topologies mixed up. I think you have a half bridge driving your push pull and that is why you measure 7 to 8 volts on drain. Your center tap on the primary must be connected to a capacitor center tap.
Click to expand...


Hi Wally:

Attached is the schematics what I am trying to implement. Here you will not find SG3525 as the final will be done with a micro-controller. For testing I am using this this, just took output from SG3525 and given feedback with 680K.

I have good PWM and clean wave at gate and output voltage is stable (287V DC, 289V DC without load) even with 400W load.

I really appreciate your support.

Thanks
RajIPS_ETD49.jpgETD_Drive.jpg
 
W

wally7856

New member
akraj said:
Hi Wally:

Attached is the schematics what I am trying to implement. Here you will not find SG3525 as the final will be done with a micro-controller. For testing I am using this this, just took output from SG3525 and given feedback with 680K.

I have good PWM and clean wave at gate and output voltage is stable (287V DC, 289V DC without load) even with 400W load.

I really appreciate your support.

Thanks
RajView attachment 3552View attachment 3553
Click to expand...


I am glad it is working now.
 
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