1kW smps project (based on MicrosiM design)

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badboy_6120

Member
badboy_6120 said:
OK no problem at all
I will re-learn the eagle because I used it about a few years ago and since then I work with express pcb
I'll make the eagle file

but first I need to run the protection part

because I'm going to bring the protection part in the main pcb (just one pcb for this smps)


tomorrow(I'm very sleepy and here it's 4:15 am) I will test the smps with 1kw load for an hour with large heatsink and if everything goes well, I'll start with protection part

Regards
Click to expand...


I think eagle is more popular than this
But whatever you say
please test it and let me know about it

regards
 
MicrosiM

MicrosiM

Administrator
Staff member
You don't have to test the SMPS @ 1kW for 1 Hour!

If it passes the 750W test for 30 minutes, the you are good to go.

You can conduct the test for experiments, but you may burn things without a proper cooling.

Good luck
 
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badboy_6120

Member
MicrosiM said:
You don't have to test the SMPS @ 1kW for 1 Hour!

If it passes the 750W test for 30 minutes, the you are good to go.

You can conduct the test for experiments, but you may burn things without a proper cooling.

Good luck
Click to expand...

I know it will produce a lot of heat and I think my heatsink will be perfect for the job
I won't turn around for a secend and will monitor the component temperature second by second
I want to make sure if anythink besides temperature won't go wrong in that much power
 
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badboy_6120

Member
Dear microsim

I want to power up the smps with 1KW load but the AC RMS current drawn from input is about 7 Amp at that much power in the output
Can the mosfets stand that much current???(I don't want them to burn internally)
I won't let the heatsink temperature to reach 80"C
 
MicrosiM

MicrosiM

Administrator
Staff member
badboy_6120 said:
Dear microsim

I want to power up the smps with 1KW load but the AC RMS current drawn from input is about 7 Amp at that much power in the output
Can the mosfets stand that much current???(I don't want them to burn internally)
I won't let the heatsink temperature to reach 80"C
Click to expand...

I don't know witch Mosfets you are using.

But if you are using IRF460, they will not hold for too long. for power above 600W I advice you to use IGBTs.


Regards
 
MicrosiM

MicrosiM

Administrator
Staff member
vdij said:
Yes, try G20N50. to 40kHz, above - resonance SMPS.
Click to expand...

Until now, and from my long research, and after investigating many commercial SMPS units.

I never saw any SMPS running above 100KHz, that have nice and clean waves across S+D while the SMPS is loaded.

specially those found into audio amplifiers.
 
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badboy_6120

Member
Hello everyone

I'm back with some test results:

Temperature of components after 1 hour driving a 600W load exactly

Mosfets: 60ºC
Output Diodes : 50ºC
input Bridge without any heatsink : 92ºC
Transformer cores: 60ºC

Is the transformer's temp Ok for this much power??
 
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badboy_6120

Member
MicrosiM said:
I don't know witch Mosfets you are using.

But if you are using IRF460, they will not hold for too long. for power above 600W I advice you to use IGBTs.


Regards
Click to expand...

Yes, that's the drivers I'm using

My supplier has these IGBTs:
1- FGL60N100
2- K75T60
3- IRGP4066
4- FGL40N120
5- FGH40n60

Witch one do you recomment for at least 1000W continues????

Dear Microsim How did you get to 600W for irfp460??? did you calculate it or you know it be experience?

I know that the maximum flat top parts of pulses on primary( and therefore on mosfets) is calculated by below equation:

I=(3.13 x Po)/Vdc

and
Vdc=(1.41x220)/1.1/1.15

For a output power of 1000W we'll get:

Vdc=(1.41x220)/1.1/1.15 >>> Vdc=245V
I=(3.13x1000)/245 >>> = 12.7A

The datasheet of IRFP460 says that the current in 25°c=20A and in 100°c=13A
Am I doing something wrong???
Please help me understand this

Thank you in advance
 
Last edited:
MicrosiM

MicrosiM

Administrator
Staff member
badboy_6120 said:
Yes, that's the drivers I'm using

My supplier has these IGBTs:
1- FGL60N100
2- K75T60
3- IRGP4066
4- FGL40N120
5- FGH40n60

Witch one do you recomment for at least 1000W continues????

Dear Microsim How did you get to 600W for irfp460??? did you calculate it or you know it be experience?

I know that the maximum flat top parts of pulses on primary( and therefore on mosfets) is calculated by below equation:

I=(3.13 x Po)/Vdc

and
Vdc=(1.41x220)/1.1/1.15

For a output power of 1000W we'll get:

Vdc=(1.41x220)/1.1/1.15 >>> Vdc=245V
I=(3.13x1000)/245 >>> = 12.7A

The datasheet of IRFP460 says that the current in 25°c=20A and in 100°c=13A
Am I doing something wrong???
Please help me understand this

Thank you in advance
Click to expand...


If you know how to tune your switching losses, then the IRFP460 will hold 600W.

I am in the progress of finalizing my 600W SMPS in a week or two, will try to post a small video or maybe some pictures.


Regards
 
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