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

  1. #301
    i have also made smps like yours in post 295 and i have blow lots of ir2153 with that schematic...
    This is true, if you mean the schematic found in the application note.

    until i made a seperated 15v supply to the ir2153 and i have not blow a single ic since that...
    In schematic published by us, there is a separated +15VDC supply

    i let the ir2153 start first and then i connect with soft start the main efter about 2-3 sec, hope this could help you a little bit...

    Thats a major trick into the IR2153, the turn on delay issue. + the shut down issue + Huge current draw from primary of transformer due the missing soft start in that chip.

    It is simple, but with limitations, see ludo notes, he finally switched to another one wit SG +IR
    www.diysmps.com & www.Micro-Audio.com

  2. #302
    diysmps Member* giololucas's Avatar
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    Quote Originally Posted by uglykid View Post
    hi giololucas.

    i have also made smps like yours in post 295 and i have blow lots of ir2153 with that schematic... until i made a seperated 15v supply to the ir2153 and i have not blow a single ic since that... i let the ir2153 start first and then i connect with soft start the main efter about 2-3 sec, hope this could help you a little bit...

    ugly
    Hi uglykid
    When it blew up I was running test same way as you said, and MicrosiM said it too.
    Its my falt not post a schematic here... .

    I think the problem was a ironing flux I have used (yellow paste), it short circuits in the board, specially in HI voltages...

    Yesterday I cleaned and fixed it.
    After initial tests with series lamps resistors and others, I runned a 3 min x 220W load (32VCC; 4R7 load; 6,87A) everything seems to be ok .

    If I have a time, tonigth I will run a longer test (15min) and post pics here.

    Thank you for your help.
    Last edited by giololucas; 08-17-2011 at 06:54 PM.

  3. #303
    diysmps Member* niss_man's Avatar
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    Hi Microsim

    I am still waiting on some of my parts for the smps but am partly done. Would I be able to use this core and bobbin from a tv transformer I have recycled. The core has a gap in it as shown in the photo and is 42mm long x 15mm thick x 21.8mm tall for each half. Would this be suitable for a 600w transformer maybe. Also if I want to build a smps with this 2nd hand transformer, am I able to use the same pcb (ludo's) with modification to fit the smaller transformer instead of the etd49? (Are all other parts the same?).

    Regards

    Niss_man
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  4. #304
    Quote Originally Posted by niss_man View Post
    Hi Microsim

    I am still waiting on some of my parts for the smps but am partly done. Would I be able to use this core and bobbin from a tv transformer I have recycled. The core has a gap in it as shown in the photo and is 42mm long x 15mm thick x 21.8mm tall for each half. Would this be suitable for a 600w transformer maybe. Also if I want to build a smps with this 2nd hand transformer, am I able to use the same pcb (ludo's) with modification to fit the smaller transformer instead of the etd49? (Are all other parts the same?).

    Regards

    Niss_man

    Yes you can use same parts, but regarding transformer, I dont know if it will work or not, but you can give it a try, and you can test at 90VAC at first and we can later tell if it works or not.

    Just complete your PCB, and make sure its working, then we skip to the transformer side!
    www.diysmps.com & www.Micro-Audio.com

  5. #305
    diysmps Member* giololucas's Avatar
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    Pcb 800w smps

    Hi everybody

    MicrosiM,
    Here is the first PCB for my SMPS.
    Transformer is the same Ive posted here, its capable of 1000W at 80Khz.
    In my first prototipe in a breadboard, it handled 250W with fan in the secondary diodes.

    Im thinking in use a 4,7R x 20A thermistor instead of using 68R resistor + relay, what do you mind?

    Waiting for comments.
    Thanks.
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    Last edited by giololucas; 08-24-2011 at 01:45 PM.

  6. #306
    Here is the first PCB for my SMPS.

    Looks OK to me, as a start and its better than wires

    Transformer is the same Ive posted here, its capable of 1000W at 80Khz.

    where did you get this info from?

    In my first prototipe in a breadboard, it handled 250W with fan in the secondary diodes.

    Let me know heat of mosftes, and type of load you have used

    Im thinking in use a 4,7R x 20A thermistor instead of using 68R resistor + relay, what do you mind?

    What is that, what is the purpose of that into your SMPS, its not clear to me
    www.diysmps.com & www.Micro-Audio.com

  7. #307
    diysmps Member* niss_man's Avatar
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    I have some pcb left over from my amps I am building but have not got enough to make a smps the same size as ludo's smps. I would like to use my transformer from my picture from post#303 and am hoping for around 600w rms. Has anyone got a design for a pcb I could make to achieve this goal.
    I have 2 pieces of pcb left, 1 is 12cm x 30cm, and other is 12cm x 15.cm.

    Regards

    Simon

  8. #308
    diysmps Member* giololucas's Avatar
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    Quote Originally Posted by MicrosiM View Post
    Here is the first PCB for my SMPS.

    Looks OK to me, as a start and its better than wires

    Transformer is the same Ive posted here, its capable of 1000W at 80Khz.
    where did you get this info from?
    This is get from a formula result prensented in magnetics design catalog. This formula is based in Wa x Wc product, this method is mentioned also in Pressman switchmode book.

    In my first prototipe in a breadboard, it handled 250W with fan in the secondary diodes.
    Let me know heat of mosftes, and type of load you have used
    IRF840 for initial tests (if blow its less expensive than IRFPs...). Temp was less than 60C with small heatsink and no fan.

    Im thinking in use a 4,7R x 20A thermistor instead of using 68R resistor + relay, what do you mind?
    What is that, what is the purpose of that into your SMPS, its not clear to me
    Thermistor is a NTC used to limit the inrush current in mains caps. When its cold, resistance is 4,7R. When current flows its temperature rises and resistance goes low, allowing normal flux to the circuit.
    Thank you, Ive made silk screen pcbs yesterday late I will post it.
    Last edited by giololucas; 08-25-2011 at 12:09 PM.

  9. #309
    diysmps Member* giololucas's Avatar
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    Pcb 800w smps

    Here are pics of silk screen home made board.
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  10. #310
    diysmps Member* niss_man's Avatar
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    A simple question regarding the core halves of the transformer. I have asked this previously and was told to buy 2 halfs, both non gapped. Is this correct or do I need one half gapped and the other half non gapped? I just need clarification that's all.

    Regards

    niss_man

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