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13th January 2012, 02:29 PM  #11 
diyAudio Member

Main voltage is 220 volts.
Yes , I will use smps's for mine modules, also for selling. What you see, is a small experiment, just for tests, final work will be very nice. Being regulated, it will offer constant tension on output in range of 175250Vac. Momentanly, I don;t have with what to measure efficiency, I will try a derivation, using clampmeter, ampermeter, voltmeter and shunt. Soon, test with fullbridge topology, with new windings on secondary and primary, made from litzwire 600 x 0.07 litz, or cooper foil of 37mm x 0,1mm. Keep close. 
13th January 2012, 06:04 PM  #12 
diyAudio Member

Leco, ignore those that want it to be something its not
your smps is awsome, I hope to see pcb and some waveforms during video Again, good job! 
20th January 2012, 12:25 AM  #13  
diyAudio Member

Quote:
Thanks for appreciation, my friend! Now, last test before send it for PCB design, and full realisation: I'm staying on Half Bridge, resonant mode topology. On first movie, we have around 109110Vdc on output on 3 dummy load 1 ohm/1000W resistors seried connected (3 ohm total). For avoiding inadequate measurements caused by tolerance of thermal derive of resistors when heating, I used 100mV/50Amps shunt, so when we have 100mV dropping on shunt, curent is 50 Amps. On first movie, in this case we have 65,17 mV on shunt, output is 109,8Vdc on dummy load. If at 100mV on shunt, we have 50Amps, at 65,17mV we will have 50 x 65,17/100= 32,585Amps In this case power was 109,8Vcc x 32,585A = 3577W The test at 3500W Smps 3500W.MOV  YouTube Now let's make last test. The test at 3500W Values are 93,2 mV on shunt, so at 93,2mV we will have 46,6A and dc out dummy load is 103,2V, total power being 103,2Volts x 46,6Amps = 4809 watts. Leco SMPS Max Load  YouTube Last edited by DjLeco; 20th January 2012 at 12:28 AM. 

20th January 2012, 07:36 AM  #14 
diyAudio Member

this is great, but waveforms or output ripple is unknown

20th January 2012, 10:23 AM  #15 
diyAudio Member

I made a small movie, loaded with 3500 watts, but in that test, smps is unregulated!
Out ripple.MOV  YouTube Storage capacitor: 
20th January 2012, 10:27 AM  #16 
diyAudio Member

why did you put it in unregulated mode?
I think I see primary ripple comming to secondary , totaly normal, I just don't see, what were V/div settings 
20th January 2012, 03:19 PM  #17 
diyAudio Member

I put in unregulated mode, because I just want to see, maximum output power, without any limmitings.
Also protection was disabled. I have LLC resonant mode SMPS, output with ground coupled, and just 3x470uF/450Vdc capacitors in parralel (equivalent of 2x1500uF seried capacitors), I don't use median coupling (200 Volts seried capacitors), because I don't ever need to use for 110Vac supply (voltage doubler), configuration. I think 4800 Watts of pure power sustained is OK, from a ETD59 core... I'm intended to use it for 3500 watts continuous (well cooled) with 4000Watts peak, before shut down (protect mode). That smps will supply mine class AB modules amplifier 2 or 4 channels (bridgeable) , or one 3000watts TD class amps (wich I will develop, soon). AB Class almost 1700Watts/2 ohm: http://www.youtube.com/watch?v=KrenN56uGY TD Class, almost 3000Watts /4 ohm, before smps shut down, protection set around 3500 watts: http://www.youtube.com/watch?v=guoLw...layer_embedded http://postimage.org/image/2zhjtkx0k/ Last edited by DjLeco; 20th January 2012 at 03:34 PM. 
20th January 2012, 03:24 PM  #18 
diyAudio Member

yea, about 5kw is what I hear you can get from 59... and you have showed it also

21st January 2012, 03:36 PM  #19 
diyAudio Member

I did some tests so try a guide to the approximate calculation of the efficiency of the SMPS, I have the three measurement devices on the same power supply (9V battery brand new) to see how each display, and whether there are differences between them:
multimeters at 9Vdc battery: multimeters at 300Vdc : The only measurement where I noticed a slight difference between devices was to measure DC current between the two multimeters (I measured a current through the resistance of 10 ohm to 13.2 VDC powered stabilized) as will be seen in pictures below. Metrahit show a current 1,316 A and M890G show 1.27 A. That is why I chose to do the movie 2, where I have replaced each measurement devices between them ... Now go to see movies, where I extracted and calculated efficiency, obtained by power obtained,dividing by power consumed. I used the ampermeter seried and voltmeter parraleled with SMPS primary input in order to accurately measure the power consumed by the ratio P = UxI. I used the ampermeter seried and voltmeter parraleled on SMPS output, loaded with dummy load , to measure the exact power obtained by the ratio P = UxI. Movie 1 SMPS loaded with 700 + W : Test 1 Randament SMPS Leco.MOV  YouTube Test 1 with Metrahit in primary Primary 296Vdc x 2.55 Amps = 754.8 Watts power consumption Secondary 120.7Vdc x 5.95 Amps = 718.165 Watts power obtained Efficiency 95.14% Continuing movie, above min 3, SMPS is loaded more than 1300Watts Primary 288Vdc x 4,726Amps = 1361,088 Watts power consumption Secondary 116,3Vdc x 11,17Amps = 1299,071 Watts power obtained Efficiency 95.44% Now I changed measurement units between them, Metrahit in secondary and primary M890G in. Movie 2, Metrahit in secondary Test 3 Randament SMPS Leco001.mkv  YouTube Primary 288Vdc x 2,55Amps = 759,9 Watts adding 2,6W losses on main rectifier bridge results 762,5W total power consumption Secondary 121,9Vdc x 6Amps = 731,4 Watts power obtained Efficiency 95.92%, Remember, in any of the tests, SMPS was UNVENTILATED! Last edited by DjLeco; 21st January 2012 at 03:39 PM. 
21st January 2012, 05:27 PM  #20 
diyAudio Member

Sorry for bad pictures above, cannot edit...
View image: Aparate Masura View image: Aparate masura detaliu View image: Tensiune secundar 300 Vcc View image: Detaliu tensiune secundar 300 Vcc View image: Curent Metrahit View image: Curent M890 G 
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