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Old 13th January 2012, 02:29 PM   #11
DjLeco is offline DjLeco  Romania
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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 175-250Vac.

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.
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Old 13th January 2012, 06:04 PM   #12
luka is offline luka  Slovenia
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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!
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Old 20th January 2012, 12:25 AM   #13
DjLeco is offline DjLeco  Romania
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Quote:
Originally Posted by luka View Post
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!
Sure I will!

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 109-110Vdc 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.
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Old 20th January 2012, 07:36 AM   #14
luka is offline luka  Slovenia
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this is great, but waveforms or output ripple is unknown
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Old 20th January 2012, 10:23 AM   #15
DjLeco is offline DjLeco  Romania
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Quote:
Originally Posted by luka View Post
this is great, but waveforms or output ripple is unknown
I made a small movie, loaded with 3500 watts, but in that test, smps is unregulated!


Out ripple.MOV - YouTube

Storage capacitor:

Click the image to open in full size.
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Old 20th January 2012, 10:27 AM   #16
luka is offline luka  Slovenia
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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
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Old 20th January 2012, 03:19 PM   #17
DjLeco is offline DjLeco  Romania
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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=KrenN56u-GY

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.
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Old 20th January 2012, 03:24 PM   #18
luka is offline luka  Slovenia
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yea, about 5kw is what I hear you can get from 59... and you have showed it also
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Old 21st January 2012, 03:36 PM   #19
DjLeco is offline DjLeco  Romania
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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:

Click the image to open in full size.

Click the image to open in full size.



multimeters at 300Vdc :

Click the image to open in full size.

Click the image to open in full size.



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 ...



Click the image to open in full size.

Click the image to open in full size.





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 Leco-001.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.
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Old 21st January 2012, 05:27 PM   #20
DjLeco is offline DjLeco  Romania
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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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