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Old 21st January 2012, 08:45 PM   #21
DjLeco is offline DjLeco  Romania
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I decided to see, how many watts can carry IGBT's...

Same setup, dropping dummy load from 3 ohms till 1,5 ohms.

Choose 720p (HD) at youtube.


Leco SMPS passing 5 Kw barrier.MOV - YouTube

I saw peak of 27Amps on clampmeter , 25-26Amps sustained after 2 secs of max load , possible not seen in videoclip...

At start to load with 1,5 ohms on output I measured 109,23mV on shunt, corresponding to 54,61Amperes through load, output tension (on load) was 95,3V.

In that case, power was 54,61Amps x 95,3Volts = 5204,33Watts.


Some interesant pictures!

30Amps main fuse before use (new one):

http://postimage.org/image/ywmgvv0qj

30Amps main fuse before after test, compaired with another new one:


http://postimage.org/image/eqsm7u0sl/

Front shunt:

http://postimage.org/image/mv09t769n/

Back shunt, observing 2 x 3mm resistive material.

http://postimage.org/image/hh62ze5wd/

Last edited by DjLeco; 21st January 2012 at 09:10 PM.
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Old 21st January 2012, 11:54 PM   #22
luka is offline luka  Slovenia
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haha, that is funny amount of power...voltage seems to drop a lot at this power, but if you use this for full bridge amp, single rail, that is still good, for 1-2R loads
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Old 22nd January 2012, 01:04 AM   #23
DjLeco is offline DjLeco  Romania
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Trafo was winded just for tests, also litz used (600x0,071) cannot carry that amount of amperes (54 amps).

Next week, I will wind trafo for desidered use (+/- 95Vdc, Class AB, regulated), or +/- 180Vdc, class D, I or TD, unregulated, and will see.

So 5200Watts obtained from a half bridge, at 62,5 Khz, also for a small ETD 59 core, I consider to be big amount of power, also alot of headroom, for 3500 watts demanded power, no?

I tried also to put 1 ohm on load (for 5200 watts was around 1,5 ohm load, excluding thermal derive of resistors), but IGBT, cannot resist ...

What's happened, you can watch here, also U will understand why I have uset that song before testing, knowing myself about final act...

Before watch mine movie, please watch fisrt 30 seconds from next clip

http://www.youtube.com/watch?v=hx4DdoSgWJ0


Mine movie, when I lowered dummy load till 1 ohm...

http://www.youtube.com/watch?v=d4H1Z...ature=youtu.be


IGBT, fallen on duty:

http://postimage.org/image/astwplz01/

Who liked that song, grab from here:

http://www.2shared.com/file/EWHQ0HYC...ch_versio.html

Last edited by DjLeco; 22nd January 2012 at 01:10 AM.
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Old 22nd January 2012, 09:35 AM   #24
luka is offline luka  Slovenia
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I consider etd59 to be pretty good size for a core, not really small anymore, but the amount of power at that freq is more then I was thinking it could do

I will watch videos later, when I get home, to normal internet

thanks for making videos, always nice too see them, and your crazy powers
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Old 22nd January 2012, 03:52 PM   #25
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Bad boy!
Quote:
Originally Posted by DjLeco View Post
IGBT, fallen on duty:
Definitely the nicest description, available

Which average or continuous output power do you target in relation to max power? ==> Thermal design.
Or do you design for certain load/no load duty cycle?
Which is the worst condition that you expect - i.e. for dubstep?

Example:
Let's assume a PSU for a class D amp with 1kW.
Further assuming the class D amp may run with an efficacy of 90%.
If we would like to reproduce a continuous sine wave, then the PSU would need to have the following capabilities:
Average continuous power: 1.11kW
Instant power: 2.22kW (factor two from the ideal ratio of max instant power vs average power of a sine wave, assuming 20Hz the required times would be already in the tens of ms.)
There is no reasonable way to avoid the short term demand of factor two, except we would place really unsaint output caps. So we have to do an electrical design that can handle 2.22kW. But for the thermal design, I am convinced that massively lower requirements can be applied.
A PSU for an 1kW amp does not need to be able to deliver continuous 1.11kW, because music is not a continuous sine wave. So the thermal design does not need to allow continuous operation at 1.11kW, or even worse 2.22kW ON/OFF 25ms/25ms.
My question is for which average load or may be which load duty cycle do we need to do the thermal design?
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Old 22nd January 2012, 06:35 PM   #26
DjLeco is offline DjLeco  Romania
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Man,the heatsink will be much bigger, the one I used on test, measures 10 cm, final heatsink will have 30 Cm, exact one that I have used at mine modules.

No problem of heat, because smps will be progressive controlled fan, cooled, depending on temperature of trafo and main heatsink.

I tested alot of amplifiers with SMPS, wich loaded 1/2 like I loaded mine, go into protection mode...

Others dropp alot, the only one SMPS that stays ROCK SOLID, was the one of I-tech series Crown Amplifiers.

In rest, many dissapointings...

I'm very satisfied with mine results.

I'm intending to use one smps per one 3000Watts TD or D class amplifier, wich I will develop soon, or for 2 or 4 AB class modules of 800Watts/4 ohm.

Must take in consideration, the music signal, of any type, including dubstep or reggae, will not load smps that hard , as I have tested.

Tomorrow I will replace faulty IGBT's, to adjust protection (overcurent) and thermal protection too.

Keep close
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Old 22nd January 2012, 09:30 PM   #27
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Quote:
Originally Posted by DjLeco View Post
No problem of heat, because smps will be progressive controlled fan, cooled, depending on temperature of trafo and main heatsink.
That's likely to be pretty helpful.
On the other hand it sounds to me that you simply make it tougher than required in order to stay trouble free.
I also tend to settle my private designs more on the rugged side, but nevertheless I was curious about numbers to hit the point which is really needed.
Of course there are the standard rules like for PA (1/3) or HiFi (1/8),
but I was interested in your view.


[QUOTE=DjLeco;2873760]
In rest, many dissapointings....
[QUOTE=DjLeco;2873760]
No wonder. In commercial projects the engineers are forced to cut costs by design until the customers start to complain.
As long as nobody complains, the engineer will be blamed for expensive overdesign.
The art of business R&D is to know, where you can cut - and where you better do not cut...

...I am a bloody Idiot, starting to apply business considerations in my hobby, while I feel that one of the main relaxing factors of a hobby is: No business considerations.
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Old 22nd January 2012, 10:05 PM   #28
DjLeco is offline DjLeco  Romania
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Quote:
Originally Posted by ChocoHolic View Post
...I am a bloody Idiot, starting to apply business considerations in my hobby, while I feel that one of the main relaxing factors of a hobby is: No business considerations.
Good said!
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Old 24th May 2012, 12:58 AM   #29
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DjLeco, do you intend to sell those amps and SMPS ? Or maybe you develop them just for personal use ?
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Old 24th May 2012, 07:29 PM   #30
DjLeco is offline DjLeco  Romania
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Also for selling, now, waiting for PCB's to arrive...
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