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Old 25th May 2012, 07:19 AM   #31
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Quote:
Originally Posted by DjLeco View Post
Man, it was just a simple test; final one, I think will be full bridge for 1/2 curent on primary, and less Ic on output switching devices.
In that test, I was limmited from small heatsink of rectifier diodes, and resonant capacitor curent cappability...

I have very low loss on switching devices, gratefully almost perfect drive of it, very low rise and fall times.

Look here:

Proper IGBT driving, on mine SMPS (100Khz half bridhe resonant soft switching mode)


Observe ULTRAFAST switching, very low rise and fall timmings.

View image: DSCN5197

Tomorrob (today better said) I will try full bridge tipology, at 62,5 , 100 , and 125 Khz.

Mine IGBT;s are WARP ones (150Khz hard switching, 300 Khz soft switching).

Not interested to use mosfets, due internal body diode, also I don;t want to complicate output topology with schottky and antiparralel diodes too.

All modern SMPS, uses IGBT, or combination of mixed IGBT with mosfet too, also not interested...

Simple one, is most time, the efficient one!

If I lose under 100 Watts per total SMPS at 4000W total load, randament is HUGE, also, musical power is not more than 1/2 from a pure sin wave, or dummy load as I tested.

Next time, I will use, maybe bigger power resistors for dummy load, for longer time testing, If I keept that test, mine 4 ohms resistor will melt itself...
So you switch more than 300V at 10ns rise time (30kV/us) and 15ns fall time (20kV/us) ?
If really so I suggest you slow it down, efficiency is important, but so is EMI.
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Old 4th June 2012, 10:17 PM   #32
DjLeco is offline DjLeco  Romania
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EMI is not so important to me, being resonant mode, and with 2 bobbins at 220Vac main supply (filter) is enough.
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Old 3rd November 2012, 05:24 PM   #33
DjLeco is offline DjLeco  Romania
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Finally PCB's arived!

I have mounted some components...

View image: DSCN6166

View image: DSCN6167

View image: DSCN6172

View image: Aux Supply OK

Click the image to open in full size.

Click the image to open in full size.

Click the image to open in full size.

Click the image to open in full size.

Output tensions:

View image: Outputs configuration

Testing signal on IGBT's gates+delay+softstart:

Leco SMPS SoftStart+Delay+Thermal Protection - YouTube

And some final tests, loading till 4300Watts:


Leco SMPS Final Part 1 - YouTube

Leco SMPS Final Part 2 - YouTube

Last edited by DjLeco; 3rd November 2012 at 05:39 PM.
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Old 4th November 2012, 06:35 PM   #34
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DjLeco, were do you buy your litz wire.
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Old 4th November 2012, 07:52 PM   #35
DjLeco is offline DjLeco  Romania
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Electrisola, Germany. 600x0.071
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Old 6th November 2012, 10:56 PM   #36
DjLeco is offline DjLeco  Romania
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More than 5Kw sustained from soket (221Vx25,5A) :

Leco Max Torture Test - YouTube

Main fuse 30A after test:

Sigurante - YouTube

Maximum draw curent from AC plug soket 26A:

Curent maxim SMPS primar.MOV - YouTube

All tests without overcurent protection...
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Old 7th November 2012, 02:25 AM   #37
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DJ Leco,

Greatwork man.

Your smps is ROBUST indeed.
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Old 7th November 2012, 05:09 AM   #38
DjLeco is offline DjLeco  Romania
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I know!

Thank you for reply!
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Old 11th December 2012, 08:24 AM   #39
DjLeco is offline DjLeco  Romania
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First SMPS made for one 1000W AB class amplifier, that I've sold last week to a friend, he asked me to make SMPS for that module.

Made at minimum costs, just +/- 100Vdc per power amp, one +12 volts for fan and one +10 volts for one small Mp3 module.

Calibrated for 1800Watts continuous, protection tripping at 2,1Kw

http://postimage.org/image/q0lo5ovtb/

http://postimage.org/image/vq1wq01zj/

http://postimage.org/image/xj4tebn67/


Uncalibrated protection test (without protection)


http://www.youtube.com/watch?v=Cf1VP...ature=youtu.be

Testing with protection enabled and calibrated:


http://www.youtube.com/watch?v=g7I2w...ature=youtu.be

And final test, a big short circuit


http://postimage.org/image/8uz0ncbgv/




Here is testing that amp loaded with 4 ohms, and power raised till around clipping level (almost 960 watts audio), put multimeter directly to + and - , to see voltage dropping at max power out:

Test Final Boxa - YouTube

Last edited by DjLeco; 11th December 2012 at 08:29 AM.
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Old 11th December 2012, 09:03 AM   #40
luka is offline luka  Slovenia
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great, just great, nice too see it being done
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