Offline full-bridge SMPS… need help

hello all , i have an issue the smps i made heats up irfp460 or 21n50c fets but if i use irf740 the heat is not present at the fets. when i put the bulb in series with smps and load a class ab with the bulb still in series the irfp460/21n50c they do heat insanely with little load and must be mounted on the sink. but irf740 are ok when smps has little or no load.
i tried changing the gate resistors from 22ohms to 47ohms but the heating was worse so i settled on the 4.7ohms it reduced the heating a little bit but did not eliminate the heating.
but when i used irf740 the smps worked well also with a little load to the amplifier the irf740s did not overheat but warmed without a heatsink.

the smps was
- gate drive transformer is ee16 trifilliar 12turns
- gate resistors 4.7ohms
- i tried with two etd39 formers
former 1 etd39 - primary turns 23turns, secondary turns 7t - 0 - 7t aux 2turns
former 2 etd39 - primary turns 42turns, secondary turns 14t - 0 - 14t aux 4turns
both formers behaved the same regarding the heating of the irfp460/21n50c
- i used a1020 and c2655 as buffers for the gdt and 1ohm resistors .(i had used 10 ohms resistor but results were similar with 1ohm)
note the same circuit i tried using igbt an year ago but it over heated abnormally a change of gate resistor didn't help in anyway .
below are the pictures . kindly help out and any opinions are highly welcomed.


wow thanks buck , but seriously i don't know whether it is hard or soft switching , i have the schematic i used , and i have been making and using smps for about a decade ago

the photos and dmm measures of the smps

Offline full-bridge SMPS....need help

Offline full-bridge SMPS....need help

Offline full-bridge SMPS....need help
 
Hello all
I had made for my friend an amplifier a while back (about over 8years ago) while ,I was still growing and learning about smps, also I was not conversant with pcb software and pcb etching.
He brought it to me recently to do some minor adjustment on the crossover and some little noise

I was shocked to see that


The amp was a class ab +/-30vlts and
the smps was half bridge with transfomer gatedrive ,also the smps had feedback.
The smps fets were cold (irfp460), even when I pushed the amplifier hard.

The only difference I noted was that I used bc546c and bc556c as gate drive transformer driver and the smps had feedback. That's the only change from my current smps I am working on
 
:D it was amature done lol :cheers:
but it is still working nicely
 

Attachments

  • IMG_20210522_164221_302.jpg
    IMG_20210522_164221_302.jpg
    550.5 KB · Views: 187
  • IMG_20210522_164229_443.jpg
    IMG_20210522_164229_443.jpg
    546.8 KB · Views: 101
  • IMG_20210522_163722_037.jpg
    IMG_20210522_163722_037.jpg
    550.2 KB · Views: 95
  • IMG_20210528_182943_584.jpg
    IMG_20210528_182943_584.jpg
    382.6 KB · Views: 102
  • IMG_20210528_160009_901.jpg
    IMG_20210528_160009_901.jpg
    682 KB · Views: 105
  • IMG_20210528_155940_876.jpg
    IMG_20210528_155940_876.jpg
    788.9 KB · Views: 111
  • IMG_20210522_163749_400.jpg
    IMG_20210522_163749_400.jpg
    700.2 KB · Views: 171
  • IMG_20210528_160914_278.jpg
    IMG_20210528_160914_278.jpg
    429.1 KB · Views: 176
  • IMG_20210522_163745_402.jpg
    IMG_20210522_163745_402.jpg
    653.3 KB · Views: 191
  • IMG_20210522_163742_107.jpg
    IMG_20210522_163742_107.jpg
    627 KB · Views: 193
Last edited:
I am busy with a resonant, I have now make a model file so I can simulate it, I have software to calculate the resonant parts and that does oke.

I have proper working feedback and resonances.


Do somebody know how to find out a transformer core from a old PC supply, I have removed two, a small and bigger one looks like ETD but is not, something chinese proberly.

regards
 

Attachments

  • softswitching.jpg
    softswitching.jpg
    423.4 KB · Views: 135
  • feedbackfreq shift.jpg
    feedbackfreq shift.jpg
    343.5 KB · Views: 146
  • mosfet currents-feedbacklock.jpg
    mosfet currents-feedbacklock.jpg
    419.7 KB · Views: 127
  • feedback low load.jpg
    feedback low load.jpg
    368.1 KB · Views: 143
If you make a resonance version, then be aware the circulating current and voltage do not exceed 650 volts. So the design
is a little tricky, a much to high Q and you have easily 1000 volts over the resonance capacitor, special when startup, therefore
these resonance smps have to start delayed on a high frequency well above resonance, not below!! (capacitieve area) and all will be fine.
 
  • Like
Reactions: 1 user
It do work, I see no feedback so it works on resonance hot spot with 470nF resonance cap. 380 volts is a little
high for 220 volt in that voltage is with a PFC here is not one, but needed with high power, it is better.

But it is build with old chips, there are better and newer ones with no need for the mosfet drive transformers.
 
  • Like
Reactions: 1 user
hi all , thanks again kee2 for the explanation . i prefer gdt to chips , cause incase of failure no need
to replace expensive chips.
here is my updated version , just wondering whether you can draft where i can place the feedback . and also will it make this smps unstable? And is this gate drive effecient to drive fets or igbt properly?

thanking you in advance steve
 

Attachments

  • gtY hp ps nice gdt schematic drive .jpg
    gtY hp ps nice gdt schematic drive .jpg
    229.3 KB · Views: 44
  • gtY hp ps nice gdt schematic .pdf
    49.3 KB · Views: 40
  • gtY hp ps nice gdt schematic .jpg
    gtY hp ps nice gdt schematic .jpg
    292.3 KB · Views: 44
Best is resonance in open loop set frequency about resonance in LLC configuration. Then it act as a normal transformer
on 50 hz grid without the size, softstart you always need otherwise it blows, splitted capacitor with diodes make it short circuit proof.

The schematic has not a splitter for Cr just double the capacitance and put between plus and ground, connect the transformer to the middle point
and two fast diodes over the capacitors for protection, but it can also done as on schematic.

calculatore.zip is for the feedback calculation, need to translate it because it is polish I think.

https://www.diysmps.com/forums/index.php?attachments/6-353-405-02-pdf.5404/

https://www.diysmps.com/forums/index.php?attachments/6-pdf.5403/

Now you can study a little and tool to calculate. for 1000 watts maybe a pfc is needed.

Resonance is not a easy task, maybe the schematic I have put here is usable, it has a fast feedback with a zener. The 2sk mosfets can also be others if
specs are right, min 600 volts or so. And be easy with the voltages are lethal.

regards
 

Attachments

  • 5-371-2.gif
    5-371-2.gif
    42.7 KB · Views: 51
  • eski5-355-4.gif
    eski5-355-4.gif
    34.2 KB · Views: 47
  • 5-355-21.jpg
    5-355-21.jpg
    79.2 KB · Views: 48
  • transformer.zip
    679.2 KB · Views: 32
  • calculatore.zip
    10.1 KB · Views: 30
  • RESONANT-CONVERTERS-LLC-DESIGN-TOOL-FOR-FSFR-SERIES.zip
    956.3 KB · Views: 42
  • Like
Reactions: 1 user