Hello Chas1,
At the moment I am currently designing an off line full bridge smps with another member on this forum.
The smps will be built around SG3525 chip and will have hick-up current protection and over current protection, optical isolated voltage feedback, ETD 44 core wound with homemade litzwire and we intend to make it run at 1KW constant output.
Our intention is to post this project on this forum with details regarding everything:
- formulas used for the number of turns in the transformer
- formulas used for the number of turns in the current transformer
- formulas used for the TL431 voltage feedback
- formulas used for the choke inductors and capacitors at the output
- a small tutorial on how to make litzwire in you're home and the winding technique chosen for the power transformer
- PCB layout tips for smps
- snubber design and calculations
- EMI friendly techniques used for PCB and also enclosures of the power transformer and other EMI generating parts like the chokes
- scope readings in the critical parts (gates of the power fets, input and output of the power transformer, etc)
As we are not professional smps designers (all that we know about smps started on this forum), I was interested in LT Spice simulation for some parts of this circuit like inrush current and others in order, to limit the amount of money spent while building this (mosfets, chips, caps, etc cost money and I want to keep this project in a tight budget as much as possible).
best regards,
Savu Silviu
How about the thought of using a Personal Computer Power Supply Case for the home of the SMPS. The power line will not work how ever, you need a 110v high amperage power cord to do some justice...the case will make it hard to probe while under power test, but very safe for the final versions...
the smps wil be powered from 230v mains.
haven't decided on the housing of the smps.
regards,
savu
haven't decided on the housing of the smps.
regards,
savu
80kHz
Is that the fsw or osc frequency?,if fsw there shouldn't be a problem.There is already one if you check a-and-t labs K6 it is a full bridge and can give you a lot of ideas.Like all things it can be improved but the idea was for a design that covered a range by switching components in the feedback.
Is that the fsw or osc frequency?,if fsw there shouldn't be a problem.There is already one if you check a-and-t labs K6 it is a full bridge and can give you a lot of ideas.Like all things it can be improved but the idea was for a design that covered a range by switching components in the feedback.
K6
Yes I can see where they might,however the basic supply will work well.To gain an insight to LTspice I ran a simulation of that supply and found the major problem was the feedback loop(inductor value and type of feedback).The first call out for the two output inductors value was 100uH but later changed to 300uH.There was a long thread on this forum about modifications and I had a chance to question Reinhard Metz about the construction of the supply and was able to complete it so I could verify my simulation,with mods(changed to coupled output inductor) and added suggestions from him the supply worked well.The most attractive part was the controller was on the secondary side and I use that in most of my forward converter designs.(removes a headache limitations of TL431)simple opamp feedback..
Yes I can see where they might,however the basic supply will work well.To gain an insight to LTspice I ran a simulation of that supply and found the major problem was the feedback loop(inductor value and type of feedback).The first call out for the two output inductors value was 100uH but later changed to 300uH.There was a long thread on this forum about modifications and I had a chance to question Reinhard Metz about the construction of the supply and was able to complete it so I could verify my simulation,with mods(changed to coupled output inductor) and added suggestions from him the supply worked well.The most attractive part was the controller was on the secondary side and I use that in most of my forward converter designs.(removes a headache limitations of TL431)simple opamp feedback..
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I am on the self imposed mission of doing a SMPS that will power my ultimate amp in my dreams. I purchased some pcb material and got a hold of a decent scope. So Before I go off and buy a lot of parts that will not work together. I am going to take time to build a simulation of the SMPS in LTSpice. I do have a couple of ETD49's...
Basic starting premise of 110v input and any where from +- 50 to +- 90 volts and 8ohm wattage to be half of 4ohm.
So I want to order a book that will launch me in to the black hole of design in my mind.
ANY suggestions as to which BOOK?
Let me state my appreciation of all this thread and its very intelligent posters have done to encourage the venture I am embarking on. THANKS a LOT, I hope I can return the favor to all.
Basic starting premise of 110v input and any where from +- 50 to +- 90 volts and 8ohm wattage to be half of 4ohm.
So I want to order a book that will launch me in to the black hole of design in my mind.
ANY suggestions as to which BOOK?
Let me state my appreciation of all this thread and its very intelligent posters have done to encourage the venture I am embarking on. THANKS a LOT, I hope I can return the favor to all.
the smps wil be powered from 230v mains.
haven't decided on the housing of the smps.
regards,
savu
So you are saying that the input voltage will be SINGLE phase 220V at 50 or60 hertz?
CAN a supply be built (not this one of course) with 110 single phase with an ETD49?
What would be the limitations Wattage and Voltage wise for a Power Amplifier?
book
There are two,Switching Power Supply Design author Abraham Pressman and the other Christophe Basso's Switch-Mode Power Supplies SPICE Simulations and Practical Designs a lot of people also purchase Marty Brown's book but there are a few errors and I wouldn't buy it at present the other two are not cheap and if you can't get both by all means get Basso's first as it will help you with your spice simualtions and design a lot of practical examples on all subjects.The most important step is to define your project on paper before you spend a dime and then do the math.If you have questions use the forum we are here to help.
There are two,Switching Power Supply Design author Abraham Pressman and the other Christophe Basso's Switch-Mode Power Supplies SPICE Simulations and Practical Designs a lot of people also purchase Marty Brown's book but there are a few errors and I wouldn't buy it at present the other two are not cheap and if you can't get both by all means get Basso's first as it will help you with your spice simualtions and design a lot of practical examples on all subjects.The most important step is to define your project on paper before you spend a dime and then do the math.If you have questions use the forum we are here to help.
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Yes I can see where they might,however the basic supply will work well.To gain an insight to LTspice I ran a simulation of that supply and found the major problem was the feedback loop(inductor value and type of feedback).The first call out for the two output inductors value was 100uH but later changed to 300uH.There was a long thread on this forum about modifications and I had a chance to question Reinhard Metz about the construction of the supply and was able to complete it so I could verify my simulation,with mods(changed to coupled output inductor) and added suggestions from him the supply worked well.The most attractive part was the controller was on the secondary side and I use that in most of my forward converter designs.(removes a headache limitations of TL431)simple opamp feedback..
considering the feedback option with opamp.
i have one question.
will it still be optical isolated?
regards,
savu
pcb
You might want to check out this board house http:www.pcbfabexpress.com up to 100 sq.in Double sided at good prices.
You might want to check out this board house http:www.pcbfabexpress.com up to 100 sq.in Double sided at good prices.
Sure, all controller circuit is on secondary side
can you share a schematic of this principle?
regards,
savu
Schematic of supply or feedback,both are used in the K6 supply . I will be posting a LTspice diagram shortly.I hope I answered your question "isolation of supply is output to input" norm is to place the controller on the input side so it can be started easy using a few parts(cap&resistor) and as the supply ramps up the aux supply takes over.I use a small transformer to furnish power to the controller circuit because the costs are about the same and the supply is more robust IMHO and I can reference all to the secondary side and have no boundary to cross.The small transformer provides isolation.If you reference the pcb layout of the K6 the isolation is provided by the grounding.
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What is the average cost per foot of Litz wire that would be needed for the project. What size, how long, gauge etc.?
You can find Litz wire on ebay and the norm its sold by roll,again wait the wire you might need can be made of small AWG in a bundle.The wire size will be detemined by the c.m./A you choose to work with along with the frequency(skin depth) the c.m./A can be between 300 c.m./A up to 600 c.m./A with 500 c.m./A industry standard.
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I want to be able to work smart on this.
Using the following scenario...
Design and evaluate, test and document in LTSpice
Draw up a schmatic
Convert that schematic to a PCB layout that I can make in my garage in quantities of 1 or 2 using a laser transfer technique?
be able to send to a board house for solder mask and silkscreen when done.
Is there a FREE or low cost PCB program that will do the above and is compatible with LTSpice?
Using the following scenario...
Design and evaluate, test and document in LTSpice
Draw up a schmatic
Convert that schematic to a PCB layout that I can make in my garage in quantities of 1 or 2 using a laser transfer technique?
be able to send to a board house for solder mask and silkscreen when done.
Is there a FREE or low cost PCB program that will do the above and is compatible with LTSpice?
Is there a FREE or low cost PCB program that will do the above and is compatible with LTSpice?
I don't know about spice compatibility but aas for schematic and PCB drawing Kicad is free and very usefull.
Mark
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