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Thread: Resonant SMPS using L6599

  1. #11
    diysmps Senior Member res_smps's Avatar
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    Thanks for the advice, fake chips are our main problem because most components are imported from china
    Previously I also bought L6599A from a local shop that could not be used and the markings faded / disappeared when rubbed using cleaning liquid

  2. #12
    diysmps Senior Member res_smps's Avatar
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    I tried a new chip on a new pcb but it didn't work either.
    finally I tried using the old pcb design and it could function well.
    so it seems the problem is in pcb design.
    I choose to be conservative, I will make a new pcb based on this old pcb with improvements:
    - the addition of more secondary capacitors
    - Improved EMI filter design

    today I tried it on an amplifier
    https://youtu.be/IxDuTM91zeM
    I have a SMPS capable of 1000W, an amplifier capable of 250 to 400W.
    but I only use it for less than 50W, hahaha ...

    by the way I got this original chip at half the price of a fake one

    chip2.jpgchip1.jpgtransistor driver.jpgold design.jpg

  3. #13
    diysmps Senior Member res_smps's Avatar
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    this is a new pcb design, using an old version of the controller module.
    Tested using a transformer from the old design, unregulated at 90kHz frequency
    new board.jpeg

  4. #14
    .... Silvio's Avatar
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    Quote Originally Posted by res_smps View Post
    this is a new pcb design, using an old version of the controller module.
    Tested using a transformer from the old design, unregulated at 90kHz frequency
    new board.jpeg
    Hi Res I see that it looks good but I think there is a lot of unused space on the pcb. Did you try to load it? What power are you expecting from it?

  5. #15
    diysmps Senior Member res_smps's Avatar
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    Dear Silvio,

    This is just the initial test to make sure its main function works.
    I have not tried to load test, I expect to be able to get 1000W (with an additional fan if needed)

    This pcb will be equipped with an extra +-15V regulated voltage (for preamps)
    and +12/24V with mains voltage detection for speaker protector

    l6599 silkscreen.jpg

  6. #16
    .... Silvio's Avatar
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    Quote Originally Posted by res_smps View Post
    Dear Silvio,

    This is just the initial test to make sure its main function works.
    I have not tried to load test, I expect to be able to get 1000W (with an additional fan if needed)

    This pcb will be equipped with an extra +-15V regulated voltage (for preamps)
    and +12/24V with mains voltage detection for speaker protector

    l6599 silkscreen.jpg
    That's more like it Res, I was saying to myself why the empty space? Well I am sure you will find a way to take the most of it. Everything that we build has its own experience but through knowledge and self taught we will succeed. That is the fun of home brew. Many a time it is not worth it as buying ready made will come far cheaper. I find every project that I make challenging and getting around all the difficulties that we find on the way makes us more wise and knowledgeable. If you come by any difficulties do not hesitate to share I will try the best I can to help out.

    I will ask you for some help in the future when I come to a real resonant smps. I mostly build for the fun of it and nothing more.

    Till then good luck

    Regards Silvio

  7. #17
    diysmps Senior Member res_smps's Avatar
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    This is a photo after all the components are installed
    some components use smd at the bottom layer
    L6599 complete.jpeg
    L6599 back.jpeg
    output voltage :
    +/-70V regulated (main output)
    +/-12V
    +12V

    the next step is to load test

  8. #18
    .... Silvio's Avatar
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    Quote Originally Posted by res_smps View Post
    This is a photo after all the components are installed
    some components use smd at the bottom layer
    L6599 complete.jpeg
    L6599 back.jpeg
    output voltage :
    +/-70V regulated (main output)
    +/-12V
    +12V

    the next step is to load test
    It looks nice Res, I hope it holds good regulation at load

  9. #19
    diysmps Senior Member res_smps's Avatar
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    Load Test

    Dear Silvio,
    please check this video
    https://youtu.be/ivXJcmac6Ww

    I set the output voltage to +-60V (120V from positive to negative) because I only have a 15 ohm 200W dummy load,
    I think +-70v is too high for testing
    I dip the dummy load in a bucket of water to improve its power capabilities, but water also slightly decreases the resistance value

    I want to test much longer but the circuit breaker in my house is trip because the capacity is only 1300VA

    You can hear my children playing around me

  10. #20
    .... Silvio's Avatar
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    Hi' Res i see you got a good result. From what I see you are loading around 1140w and input sees 1760w that is around 60% eff. This may not be true as bad power factor tend to draw more current than what really is drawn from smps. You need to see the actual watts at the input with a watt meter. Above all regulation seem to hold well with only a 2v drop. Well done Res.

    I ask you some questions. How does the smps behaves with no load and full load regarding regulation? I guess you need a minimum load. When I added regulation to my smps it needed this as with no load the trafo was ticking meaning switching on and off. Even so from a peak voltage of 80-0-80v I had to set for 60-0-60 as there was not enough headroom for regulation higher than this. Voltage drop in the output inductor and other losses etc.

    If the smps is intended for audio than do not trouble yourself much about holding full power for a long time. This week I was testing my 1000w amplifier and adjusted it at full blast with the clip indicator showing slightly at times. The average wattage was around 200-250w drawn by the amplifier smps at the input. You see although the smps can give more than a 1000w the average is somewhat quite smaller. During my bench tests when I was testing my smps (I have a cpu heatsink attached to my mosfets and diodes) It could hold 900w continuous without any problems with a very moderate temperature rise of around 50 degrees and held to that temperature for half an hour.
    Last edited by Silvio; 09-01-2019 at 12:34 PM.

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