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Thread: Llc hb smps 2000w

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    .... Silvio's Avatar
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    Llc hb smps 2000w

    Here is an smps that I have been working on for the last 6 months. This is my first prototype and apart from the simplicity this smps has a lot of features for it to work on an audio amplifier.

    1) Over input voltage protection with a Varistor

    2) A good input filter to reduce EMI as much as possible

    3) Generous input and output capacitance 2700uF in the 320v input and 10,000uF on the output

    4) A good soft start design

    5) A good short circuit protection which is self reset after 3 seconds and turns to hiccup mode if the short is still present. Eventually it will turn to thermal protection sensing the heat on the soft start resistors.

    6) Thermal protection with a normally open bi-metal switch on the IGBT heat sink

    7) Temperature controlled fan speed for 3 X 12v 80mm fans.

    8) Being LLC has a sinusoidal current wave form. This helps a lot in reducing EMI and noise

    9) From my initial tests it seems very promising and very strong.

    10) The SMPS peaked 2300w with a modest voltage drop of 11% on the output voltage.

    11) The power factor was 0.65 with no load and 0.98 at full load.

    12) The efficiency reached around 89%

    13) Lastly the fuse was omitted from the PCB as this is to be attached on the amp chassis.

    2000w smps 1.JPG2000w smps 2.JPG2000w smps 3.JPG2000w smps 4.JPG2000w smps 5.JPG
    Last edited by Silvio; 07-24-2019 at 05:47 PM.

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    diysmps Senior Member res_smps's Avatar
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    Good work Silvio, it looks great. are you going to share this smps schematic or only for commercial?

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    .... Silvio's Avatar
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    Not really its 100% my design and i spent a lot of time perfecting each section so that i will have a reliable smps.
    In my early versions I had a problem with start up issues. Now it can start facing a 1.5 Kw or more load. The smps is true 2K which can be sustained for 10 min at cont load with propper cooling. Its size is quite small for its power being 18 x 22cm. I might share it but with a different control circuit that use Ir 2153 chip. The SC will be latching type not auto reset. I may also include the thermal protection aswell.

  4. #4
    Nice work as usual Silvio
    www.diysmps.com & www.Micro-Audio.com

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    diysmps Senior Member res_smps's Avatar
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    Quote Originally Posted by Silvio View Post
    I might share it but with a different control circuit that use Ir 2153 chip. The SC will be latching type not auto reset. I may also include the thermal protection aswell.
    I am happy that you also developed a resonant smps and shared it here because all this time I felt alone (only a few were interested) to learn resonant smps. Initially I learned LLC Resonant Smps from the application note from IRS27951 and performed a simulation using IR2153. I have ltspice model ir2153 and llc smps simulation, do you need it?

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    .... Silvio's Avatar
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    Here is the link for the load test on youtube

    https://www.youtube.com/watch?v=n4R7...ature=youtu.be
    Last edited by Silvio; 07-25-2019 at 07:35 PM.

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    .... Silvio's Avatar
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    Thanks Microsim

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    .... Silvio's Avatar
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    Quote Originally Posted by res_smps View Post
    I am happy that you also developed a resonant smps and shared it here because all this time I felt alone (only a few were interested) to learn resonant smps. Initially I learned LLC Resonant Smps from the application note from IRS27951 and performed a simulation using IR2153. I have ltspice model ir2153 and llc smps simulation, do you need it?
    Thanks for the offer RES but I do not have spice simulation. I always try the real thing that is where I get my results. I have been developing this smps for the last 6 months a bit by bit, The oscillator and protection was the big headache but finally I succeeded in using a voltage comparator sensing both high an low side pulse. The LLC inductor doubles for current sense and added inductance needed for LLC operation. I made a two turn coupling loop around the LLC inductor PS not all cores work here it has to be those brown ones that I find to work well. I did not have a large one so I stacked 2 of them together. That is why it looks longish. I had to use a snubber on this as well to tame down the spikes it creates. The second task was to create a small delay when it comes to reset on the 555 timer but I did some reserch and took a few ideas and I managed to create it as well. The last thing was the thermal shut off which I did with a few transistors creating the initial relay delay on soft start and thermal shut down combined together. These are partly on the main pcb.

    Summing up and gathering everything together was my last task so that in the event of breakdown the main pin header was easily pulled out and repaired. The pin header came out a bit high as it is on a single sided pcb. I already designed one in smd which this will sit flush with the same height of the bulk capacitors.

    Pin header in smd
    Attachment 6975

  9. #9
    diysmps Senior Member res_smps's Avatar
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    Quote Originally Posted by Silvio View Post
    not all cores work here it has to be those brown ones that I find to work well. I did not have a large one so I stacked 2 of them together. That is why it looks longish.
    I use an iron core that is commonly used for class d output inductors

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    .... Silvio's Avatar
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    Quote Originally Posted by res_smps View Post
    I use an iron core that is commonly used for class d output inductors
    In fact that is what I used. The permeability has to be very low. Other types do not seem to work and tend to generate a lot of spikes. Even the waveform across the core seems to change with an unsuitable core material.
    Last edited by Silvio; 07-26-2019 at 09:25 AM.

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