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DIY circuits for ir2153. A simple switching power supply based on IR2153(D) for an amplifier and more. Load testing moment

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For a long time I was interested in the topic of how you can use the power supply from a computer to power a power amplifier. But remaking a power supply is still fun, especially a pulsed one with such a dense installation. Even though I’m used to all sorts of fireworks, I really didn’t want to scare my family, and it’s dangerous for myself.

In general, studying the issue led to a fairly simple solution that did not require any special details and practically no setup. Assembled, turned on, works. Yes, and I wanted to practice etching printed circuit boards using photoresist, since recently modern laser printers have become greedy for toner, and the usual laser-iron technology has not worked out well. I was very pleased with the result of working with photoresist; for the experiment, I etched the inscription on the board with a line 0.2 mm thick. And she turned out great! So, enough preludes, I will describe the circuit and process of assembling and setting up the power supply.

The power supply is actually very simple, almost all of it is assembled from parts left over after disassembling a not very good pulse generator from a computer - one of those parts that are not “reported” on. One of these parts is a pulse transformer, which can be used without rewinding in a 12V power supply, or converted, which is also very simple, to any voltage, for which I used Moskatov’s program.

Switching power supply unit diagram:

The following components were used:

driver ir2153 is a microcircuit used in pulse converters to power fluorescent lamps, its more modern analogue is ir2153D and ir2155. In the case of using the ir2153D, the VD2 diode can be omitted, since it is already built into the chip. All 2153 series microcircuits already have a built-in 15.6V zener diode in the power circuit, so you shouldn’t bother too much with installing a separate voltage stabilizer to power the driver itself;

VD1 - any rectifier with a reverse voltage of at least 400V;

VD2-VD4 - “fast-acting”, with a short recovery time (no more than 100ns) for example - SF28; In fact, VD3 and VD4 can be excluded, I did not install them;

as VD4, VD5 - a dual diode from the computer power supply “S16C40” is used - this is a Schottky diode, you can use any other, less powerful one. This winding is needed to power the ir2153 driver after the pulse converter starts. You can exclude both diodes and winding if you do not plan to remove power of more than 150 W;

Diodes VD7-VD10 - powerful Schottky diodes, for a voltage of at least 100V and a current of at least 10 A, for example - MBR10100, or others;

transistors VT1, VT2 - any powerful field-effect ones, the output depends on their power, but you shouldn’t get too carried away here, just as you shouldn’t remove more than 300 W from the unit;

L3 - wound on a ferrite rod and contains 4-5 turns of 0.7 mm wire; This chain (L3, C15, R8) can be eliminated altogether; it is needed to slightly facilitate the operation of the transistors;

Choke L4 is wound on a ring from the old group stabilization choke of the same power supply from the computer, and contains 20 turns each, wound with a double wire.

Capacitors at the input can also be installed with a smaller capacity; their capacity can be approximately selected based on the removed power of the power supply, approximately 1-2 µF per 1 W of power. You should not get carried away with capacitors and place a capacitance of more than 10,000 uF at the output of the power supply, as this can lead to “fireworks” when turned on, since they require a significant current for charging when turned on.

Now a few words about the transformer. The parameters of the pulse transformer are determined in the Moskatov program and correspond to an W-shaped core with the following data: S0 = 1.68 sq. cm; Sc = 1.44 cm2; Lsr.l. = 86cm; Conversion frequency - 100 kHz;

The resulting calculation data:

Winding 1- 27 turns 0.90mm; voltage - 155V; Wound in 2 layers with wire consisting of 2 cores of 0.45 mm each; The first layer - the inner one contains 14 turns, the second layer - the outer one contains 13 turns;

winding 2- 2 halves of 3 turns of 0.5mm wire; this is a “self-supply winding” with a voltage of about 16V, wound with a wire so that the winding directions are in different directions, the middle point is brought out and connected on the board;

winding 3- 2 halves of 7 turns, also wound with stranded wire, first - one half in one direction, then through the insulation layer - the second half, in the opposite direction. The ends of the windings are brought out into a “braid” and connected to a common point on the board. The winding is designed for a voltage of about 40V.

In the same way, you can calculate a transformer for any desired voltage. I have assembled 2 such power supplies, one for the TDA7293 amplifier, the second for 12V to power all sorts of crafts, used as a laboratory one.

Power supply for amplifier for voltage 2x40V:

12V switching power supply:

Power supply assembly in housing:

Photo of tests of a switching power supply - the one for an amplifier using a load equivalent of several MLT-2 10 Ohm resistors, connected in different sequences. The goal was to obtain data on power, voltage drop and voltage difference in the +/- 40V arms. As a result, I got the following parameters:

Power - about 200W (I didn’t try to shoot anymore);

voltage, depending on load - 37.9-40.1V over the entire range from 0 to 200W

Temperature at maximum power 200W after a test run for half an hour:

transformer - about 70 degrees Celsius, diode radiator without active blowing - about 90 degrees Celsius. With active airflow, it quickly approaches room temperature and practically does not heat up. As a result, the radiator was replaced, and in the following photos the power supply is already with a different radiator.

When developing the power supply, materials from the vegalab and radiokot websites were used; this power supply is described in great detail on the Vega forum; there are also options for the unit with short-circuit protection, which is not bad. For example, during an accidental short circuit, a track on the board in the secondary circuit instantly burned out

Attention!

The first power supply should be turned on through an incandescent lamp with a power of no more than 40W. When you turn it on for the first time, it should flash briefly and go out. It should practically not glow! In this case, you can check the output voltages and try to lightly load the unit (no more than 20W!). If everything is in order, you can remove the light bulb and begin testing.

Four switching power supplies based on IR2153. Switching Power Supply on IR2153

Hello dear readers, this is my first blog so don’t judge strictly and I’ve never written articles. To be honest, I’m really tired of crude power supply circuits on the Internet, since I’ve been working on switching power supplies for 15 years and I immediately see a mistake in the circuit, but after all, people collect these schemes!!! they waste time and money and they don’t work or work but with problems. Well, I had some time and I decided to create a blog on power supplies that really work as they should.
Well, let's start with this very popular circuit that is lying around in almost every forum or website dedicated to electronics.

Here is the diagram. There is nothing unusual in appearance, it has the right to life, but not like that!!! I will also note that in this circuit they at least installed a 1MF250V capacitor, otherwise in most cases it is not there at all and how it works without it you can only imagine or wait for it to come it will explode anyway! Although, in principle, if you assemble this circuit, you have to wait for it to explode! In other words, it needs to be modified and this power supply will serve you for many years. On many sites I visited, it is mainly used for screwdrivers whose batteries are dead and it is mounted in the battery compartment. Well, my batteries also died in an expensive screwdriver that has long been discontinued and I simply can’t find them. So I decided to assemble a simple compact power supply from an old ATX power supply lying around and modify it accordingly. Well, let's start opening it)))

Well, let's take it in order, the first thing that catches your eye is 1MF250V (I don’t understand how people haven’t had it explode yet) after the diode bridge, the voltage becomes 310 volts, which means it must be at least 1MF400V.

Next is another capacitor 220mf 16v, this voltage is very close, if you read the datasheet then inside this circuit there is a zener diode of 15.6 volts, this means there is only 0.4 volts in reserve, this is not enough. We change it to 220mf 35v or you can 100mf 35v, this the circuit is not critical to the capacitance, just an additional filter to power the microcircuit, I set here from 47 to 220 microfarads and it did not affect the operation in any way.

And also SF38 3A 600V, but for example, how many screwdrivers have I met, the peak current is on average 7-8 amperes, and in mine it is already 10-11 amperes, so these diodes are completely out of place here and you can’t attach them to a radiator, but they will heat up they will be. So, feel free to change them to the MBR2040 diode assembly, it is 20 amperes 40 volts (with a margin).
Next, at the output of the rectifier there is 100 μF 100V, why such a small capacitance and such a high voltage I don’t understand! (The author of this circuit clearly has some strange idea about electronics) Here you need to put 1000 μF 16V, or better yet two in parallel. We will still have an inductive load, we will turn the motor.
Almost finished)) a couple more little things. There is a 100uH inductor at the output, WHY?!!! Like let it be? It’s not needed there at all, we’re not assembling a power supply for an amplifier, and the inductance from the “flashlight” is written and I haven’t seen normal amplifiers with a single polar power supply, feel free to throw it out from the diagram it is an extra element.
Well, and finally, let’s say to put an end to it)) The calculated frequency of the converter in this circuit is 66.7 kHz, and the factory calculated the transformer at 100 kHz, so it will heat up and work unstably, and not only it, but also the field workers. To be honest, I generally doubt that it is possible to squeeze more than 4-5 amperes from this transformer by short-circuiting the windings as shown in the figure above, and even from a 5 volt winding, but we need 12 volts. In general, it’s better, of course, to rewind the transformer yourself, this will be more reliable and more confident that everything will work as it should. To be honest, I don’t trust these Chinese, everything works to the limit of their capabilities.
And so let's start assembling our power supply

From all of the above, we draw conclusions and replace the details with those that should be in reality. So we got this diagram.

And so what can we take from the power supply, since our unit should turn out to be budget-friendly, we will take a lot of things from an unnecessary ATX power supply.

1) D1-D4 - RL205 or RL207
2) C1-C2 - 220u200v or 330u200v
3) NTC - anyone who stands there
4) D5 - HER108 or FR107
5) C5 - 1u50v
6) D6 - MBR2040 or a similar assembly located there
7) C7-C8 - 1000u16v
8) C9 - 100n
9) Tr1 - transformer (the largest of the three on the board)
10) F1 - you can also gnaw it out if it remains alive))

In my circuit I used the smallest transformer from the ATX family, 3 in the photo.

Well, all that remains is to buy (or find on your shelves) quite a few parts))
By the way, I highly recommend it IR2151 replaced by IR2153, of course, both of these microcircuits will work, but the IR2153 is more durable, and I came across too many defective IR2151s and they burned for unknown reasons, and with it the field workers for company)) I have long given up IR2151 is printed and immediately under the iron (opens with any program)

photo of the board, we print the top and go straight under the iron (opens with any program)

There is one jumper on the board, don’t forget about it and I strongly recommend that you carry out the first startup through a 60-100W light bulb to avoid explosions and fireworks)))

Well, let's finish here, good luck with the assembly and all the best to you)))

IR2161 VS IR2153. Switching power supply for IR 2161

This article will be of interest to those who assembled SMPS based on IR2153. In fact, the IR2153 is poorly suited for creating an SMPS, due to the lack of a standard protection system against short circuits and overloads, and the impossibility of “dimming” and creating feedback on voltage and current if necessary.

More suitable for creating SMPS IR2161. This is a half-bridge switching converter for powering halogen lamps. Features of 2161 - protection against overloads and short circuits with automatic reset, soft start, the ability to dim (several ways), the ability to build feedback. After constructing the input and output stages, a switching power supply is obtained.
Here is the SMPS diagram for 2161.

The supply voltage and current of these microcircuits are approximately the same, which means that for 2161 you can use a power supply circuit like that of 2153 on resistors R2 and R3 of 2 W each, or you can use a Chinese “brick” of 5 W at 18-30 kOhm.

On board 2161 there is a soft start function (soft start). It works something like this: immediately after startup, the frequency of the internal clock generator of the microcircuit is about 125 kHz, which is significantly higher than the operating frequency of the output circuit C13C14Tr1 (about 36 kHz), as a result, the voltage on the secondary winding of T1 will be low. The internal oscillator of the microcircuit is controlled by voltage, its frequency is inversely proportional to the voltage on capacitor C7. Immediately after switching on, the C7 begins to charge from the internal current source of the microcircuit. In proportion to the increase in voltage across it, the frequency of the microcircuit generator will decrease. When it reaches 5V (about 1 sec.), the frequency will decrease to the operating value, about 36 kHz, and the voltage at the circuit output will accordingly reach the nominal value. This is how a soft start is implemented; after its completion, IC1 goes into operating mode.

The CS pin (pin 4) of IC1 is the input of the internal error amplifier and is used to control the load current and voltage at the half-bridge output. In the event of a sharp increase in load current, for example, during a short circuit, the voltage drop across the current-measuring resistor R7 will exceed 0.56V, and therefore at pin 4 of IC1, the internal comparator will switch and stop the clock generator. . The apnot and datasheet contain calculations of the resistor-current sensor R7. The conclusion can be drawn immediately: 0.33 Ohm - 100W, 0.22 Ohm - 200W, 0.1 Ohm - 300W, I haven’t tested it, but you can try 2 resistors in parallel, 0.1 Ohm each - then the maximum load will be 400W. I showed the short circuit protection test in a video. The operating modes of the IR2161 chip are discussed in more detail in the datasheet.
Capacitor C3 with a capacity of at least 1 µF per 1 W of output power. With such a capacitor, it is necessary to use the NTC1 thermistor, for example from a computer power supply.

Switching Power Supply on IR2153.

About the article.
There are a lot of circuits in the global trash heap using this microcircuit and describing it like this... But how and why? Will it work? But the last question very often the answer is no!! There are a lot of “Miraculous” seals and advice to use exactly a 1000uF x 500V capacitor, which cannot be found or will cost half your salary.
I will try to describe what I had to face when building the device, how it was decided, to reduce everything to simple and understandable principles, using which everyone can decide what they need.

About the Irka itself - IR2153.
The microcircuit is designed for use in electronic ballasts of economical lamps; these are devices of microscopic power, operate at frequencies of about 30 KHz, and do not have specially designed protection and control circuits. This gives something to think about!
The IR2153 has low power consumption and can be powered simply through a pull-down resistor, and there is also separation for the upper and lower switches of the half-bridge, so there is no need to wind transformers or use optical separation of switch control signals.
This makes the microcircuit attractive not only for amateurs, but also for serious brands that produce products in series!

And so, the project itself.

The goal was to build a simple, as universal as possible, power module with a power of about 200W.
Scope of application from power supply of halogen lamps to UMZCH, etc. , oddly enough, in terms of the cost of materials, this module can compete with factory ones transformers for halogen lamps, and even more so in other areas of application.

The electrical circuit diagram of an electronic ballast based on IR2153 is shown in Fig. 3.15.

IR2153 is a high-power insulated gate field-effect transistor (MOSFET) driver with an internal oscillator. It is an exact copy of the generator used in the 555 series timer, the domestic analogue is KR1006VI1. Operates directly from the DC bus through the quenching resistor R1.

Internal voltage regulation prevents Vcc from exceeding 15.6 V. Undervoltage lockout disables both gate drive outputs VT1 and VT2 when Vcc is below 9 V.

DA1 has two control outputs:

  • lower 5 for controlling VT2;
  • The top 7 output for controlling VT1 is “floating”, since the pulse shaper for controlling the field-effect transistor VT1 is powered by a floating power source, which is formed by elements VD2, C7).


Rice. 3.15. Schematic diagram of an electronic ballast based on IR2153

When managing power keys(VT1, VT2), the IR2151 chip provides a switching delay of 1.2 μs to prevent a situation where transistors VT1 and VT2 are simultaneously open and through current flows through them, which instantly disables both transistors.

This ballast is designed to power one or two lamps with a power of 40 (36) W (lamp current - 0.43 A) from an alternating current network of 220 V 50 Hz. When using two 40 W lamps, it is necessary to add the elements highlighted in dotted lines (EL2, L3, C11, RK3). It should be noted that for stable operation, the ratings of the elements in parallel branches must be equal (L3, C11 = L2, C10), and the length of the wires connected to the lamps must be the same.

Advice. When operating one driver for two lamps, it is preferable to use frequency heating of the electrodes (without posistors). This method will be described below (when describing the electronic ballasts on the IR53HD420 chip).

When using lamps of a different power (18-30 W), the ratings should be changed L2 = 1.8-1.5 mH (respectively); when using lamps with a power of 60-80 W - L2 = 1-0.85 mH, and R2 - from the condition of fulfilling F g ~ F b (formulas for calculating these frequencies are given below).

Mains voltage 220 V is supplied to network filter(electromagnetic compatibility filter) formed by elements C1, L1, C2, SZ. The need for its use is due to the fact that key converters are sources of electromagnetic radio frequency interference, which network wires radiate into the surrounding space like antennas.

Current Russian and foreign standards regulate the levels of radio interference generated by these devices. Two-tier LC filters and shielding of the entire structure give good results.

At the input of the network filter, a traditional unit for protection against network surges and impulse noise is included, including a varistor RU1 and a fuse FU1. The negative temperature coefficient (NTC) thermistor RK1 limits the input current surge caused by the charge of the capacitive filter C4 at the inverter input when the electronic ballast is connected to the network.

Next, the network voltage is rectified by the diode bridge VD1 and smoothed by capacitors C4. The R1C5 chain powers the DAI chip - IR2153. The frequency of the internal oscillator FT of the microcircuit is set by the elements R2 = 15 kOhm; C6 = 1 nF according to the formula

The resonant frequency of the ballast circuit F6 is set by the elements L2 = 1.24 mH; C10 = 10 nF according to the formula

To ensure good resonance, the following condition must be met: the frequency of the internal oscillator must be approximately equal to the resonant frequency of the ballast circuit, i.e. Fg ~ Fb.

Construction and details. The line filter choke L1 is wound on a ferrite ring K32x20x6 M2000NM with a two-core network wire until the window is completely filled. It is possible to replace the power supply of a TV, VCR, or computer with a choke from a PFP.

Good noise suppression results are obtained by specialized EPCOS filters: B8414-D-B30; В8410-В-А14.

The choke of the electronic ballast L2 is made on a W-shaped magnetic core made of M2000NM ferrite. Core size W5x5 with gap 8 = 0.4 mm. The size of the gap in our case is the thickness of the gasket between the contacting surfaces of the halves of the magnetic circuit. It is possible to replace the magnetic core with Ш6x6 with a gap of δ = 0.5 mm; Ш7х7 with gap

δ = 0.8 mm.

To make a gap it is necessary to lay gaskets made of non-magnetic material (non-foil fiberglass or getinax) of appropriate thickness between the contacting surfaces of the magnetic circuit halves and fasten them with epoxy glue.

The value of the inductance of the inductor (at a constant number of turns) depends on the size of the non-magnetic gap. As the gap decreases, the inductance increases, and as it increases, it decreases. It is not recommended to reduce the gap size, as this leads to saturation of the core.

When the core is saturated, its relative magnetic permeability decreases sharply, which entails a proportional decrease in inductance. A decrease in inductance causes an accelerated increase in current through the inductor and its heating. The current passing through the LL also increases, which negatively affects its service life. The rapidly increasing current through the inductor also causes shock current overloads of power switches VT1, VT2, increased ohmic losses in the switches, their overheating and premature failure.

Winding L2- 143 turns of PEV-2 wire with a diameter of 0.25 mm. Interlayer insulation - varnished fabric. Winding - turn to turn. Main dimensions of W-shaped cores c (consist of two identical W-shaped cores) made of soft magnetic ferrites (according to GOST 18614-79) are given in table. 3.2.

Table 3.2. Main dimensions of W-shaped cores


Transistors VT1, VT2 - IRF720, high-power field-effect transistors with an insulated gate. MOSFET is Metal Oxide Semiconductor Field Effect Transistor; in the domestic version, MOS PTs are field-effect transistors of the metal-oxide-semiconductor structure.

Let's look at their parameters:

  • constant drain current (ID) - 3.3 A;
  • pulse drain current (I DM) -13 A;
  • maximum drain-source voltage (V DS) - 400 V;
  • maximum power dissipation (P D) - 50 W;
  • operating temperature range (Tj) - from -55 to +150 °C;
  • open resistance -1.8 Ohm;
  • total gate charge (Q G) - 20 nC;
  • input capacitance (C ISS) - 410 pF.

When selecting and replacing transistors(comparison in Table 3.3) for electronic ballasts should be remembered that today the number of companies producing field-effect transistors is quite large (IR, STMicro, Toshiba, Fairchild, Infineon, etc.). The range of transistors is constantly expanding, and more advanced ones with improved characteristics are appearing. Parameters that you should pay special attention to:

  • constant drain current (ID);
  • maximum drain-source voltage (VDS);
  • on-state resistance, RDS(on);
  • total gate charge (QG);
  • input capacitance CISS.

Possible replacing transistors for electronic ballast: IRF730, IRF820, IRFBC30A (International Rectifier); STP4NC50, STP4NB50, STP6NC50, STP6NB50 (STMicroelectronics); field-effect transistors from Infineon (http:// www.infineon.com) LightMos, CoolMOS, SPD03N60C3, ILD03E60, STP03NK60Z series; PHX3N50E from PHILIPS, etc.

The transistors are installed on small plate radiators. The length of the conductors between driver outputs 5, 7, resistors in the gate circuits R3, R4 and the gates of field-effect transistors should be minimal.

Table 3.3. Comparison table with the parameters of some transistors for electronic ballasts



Rice. 3.16. Main dimensions of the core (to table 3.2)

Diode bridge VD1 - imported RS207; permissible forward current 2 A; reverse voltage 1000 V. Can be replaced with four diodes with the appropriate parameters.

Diode VD2 ultra-fast class (ultra-fast) - reverse voltage of at least 400 V; permissible direct direct current - 1 A; reverse recovery time - 35 ns. Suitable: 11DF4, BYV26B/C/D, HER156, HER157, HER105-HER108, HER205-HER208, SF18, SF28, SF106-SF109, BYT1-600. This diode should be located as close to the chip as possible.

The DAI chip is IR2153, it is replaceable with IR2152, IR2151, IR2153D, IR21531, IR2154, IR2155, L6569, MC2151, MPIC2151. When using the IR2153D, the VD2 diode is not required, since it is installed inside the chip.

Resistors R1-R5 - OMLT or MLT.

Capacitors S1-SZ - K73-17 at 630 V; C4 - electrolytic (imported) with a rated voltage of at least 350 V; C5 - electrolytic at 25 V; C6 - ceramic 50 V; C7 - ceramic or K73-17 for a voltage of at least 60 V; C8, C9 - K73-17 at 400 V; SYU - polypropylene K78-2 at 1600 6.

Varistor RU1 from EPCOS - S14K275, S20K275, replace it with TVR (FNR) 14431, TVR (FNR) 20431 or domestic CH2-1a-430 V.

Thermistor (thermistor) RK1 with negative temperature coefficient (NTC - Negative Temperature Coefficient) - SCK 105 (10 Ohm, 5 A) or from EPCOS - B57234-S10-M, B57364-S100-M.

The thermistor can be replaced with a 4.7 Ohm wirewound resistor with a power of 3-5 W.

The RK2 posistor is a PTC (Positive Temperature Coefficient) thermistor with a positive temperature coefficient. The developers of IR2153 recommend using a posistor from Vishay Cera-Mite - 307C1260. His Main settings:

  • nominal resistance at +25 °C - 850 Ohm;
  • instantaneous (maximum permissible) rms voltage applied to the posistor when the lamp is ignited - 520 V;
  • constant (maximum permissible) rms voltage applied to the posistor during normal operation of the lamp, -175 V;
  • maximum permissible switching current (transferring the posistor to a high-resistance state) -190 mA;
  • posistor diameter - 7 mm.

A possible replacement for the RK2 posistor is pulse posistors from EPCOS (number of switching cycles 50000-100000): B59339-A1801-P20, B59339-A1501-P20, B59320-J120-A20, B59339-A1321-P20.

PTC resistors with the necessary parameters in quantities sufficient for eight electronic ballasts can be made from the widely used ST15-2-220 PT resistor from the ZUSTST TV demagnetization system. Having disassembled the plastic case, two “tablets” are removed. Using a diamond file, make two cross-cuts on each one, as shown in Fig. 3.17, and break it along the notches into four parts.

Advice. It is very difficult to solder leads to the metallized surfaces of a posistor made in this way. Therefore, as shown in Fig. 3.18, make a rectangular hole in the printed circuit board (item 3) and clamp a piece of the “tablet” (item 1) between the elastic contacts (item 2) soldered to the printed conductors. By selecting the size of the fragment, you can achieve the desired duration of warming up the lamp.


Rice. 3.17. "Tablet" posistor with notches

Rice. 3.18. Mounting a homemade posistor on the board

Advice. If the fluorescent lamp is intended to be used in infrequent on-off mode, then the posistor can be omitted.

Settings. The spread of parameters of elements C6, L2, SY may require adjustment of the driver frequency. The easiest way to achieve equality of the frequency of the master oscillator of the IR2153 microcircuit with the resonant frequency of the L2C10 circuit is by selecting the frequency-setting resistor R2. To do this, it is convenient to temporarily replace it with a pair of series-connected resistors: constant (10-12 kOhm) and trimmer (10-15 kOhm). The criterion for correct setting is reliable starting (ignition) and stable burning of the lamp.

The ballast is assembled on a printed circuit board made of foil fiberglass and placed in an aluminum shielding casing. The printed circuit board and the arrangement of elements are shown in Fig. 3.19.

Rice. 3.19. Printed circuit board and arrangement of elements

Hello everybody!

Background:

On the site there is a diagram of audio frequency power amplifiers (ULF) 125, 250, 500, 1000 Watt, I chose the 500 Watt option, because in addition to radio electronics, I am also a little interested in music and therefore I wanted something of better quality from ULF. The circuit on the TDA 7293 did not suit me, so I decided on the option of 500 watt field-effect transistors. From the beginning I almost assembled one ULF channel, but work stopped for various reasons (time, money and unavailability of some components). As a result, I bought the missing components and completed one channel. Also, after a certain time, I assembled the second channel, set it all up and tested it on a power supply from another amplifier, everything worked at the highest level and I really liked the quality, I didn’t even expect that it would be like this. Special, huge thanks to the radio amateurs Boris, AndReas, Nissan, who throughout the entire time I assembled it, helped in setting it up and in other nuances. Next, it became a matter of the power supply. Of course, I would like to make a power supply on a regular transformer, but again everything stops on the availability of materials for the transformer and their cost. Therefore, I decided to stick with the UPS.

Well, now about the UPS itself:






I used IRFP 460 transistors, since I did not find those indicated on the diagram. I had to install the transistors the other way around, turning them 180 degrees, drill more holes for the legs and solder them together with wires (you can see it in the photo). When I made the printed circuit board, I only realized later that I couldn’t find the transistors I needed as in the diagram, so I installed the ones I had (IRFP 460). Transistors and output rectifier diodes must be installed on a heat sink through heat-insulating gaskets, and the radiators must also be cooled with a cooler, otherwise the transistors and rectifier diodes may overheat, but the heating of the transistors, of course, also depends on the type of transistors used. The lower the internal resistance of the field switch, the less it will heat up.


Also, I have not yet installed a 275 Volt Varistor at the input, since it is not in the city and neither is mine, and it is expensive to order one part via the Internet. I will have separate electrolytes at the output, because they are not available for the required voltage and the standard size is not suitable. I decided to put 4 electrolytes of 10,000 microfarads * 50 volts, 2 in series in the arm, in total in each arm it will be 5000 microfarads * 100 volts, which will be completely enough for the power supply, but it is better to put 10,000 microfarads * 100 volts in the shoulder.

The diagram shows a resistor R5 47 kOhm 2 W for powering the microcircuit, it should be replaced with 30 kOhm 5 W (preferably 10 W) so that under a heavy load, the IR2153 microcircuit has enough current, otherwise it may go into protection against a lack of current or will pulsate tension which will affect the quality. In the author’s circuit it is 47 kOhm, which is a lot for such a power supply. By the way, resistor R5 will heat up very much, don’t worry, the type of circuits with IR2151, IR2153, IR2155 power supply is accompanied by strong heating of R5.

In my case, I used an ETD 49 ferrite core and it fit very hard on the board. At a frequency of 56 KHz, according to calculations, it can deliver up to 1400 watts at this frequency, which in my case has a margin. You can use a toroidal or other shaped core, the main thing is that it is suitable in terms of overall power, permeability and, of course, there is enough space to place it on the board.



Winding data for ETD 49: 1 = 20 turns with 0.63 V wire 5 wires (winding 220 volts). 2 = main power bipolar 2*11 turns of 0.63 V wire 4 wires (winding 2*75-80) volts. 3 = 2.5 turns of wire 0.63 in 1 wire (winding 12 volts, for soft start). 4 = 2 turns of wire 0.63 in 1 wire (additional winding for powering preliminary circuits (tone block, etc.). The transformer frame needs a vertical design, I have a horizontal one, so I had to fence it. It can be wound in a frameless design. On other types you will have to calculate the core yourself, you can use the program that I will leave at the end of the article.In my case, I used a bipolar voltage of 2 * 75-80 volts for a 500 watt amplifier, why less, because the amplifier load will not be 8 Ohms but 4 Ohms.

Setup and first launch:

When starting the UPS for the first time, be sure to install a 60-100 watt light bulb in the gap between the network cable and the UPS. When you turn it on, if the light does not light, then it’s good. At the first start-up, short-circuit protection may turn on and the HL1 LED will light up, since the electrolytes have a large capacity and take a huge current at the moment of switching on. If this happens, then you need to twist the multi-turn resistor clockwise until it stops, and then wait until the LED goes out off state and try to turn it on again to make sure the UPS is working, and then adjust the protection. If everything is soldered correctly and the correct part ratings are used, the UPS will start. Next, when you have made sure that the UPS turns on and there is all voltage at the output, you need to set the protection threshold. When setting up protection, be sure to load the UPS between the two arms of the main output winding (which is used to power the ULF) with a 100-watt light bulb. When the HL1 LED lights up when turning on the UPS under load (100-watt light bulb), you need to turn the variable multi-turn resistor R9 2.2 kOhm a little counterclockwise until the power-on protection is triggered. When the LED lights up when you turn it on, you need to turn it off and wait until it goes out and gradually turn it clockwise in the off state and turn it on again until the protection stops working,
You just need to turn it little by little, for example 1 turn and not 5-10 turns at once, i.e. turned it off, tweaked it and turned it on, the protection worked - again the same procedure several times until you achieve the desired result. When you set the required threshold, then, in principle, the power supply is ready for use and you can remove the mains voltage light and try to load the power supply with an active load, for example, 500 watts. Of course, you can play around with the protection as you like, but I don’t recommend doing tests with Short circuit, since this can lead to a malfunction, even though there is protection, some capacity will not have time to discharge, the relay will not respond instantly or will stick and there may be trouble. Although I accidentally and not accidentally made a number of short circuits, the protection works. But nothing is eternal.

Measurements after UPS assembly:

Measurements between shoulders:
U in - 225 volts, load - 100 watts, U out +- = 164 volts
U in - 225 volts, load - 500 watts, U out +- = 149 volts
U in - 225 volts, load - 834 watts, U out +- = 146 volts

Of course there is subsidence. With a load of 834 watts before the input rectifier, the voltage sags from 225 volts to 220 volts, after the rectifier it sags by as much as 20 volts from 304 volts to 284 volts with a load of 834 watts. But in principle, the output sag on each arm is 9 volts, which is in principle acceptable, since the UPS is not stabilized.

Thanks everyone for your attention.

The power supply is built using a semi-bridge circuit based on the IR2153 microcircuit. At the output of this block you can get any voltage you need, it all depends on the parameters of the secondary winding of the transformer.

Let's take a closer look at the switching power supply circuit.

The power of the power supply with these components is about 150 watts.

The AC mains voltage is supplied to the diode rectifier through a fuse and thermistor.

After the rectifier there is an electrolytic capacitor, which will be charged with a large current when the unit is turned on to the network; the thermistor just limits this current. A capacitor is needed with a voltage of 400-450 Volts. Next, constant voltage is supplied to the power switches. At the same time, power is supplied to the IR2153 microcircuit through a limiting resistor and a rectifying diode.

You need a powerful resistor, at least 2 watts, it is better to take a 5-watt one. The supply voltage for the microcircuit is additionally smoothed by a small electrolytic capacitor with a capacity of 100 to 470 μF, preferably 35 Volts. The microcircuit begins to produce a sequence of rectangular pulses, the frequency of which depends on the rating of the components of the timing circuit; in my case, the frequency is around 45 kHz.

A rectifier with a midpoint is installed at the output. Rectifier in the form of a diode assembly in a to-220 housing. If the output voltage is planned to be within 40 volts, then you can use diode assemblies soldered from computer power supplies.

The voltage boost capacitor is designed for correct operation of the upper field switch; the capacitance depends on which transistor is used, but on average 1 μF is enough for most cases.

Before starting, you need to check the operation of the generator. For these purposes, about 15 volts of direct voltage is supplied from an external power source to the indicated pins of the microcircuit.
Next, the presence of rectangular pulses on the gate of the field switches is checked; the pulses must be completely identical, of the same frequency and filling.
The first start of the power source must be done through a 220 Volt safety incandescent lamp with a power of about 40 watts, be extremely careful not to touch the board during operation, after disconnecting the unit from the network, wait a few minutes until the high-voltage capacitor is discharged through the corresponding resistor.
It is very important to point out that this circuit does not have protection against short circuits, so any short circuits, even short-term ones, will lead to failure of the power switches and the IR2153 microcircuit, so be careful.

Self-clocked half-bridge driver

Distinctive features:

  • Integrated 600V half bridge driver
  • 15.6V Zener diode on Vcc line
  • Actual micropower at start
  • Tighter initial pause time control
  • Low temperature coefficient of pause duration
  • Shutdown function (1/6 of Vcc at CT pin)
  • Increased blocking hysteresis when voltage drops (1 V)
  • Lower power level conversion circuit
  • Constant pulse width LO,HO at start
  • Reduced di/dt for better noise immunity
  • Low level driver output in phase with RT
  • Internal 50ns trigger diode (IR2153D)
  • Increased snap resistance on all inputs and outputs
  • ESD protection on all pins
  • Bias voltage V OFFSET no more than 600V
  • Duty factor 2 (meander)
  • Tr/Tp 80/40ns
  • Vclamp 15.6V
  • Pause 1.2 µs

Typical connection diagram:

Block diagram:


Pin locations:

Description of pins:

Description:

IR2153 is an improved version of the IR2155 and IR2151 drivers, which contains a high-voltage half-bridge driver with a generator similar to the 555 industrial timer (K1006VI1). The IR2153 offers better functionality and is easier to use than previous ICs. The shutdown function in this device is combined with the CT output, and both channels are turned off when a low-level control signal is applied.

In addition, the formation of output pulses is associated with the moment the increasing voltage on Vcc crosses the threshold of the undervoltage blocking circuit, thereby achieving higher stability of the pulses at startup.

Noise immunity has been significantly improved by reducing the rate of change of driver current (di/dt) and also by increasing the hysteresis of the undervoltage blocking circuit (to 1V). Finally, significant attention was paid to improving latching resistance and providing comprehensive ESD protection on all pins.

So the first power supply, let’s call it “high-voltage”:

The circuit is classic for my switching power supplies. The driver is powered directly from the network through a resistor, which reduces the power dissipated by this resistor compared to power supply from the +310V bus. This power supply has a soft start (inrush current limiting) circuit on the relay. Soft start is powered through quenching capacitor C2 from a 230V network. This power supply is equipped with protection against short circuit and overload in secondary circuits. The current sensor in it is resistor R11, and the current at which the protection is triggered is regulated by trimming resistor R10. When the protection is triggered, the HL1 LED lights up. This power supply can provide a bipolar output voltage of up to +/-70V (with these diodes in the secondary circuit of the power supply). The pulse transformer of the power supply has one primary winding of 50 turns and four identical secondary windings of 23 turns each. The wire cross-section and transformer core are selected based on the required power that must be obtained from a particular power supply.

The second power supply, we will conventionally call it a “self-powered UPS”:

This unit has a circuit similar to the previous power supply, but the fundamental difference from the previous power supply is that in this circuit, the driver powers itself from a separate winding of the transformer through a quenching resistor. The remaining nodes of the circuit are identical to the previous presented circuit. The output power and output voltage of this unit is limited not only by the parameters of the transformer and the capabilities of the IR2153 driver, but also by the capabilities of the diodes used in the secondary circuit of the power supply. In my case it is KD213A. With these diodes, the output voltage cannot be more than 90V, and the output current cannot be more than 2-3A. The output current can be higher only if radiators are used to cool the KD213A diodes. It is worth additionally stopping at the T2 throttle. This inductor is wound on a common ring core (other types of cores can also be used), with a wire of a cross-section corresponding to the output current. The transformer, as in the previous case, is calculated for the appropriate power using specialized computer programs.

Power supply number three, let’s call it “powerful with 460 transistors” or simply “powerful 460”:

This scheme is already more significantly different from the previous schemes presented above. There are two main big differences: protection against short circuit and overload here is performed on a current transformer, the second difference is the presence of additional two transistors in front of the keys, which allow isolating the high input capacitance of powerful switches (IRFP460) from the driver output. Another small and insignificant difference is that the limiting resistor of the soft start circuit is located not in the +310V bus, as was the case in previous circuits, but in the 230V primary circuit. The circuit also contains a snubber connected in parallel with the primary winding of the pulse transformer to improve the quality of the power supply. As in previous schemes, the sensitivity of the protection is regulated by a trimming resistor (in this case R12), and the activation of the protection is signaled by the HL1 LED. The current transformer is wound on any small core that you have at hand, the secondary windings are wound with a wire of small diameter 0.2-0.3 mm, two windings of 50 turns each, and the primary winding is one turn of wire of a cross-section sufficient for your output power.

And the last pulse generator for today is a “switching power supply for light bulbs,” let’s call it that.

Yes yes, don't be surprised. One day there was a need to assemble a guitar preamplifier, but I didn’t have the necessary transformer at hand, and then this impulse generator, which was built just for that occasion, really helped me out. The scheme differs from the previous three in its maximum simplicity. The circuit does not have protection against short circuits in the load as such, but there is no need for such protection in this case, since the output current on the secondary +260V bus is limited by resistor R6, and the output current on the secondary +5V bus is limited by the internal overload protection circuit of the stabilizer 7805. R1 limits the maximum starting current and helps cut off network noise.