Ir2153 power supply with protection. A simple, home-made switching power supply on the IR2153 with your own hands
So the first power supply, let's conditionally call it "high-voltage":
The circuit is classic for my switching power supplies. The driver is powered directly from the mains through a resistor, which reduces the power dissipated on this resistor, compared to powering from the +310V bus. This power supply has a soft start (inrush current limit) circuit on the relay. Soft start is powered by a quenching capacitor C2 from a 230V network. This power supply is protected against short circuit and overloads in secondary circuits. The current sensor in it is the resistor R11, and the current at which the protection is triggered is regulated by the tuning resistor R10. When the protection is triggered, the HL1 LED lights up. This power supply can provide output bipolar voltage 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. The cross section of the wire and the core of the transformer are selected based on the required power that must be obtained from a particular power supply.
The second power supply, we will conditionally 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 feeds itself from a separate transformer winding through a quenching resistor. The remaining nodes of the scheme are identical to the previous presented scheme. output power and output voltage of this block 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, this 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 worthwhile to additionally dwell on the T2 throttle. This inductor is wound on a common ring core (other types of cores can also be used), with a wire of the section corresponding to the output current. The transformer, as in the previous case, is calculated for the corresponding power using specialized computer programs.
Power supply number three, let's call it "powerful on 460x 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 is performed here 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 keys (IRFP460) from the driver output. Another small and not significant difference is that the limiting resistor of the soft start circuit is located not in the +310V bus, as it was in the previous circuits, but in the 230V primary circuit. The circuit also has a snubber connected in parallel with the primary winding of the pulse transformer to improve the quality of the power supply. As in the previous schemes, the protection sensitivity is regulated by a trimmer resistor (in this case, R12), and the HL1 LED signals the protection operation. 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 sufficient for your output power section.
And the last impulse for today is a “switching power supply for light bulbs”, we will conditionally call it that.
Yes, don't be surprised. Once there was a need to assemble a guitar preamplifier, but the necessary transformer was not at hand, and then this impulse converter, which was built just for that occasion, helped me a lot. The scheme differs from the previous three in its maximum simplicity. The circuit does not have, as such, protection against a short circuit in the load, but there is no need for such protection in this case, since the output current through the secondary bus + 260V is limited by resistor R6, and the output current through the secondary bus + 5V is limited by the internal overload protection circuit of the stabilizer 7805. R1 limits the maximum inrush current and helps cut off mains noise.
Hello everybody!
Background:
The site has a circuit for audio frequency power amplifiers (ULF) 125, 250, 500, 1000 watts, I chose the 500 watt option, because in addition to radio electronics, I’m also a little fond of music and therefore I wanted something better from ULF. The scheme on the TDA 7293 didn’t suit me, so I decided on the option field effect transistors 500 watts. From the beginning, I almost assembled one ULF channel, but work stopped for various reasons (time, money, and the unavailability of some components). As a result, I bought the missing components and finished one channel. Also, after a certain time, I collected the second channel, set it all up and tested it on the power supply from another amplifier, everything worked at the highest level and I liked the quality very much, I didn’t even expect it to be so. Separate, many thanks to the radio amateurs Boris, AndReas, nissan who have collected it all the time, helped in setting it up and in other nuances. Next up was the power supply. Of course, I would like to make a power supply on a conventional transformer, but again, everything stops at the availability of materials for the transformer and their cost. Therefore, I decided to stop at the UPS after all.
Well, now about the UPS itself:
I used IRFP 460 transistors, because I did not find them indicated on the diagram. I had to put the transistors on the contrary by turning 180 degrees, drill more holes for the legs and solder the wires (see the photo). When I made a printed circuit board, I later only realized that I couldn’t find the transistors I needed as in the diagram, I installed those that were (IRFP 460). Transistors and output rectifier diodes must be installed on the heat sink through insulating heat-conducting gaskets, and radiators must also be cooled with a cooler, otherwise transistors and rectifier diodes may overheat, but the heating of transistors of course also depends on the type of transistors used. The lower the internal resistance of the field worker, the less they will heat up.
Also, I have not yet installed a 275 Volt Varistor at the input, since it is not in the city and I do not have it either, but it is expensive to order one part via the Internet. I will have separately rendered electrolytes at the exit, because they are not available on the right voltage and size doesn't fit. I decided to put 4 electrolytes of 10,000 microfarads * 50 volts, 2 in series per arm, in total, each arm will have 5000 microfarads * 100 volts, which will be completely enough for the power supply, but it is better to put 10,000 microfarads * 100 volts per arm.
The diagram shows the resistor R5 47 kOhm 2 W for powering the microcircuit, it should be replaced with 30 kOhm 5 W (preferably 10 W) in order for the IR2153 chip to have enough current at a heavy load, otherwise it may go into protection against a lack of current or it will pulsate voltage will affect the quality. In the author's circuit, it costs 47 kOhm, which is a lot for such a power supply unit. By the way, the resistor R5 will get very hot, don't worry, the type of these circuits on IR2151, IR2153, IR2155 for power supply is accompanied by a strong heating of R5.
In my case, I used an ETD 49 ferrite core and it was very hard for me to fit onto the board. At a frequency of 56 kHz, according to calculations, it can give up to 1400 watts at this frequency, which in my case has a margin. You can also use a toroidal or other shape of the core, the main thing is that it would be suitable in terms of overall power, permeability and, of course, that there would be enough space to place it on the board.
Winding data for ETD 49: 1 = 20 turns with 0.63 wire in 5 wires (220 volt winding). 2-ka \u003d main power bipolar 2 * 11 turns with a wire 0.63 in 4 wires (winding 2 * 75-80) volts. 3-ka \u003d 2.5 turns with a wire 0.63 in 1 wire (12 volt winding, for soft start). 4-ka \u003d 2 turns with a wire 0.63 in 1 wire (winding additional for power preliminary schemes(tone block, etc.). The frame of the transformer needs a vertical design, I have a horizontal one, so I had to fence. Can be wound in a frameless design. On the other types of core, you will have to calculate it 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 run:
When starting up the UPS for the first time, be sure to install network cable and UPS light bulb 60-100 watts. When you turn it on, if the light does not light up, then it's already good. At the first start, short circuit protection may turn on and the HL1 LED will light up, since high-capacity electrolytes 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 in turned off 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. Further, when you make sure that the UPS turns on and there are all voltages 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 for powering the ULF) with a 100-watt light bulb. When the HL1 LED lights up when the UPS is turned on under load (a 100-watt lamp), you need to turn the variable multi-turn resistor R9 2.2 kOhm counterclockwise until the protection is activated when turned on. When the LED lights up when turned on, you need to turn it off and wait until it goes out and gradually twist it clockwise in the off state and turn it on again until the protection stops working,
you just need to turn a little, for example, 1 turn and not immediately by 5-10 turns, i.e. turned it off, turned it on and turned it on, the protection worked - again the same procedure several times until you reach the desired result. When you set the desired threshold, then, in principle, the power supply is ready for use and you can remove the light bulb by mains voltage and try to load the power supply with an active load, for example, 500 watts. There, of course, you can play around with protection as you like, but I don’t recommend testing with a short circuit, as this can lead to a malfunction, although there is protection, some capacity will not have time to discharge, the relay will not respond instantly or stick and may be a nuisance. Although I accidentally and not accidentally made a number of closures, the protection works. But nothing is eternal.
For a long time I was worried about the topic of how you can use a power supply from a computer as a power amplifier. But remodeling the power supply is still fun, especially a pulsed one with such a dense installation. Although I am accustomed to all kinds of fireworks, I really didn’t want to scare my family, and it’s also dangerous for myself.
In general, the study of the issue led to quite simple solution, which does not require any special details and almost no adjustment. Collected-turned-works. Yes, and I wanted to practice etching printed circuit boards with the help of a photoresist, since recently modern laser printers have become greedy for toner, and the usual laser ironing technology has not worked out. I was very pleased with the result of working with the 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 scheme and the process of assembling and adjusting the power supply.
The power supply is actually very simple, almost all of the parts left after disassembling the not-so-good impulse from the computer are assembled - from those that are not “reported” to. One of these parts is a pulse transformer, which can be used without rewinding in a 12V power supply, or recalculated, which is also very simple, for any voltage, for which I used the Moskatov program.
Block diagram impulse block food:
The following were used as components:
ir2153 driver - a microcircuit used in pulse converters for power supply fluorescent lamps, its more modern counterpart is ir2153D and ir2155. In the case of using ir2153D, the VD2 diode can be excluded, since it is already built into the microcircuit. All microcircuits of the 2153 series already have a built-in 15.6V zener diode in the power circuit, so you should not bother too much with the device of a separate voltage regulator to power the driver itself;
VD1 - any rectifier with reverse voltage not lower than 400V;
VD2-VD4 - "high-speed", with a short recovery time (no more than 100ns) for example - SF28; In fact, VD3 and VD4 can be excluded, I did not set them;
as VD4, VD5 - a dual diode from a computer power supply "S16C40" is used - this is a Schottky diode, you can put any other, less powerful one. Need this winding to power the ir2153 driver after it starts pulse converter. You can exclude both diodes and winding if you do not plan to remove power more than 150W;
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, the output depends on their power, but you should not get carried away here much, as well as remove more than 300W from the unit;
L3 - wound on a ferrite rod and contains 4-5 turns of 0.7mm wire; This chain (L3, C15, R8) can be excluded altogether, it is needed to slightly facilitate the operation of transistors;
The L4 inductor is wound on a ring from the old group stabilization inductor 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 supplied with a smaller capacity, their capacity can be roughly selected based on the power output of the power supply, approximately 1-2 microfarads per 1 W of power. Do not get carried away with capacitors and put capacitances greater than 10,000 microfarads on the output of the power supply, as this can lead to a "salute" when turned on, since they require significant current to charge 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 E-shaped core with the following data: S0 = 1.68 sq. cm; Sc = 1.44 sq. cm; Lav.l. = 86cm; Conversion frequency - 100kHz;
The resulting calculated data:
Winding 1- 27 turns 0.90mm; voltage - 155V; Wound in 2 layers with a wire consisting of 2 cores of 0.45 mm; The first layer - inner contains 14 turns, the second layer - outer contains 13 turns;
winding 2- 2 halves of 3 turns with a wire of 0.5 mm; this is a “self-powered winding” for a voltage of about 16V, it is wound with a wire so that the winding directions are in different directions, the middle point is brought out and connected to the board;
winding 3- 2 halves of 7 turns, wound with the same 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 the "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 the transformer for any desired voltage. I have assembled 2 such power supplies - one for the amplifier on the TDA7293, the second - for 12V to power all kinds of crafts - is used as a laboratory one.
Power supply for the amplifier for voltage 2x40V:
12V switching power supply:
Power supply assembly in the case:
A photo of testing a switching power supply - that for an amplifier using a load equivalent of several MLT-2 resistors of 10 Ohms included in different sequence. The goal was to get data on power, voltage drop and voltage difference in the arms +/- 40V. As a result, I got the following parameters:
Power - about 200W (I no longer tried to shoot);
voltage, depending on the load - 37.9-40.1V in 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 blowing, 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 sites were used, this power supply is described in great detail on the Vega forum, there are also options for a block with short circuit protection, which is not bad. For example, with an accidental short circuit, the 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 not more than 40W. When you first turn on the network, it should flash for a short time and go out. It shouldn't glow at all! At the same time, 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 start testing.
We recently talked about creating . Today we will take a step-by-step look at how to create a universal switching power supply on the IR2153 chip. The Internet is full of power supply circuits for IR2153, but each of them has its drawbacks, but the presented circuit is universal.
Scheme of a switching power supply on IR2153, necessary components
Detailed diagram of a switching power supply
The first thing that catches your eye is the use of two high voltage capacitors instead of one for 400V. Thus, you can immediately kill two birds with one stone. These capacitors can be obtained from old computer power supplies without spending money on them.
If there is no block, then the prices for a pair of such capacitors are lower than for one high-voltage one. The capacitance of the capacitors is the same and should be at the rate of 1 uF per 1 W of output power. This means that for 300 watts of power output you will need a pair of 330uF capacitors.
It is also important to consider the following correspondence:
- 150 W = 2x120 uF
- 300 W = 2x330 uF
- 500 W = 2x470 uF
The next feature of the circuit is power supply for IR2153. Everyone who built blocks on it faced with strong heating of the supply resistors.
Even if they are set from a break, a lot of heat is released. To avoid this, we use a capacitor instead of a resistor. This will prevent the element from heating up.
Also, the board is equipped with protection, but in the original version of the circuit it was not.
After tests on the layout, it turned out that there was too little space to install the transformer and therefore the circuit had to be increased by 1 cm, this gave extra space on which to install protection. If it is not needed, you can simply put jumpers instead of a shunt and do not install the components marked in red.
The protection current is adjusted using a trimmer resistor:
The shunt resistor values vary depending on the maximum output power. The larger it is, the less resistance is needed. For example, for power up to 150 W, 0.3 ohm resistors are needed. If the power is 300 W, then it is better to use 0.2 ohm resistors. At 500 W and above, we put resistors with a resistance of 0.1 Ohm. This unit should not be assembled with a power higher than 600 watts.
You also need to say a few words about the work of protection. She hiccups here. The start frequency is 50 Hz. This is because the power is taken from the AC, therefore the latch is reset at the mains frequency.
If you need a latched option, then in this case the power supply of the IR2153 chip must be taken constant, or rather, from high-voltage capacitors. The output voltage of this circuit will be taken from a full-wave rectifier.
The main diode will be a Schottky diode in the TO-247 package, choose the current for your transformer.
If there is no desire to take a large case, then in the Layout program it is easy to change it to TO-220. There is a 1000 uF capacitor at the output, it is enough for any currents, since at high frequencies the capacitance can be set less than for a 50 hertz rectifier.
It is also necessary to note the use of some auxiliary elements in the transformer piping:
Snubbers
Smoothing capacitors
Also, do not forget about the Y-capacitor between the grounds of the high and low sides, which dampens noise on the output winding of the power supply.
Y-capacitor
You can not skip the frequency-setting part of the circuit.
This is a 1 nF capacitor, the author does not recommend changing its value, but he put a tuning resistor in the driving part, there were reasons for this. The first of them is the exact selection of the desired resistor, and the second is a small adjustment of the output voltage using the frequency. And now a small example, let's say you are making a transformer and you see that at a frequency of 50 kHz the output voltage is 26V, and you need 24V. By changing the frequency, you can find a value at which the output will be the required 24V. When installing this resistor, we use a multimeter. We clamp the contacts into crocodiles and rotate the resistor knob, we achieve the desired resistance.
This is a 1 nF capacitor, we do not recommend changing its value, but you can install a tuning resistor for the driving part, there are reasons for this. The first of them is the exact selection of the desired resistor, and the second is a small adjustment of the output voltage using the frequency.
A small example: let's say you are making a transformer and you see that at a frequency of 50 kHz the output voltage is 26 V, and you need 24 V. By changing the frequency, you can find a value at which the required 24 V will be output. When setting this resistor, we use multimeter. We clamp the contacts into crocodiles and, by rotating the resistor knob, we achieve the desired resistance.
The printed circuit board for the switching power supply on the IR2153 can be downloaded below:
Downloads:
Switching power supply on IR2153 - do-it-yourself assembly
Now you can see 2 breadboards on which the tests were carried out. They are very similar, but the protection board is slightly larger.
Breadboards are made in order to be able to order the manufacture of this board in China.
Here is the board ready. Everything looks like this. Now let's quickly go through the main elements not previously mentioned. First of all, these are fuses. There are 2 of them, on the high and low side.
Next we see the filter capacitors.
You can get them from an old computer power supply. We wind the throttle on the ring t-9052, 10 turns with a wire with a cross section of 0.8 mm 2 cores. However, you can use a choke from the same computer power supply. Diode bridge - any, with a current of at least 10 A.
There are also 2 resistors on the board for discharging the capacitance, one on the high side, the other on the low side.
If everything is working normally, then the lamp can be folded back. We check the scheme for work. As you can see, the output voltage is present. Let's see how the protection reacts. Fingers crossed and eyes closed, we short the conclusions of the secondary.
As you can see, the protection worked, everything is fine. Now you can load the block more. To do this, we use our electronic load. Connect 2 multimeters to monitor current and voltage. We begin to gradually raise the current.
As you can see, at a load of 2A, the voltage dipped slightly. If you put a more powerful transformer, then the drawdown will decrease, but it will still be, since this unit does not have feedback, so it is preferable to use it for less whimsical schemes.
- See also how to create
Video about creating a switching power supply on the IR2153 with your own hands:
Attention! This scheme not recommended for assembly! There is a more advanced and reliable scheme:
I present to your attention just a switching power supply on the IR2153 chip.
The switching power supply circuit is a standard circuit from the datasheet. The difference between the circuit and the datasheet one is only in the original way of powering the driver and simple, highly effective protection against short circuits and overloads.
The driver is powered directly from the mains, through a diode and a quenching resistor, and not after the main rectifier from the +310V bus, as is usually done. This method of powering gives us several advantages at once:
1. Reduces the power dissipated in the quenching resistor. This reduces the heat generation on the board and increases the overall efficiency of the circuit.
2. V differs from power supply via the +310V bus provides a lower level of driver supply voltage ripple.
Overload and short circuit protection is made on a pair of 2N5551/5401 transistors. As a current sensor in this circuit, resistors included in the source of the lower arm of the converter are used. This eliminates the laborious process of winding the current transformer. Using R6, the protection threshold is configured.
In the event of a short circuit or overload, when the voltage drop across R10 R11 reaches a predetermined value, such a value at which the voltage on the basis of VT1 becomes more than 0.6 - 0.7V, the protection will work and the power supply of the microcircuit will be shunted to ground. Which in turn disables the driver and the entire PSU as a whole. As soon as the overload or short circuit is eliminated, the power supply to the driver is restored and the power supply unit continues to operate normally. LED HL1 signals the operation of the protection.
Protection is set up like this. Powerful 10 Ohm "resistors are connected to the output of each arm of the power supply. The power supply is connected to the network. By rotating the R6 slider, we make HL1 go out, and then set the slider to such a position that HL1 is not yet on, but with a minimum turn of the slider to the side If the protection trip current decreases, the LED will light up.With this protection setting, it will work at an output power of approximately 300 W. This mode of operation is safe for these keys (IRF740) and the driver.
The transformer is wound on an ER35/21/11 core. The primary winding is wound in two wires 0.63 mm2 and contains 33 turns. Secondary winding consists of two halves wound in three wires 0.63 mm2 and each half contains 9 turns.
The printed circuit board is made in . Printout on laser printer you don't need to mirror it.
List of radio elements
| Designation | Type | Denomination | Quantity | Note | Shop | My notepad |
|---|---|---|---|---|---|---|
| Power driver and MOSFET | IR2153 | 1 | To notepad | |||
| VT1 | bipolar transistor | 2N5551 | 1 | To notepad | ||
| VT2 | bipolar transistor | 2N5401 | 1 | To notepad | ||
| VT3, VT4 | MOSFET transistor | IRF740 | 2 | To notepad | ||
| VD1, VD2 | rectifier diode | HER108 | 2 | To notepad | ||
| VDS1 | Diode bridge | RS405L | 1 | Or other up to 1000V | To notepad | |
| VDS2 | rectifier diode | FR607 | 4 | Or Schottky with similar characteristics | To notepad | |
| VDR1 | Thermistor | 250V | 1 | To notepad | ||
| R1, R5 | Resistor | 10 kOhm | 2 | 0.25W | To notepad | |
| R2 | Resistor | 18 kOhm | 1 | 2 W | To notepad | |
| R3, R9 | Resistor | 100 ohm | 2 | 0.25W | To notepad | |
| R4 | Resistor | 15 kOhm | 1 | 0.25W | To notepad | |
| R6 | Variable resistor | 10 kOhm | 1 | To notepad | ||
| R7, R8 | Resistor | 33 ohm | 2 | 2 W | To notepad | |
| R10, R11 | Resistor | 0.2 ohm | 2 | Can cement axial | To notepad | |
| C1-C3, C15, C16 | Capacitor | 100nF 1000V | 5 | Film | To notepad | |
| C4 | electrolytic capacitor | 220uF x 16V | 1 | To notepad | ||
| C5, C6 | Capacitor | 1nF x 50V | 2 | Ceramic | To notepad | |
| C7 | Capacitor | 680nF 50V | 1 | Ceramic |