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Switching power supply on IR2153

Greetings the inhabitants of our site!
In this article, together with Roman (author of the YouTube channel "Open Frime TV"), we will assemble a universal power supply unit on the IR2153 chip. This is a kind of "Frankenstein", which contains the best qualities from different schemes.

The Internet is full of power supply circuits on the IR2153 chip. Each of them has some positive features, but the author has not yet met a universal scheme. Therefore, it was decided to create such a scheme and show it to you. I think you can immediately go to her. So let's get it right.

The first thing that catches your eye is the use of two high-voltage capacitors instead of one on 400V. Thus we kill two birds with one stone. These capacitors can be obtained from old computer power supplies without spending money on them. The author specially made several holes in the board for different sizes of capacitors.




If the unit is not available, then the prices for a pair of such capacitors are lower than one high voltage. The capacitance of the capacitors is the same and should be at the rate of 1 μF per 1 W of output power. This means that for 300 W of output power, you need a pair of capacitors of 330 microfarads each.


Also, if you use such a topology, there is no need for a second decoupling capacitor, which saves us space. And that's not all. The isolation capacitor voltage should already be not 600 V, but only 250 V. Now you can see the sizes of capacitors at 250V and 600V.


The next feature of the circuit is powering for the IR2153. Everyone who built the blocks on it faced unrealistic heating of supply resistors.


Even if they are set from a break, a lot of heat is released a lot. An ingenious solution was immediately applied, using a capacitor instead of a resistor, and this gives us the fact that there is no heating of the element by power.

The author of this home-made saw such a decision with Yuri, the author of YouTube channel "Red Shade". The board is also equipped with protection, but in the original version of the circuit it was not.



But 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 the author installed protection. If it is not needed, then you can simply put jumpers in place of the shunt and not install the components marked in red.


The protection current is regulated using this tuning resistor:

The values ​​of the shunt resistors vary depending on the maximum output power. The more power, the less resistance is needed. For example, for power below 150 watts, 0.3 ohm resistors are needed. If the power is 300 W, then we need 0.2 Ohm resistors, well, at 500 W and above we put resistors with a resistance of 0.1 Ohms.

This unit should not be assembled with power above 600 watts, and also a few words about the protection work. She's hiccuping here. The starting frequency is 50 Hz, this is because the power is taken from the alternating current, therefore, the latch is reset at the mains frequency.


If you need a snap-in option, then in this case, the IR2153 microcircuit needs to be powered continuously, or rather, from high-voltage capacitors. The output voltage of this circuit will be removed from the half-wave rectifier.

The main diode will be the Schottky diode in the TO-247 package, select 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. At the output, there is a capacitor of 1000 μF, it is enough for all currents, since at high frequencies the capacitance can be set less than for a 50 Hz rectifier.


It is also necessary to note such auxiliary elements as snubber in the transformer harness;

smoothing capacitors;

and also a Y-capacitor between the high and low ground, which dampens the noise on the output winding of the power supply.

About these capacitors there is an excellent video on YouTube (the author attached a link in the description under his video (the SOURCE link at the end of the article)).

You can not skip the frequency-setting part of the circuit.

This is a 1 nF capacitor, the author does not recommend changing its rating, but he set the resistor of the master part to tuning, there were reasons for this. The first one 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 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 required 24V is output. When installing this resistor, we use a multimeter. We clamp the contacts into crocodiles and rotating the handle of the resistor, we achieve the desired resistance.


Now you can see the 2nd breadboard on which tests were carried out. They are very similar, but the protection board is slightly larger.

The author made mock-ups in order to order the manufacture of this board in China with a calm soul. In the description under the original video of the author, you will find an archive with this board, circuit and signet. There will be in the two shawls and the first and second options, so you can download and repeat this project.

After the order, the author was looking forward to the board, and now they have arrived. We open the package, the boards are reasonably well packed - you won’t get into trouble. Visually inspect them, everything seems to be fine, and immediately proceed to solder the board.




And now she is ready. Everything looks that way. 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. The author applied such round ones, because their sizes are very modest.


Next we see the filter capacitors.

You can get them from the old computer power supply. The author wound the inductor on the t-9052 ring, 10 turns with a wire of 0.8 mm 2 core, but you can use the inductor 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 capacitance, one on the high side and the other on the low.


Well, the throttle remains on the low side, we wind it 8-10 turns on the same core as the network one.
As you can see, this board is designed for toroidal cores, since they are of the same size with the W-shaped, have a large overall power.

It is time to test the device. So far, the main advice is to make the first inclusion through a 40 W bulb.


If everything works as usual, the lamp can be thrown back. Check the circuit for work. As you can see, the output voltage is present. Let's check how the protection reacts.Crossing your fingers and closing your eyes, short the conclusions of the secondary.

As you can see, the protection worked, everything is fine, now you can load the block harder. For this we use our e load. Connect 2 multimeters to monitor current and voltage. We begin to gradually raise the current.


As we 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 has no feedback, so it is preferable to use it for less capricious circuits.

And that’s all. Thank you for attention. See you soon!

Video:
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23 commentary
if ceramics survive ...))
Soldering iron heating power adjustment
Quote: toshen
The fact is that the current through the capacitor never flows, even with alternating voltage.

1) But what about the scheme for regulating the heating of the soldering iron through a set of capacitors published in the journal "RADIO". 2) If your current never flows through the conder and even the alternating one, take the conder by one end and the other plug into the phase wire into a socket holding on to the heating battery - if you survive, you will be right; ^)
I do not agree! For a mid-point (two capacitors in series), one capacitor works in each half-wave, and therefore, with a capacity of 330 microfarads, the undistorted voltage and current power can reach 350 watts. The author has no errors!
Anonimus
Well, I read the textbooks, which I also wish you. However, it’s your business, only those who decided to repeat will have a haemorrhage.
Your request is too general and not specific. For the correct query, see above.
Not on the forum, you need to ask, but open the textbook and see the L-shaped filter. If you are too lazy to look for a tutorial, just ask for the "l-shaped filter rectifier" or "l-shaped smoothing filter".
Anonimus
They didn’t give a link to insert, however, everything is easily searched for on request - the inductor in the power supply
By the way, protection works only for one half-period.
Anonimus
Here, the inductor accumulates energy, and when the voltage drops, it transfers it to the load. After the capacitor, the ripple is less. It’s a pity you can’t insert pictures, however I suggest asking a question on any radio forum, maybe this is in the FAQ.
In the LC filter, the inductor does not stand after the filter capacitor, but before it.
Anonimus
Quote: Ivan_Pokhmelev
But why then do LC filters be used on mains voltage rectifiers? There is definitely no PWM there.

In the LC filter, the inductor stands after the filtering capacitor and smooths out the ripple, here it stands in front of the capacitor.
But why then do LC filters be used on mains voltage rectifiers? There is definitely no PWM there.
Anonimus
The inductor together with the filter capacitor forms an integrating circuit which should regulate the voltage on the capacitor in proportion to the increase in pulse width during PWM stabilization. There is no PWM and no stabilization, the voltage is simply extinguished on the inductor.
In ATX units, a 12V line is blanked out on a 12V line, so you can take a ready-made transformer and get 20-25V
According to the diodes, for a 50Hz sinusoidal transformer with a half-wave circuit, 1.5U is enough, but for a rectangular pulse everything is not so simple - when switching, a voltage surge is generated, which partially must cancel the snubber-RC circuit parallel to the winding.What amplitude the voltage pulse will remain depends on the transformer inductance and the snubber parameters. In the same 12 volt ATX blocks, there are 200V Fast assemblies.
ATX means a push-pull half-bridge circuit, which used to be the most common, but there were others.
Anonimus
According to the diodes, for a 50Hz sinusoidal transformer with a half-wave circuit, 1.5U is enough, but for a rectangular pulse everything is not so simple - when switching, a voltage surge is generated, which partially must cancel the snubber-RC circuit parallel to the winding. What amplitude the voltage pulse will remain depends on the transformer inductance and the snubber parameters. In the same 12 volt ATX blocks, there are 200V Fast assemblies.
ATX means a push-pull half-bridge circuit, which used to be the most common, but there were others.
Anjnimus
The inductor together with the filter condenser forms an integrating chain - it simply changes the voltage across the capacitor in proportion to the pulse width. But all this is necessary only if the pulse width changes, i.e. with PWM stabilization. Here, the pulse width is constant, there is no stabilization, and the inductor simply reduces the voltage. Alternatively, you can adjust the inductance with an inductance if there is a ready-made transformer. For example, a tr of ATX power supplies on a 12V line without a group stabilization choke produces 20-25V, and it reduces this very choke to 12V.
Quote: Anonimus
Choke in the secondary beforeextra capacitor,
Why?
Quote: Anonimus
schottky need 200v or better fast diodes 200-400v [/ b] [/ u]
Why?
Anonimus
Choke in the secondary beforeextra capacitor, schottky need 200v or better fast diodes 200-400v
Guest Edward
Yes, the author has incorrectly calculated the ratio of the total capacity of high-voltage capacitors and output power. The total output power will be 2 times less than what is indicated.
Quote: NickF
The author has a standard doubler circuit, although it is doubtful that it will work after the bridge.

The doubler is not after the bridge.
The circuit works in terms of power IR-ki. True network conder 470 nF, I would increase to 1 uF. And I would shunt the resistor 300 kOhm at 0.5 watts. Checked in LTSpice. So "TOSHEN" learn materiel. And google on the internet - a half-wave rectifier with a voltage doubler.
Well, such TOSHEN type loggers send comments, and he himself hasn’t digged an ear. You type in google "rectifier with doubling the voltage." The author has a standard doubler circuit, although it is doubtful that it will work after the bridge.
Quote: toshen
the current through the capacitor never flows,

Is he the perfect insulator?
The fuse needs another varistor.
The power supply zener diode is not needed. in the chip itself it is already there.
How the microcircuit receives power through the capacitor is generally not clear. The fact is that the current through the capacitor never flows, even with alternating voltage.
The capacitance of the capacitors is the same and should be at the rate of 1 μF per 1 W of output power. This means that for 300 W of output power, you need a pair of capacitors of 330 microfarads each.

This is a clear mistake! These two Conders are placed in series, as a result of which the assembly voltage becomes 400 V (2 to 200 V), but the capacitance of the capacitors decreases by half to 165 μF. Then 1 microfarad per 1 W of output power does not work.

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