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DC-DC Converters

12/25/2010 11:26 PM

28 VDC TO 280 VDC CONVERTER 300 WATTS: DESIGN/AVIALABILITY IN INDIA

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#1

Re: DC-DC CONVERTERS

12/25/2010 11:59 PM

I really am starting to hate lazy guests. First explain to me why I should do your work? Don't give me that you...

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#2

Re: DC-DC CONVERTERS

12/26/2010 12:16 AM

And please turn off the caps lock key.

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#3

Re: DC-DC CONVERTERS

12/26/2010 1:37 AM
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#4

Re: DC-DC CONVERTERS

12/26/2010 2:58 AM

Question is too vague please explain, do you want to copy a design ?

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#5
In reply to #4

Re: DC-DC CONVERTERS

12/26/2010 7:24 AM

I want to use this as the input in a high voltage power supply being designed by me which needs to operate from 24-28 VDC input. I have the design for 280 VDC to 10 KV DC converter. I wish to copy a design or purchase the unit. It should be small in size for OEM useage.

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#6
In reply to #5

Re: DC-DC CONVERTERS

12/26/2010 12:19 PM

300 watts is a lot of juice for a 10kV converter! Actual, 280V DC is a pretty sensible starting point for all kinds of things, a bus voltage, if you will, for converters to other voltages. 365V or so is even better, being in the vicinity of voltages rectified from the AC line, or developed with a PFC off-line input stage.

A quick look about didn't reveal any 28 to 300-volt, etc., DC-DC converters. Lots of 28V to AC-line converters, yes. But that approach means unnecessary electronics, first to create the 60Hz "modified sine" wave, and second to rectify and filter it to DC. If you were building something, it would make more sense to make an efficient direct dc-dc converter. I do agree that when going from 28V to 10kV, it may be wise to do it in two steps, because the transformer turns ratio can get pretty crazy otherwise.

Given that your 28V input is predictable, you could use an unregulated Bus Converter, like I wrote about yesterday in this DC-transformer posting. The design I showed there uses a simple 8-pin IR2805 chip with two FETs. IR designed that chip to run a half-bridge or similar Bus Converter, with a fixed 50% duty cycle.

To go to voltages above 100V with an IR2805, it's necessary to use a transformer. But as the drawing below shows, the circuit is conceptually very simple (some parts have been omitted for simplicity). (Note, this isn't a "DC transformer" as I discussed in the other post, but it is an interesting useful Bus-Converter circuit.)

The only slightly sobering part is the 1:10 stepup transformer, but keep in mind you'll be running it at 250kHz, etc., so it's not very large, even for 300W. And at that high frequency it won't need very many turns, so you can easily wind it by hand on a ferrite coil-form.

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#7
In reply to #6

Re: DC-DC CONVERTERS

12/26/2010 12:27 PM

Another good answer. Actually I felt your posting on "Why Not DC" was more appropriate here. I guess it should now be up to the OP to find a way to implement this in India.

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#9
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Re: DC-DC CONVERTERS

12/27/2010 4:43 PM

Thanks very much, redfred. Yes, the "DC transformer" in my other post is interesting and quite useful, but with the IR2805s chip it's limited to voltages below 100V (IR does make 600V self-oscillating drivers, like the IRS2153 and IRS21531, but they're slower parts, e.g., with 0.6us deadtime). That circuit also has the disadvantage that all the converted energy is carried by the inductor, which charges in one portion of the cycle and discharges in the other. This forces one to use larger inductors (like the big one shown in my PCB drawing), and limits the maximum operating power.

By contrast, the circuit in my latest post, above, is a half-bridge converter, which transmits power on both halves of the cycle. It uses a real transformer, which does not require energy storage, and therefore can be smaller than the storage inductor in my previous post (the output inductor shown in the drawing above is small, and simply provides a little bit of optional filtering). It also has the advantage of being easily used for high output voltages and with high voltage ratios. Since the output has a diode bridge rectifier, rather than a MOSFET synchronous rectifier, the circuit can operate in one direction only, and hence is not capable of DC transformer operation.

The half-bridge converter is attractive in that, although it has a nominal 50% duty cycle, helping to prevent transformer DC-current saturation, the transformer is intrinsically AC coupled, so the capacitive-divider node simply moves up or down a bit to insure honest 50:50 waveform areas to the transformer primary. It's self-correcting.

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#8

Re: DC-DC Converters

12/26/2010 6:03 PM

There are plenty of 12/24 V to 240 volt 300watt inverters available and they cost next to nothing, put a bridge rectifier and suitable sized capacitor and there is your 280VDC.

Ebay, Alibaba are first port of call on line but most major electronics emporiums carry them.

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