High power SMPS application with IR2153 Welding machine. Used in profile welding etc. works well. Explanation for adjustment: The only adjustment to be made is to set the frequency for maximum current at 2-3 kW with a resistance of 0.25Ω using a 1000w/230v bulb instead of a 10 Ampere fuse.
The bulb should light up for a short time at maximum no-load start with the load resistance. This should correspond to the position of the potentiometer at minimum and if this does not happen, it can be corrected by series resistors parallel to that potentiometer. In this case the frequency is 65 Khz and when we open the potentiometer the frequency drops to about 55 Khz and thus the power of the inverter decreases.
Schematic of the latest version of the SMPS IR2153 Welding machine tested and updated according to the problems
I am adding some changes made until the circuit is finalized to give an idea.
The capacitors in the resonance group are 96nF (4 pieces of 0.33 connected in parallel). This capacity is insufficient, it should be at least 150nF and the resonance coil should be recalculated or the frequency should be reduced a little, the current setting range is between 62 and 70Khz.
The resonance coil is made of a very small cross-section ferrite and even if we leave a 3mm air gap, it limits the maximum current.
The radiator on the rectifier bridge is overheating, it is 105x50x3mm but it seems insufficient, I hope that when I install the side covers, they will direct the air flow and also cool it down since there is not much space for another radiator.
Mosfet (NTHL020N120SC1) inverter Although its amperage is a bit better than the other small IGBT (FGH40T65SHDF) one, there was a heating problem in the radiators, probably the ir2153 cannot control the mosfets properly etc., in the small IGBT inverter, although the radiators are much smaller, there was no heating problem.
