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Re: [Amps] winding an HV transformer

To: Paul Decker <kg7hf@comcast.net>
Subject: Re: [Amps] winding an HV transformer
From: KD7QAE <KD7QAE@ARRL.NET>
Date: Tue, 31 Mar 2009 22:33:47 -0700
List-post: <amps@contesting.com">mailto:amps@contesting.com>
Paul,

At a 6:1 ratio, assuming the core are supports the flux created by 340V 
and 6 turns, you will have an output of 6x340 or 2040V.  The transformer 
takes the 680Vp-p primary square wave and delivers 4080Vp-p to the FWB 
which 'inverts' the negative pulses and adds them into the gaps between 
the positive pulses to give you the 2040Vdc output. 

Since this is a square wave, a capacitive filter will suffice to fill in 
the small gaps due to switch rise and fall times and transformer 
response.  I would build this filter as a high frequency filter followed 
by a few hundred uF of energy storage caps. 

If you want to pull the maximum out of the AC line you have to power 
factor correct the input rectifier so the PS looks resistive to the 
incoming AC.  This is a simple matter of either building a PFC circuit 
from PS controller application guides, or, better yet, buying a surplus 
2kW computer (server) power supply and reusing the AC front end to get 
the PFC and even the power MOSFETS.  By the way, this approach will give 
you line regulation and, if you reuse more of the PSU, load regulation 
as well.

On a final note, while the 50% square wave chopper is an easy circuit, I 
see a major drawback in that it has no load or line regulation.  If you 
were to add a simple PWM controller to this so that the duty cycle of 
the square wave were variable, and add an output inductor filter, you 
would then have a regulated HV PSU for not much more trouble than what 
you are now building.

Tomm, KD7QAE

Paul Decker wrote:
>
>
> I've been holding this question for a couple of days now, I'm sure it is very 
> simple and perhaps I just need some reassurance on the answer. 
>
>
>
> If you have been following some of this smps discussion, I've got 100Khz 
> pulsed DC (0 - 340v) which is generated by directly rectifing and filtering 
> the 240 V AC mains and providing that into an h-bridge.   The h-bridge dumps 
> the 340 V 100Khz square wave into the transformer. 
>
>
>
> As the QST article recomends, I've wound the transformer with five turns on 
> the primary and had calculated that I need 30 turns on the secondary.   
> Performing some small signal tests, inputting 3.4v pk-pk square wave from my 
> signal generator yeilds about 20.4 volts pk-pk square wave.   I believe this 
> relationship should be linear and inputting 340 V will yeild 2040 volts on 
> the secondary.    
>
>
>
> At this point the secondary dumps into a full wave bridge rectifier followed 
> by a filter capacitor.   This is where I am unclear.    When I rectify this 
> with the full wave bridge, will I get 2040 * 0.90 or will I get  2040 * 1.414 
> as the final DC output?     Part of me says I get the 1.414 value of 2885 
> VDC, however reading through the handbook, I seem to be reading I'll get 0.90 
> the output voltage. 
>
>
>
> thanks, 
>
> Paul 
>
>
>
>   
>
>
>
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