POWER SUPPLY

Intro:
Pulse electronics it's facken evil!
If you can use a working the scheme, use it,
but if it not working at once, welcome to hell:)

Approximately calculate, how power is necessary for all devices:
100W - PC
200W - step motors
100W - lubeoil pump
200W - spindel
Total - 600W

Duty power:
It's first what I made, device based on a chip TOP221(Not a bad the thing,
despite all the torture, chip survived), have 10W power.



Breadboard:
If you develop new device, not hurry make the PCB for it,
first debug the device on a the breadboard.



First version:
I have a ferit core, from what it's industrial power unit,
but 400W it's all what he was capable of.
When I connect 600W, it work only 2 seconds, then switches exploded.


For test I make the resist on a 1kW(24V*45A).



Second version:
I buy core E63/38/28 N87 from EPCOS, overall power 1.3kW on a 60kHz frequency.
For calculation the transformer I use Eranosyan technique.

Then after 3 weeks, 6 pairs of transistors, 4 drivers, 1 big capacitor, and a few other small things,
I'm debug the scheme, and get 1kW.

Making PCB:
For making PCB I use film photo resist.
First what a need do, it find the exposure time.
I make test PCB, of 8 parts, hiding them in turn with foil, every 4 minutes.
As photo template I use paper, printed image on a laser printer,
and made transparent with oil. For exposure use black light lamp with the capacity 26W.
After washing in silicate glue:

After etching with ferric chloride:

You will aslo need to choose exposure time, because it process very sensitive to details.

Ok, next I cut pieces of desired size:

Inflicted on them photoresist(if you do not have laminator, it is better to do it under water):

Then smoothed iron(it should not be too hot 90-110*C):

Using a scotch to attached photo template:


Reflector hastily:

Exposure:

That's what happened after washing:


Etching with ferric chloride:


And then drilling:





Assembling:
I transferred the components from the prototyping board to the PCB.


To improve the thermal efficiency, I posted
transistors on aluminum plates:


The back side after desoldering all the components:
Fully finished device, after washing flux:

In the archive you will find the scheme and drawings of the PCB: Power.rar