2kw Power supply

Discussion in 'The Projects Forum' started by ahmelsayed, Dec 2, 2011.

  1. ahmelsayed

    Thread Starter New Member

    Dec 1, 2011
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    Hello, Everyone

    I'm trying to build a power supply that is nearly 2kW which supplies 48 Vdc and 40A. - I know it is high power but i want to build it at home :) -
    so please, is there any suggestions ??

    Thanks in advance
     
  2. thatoneguy

    AAC Fanatic!

    Feb 19, 2009
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    You would need to start with an outlet capable of at least 20A.

    Most outlets in the US are 15 or sometimes 20A, except for 220V, which are 40A

    For a non-SMPS solution, the amount of money required for the build will be rather large, around $1,000 for the transformer alone.

    Where are you located?
     
  3. bountyhunter

    Well-Known Member

    Sep 7, 2009
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    Don't try it. Electronic Measurements Inc used to make the lowest cost 2 kW supplies.
     
  4. bountyhunter

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    Sep 7, 2009
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    Single phase power factor is about 0.6, so a 2kW p/s will draw more like 40A off 115VAC. We only built up to 1kW supplies in 115V single phase. Went to 230V single for 2kW and 208V 3-phase for 5kW.
     
  5. bountyhunter

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    A non SM design would probably be the size of a coke machine.
     
  6. SgtWookie

    Expert

    Jul 17, 2007
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    Electronic Measurements Inc. is now a part of TDK-Lambda Americas High Power Division:
    http://www.us.tdk-lambda.com/hp/
     
  7. SgtWookie

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    Send a big truck to pick that up.
     
  8. strantor

    AAC Fanatic!

    Oct 3, 2010
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    Maybe a power supply from a welder? I picked up a 110A craftsman migwelder (runs off 120vac outlet) on craigslist for 80$. You could probably get one even cheaper if it had a bad wirefeed mechanism or something. I think it only puts ~20V though; but you could maybe find one that goes up to ~40V (that's the highest I've seen). if not, you may be able to modify it to put out 48V. just a thought, not sure how feasible it is.
     
  9. thatoneguy

    AAC Fanatic!

    Feb 19, 2009
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    Those are mostly a transformer and high power rectifier, not usually meant for 24/7 100% duty cycle.

    The voltage and current limiting aren't "Regulated supply" quality, though some are fairly advanced, they still weigh a ton, need 220V, and cost quite a bit when you get to 2kW output.
     
  10. bountyhunter

    Well-Known Member

    Sep 7, 2009
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    Exactly, not regulated voltage supply.

    Look for a used Power Ten Inc supply or EMI (electronic measurements Inc) supply online. We made them in 19" rack 1 3/4" high and 3" high.

    Here's a 20V/50A unit for $600:

    http://www.accusrc.com/ccp5640-powe...v--0-50a--1kw--120v-3300d-2050-3300d-2050.htm

    We made them in dozens of different output voltage/current combos

    150V/33A:

    http://www.accusrc.com/commerce/ccp...5kw--requires-190-4600d-15033-4600d-15033.htm
     
  11. bertus

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  12. bountyhunter

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  13. thatoneguy

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    Feb 19, 2009
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    That is quite impressive. The 90A Inrush current is a bit high, but the size is smaller than I'd expected. 12" x 6" x 1.5". 22Watts per cubic inch. Plus an internal 12V 2A supply to run the fans.

    For less than the transformer alone would cost for a linear supply.

    Though I can't think of a use for a 48V supply. at all. It's in that "weird range" from 30 to 80 volts that doesn't seem to "fit" anything, other than as a +/- supply internal to an amplifier.
     
  14. ahmelsayed

    Thread Starter New Member

    Dec 1, 2011
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    Thanks everyone,

    but i don't want to buy it , i want to made it at home-it is a challenge-. I had the transformer needed and a bridge rectifier for it, but i can't find a regulator that can give me my desired output (48V/40A), so Is there any IC (regulator) can do that ?? if not, Is there any other way ??
     
  15. kubeek

    AAC Fanatic!

    Sep 20, 2005
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    What transformer do you have? Volts, amps.
     
  16. R!f@@

    AAC Fanatic!

    Apr 2, 2009
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    OP must be crazy
     
  17. kubeek

    AAC Fanatic!

    Sep 20, 2005
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    So... You don´t wanna buy anything. That means you will wind your own from scrap metal? 2kW? That is absolutely bonkers.
     
  18. Kermit2

    AAC Fanatic!

    Feb 5, 2010
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    I have Two 48 Volt battery chargers(for Golf carts).

    They are transformer based and are quite simple electronically. The output is actually around 58 volts DC(because of the battery charging requirements) and the DC has a significant amount of AC riding on it. They were only $200 each, so the price is good if just for the transformer they contain. The weight is around 45 pounds(about 20Kg).

    These units put out 25 amps @ 52 volts which is around 1.3 KW. To get any more than this you WILL need to use something other than a standard 120VAC outlet for a power input.
     
  19. bountyhunter

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    Sep 7, 2009
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    Actually, it's basically impossible for an amatuer. I used to do it for a living.
     
  20. bountyhunter

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    A battery charger like this is basically about as similar to a regulated power supply as a mouse is to an elephant.
     
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