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Building my first High Current SMPS...

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There is one thing about the IR2110 series to be aware of: if you have a pretty loose layout and poor decoupling of the power stage, then, with an inductive load, when the upper switch turns off the midpoint can swing to below gnd for a short while, this has the effect of bringing into play the intrinsic internal diodes in the 2110 chip and can be destructive and or detrimental to operation, buffering will not necessarily solve this problem as it is the tie point in the middle of the power xtor pair that still connects to the IC, this is possibly why GDT's help the operation so much, as it cuts this connection and the IC (2110) is now unaffected by the source of the upper devices going several volts below gnd.
You see on some datasheets for hi/lo 1/2 bridge drivers, a voltage limit spec for this and sometimes a duration or dv/dt spec as well.
 
Well I achieved some success today. I have half of the bridge running at 90VDC at the bridge and the only thing that is getting even slightly warm is my 240R dummy load resistor.

I managed to solve the switching issue, which as everybody kept telling me was due to interference of some sort(you all were right :) ), by moving the main polarized storage caps from the main's bridge and mounting them directly to the half-bridge's pos/neg rails. Since I'm only testing right now the storage cap consists of a single 470uF cap but by mounting it directly to the half of the bridge I was testing along with the 1uF filter cap that was suggested on here, the switching issues seem to have went away while driving with the IR2110. So far I have only tested it to 90VDC but as I said, nothing got hot, and the frequency counter sat rock solid, as did the average DC voltage of the bridges output. Also after doing this I was able to reduce my gate drive resistors down to 10R paralleled with a reverse diode to speed turn-off time, this also allowed me to reduce the gate-emitter resistor down to 1K as well.

Attached is the current schematic of the test rig I made to try and solve these switching issues. C2 on the bridge is the cap I moved and mounted directly to the power rails. I just whipped up these drawings. Hopefully I didn't forget anything although that's just wishful thinking.

View attachment Half Bridge Test 2 (IR2110).pdf
View attachment Half Bridge Test (IR2110).pdf
 

Very good, although when you are turning on serious current thru the transformer into a diode rectifying load you may well find that extra interference is produced, necessitating and increase in Rg turn on value to slow the dv/dt and di/dt the igbt's will be creating.
We all look forward to hearing the next installment...
 
Thanks for the tip. I'm still building the med-power test rig so everything can be easily swapped if need be. Thanks for all the help so far.
 

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