Notes On The Troubleshooting and Repair of Small Switchmode Power Supplies

2/12/2016
NotesontheTroubleshootingandRepairofSmallSwitchmodePowerSupplies
NotesontheTroubleshootingandRepairof
SmallSwitchmodePowerSupplies
Version2.86(28Jan14)
Copyright19942014
SamuelM.Goldwasser
AllRightsReserved
Forcontactinfo,pleaseseetheSci.Electronics.RepairFAQEmailLinksPage.
Reproductionofthisdocumentinwholeorinpartispermittedifbothofthefollowingconditionsaresatisfied:
1.Thisnoticeisincludedinitsentiretyatthebeginning.
2.Thereisnochargeexcepttocoverthecostsofcopying.
TableofContents
Preface
AuthorandCopyright
DISCLAIMER
Introduction
Theswitchmodepowersupply(SMPS)
Switchmodepowersupplyrepair
MostCommonProblems
Repairorreplace
RelatedInformation
SwitchmodePowerSupplies
PowerSupplyFundamentals
Linearpowersupplies(LPSs)
Whatisaswitchmodepowersupply?
DescriptionoftypicalflybacktypeSMPS
AdvantagesofSMPSscomparedtoLPSs
WhereareSMPSsused?
SwitchmodePowerSupplyTroubleshooting
http://www.repairfaq.org/sam/smpsfaq.htm
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SAFETY
TipsonSMPStroubleshooting
Testequipment
Incrediblyhandywidgets
Safedischargingofcapacitorsinswitchmodepowersupplies
Capacitordischargetool
Capacitordischargeindicatorcircuit
Voltagecheckers
Theserieslightbulbtrick
WhataboutSMPSsinTVsandmonitors?
CommentsonSMPScapacitordischargingandtestingwithseriesloads
SMPSfailuremodes
SoundsthatSMPSsmake
GeneralSMPStroubleshootingapproach
TroubleshootingSMPSsusingdiscretecontrollers
TroubleshootingSMPSsusingintegratedcontrollers
Initialpostrepairtesting
Somegeneralswitchmodepowersupplyrepaircomments
Periodicpowercyclingproblems
TestingaSMPSwithoutstartupdrive
ComponentsFoundinSwitchmodePowerSupplies
Common,unusual,andstrange
Switchmode(chopper)transistorsandothersemiconductors
Capacitors(filterandbypass)
Resistors(normalandflameproof),NTCthermistors,MOVs
Transformersandinductors
Fans
ItemsofInterest
PanasonicVCRSMPS
TypicalcontrollerICsfoundinsmallswitchmodepowersupplies
UnitrodeUC3840programmableofflinePWMcontroller
UnitrodeUC3842offlinePWMcontroller
DescriptionofUC3842startupoperationandcyclingproblems
Switchingbetween115VACand230VACinput
Changingtheinputvoltageofaswitchmodepowersupply
SlightlymodifyingtheoutputvoltageofaPCpowersupply
Useofsurgesuppressorsandlinefilters
GFCItrippingwithmonitor(orotherhightechequipment)
Whydopowersuppliesseemtofailafterapoweroutage?
BuzzingorothersoundsfromSMPSs
CoolelectrolyticstemperatureratingversusESR
Whenbettermaybeworse
Alan'sSMPStroubleshootingtechnique
John'snotesonSMPSrepair
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Russell'scommentsonSMPSrepair
Bob'sdescriptionofhowatypicalPCpowersupplyworks
Steve'scommentsonPCpowersupplyoperationandrepair
PCpowersupplyinformation(pinouts,testingandnonstandarduses)
SafePCpowersupplyloading
TypicalPCandATXpowersupplyschematic
NotesonATXpowersupplytesting
DetailedProcedureforATXPowerSupplyFaultDiagnosis
WarstoriestheBoschert2stageSMPSU
Capacitors,startup,andlowvoltagetesting
Whyisthemainfuseratingsobig?
ServiceInformation
Advancedtroubleshooting
SMPSinfoanddatasheetsonline
ReferencesonSMPStechnologyandtroubleshooting
Partsinformation
InformationsourcesontheInternet
Interchangeabilityofcomponents
Replacementpowertransistorswhiletesting
Testingofreplacementchoppertransistors
Repairpartssources
BacktoSMPSRepairFAQTableofContents.
Preface
AuthorandCopyright
Author:SamuelM.Goldwasser
Forcontactinfo,pleaseseetheSci.Electronics.RepairFAQEmailLinksPage.
Copyright19942014
AllRightsReserved
Reproductionofthisdocumentinwholeorinpartispermittedifbothofthefollowingconditionsaresatisfied:
1.Thisnoticeisincludedinitsentiretyatthebeginning.
2.Thereisnochargeexcepttocoverthecostsofcopying.
DISCLAIMER
Carelesstroubleshootingofalinepoweredswitchmodepowersupplycanresultinsevereelectricalshockor
electrocution.ThisispotentiallymorelethalthanthehighvoltagesectionofaTVormonitorduetothehigh
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currentavailability.Eventhechargedonthemainfiltercapacitorswiththeunitunpluggedcankill.
Wewillnotberesponsiblefordamagetoequipment,yourego,countywidepoweroutages,spontaneously
generatedmini(orlarger)blackholes,planetarydisruptions,orpersonalinjuryorworsethatmayresultfromthe
useofthismaterial.
Introduction
Theswitchmodepowersupply(SMPS)
Untilthe1970sorso,mostconsumerelectronicequipmentusedabasicpowertransformer/rectifier/filter
capacitortypeofpowersupplyforconvertingtheAClineintothevariousvoltagesneededbyinternalcircuitry.
EvenregulationwaspresentonlywhereabsolutelyneededthehighvoltagesuppliesofcolorTVsets,for
example.RememberthoseoldTVswithboatanchortypepowertransformers?(Ofcourse,ifyourecallthose,
youalsorecallthefonddaysofvacuumtubesetsandthecornerdrugstorewithapublictubetester!)
Switchmodesupplieshadbeencommonplaceinmilitaryandavionicequipmentlongbeforetheyfoundtheirway
intoconsumerelectronics.IhavesomeDCDCandDCACconvertermodulesfromaMinutemanImissile
fromaround1962asoneexample.Isupposethatthecostoftheswitchingtransistorswasn'tasbigadealwitha
$100millionmissileasa$300TV(evenin1960sdollars).
Nowadays,allTVs,monitors,PCsmostlaptopandcamcorderpowerpacksmanyprinters,faxmachines,and
VCRsandevencertainaudioequipmentlikeportableCDplayersusethistechnologytoreducecost,weight,
andsize.
Switchmodepowersupplyrepair
UnlikePCsystemboardswhereanydisastersarelikelytoonlyaffectyourpocketbook,powersupplies,
especiallylineconnectedswitchmodepowersupplies(SMPSs)canbedangerous.Read,understand,andfollow
thesetofsafetyguidelinesprovidedlaterinthisdocumentwheneverworkingonlineconnectedpowersupplies
aswellasTVs,monitors,orothersimilarhighvoltageequipment.
Havingsaidthat,repairingapowersupplyyourselfmayinfactbetheonlyeconomicaloption.Itisverycommon
forservicecenterstosimplyreplacetheentirepowersupplyboardormoduleeveniftheproblemisa25cent
capacitor.Itmaysimplynotpayforthemtotakethebenchtimetodiagnosedowntothecomponentlevel.
Manyproblemswithswitchmodepowersuppliesareeasytofindandeasyandinexpensivetofix.Notall,but
surprisinglymany.
Thisdocumentwillprovideyouwiththeknowledgetodealwithalargepercentageoftheproblemsyouare
likelytoencounterwiththecommonsmallswitchmodepowersuppliesfoundinmanytypesofconsumer
electronicequipmentincludingPCs,printers,TVs,computermonitors,andlaptoporcamcorderpowerpacks.It
willenableyoutodiagnoseproblemsandinmanycases,correctthemaswell.Withminorexceptions,specific
manufacturersandmodelswillnotbecoveredastherearesomanyvariationsthatsuchatreatmentwould
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requireahugeandverydetailedtext.Rather,themostcommonproblemswillbeaddressedandenoughbasic
principlesofoperationwillbeprovidedtoenableyoutonarrowtheproblemdownandlikelydetermineacourse
ofactionforrepair.Inmanycases,youwillbeabletodowhatisrequiredforafractionofthecostthatwouldbe
chargedbyarepaircenterassumingtheywouldevenbother.
Shouldyoustillnotbeabletofindasolution,youwillhavelearnedagreatdealandbeabletoaskappropriate
questionsandsupplyrelevantinformationifyoudecidetoposttosci.electronics.repair.Itwillalsobeeasierto
dofurtherresearchusingarepairtextsuchastheoneslistedattheendofthisdocument.Inanycase,youwill
havethesatisfactionofknowingyoudidasmuchasyoucouldbeforetakingitinforprofessionalrepair.With
yournewfoundknowledge,youwillhavetheupperhandandwillnoteasilybesnowedbyadishonestor
incompetenttechnician.
MostCommonProblems
Thefollowingprobablyaccountfor95%ormoreofthecommonSMPSailments:
Supplydead,fuseblownshortedswitchmodepowertransistorandothersemiconductors,openfusable
resistors,otherbadparts.Note:actualcauseoffailuremaybepowersurge/brownout/lightningstrikes,
randomfailure,orprimarysideelectrolyticcapacitor(s)withgreatlyreducedcapacityorentirelyopen
testthembeforepoweringuptherepairedunit.
Supplydead,fusenotblownbadstartupcircuit(openstartupresistors),openfusableresistors(dueto
shortedsemiconductors),badcontrollercomponents.
Supplymostlydeadortakesalongtimetocomealive.TheremaybeanLEDflashingbuttheequipment
doesn'trespondtopowerbutton(ortakesawhile)badelectrolyticcapacitors.Visuallyinspectfor
capacitorswithbulgingtopsorthathaveleaked.IfanESRmeterisavailable,testthecaps.Ifanybad
onesarefound,replace*all*electrolyticcapacitors(oratleastallcapsfromthesamemanufacturer).
CapacitorkitsareavailableformanyflatscreenTVs,computerdisplays,andotherconsumerelectronics.
Searchbymodel(includingoneBay).
Oneormoreoutputsoutoftoleranceorwithexcessiverippleatthelinefrequency(50/60Hz)ortwice
thelinefrequency(100/120Hz)driedupmainfiltercapacitor(s)onrectifiedACinput.
Oneormoreoutputsoutoftoleranceorwithexcessiverippleattheswitchingfrequency(10sofkHz
typical)drieduporleakyfiltercapacitorsonaffectedoutputs.
Audiblewhinewithlowvoltageononeormoreoutputsshortedsemiconductors,faultyregulator
circuitryresultinginovervoltagecrowbarkickingin,faultyovervoltagesensingcircuitorSCR,faulty
controller.
Periodicpowercycling,tweettweet,flubflub,blinkingpowerlightshortedsemiconductors,faultyover
voltageorovercurrentsensingcomponents,badcontroller.
Inallcases,badsolderconnectionsareapossibilityaswellsincethereareusuallylargecomponentsinthese
suppliesandsolderingtotheirpinsmaynotalwaysbeperfect.Anexcessiveloadcanalsoresultinmostofthese
symptomsormaybetheoriginalcauseofthefailure.Anddon'toverlookthetrivial:alinevoltageselectswitchin
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thewrongpositionorbetweenpositions(possiblybyaccidentwhenmovingthesupply,particularlywithPCs),
ordamaged.
Repairorreplace
Somemanufacturershaveinexpensiveflatrateservicepoliciesforpowersupplies.Ifyouarenotinclinedornot
interestedindoingthediagnosisandrepairyourself,itmaybeworthwhiletolookintothese.Insomecases,$25
willgetyouareplacementsupplyregardlessoforiginalcondition.However,thisisprobablytheexceptionand
replacementscouldrunmorethanthetotaloriginalcostoftheequipmentespeciallyasinthecaseofmostTVs
andmanycomputermonitors,wherethepowersupplyisbuiltontothemaincircuitboard.
Nothingreallydegradesinaswitchmodepowersupplyexceptpossiblytheelectrolyticcapacitors(unlessa
catastrophicfailureresultedinatotalmeltdown)andthesecanusuallybereplacedforatotalcostofafew
dollars.Therefore,itusuallymakessensetorepairafaultysupplyassumingitcanbedonereasonablyquickly
(dependingonhowmuchyouvalueyourtimeandthedowntimeoftheequipment)and,ofcourse,assumingthat
theequipmentitpowersisworththeeffort.Mostreplacementpartsarereadilyavailableandkitscontaining
commonservicecomponentsarealsoavailableformanypopularpowersupplies(suchasthosefoundinsome
terminals,MacIntoshandotherApplecomputers,variousbrandsofvideomonitors,andsomeTVsandVCRs).
Whereanexactreplacementpowersupplyisnolongeravailableorexcessivelyexpensive,itmaybepossibleto
simplyreplacethegutsifspaceallowsandthemountingarrangementiscompatible.Forexample,foranolder
fullsizePCtower,theoriginalpowersupplymaybeinanonstandardboxbutthecircuitboarditselfmayusea
standardholeconfigurationsuchthataninexpensivereplacementmaybeinstalledinitsplace.
Alternatively,manysurpluselectronicsdistributorshaveawideselectionofpowersuppliesofallshapes,sizes,
outputvoltages,andcurrentcapacities.Oneofthesemaymakeasuitablereplacementforyourcustomsupply
withalotlesshasslethanattemptingtorepairyourundocumentedoriginal.Itwilllikelybemuchneweraswell
withnoendoflifeissueslikedriedupelectrolyticcapacitorstodealworryabout.Ofcourse,youmustknowthe
voltageandcurrentmaximumcurrentrequirementsofeachoftheoutputsinordertomakeaselection.
ForthespecificcaseofSMPSsforstandardcomputers(PC,Macs,workstations,servers),itoftendoesn't
makesensetospendmuchtimeormoneyonrepair.ThecostofreplacementofpowersuppliesforPCsin
particularissolow,thatjustbuyinganewpowersupplymaybethebestcourseofaction.Furthermore,therisk
ofafaultyrepaircausingexpensiveorfataldamagetothemainboardandperipheralsincludingtotallossofall
datastoredondisk,makesrepairariskyendeavorunlessthoroughtestingcanbeperformedbeforeinstallation.
However,itwon'thurttocheckforobviousproblemslikebadconnections.Putthedeadoneasideand
consideringtryingtorepairitifthereisn'tanythingbettertodo.Realistically,thiswillbenever.:)
RelatedInformation
Seethemanualson"FailureDiagnosisandRepairofTVs"and"FailureDiagnosisandRepairofComputerand
VideoMonitors"forproblemsspecifictothattypeofequipment.Forcomputerpowersuppliesandother
generalinfo,alsosee:"PCSwitchmodePowerSupplies".TheseareallavailableatthissiteundertheRepair
Menu.
Lazar'sSMPSDesignCornerhasmanylinkstoswitchmodepowersupplyinformationandsuppliers.
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SwitchmodePowerSupplies
PowerSupplyFundamentals
Atypicallineconnectedpowersupplymustperformthefollowingfunctions:
Voltageconversionchangingthe115/230VAClinevoltageintooneormoreothervoltagesas
determinedbyapplication.
RectificationturningtheACintoDC.
Filteringsmoothingtherippleoftherectifiedvoltage(s).
Regulationmakingtheoutputvoltage(s)independentoflineandloadvariations.
IsolationseparatingthesupplyoutputsfromanydirectconnectiontotheACline.
Linearpowersupplies(LPSs)
Atypicallinearpowersupplyofthetypefoundinmostaudioequipmentincludesalinepowertransformerwhich
convertsthe115/230VAC50/60Hztoother(usuallylower)voltages(nowthatmostequipmenthasdoneaway
withvacuumtubesexceptforCRTs,moreonthatlater).Thepowertransformeralsoprovidestheisolation
betweentheloadandtheline.Theoutputsarerectifiedbyadiodebridgeorothersolidstateconfiguration.
Filteringisaccomplishedwithelectrolyticcapacitorsandsometimesinductorsorresistorsarrangedasalowpass
filterCLC(pi)orCRCorotherconfiguration.
Whereregulationisimportantthatis,itisdesirablefortheoutputvoltagetoberelativelyindependentoflineor
loadvariations,aregulatorstageisadded.ThismaytaketheformofaZenerdiodeifthecurrentrequirements
aremodest,discretetransistorcircuit,oranintegrated3terminalregulatorlikeanLM317(variable),7805(+5),
or7912(12).Therearemanymoreaswellaslinearregulatorsforhighervoltagessuchas+115VDCor+125
VDCforTVpowersuppliesandmultipleoutput(e.g.,+5.1VDC,+12VDC)hybridregulatorsforVCRs.
Theregulatorcircuitessentiallycomparestheoutput(possiblyonlyoneiftherearemultipleoutputsinthesame
package)withareferenceandadjuststhecurrentflowtomaketheoutput(s)asnearlyequaltothedesired
voltageaspossible.However,asignificantamountofpowermaybelostintheregulatorespeciallyunderhigh
linevoltage/highloadconditions.Therefore,theefficiencyoflinearpowersuppliesisusuallyquitelowunder
50%overallistypical.
NotablecharacteristicsofLPSsareexcellentregulationandlowoutputrippleandnoise.
Whatisaswitchmodepowersupply?
Alsocalledswitchingpowersuppliesandsometimeschoppercontrolledpowersupplies,SMPSsusehigh
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frequency(relativeto50/60Hz)switchingdevicessuchasBipolarJunctionTransistors(BJTs),MOSFETs,
InsulatedGateBipolarTransistors(IGBTs),orThyristors(SCRsortriacs)totakedirectlyrectifiedlinevoltage
andconvertittoapulsedwaveform.
MostsmallSMPSsuseBJTsorMOSFETs.IGBTsmaybefoundinlargesystemsandSCRsortriacsareused
wheretheiradvantages(latchingintheonstateandhighpowercapability)outweightheincreasedcomplexityof
thecircuitrytoassurethattheyturnoffproperly(sinceexceptforspecialGateTurnOff(GTO)thyristors,the
gateinputisprettymuchignoredoncethedeviceistriggeredandthecurrentmustgotozerotoresetittotheoff
state.)
Theinputtotheswitchesisusuallyeither150160VDCafterrectificationof115VAC,or300320VDCafter
doublingof115VACorrectificationof220240VAC.Uptothispoint,thereisnolineisolationasthereisno
lineconnected(large,bulky,heavy)powertransformer.
Arelativelysmallhighfrequencytransformerconvertsthepulsedwaveformintooneormoreoutputvoltages
whicharethenrectifiedandfilteredusingelectrolyticcapacitorsandsmallinductorsina'pi'configurationCLC,
orforoutputsthatarelesscritical,justacapacitor.
Thishighfrequencytransformerprovidestheisolationbarrierandtheconversiontogeneratethemultiplevoltages
oftenprovidedbyaSMPS.
Feedbackisaccomplishedacrosstheisolationbarrierbyeitherasmallpulsetransformeroroptoisolator.The
feedbackcontrolsthepulsewidthorpulsefrequencyoftheswitchingdevicestomaintaintheoutputconstant.
Sincethefeedbackisusuallyonlyfromthe"primary"output,regulationoftheotheroutputs,ifany,isusually
worsethanfortheprimaryoutput.Also,becauseofthenatureoftheswitchingdesigns,theregulationevenofthe
primaryoutputisusuallynotnearlyasgoodbothstaticallyanddynamicallyasadecentlinearsupply.
DCDCconvertersareswitchmodepowersupplieswithoutthelineinputrectificationandfiltering.Theyare
commonlyfoundinbatteryoperatedequipmentlikeCDplayersandlaptopcomputers.Theyhavesimilar
advantagestoSMPSsinbeingcompact,lightweight,andhighlyefficient.
DescriptionoftypicalflybacktypeSMPS
ProbablythemostcommontopologyforsmallswitchersistheflybackcircuitshownbelowandinBlock
DiagramofBasicFlybackSwitchmodePowerSupply.
CR1CR2L:::::
Ho|>|+++T1+|>|+^^^^^++oV+
line||)||(Main+_|_+_|_|Main
rect.|/)||(outputC___LCPiC___|Output
|\R1)||(rect.|filter||
ACHV+_|_/+++++|oV
Linefilter___\||
incap|||/++++++
|++|PWM|<|Isolation|<|REF|
|Q1|\++++++
||
No++
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TheinputtothesupplyistheAClinewhichmayhaveRFIandsurgeprotection(notshown).Theremaybe
severalinductors,coupledinductors,andcapacitorstofilterlinenoiseandspikesaswellastominimizethe
transmissionofswitchinggeneratedradiofrequencyinterferencebackintothepowerline.TheremaybeMOV
typeofsurgesuppressorsacrossthethreeinputleads(H,N,G).Alinefuseisusuallypresentaswelltoprevent
ameltdownincaseofacatastrophicfailure.Itrarelycanpreventdamagetothesupplyintheeventofan
overload,however.
Linerectificationisusuallyviaavoltagedoublerordiodebridge.Onecommoncircuitusesabridgerectifierasa
doublerornormalbridgebychangingonejumper.Thevoltageacrosstheswitchingtransistorisusuallyaround
160320V.Someuniversalsuppliesaredesignedtoacceptawiderangeofinputvoltages90240VAC
(possiblyupto400Hzormore)orDCandwillautomaticallyworkjustaboutanywhereintheworldaslong
asasuitableplugadaptercanbefound.
WhenQ1turnson,currentincreaseslinearlyinT1basedonthevoltageappliedandtheleakageinductanceof
T1'sprimarywinding.Littlepoweristransferredtothesecondaryduringthisphaseofthecycle.WhenQ1turns
off,thefieldcollapsesandthistransferspowertotheoutput.ThelongerQ1ison,themoreenergyisstored
(untilsaturationatwhichpointitblowsup).Thus,controllingthepulsewidthoftheQ1ontimedeterminesthe
amountofpoweravailablefromtheoutput.
Theoutputrectifier,CR2,mustbeahighefficiency,highfrequencyunita1N400Xwillnotwork.Thepifilter
ontheoutputsmoothsthepulsesprovidedbyCR2.Sometimes,afullwaveconfigurationisusedwithacenter
tappedtransformersecondary.
Notethatthetransformer,T1,isaspecialtypewhichincludesanairgapinitscore(amongotherthings)to
providetheinductivecharacteristicsneededforoperationinflybackmode.
MultipleoutputwindingsonT1provideforuptoahalfdozenormoreseparate(andpossiblyisolatedaswell)
positiveornegativevoltagesbutasnoted,onlyoneoftheseisusuallyusedforregulation.
Areferencecircuitmonitorsthemainoutputandcontrolsthedutycycleoftheswitchingpulsestomaintaina
constantoutputvoltage.(Secondaryoutputsarenotshownintheaboveschematic.)
R1isthestartupresistor(somestartupcircuitsaremoresophisticated)andprovidestheinitialcurrenttothe
switchmodetransistorbase.Intheolddays,SMPScontrollersweredesignedwithdiscretecomponents.
AssuringstableoperationisachallengewithanySMPSbutparticularlywiththeflybacktopologywhereleaving
thedriveonfortoolongwillresultintransformercoresaturationandinstantsmoke.Nowadays,anICPWM
controllerchipisalmostalwaysused.TheblockdiagramofaoneverypopularPWMcontrollerICisshown
below.
ManysmallSMPSsuseoptoisolatorsforthefeedback.AnoptoisolatorissimplyanLEDandaphotodiodein
asinglepackage.Asitsnameimplies,anoptoisolatorprovidestheisolationbarrier(betweenthelowvoltage
secondaryoutputsandthelineconnectedprimary)forthefeedbackcircuit.Typically,areferencecircuitonthe
outputsidesensestheprimaryoutputvoltageandturnsontheLEDoftheoptoisolatorwhentheoutputvoltage
exceedsthedesiredvalue.ThephotodiodedetectsthelightfromtheLEDandcausesthepulsewidthofthe
switchingwaveformtobereducedenoughtoprovidejusttherightamountofoutputpowertomaintainthe
outputvoltageconstant.ThiscircuitmaybeassimpleasputtingthephotodiodeacrossthebasedrivetotheBJT
switchthuscuttingitoffwhentheoutputvoltageexceedsthedesiredvalue.ThereferenceisoftenaTL431or
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similarshuntregulatorchipmonitoringavoltagedividedversionoftheprimaryoutput.Whentheshuntregulator
kicksin,theoptoisolatorLEDturnsonreducingtheswitchmodetransistordrive.Theremaybeanadjustment
fortheoutputvoltage.
Otherdesignsusesmallpulsetransformerstoprovideisolatedfeedback.
Whereadditionalregulationisneeded,smalllinearregulatorsmaybeincludedfollowingtheoutput(s).
Therearemanyothertopologiesforswitchingpowersupplies.However,thebasicprinciplesaresimilarbutthe
detaildifferdependingonapplication.Theflybacktopologydescribedaboveisoneofthemostcommonfor
smallmultioutputsupplies.However,youmayfindothertypesofcircuitsinTVsandmonitors.Someare
downrightstrange(tobepolite).Isometimeswonderifengineersaregivenbonusesbasedontheuniquenessand
difficultylevelofunderstandingtheirdesigns!
AdvantagesofSMPSscomparedtoLPSs
Thebenefitsprovidedbyimplementingswitchmodeoperationarewithrespecttosize,weight,andefficiency.
Sizeandweightsincethetransformerandfinalfilter(s)runatahighfrequency(wearetalkingabout10
kHzto1MHzormore),theycanbemuchsmallerandlighterthanthebigbulkycomponentsneededfor
50/60Hzoperation.PowerdensityforSMPSscomparedtoLPSsmayeasilyexceed20:1.
Efficiencysincetheswitchingdevicesare(ideally)fullyonorfullyoff,thereisrelativelylittlepowerlost
sothattheefficiencycanbemuchhigherforSMPSsthanforLPSs,especiallynearfullload.Efficiencies
canexceed85%(comparedto5060%fortypicalLPSs)withimprovementsbeingmadecontinuouslyin
thistechnology.
Sincetheadventofthelaptopcomputer,cellularphone,andotherportabledevices,theimportanceofoptimizing
powerutilizationhasincreaseddramatically.TherearenowmanyICsforcontrollingandimplementingSMPSs
withrelativelyfewexternalcomponents.Maxim,LinearTechnology,andUnitrode(nowpartofTexas
Instruments)arejustafewofthemajormanufacturersofcontrollerICs.
WhereareSMPSsused?
Switchmodepowersuppliesarecommonlyusedincomputerandotherdigitalsystemsaswellasconsumer
electronicsparticularlyTVsandnewerVCRsthoughaudioequipmentwilltendtouselinearpowersupplies
duetonoiseconsiderations.YouwillfindSMPSsin:
PCs,workstations,minicomputers,largecomputers.
Laptopandnotebookcomputers,PDAsbothinternalDCDCconvertersandtheirACpowerpacks.
Printers,faxmachines,copiers.
Peripheralandexpansionboxes
Xterminalsandvideoterminals,pointofsaleregisters.
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TVs,computerandvideomonitors.
ManyVCRs.
CamcorderACadapters.
Inadditional,youwillfindDCDCconverterswhichareSMPSswithouttheAClineconnection,internallyinan
increasingnumberofconsumerandindustrialapplicationsincludingthingslikeportableCDplayers.
Theupsideisthattheyareusuallyquitereliable,efficient,andcoolrunning.
Thedownsideisthatwhenafailureoccurs,itmaytakeoutmanypartsinthesupply,thoughnotusuallythe
equipmentbeingpoweredunlessthefeedbackcircuitryscrewsupandthereisnoovervoltageprotection.
SwitchmodePowerSupplyTroubleshooting
SAFETY
TheprimarydangertoyouisfromtheinputsideofthesupplywhichisdirectlyconnectedtotheAClineandwill
havelargeelectrolyticcapacitorswith320VorgreaterDCwhenpowered(often,evenifthesupplydoesnot
workcorrectly)andforsometimeafterbeingunplugged(especiallyifthepowersupplyisnotworkingcorrectly
butdoesnotblowfuses).
WARNING:Thefiltercapacitorsusedinmanyswitchmodepowersuppliescanstoreanamountofenergythat
cankillalwaysdischargeandconfirmthisbeforetouchinganything.
Thereisalsoriskofinstantlydestroyingexpensivepartsofthesupply(andanyattachedequipmentaswell)like
theswitchmodepowertransistorifyourprobeshouldslipandshortsomethingeitherdirectlyorbykillingthe
feedbackcircuit.
Theseguidelinesaretoprotectyoufrompotentiallydeadlyelectricalshockhazardsaswellastheequipment
fromaccidentaldamage.
Notethatthedangertoyouisnotonlyinyourbodyprovidingaconductingpath,particularlythroughyourheart.
Anyinvoluntarymusclecontractionscausedbyashock,whileperhapsharmlessinthemselves,maycause
collateraldamagetherearemanysharpedgesinsidethistypeofequipmentaswellasotherelectricallylive
partsyoumaycontactaccidentally.
Thepurposeofthissetofguidelinesisnottofrightenyoubutrathertomakeyouawareoftheappropriate
precautions.RepairofTVs,monitors,microwaveovens,andotherconsumerandindustrialequipmentcanbe
bothrewardingandeconomical.Justbesurethatitisalsosafe!
Don'tworkaloneintheeventofanemergencyanotherperson'spresencemaybeessential.
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Alwayskeeponehandinyourpocketwhenanywherearoundapoweredlineconnectedorhighvoltage
system.
Wearrubberbottomshoesorsneakers.
Don'twearanyjewelryorotherarticlesthatcouldaccidentallycontactcircuitryandconductcurrent,or
getcaughtinmovingparts.
Setupyourworkareaawayfrompossiblegroundsthatyoumayaccidentallycontact.
Knowyourequipment:TVsandmonitorsmayusepartsofthemetalchassisasgroundreturnyetthe
chassismaybeelectricallylivewithrespecttotheearthgroundoftheACline.Microwaveovensusethe
chassisasgroundreturnforthehighvoltage.Inaddition,donotassumethatthechassisisasuitable
groundforyourtestequipment!
Ifcircuitboardsneedtoberemovedfromtheirmountings,putinsulatingmaterialbetweentheboardsand
anythingtheymayshortto.Holdtheminplacewithstringorelectricaltape.Propthemupwithinsulation
sticksplasticorwood.
Ifyouneedtoprobe,solder,orotherwisetouchcircuitswithpoweroff,discharge(across)largepower
supplyfiltercapacitorswitha2Worgreaterresistorof550ohms/Vapproximatevalue(e.g.,fora200
Vcapacitor,usea1K10Kohmresistor).Monitorwhiledischargingand/orverifythatthereisnoresidual
chargewithasuitablevoltmeter.InaTVormonitor,ifyouareremovingthehighvoltageconnectionto
theCRT(toreplacetheflybacktransformerforexample)firstdischargetheCRTcontact(underthe
insulatingcupattheendofthefatredwire).Usea1M10Mohm1Worgreaterwattageresistoronthe
endofaninsulatingstickortheprobeofahighvoltagemeter.Dischargetothemetalframewhichis
connectedtotheoutsideoftheCRT.
ForTVsandmonitorsinparticular,thereistheadditionaldangerofCRTimplosiontakecarenotto
bangtheCRTenvelopewithyourtools.Animplosionwillscattershardsofglassathighvelocityinevery
direction.ThereisseveraltonsofforceattemptingtocrushthetypicalCRT.Alwaysweareyeprotection.
Connect/disconnectanytestleadswiththeequipmentunpoweredandunplugged.Useclipleadsorsolder
temporarywirestoreachcrampedlocationsordifficulttoaccesslocations.
Ifyoumustprobelive,putelectricaltapeoverallbutthelast1/16"ofthetestprobestoavoidthe
possibilityofanaccidentalshortwhichcouldcausedamagetovariouscomponents.Clipthereferenceend
ofthemeterorscopetotheappropriategroundreturnsothatyouneedtoonlyprobewithonehand.
Useaproperhighvoltageprobeorhighvoltagemetertomeasurevoltageswhicharepotentiallybeyond
thecapabilitiesofyourDMMorVOMnotsomethingcobbledtogetherfrom1/4wattresistors!Note
thatfaultconditionsoreventestingat*reduced*inputvoltagemayresultingreatlyexcessivevoltageon
oneormoreoutputsduetolackofregulation.
Itmaybepossibletoperformsomeofthetestsatgreatlyreducedvoltage(e.g.,30VDCtothechopper
insteadof300VDC)bysupplyingexternalpowertothecontrollerchip(ifused)andinjectingbase/gate
drivefromasignalgenerator.Thiswouldgreatlyreducetheshockhazardaswellasequipmentdamage
fromaslippedprobeormissedfaultycomponent.
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Performasmanytestsaspossiblewithpoweroffandtheequipmentunplugged.Forexample,the
semiconductorsinthepowersupplysectionofaTVormonitorcanbetestedforshortcircuitswithan
ohmmeter.
Useanisolationtransformerifthereisanychanceofcontactinglineconnectedcircuits.AVariac(tm)is
notanisolationtransformer!TheuseofaGFCI(GroundFaultCircuitInterrupter)protectedoutletisa
goodideabutwillnotprotectyoufromshockfrommanypointsinalineconnectedTVormonitor,orthe
highvoltagesideofamicrowaveoven,forexample.(Notehowever,that,aGFCImaynuisancetripat
poweronoratotherrandomtimesduetoleakagepaths(likeyourscopeprobeground)orthehighly
capacitiveorinductiveinputcharacteristicsoflinepoweredequipment.)Afuseorcircuitbreakeristoo
slowandinsensitivetoprovideanyprotectionforyouorinmanycases,yourequipment.However,these
devicesmaysaveyourscopeprobegroundwireshouldyouaccidentallyconnectittoalivechassis.
Don'tattemptrepairworkwhenyouaretired.Notonlywillyoubemorecareless,butyourprimary
diagnostictooldeductivereasoningwillnotbeoperatingatfullcapacity.
Finally,neverassumeanythingwithoutcheckingitoutforyourself!Don'ttakeshortcuts!
TipsonSMPStroubleshooting
Thediagnosisofproblemsinswitchmodepowersuppliesissometimesmadecomplicatedduethe
interdependenceofcomponentsthatmustfunctionproperlyforanyportionofthepowersupplytobeginto
work.Dependingondesign,SMPSmayormaynotbeprotectedfromoverloadconditionsandmayfail
catastrophicallyunderaheavyloadevenwhensupposedlyshortcircuitproof.Thereisparticularstressonthe
switchingdevices(theyareoften800Vtransistors)whichcanleadtoearlyorunexpectedfailure.Also,SMPS
mayfailuponrestorationofpowerafterablackoutifthereisanykindofpowerspikesinceturnonisavery
stressfulperiodsomedesignstakethisintoaccountandlimitturnonsurge.
However,thecauseofmanyproblemsareimmediatelyobviousandhavesimplefixestheblownchopper
transistorordriedupmainfiltercapacitor.Don'tassumeyourproblemiscomplexandconvoluted.Mostarenot.
Youshouldnotavoidattemptingarepairjustbecausethereisaslightchanceitwillbemorechallenging!
Alowpower(e.g.,25W)finetipsolderingironandfinerosincoresolderwillbeneededifyoushouldneedto
disconnectanysolderedwires(onpurposeorbyaccident)orreplacesolderedcomponents.Ahigherpower
ironorsmallsolderinggunwillbeneededfordealingwithlargercomponents.Neveruseacidcoresolderorthe
typeusedforsweatingcopperpipes!
CAUTION:Youcaneasilyturnasimplerepair(e.g.,badsolderconnections)intoanexpensivemessifyouuse
inappropriatesolderingequipmentand/orlackthesolderingskillstogoalongwithit.Ifindoubt,findsomeone
elsetodothesolderingoratleastpractice,practice,practice,solderinganddesolderingonajunkcircuitboard
first!Seethedocument:TroubleshootingandRepairofConsumerElectronicEquipmentforadditionalinfoon
solderingandreworktechniques.
Testequipment
Themostvaluablepieceoftestequipment(inadditiontoyoursenses)willbeaDMMorVOM.Thesealonewill
sufficeformostdiagnosisoffaultycomponents(likeshortedsemiconductorsoropenfusableresistors).
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CAUTION:IftheSMPS(oranyotherpieceofequipment)iscapableofproducingvoltagesbeyond1,000V
(orthemaxrangeonyourmeter),makesureyouuseaproperhighvoltageprobeorhighvoltagemeterfault
conditionscouldeasilyresultinvoltagesinthesystemthatarewaybeyondthosethatareexpected,evenifrunat
reducedinputvoltageand/orwithaseriescurrentlimiter.
IndesignsusingcontrollerICs,anoscilloscopecomesinhandywhentherearestartuporovercurrent/voltage
shutdownorcyclingproblems.Sinceeverythingrunsatarelativelylowfrequency,almostanyscopewilldo.
Incrediblyhandywidgets
Thesearethelittlegadgetsandhomemadetestersthatareusefulformanyrepairsituations.Herearejustafew
ofthemostbasic:
SerieslightbulbforcurrentlimitingduringthetestingofTVs,monitors,switchingpowersupplies,audio
poweramplifiers,etc.Ibuiltadualoutletboxwiththeoutletswiredinseriessothatalampcanbe
pluggedintooneoutletandthedeviceundertestintotheother.Foraddedversatility,addaregularoutlet
and'kill'switchusingaquadboxinstead.Theuseofaseriesloadwillpreventyourexpensivereplacement
partlikeaswitchmodepowertransistorfromblowingifthereisstillsomefaultinthecircuityouhavefailed
tolocate.(Now,ifIwouldonlyremembertodothismoreoften!).Seethesection:Theserieslightbulb
trick.
AVariac.Itdoesn'tneedtobelargea2AVariacmountedwithaswitch,outletandfusewillsufficefor
mosttasks.However,a5amporlargerVariacwon'thurt.Ifyouwillbetroubleshooting220VAC
equipmentintheUS,thereareVariacsthatwilloutput0240VACfroma115VACline(justmakesure
youdon'tforgetthatthiscaneasilyfryyour115VACequipment.)Byvaryingthelinevoltage,notonly
canyoubringupanewlyrepairedmonitorgraduallytomakesuretherearenoproblemsyoucanalso
evaluatebehavioratlowandhighlinevoltage.Thiscangreatlyaidintroubleshootingpowersupply
problems.WARNING:aVariacisanautotransformernotanisolationtransformeranddoesnothelp
withrespecttosafety.Youneedanisolationtransformeraswell.
Note:SomeSMPSdesignsrequirepowertobeappliedinstantlytoprovidethestartupvoltagetothe
controller.Ifthisisthecasewithyours,itwon'tbepossibletobringupthevoltageslowly(unlessyou
powerthatchipseparately).However,itshouldstillbepossibletoruntheunitsomewhatreducedline
voltage.Also,runninganySMPSatreducedlinevoltageisstressful.Itmayalsoresultinoutputsthatare
notproperlyregulatedandgomuchhigherthannormal.Thus,aVariacshouldbeusedwithcautionwith
theoutputsconnectedtodummyloadsinsteadofthepoweredequipmentandaseriescurrentlimiter(e.g.,
lightbulb)intheinput.
Isolationtransformer.Thisisveryimportantforsafelyworkingonlivechassisequipmentlikeline
connectedswitchmodepowersupplies(primaryside).Youcanbuildonefromapairofsimilarpower
transformersbacktoback(withtheirhighestratedsecondariesconnectedtogether.Ibuiltminefroma
coupleofsimilaroldtubetypeTVpowertransformersmountedonaboardwithanoutletboxincludinga
fuse.Theirsecondaryhighvoltagewindingswereconnectedtogethertocouplethetwotransformers
together.Theunusedlowvoltagewindingscanbeputinserieswiththeprimaryoroutputwindingsto
adjustvoltage.Alternatively,commerciallineisolationtransformerssuitableforTVtroubleshootingare
availableforlessthan$100wellwortheverypenny.
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ThereisabsolutelynoimaginablereasonnottouseanisolationtransformerfortroubleshootingSMPSs
exceptpossiblyforthefinaltestwhereconfirmationisneededthattheinrushfromadirectlineconnection
(whichwillhavevirtuallyunlimitedinstantaneouscurrentcapability)willnotdamagethenewlyrepaired
supply.
Variableisolationtransformer.Youdon'tneedtobuyafancycombinationunit.AVariaccanbefollowed
byanormalisolationtransformer.(Theoppositeorderalsoworks.Theremaybesomesubtledifferences
inloadcapacity.).
Safedischargingofcapacitorsinswitchmodepowersupplies
AworkingSMPSmaydischargeitscapacitorsfairlyquicklywhenitisshutoffbutDONOTcountonthis.The
mainfiltercapacitorsmayhavebleederresistorstodraintheirchargerelativelyquicklybutresistorscanfailand
theterm'quickly'mayberelativetotheageoftheuniverse.Don'tdependonthem.
ThetechniqueIrecommendistouseahighwattageresistorofabout5to50ohms/Voftheworkingvoltageof
thecapacitor.Thisisn'tcriticalabitmoreorlesswillbefinebutwillaffectthetimeittakestofullydischargethe
capacitor.Theuseofacurrentlimitingresistorwillpreventthearcweldingassociatedwithscrewdriver
dischargebutwillhaveashortenoughtimeconstantsothatthecapacitorwilldroptoalowvoltageinatmosta
fewseconds(dependentofcourseontheRCtimeconstantanditsoriginalvoltage).
Thencheckwithavoltmetertobedoublesure.Betteryet,monitorwhiledischarging.
Obviously,makesurethatyouarewellinsulated!
Forthepowersupplyfiltercapacitorswhichmightbe400uFat200V,a2Kohm10Wresistorwouldbe
suitable.RC=.8second.5RC=4seconds.Alowerwattageresistor(comparedtothatcalculatedfromV^^2/
R)canbeusedsincethetotalenergystoredinthecapacitorisnotthatgreat(butstillpotentiallylethal).
Thedischargetoolandcircuitdescribedinthenexttwosectionscanbeusedtoprovideavisualindicationof
polarityandchargeforTV,monitor,SMPS,powersupplyfiltercapacitorsandsmallelectronicflashenergy
storagecapacitors,andmicrowaveovenhighvoltagecapacitors.
Reasonstousearesistorandnotascrewdrivertodischargecapacitors:
Itwillnotdestroyscrewdriversandcapacitorterminals.
Itwillnotdamagethecapacitor(duetothecurrentpulse).
Itwillreduceyourspouse'sstresslevelinnothavingtohearthosescarysnapsandcrackles.
Capacitordischargetool
Asuitabledischargetoolforeachoftheseapplicationscanbemadeasquiteeasily.Thecapacitordischarge
indicatorcircuitdescribedbelowcanbebuiltintothistooltoprovideavisualdisplayofpolarityandcharge(not
reallyneededforCRTsasthedischargetimeconstantisvirtuallyinstantaneousevenwithamultiMohmresistor.
Solderoneendoftheappropriatesizeresistor(foryourapplication)alongwiththeindicatorcircuit(if
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desired)toawellinsulatedclipleadabout23feetlong.Forsafetyreasons,theseconnectionsmustbe
properlysolderednotjustwrapped.
Soldertheotherendoftheresistor(anddischargecircuit)toawellinsulatedcontactpointsuchasa2
inchlengthofbare#14copperwiremountedontheendofa2footpieceofPVCorPlexiglasrodwhich
willactasanextensionhandle.
Secureeverythingtotheinsulatingrodwithsomeplasticelectricaltape.
Thisdischargetoolwillkeepyousafelyclearofthedangerarea.
Again,alwaysdoublecheckwithareliablevoltmeterorbyshortingwithaninsulatedscrewdriver!
Capacitordischargeindicatorcircuit
Hereisasuggestedcircuitwhichwilldischargethemainfiltercapacitorsinswitchmodepowersupplies,TVs,
andmonitors.Thiscircuitcanbebuiltintothedischargetooldescribedabove.
Avisualindicationofchargeandpolarityisprovidedfrommaximuminputdowntoafewvolts.
Thetotaldischargetimeisapproximately1secondper100uFofcapacitance(5RCwithR=2Kohms).
Safecapabilityofthiscircuitwithvaluesshownisabout500Vand1000uFmaximum.Adjustthecomponent
valuesforyourparticularapplication.
(Probe)
<+
In1|
/
\2K,25WUnmarkeddiodesare1N400X(whereXis17)
/orothergeneralpurposesiliconrectifiers.
\
|
+++
__|____|__|
_\_/__/_\_/
||\100ohms
__|____|__/
_\_/__/_\_|
||++
__|____|____|____|__AnygeneralpurposeLEDtype
_\_/__/_\__\_/_LED_/_\_LEDwithoutaninternalresistor.
|||+|Usedifferentcolorstoindicate
__|____|__++polarityifdesired.
_\_/__/_\_|
In2|||
>+++
(GNDClip)
Thetwosetsof4diodeswillmaintainanearlyconstantvoltagedropofabout2.83VacrosstheLED+resistor
aslongastheinputisgreaterthanaround20V.Note:thismeansthatthebrightnessoftheLEDisNOTan
indicationofthevalueofthevoltageonthecapacitoruntilitdropsbelowabout20volts.Thebrightnesswillthen
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decreaseuntilitcutsofftotallyataround3volts.
Safetynote:alwaysconfirmdischargewithavoltmeterbeforetouchinganyhighvoltagecapacitors!
Voltagecheckers
Whereasamultimeterisintendedtomeasurevoltages(andotherthings),acheckerisusedmostlytojust
produceaquickindicationofthepresenseofvoltage,itspolarity,andotherbasicparameters.Oneuseisa
quick,butreliableindicationofthestatusofthechargeonaBIGcapacitor.An,exampleofasimpleversionof
suchadeviceisthe"capacitordischargeindicatorcircuit"describedabove.
(From:IanField(ionfieldmonitors@ic24.net).)
TheversionofthecheckerthatIhave,alsocontainsaminiature12Vbatteryforcontinuitycheckingany
resistancelessthanabout22Kwillproducesomeglow.It'shandyforquickchecksofsemiconductorjunctions
ingeneralifitproducesaslightglowit'sleaky,buttransistorB/Ejunctionshaveaninherentzenervoltage,so
thereisusuallysomeglow.Alsoschottkybarrierdiodesgiveareverseleakageglowthisdoesnotmeanthey're
faulty,checktheVfwiththediodecheckonaDMMbeforebinning!Anyzenerdiodeabove1011Vcanbe
givenaquicktestforS/C,lowerVzwillproducesomeglowagaincheckVfbeforebinning.
Thesecheckersaregettinghardtoobtain,mostofthecomponentstockistshereonlycarryvastlyover
complicated(andexpensive)versionswithbuiltinmeasurementcomputerandLCDthesewouldn'tlast5min's
aroundflybackcircuitry!SomeAutomotiveaccessoryshopshaveasimplerversionwithnobatteryalways
checkthatit'sstatedtobecapableofmeasuringACorDCat4to380Vbeforepartingwithmoney!The
internalcircuitshouldcontaintheLED's,a15ohmresistortolimitthemaximumsurgecurrentwhenthePTCis
coldandthespecialPTCfilmthermistor.ThebatterycanbeaddedwithabuttonfromaVCRfrontpanelbut
don'tblamemeifyoukillyourselfbecauseyoudidn'tinsulatetheaddedcomponentsproperly!Thereisamore
complicatednonbatteryversionwith2LED'sclosetothefrontofthehandletoindicatepolarityandarowof
LED'salongthelengthofthehandletoindicatethevoltagerange.Thisversioncontains2specialPTC'sanda
discretetransistorbargraphcircuittheremightberoomtoaddabatteryinsidethecase.Asforthespecial
PTCthisistheonlyplaceI'veseenthemonepossibilitythatmightbeworthyoflookingintoistheSiemens
PTCSMPSUstartupthermistorforTDA4600controlchips,thisusuallyhasaseriesresistorofatleast270
ohmsandismorelikelytoturnupinEuropeanTVset's,butIhaveseenitinearlyMatsushitaIBMdisplaysand
afewothers(possiblyTandon)thePTCthermistorisalwaysblueandlookslikeaveryminiaturecopyofthe
PhilipswhiteplasticPTCdegaussthermistor.
Theserieslightbulbtrick
Whenpoweringupamonitor(oranyothermodernelectronicdeviceswithexpensivepowersemiconductors)
thathashadworkdoneonanypowercircuits,itisdesirabletominimizethechanceofblowingyournewly
installedpartsshouldtherestillbeafault.Therearetwowaysofdoingthis:UseofaVariactobringuptheAC
linevoltagegraduallyandtheuseofaseriesloadtolimitcurrenttopowersemiconductors.
ActuallyusingaseriesloadalightbulbisjustareadilyavailablecheaploadisbetterthanaVariac(wellboth
mightbebetterstill)sinceitwilllimitcurrentto(hopefully)nondestructivelevels.
CAUTION:RunninganySMPSatgreatlyreducedlinevoltagewillbestressfulforit,especiallyiftheoutputload
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isasignificantfractionofitsfullloadratings.Inaddition,atsomerangeoflinevoltage,theoutputregulationmay
notworkproperlyandtheoutput(s)maygomuchhigherthanexpected.Usedummyloadsinplaceofthe
valuableequipmentifpossiblewhendoingsuchtesting!
Whatyouwanttodoislimitcurrenttothecriticalpartsusuallytheswitchmode(chopper)powertransistorof
anSMPSorhorizontaloutputtransistor(HOT)ofaTVormonitor.Mostofthetimeyouwillgetawaywith
puttingitinserieswiththeACline.However,sometimes,puttingalightbulbdirectlyintheB+circuitwillbe
neededtoprovideadequateprotection.Inthatlocation,itwilllimitthecurrenttotheHOTfromthemainfilter
capacitorsoflineconnectedpowersupplies.Thismayalsoberequiredwithsomeswitchmodepowersupplies
astheycanstillsupplyburstsoffull(orexcessive)currentevenifthereisalightbulbinserieswiththeACline.
Actually,anactualpowerresistorisprobablybetterasitsresistanceisconstantasopposedtoalightbulbwhich
willvaryby1:10fromcoldtohot.Thelightbulb,however,providesanicevisualindicationofthecurrentdrawn
bythecircuitundertest.Forexample:
Fullbrightness:shortcircuitorextremelyheavyloadamajorfaultprobablyisstillpresent.
Initiallybrightbutthensettlesatreducedbrightness:filtercapacitorscharge,thenlowercurrenttorestof
circuit.Thisiswhatisexpectedwhentheequipmentisoperatingnormally.Therecouldstillbeaproblem
withthepowercircuitsbutitwillprobablynotresultinanimmediatecatastrophicfailure.
Pulsating:powersupplyistryingtocomeupbutshuttingdownduetoovercurrentorovervoltage
condition.Thiscouldbeduetoacontinuingfaultorthelightbulbmaybetoosmallfortheequipment.
Note:foraTVormonitor,itmaybenecessary(anddesirable)tounplugthedegausscoilasthisrepresentsa
heavyinitialloadwhichmaypreventtheunitfromstartingupwiththelightbulbinthecircuit.
Thefollowingaresuggestedstartingwattages:
40WbulbforVCRorlaptopcomputerswitchingpowersupplies.
100Wbulbforsmall(i.e.,B/Wor13inchcolor)monitorsorTVs.
150200WbulbforlargecolormonitorsorprojectionTVs.
A50/100/150W(orsimilar)3waybulbinanappropriatesocketcomesinhandyforthisbutmarktheswitch
sothatyouknowwhichsettingiswhich!
Dependingonthepowerratingoftheequipment,thesewattagesmayneedtobeincreased.However,startlow.
Ifthebulblightsatfullbrightness,youknowthereisstillamajorfault.IfitflickersortheTV(orotherdevice)
doesnotquitecomefullyup,thenitshouldbesafetogotoalargerbulb.Resistthetemptationtoimmediately
removetheserieslightbulbtotallyfromthecircuitatthispointIhavebeenscrewedbydoingthis.Tryalarger
onefirst.Thebehaviorshouldimprove.Ifitdoesnot,thereisstillafaultpresent.
NotethatsomeTVsandmonitorssimplywillnotpowerupatallwithanykindofseriesloadatleastnotwith
onesmallenough(intermsofwattage)toprovideanyrealprotection.Themicrocontrollerapparentlysensesthe
dropinvoltageandshutstheunitdownorcontinuouslycyclespower.Fortunately,theseseemtobethe
exceptions.
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WhataboutSMPSsinTVsandmonitors?
TVsandmonitorshaveatleastoneSMPSthehorizontaldeflectionflybackcircuitandmayhaveanadditional
SMPStoprovidethelowvoltagesortheDCforthehorizontaloutputtransistor.Mostofthetheoryofoperation
andtroubleshootingtechniquesapplytotheseaswell.However,manufacturersofTVsandmonitorstendtobe
reallycreative(canyousay,obscure?)whenitcomestothesedesignssoalittlemoreheadscratchingisoften
necessarytodecipherthecircuitandgetintothemindofthedesigner.However,thebasicfailuremodesare
similarandthesametestproceduresmaybeused.
CommentsonSMPScapacitordischargingandtestingwithseriesloads
(From:IanField(ionfieldmonitors@ic24.net).)
Atapinch,dischargingBIGelectrolyticcapacitorswithatestlamp(230V,60WintheUK115V,25Win
seriesintheUS)willdo,butifthelamphasblownyouareinforanastysurprise!WhileIamnotcriticisingthe
useofsparehighwattageresistors,Itendtofindthatthesegettidiedaway,sothere'snoneaboutwhenyou
needone!
Thelampsometimesget'susedifIcan'tfindanNTC,butIalwayscheckwithavoltagecheckerbecauseofthe
risk!powerresistorscangoO/CaswellwhereasNTCthermistorsgenerallyfailS/Cwhichusuallyhappens
asaresultofsometransientphenomenonsuchasalightningstrikeneartheundergroundpowerline.
Thisisunlikelywiththeenergydumpofdischarginganofflineelectrolytic(unlesstheequipmentisstillpowered
atthetime!).Mybenchisn'tthetidiestintheworld,sogadgetstendtogetmisplacedincludingpowerresistors
withaddeddischargeprogressLEDindicators.ThisiswhereaninrushsuppressorNTCcomesintoit'sown,
evenwithoutselectingthetypeitwilldischargeacapacitoralmostinstantaneouslywiththeminimumofarcburn
onthesolderpads.Obviouslytheenergycausessomeheatinginthecaseoflargeelectrolyticsdirectoffline
rectifiersmoothing/reservoirtheamountofheatingisjustsufficienttogiveanideaoftheconditionofthe
capacitorcapacitorfailureiscomparativelyrare,soit'snotoftenanticipatedandcancausemisleading
symptomssomakingthisdoubleasaroutinecheckoccasionallysavesahellofalotoftime!
ThetrickIhavefoundworksevenbetteristouseaNTCinrushcurrentsuppressorthermistor.Theseitemscan
besalvagedfromascrapmonitororPSU,andcarefulselectionmayrevealsometypeswitha"room
temperatureresistance"ofseveralkohmswiththelinevoltageonacapacitordischargingthroughthem,self
heatingreducestheresistancetoafewohms.Thisreducestheweldingsputterasthecontactcurrentisonlya
fewmilliampsthisrisestoafewamperesasthecapacitor"dumps"itschargeastheNTCresistancefall'swith
selfheating.
OnepointIwoulddisagreeonisthatnotallofthemanyelectrolyticsneeddischarging!MostSMPSU'sofany
appreciablepowerhavehighenergyelectrolyticsinthesecondarywhetherthisisexpressedashighvoltageor
highcurrent.Inthecaseofmonitors,thepostPWMB+railhasalargestorageelectrolyticwhichcando
appreciabledamageintheeventthatlinedrivefailurehaspreventeduseofit'senergy.TheNTCthermistor
methodhelpshereafter"dumping"thelinevoltageelectrolyticstheNTCisatalowerresistanceandreadyfor
followinguponthelowerchargeelectrolytics.
Thereisapointconcerning"testlampdummyloads"thishasmoretodowithmonitorsthanSMPSUboxes.As
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wellasthesuggestedusetolimitinrushcurrenttoasafevalueonSMPSUboxesIalsousethismethodonline
O/PstagesespeciallytoverifythatflybacktransformerfailurewasnottheoriginalcauseofB+PWMor
SMPSUblowup.RecentlyIhavebeencaughtoutafewtimesbecausesome"energystar"designsareso
efficientthattheinrushcurrentofthelampitselfisampletocausecatastrophicdamage!TheUK220/230V60
WtestlampIhaveherehasacalculatedoperatingresistanceof806.7/881.7ohmscomparedtoameasured
coldresistanceofabout67ohmssothePTCeffectofthefilamenttendstolimittheadvantage!
ToclarifymycommentonconfirmingwhetherafaultyflybacktransformerhasdamagedtheB+PWMolder
circuitsuseaMOSFETbuckregulator,inwhichS/CfailureoftheMOSFETfeedsunregulatedB+totheline
O/PstageThisinvariablydestroystheHOTandsometimesthetransformer,buteithercouldaseasilybethe
originalcause.InanyeventbypassingtheB+PWMMOSFETviathetestlamppassesjustenoughcurrentto
seeifthetransformerisoperablewiththepriceofreplacements,veryfewquotesareacceptedsoit'swell
worthmakingsurebeforeorderinganexpensivereplacementordoingtoomuchrepairwork!Morerecently,the
trendhasbeenforflybackstepupB+regulators.WhentheB+MOSFETfailsS/Citsimplystallsthemain
SMPSU(sometimesdestroyingtherectifier!).SincethistypeofB+PWMisstepup,theoperabilityofthe
flybacktransformercanbecheckedbysimplyremovingtheS/CMOSFET.Themostrecentdesignsappearto
bebasedonsemiresonantSMPSUtopologytheyresemblebuckregulatorPWMcontrollers,butthePWM
MOSFETisatchassispotentialandthetransformerprimaryisatfullPSUrail,thelineO/Ptransistorisbetween
thetwowiththedrivetransformerconnectedtoprovideanemittercoupledblockingoscillatorconfiguration,to
add"regen"tothebasedrive.Theboostdiodeoftenincludesthebuckregulators"ringingchoke"inthe"net
inductivecomponent"thatitrecoversenergyfrom!Asthelaterconfigurationmostcloselyresemblesthebuck
regulatortype,thetestlampisrequiredtoconfirmtransformeroperabilitybuttheweirdandwonderfulcircuit
arrangementscanmakeitlotsoffunworkingoutwheretoconnectit!
AvoltagecheckerthatIfindindispensableistheSteinelMastercheck3fromSteinelGmbH&Co.(KG
Dieselstrabe8086D4836Hertzebrock1,Germany).TheversionIhaveconsistsofapairof"inverseparallel"
LED'sinserieswithametalfilmPTCthermistoronatinyceramictubeformerthishasaverylowthermal
inertiasothePTCthermistorlimitsthecurrenttoasafevaluefortheLED'sforanyappliedvoltagebetween4&
380Vthecombinationof2LED'sgiveaclearindicationofACorDCpolarity.Whenthischeckerisused
aroundSMPSU's,youcanclearlyseetheeffectofminoritycarriertransitiontimelossesintherectifiers,because
theleadingedgeofthewaveformpushestherectifiersVfwellinexcessof0.7Vfortheminoritycarrierinjection
delaybeforetherectifierbeginstoconduct.WhereaPSUrectifierhastwoelectrolyticsandachokeinaPi
filter,thecheckerwilloftenrevealnegativetransientsontheelectrolyticclosesttotherectifierwhichisaclear
signofcapacitorESRfailure.
SMPSfailuremodes
Alsoseethesection:SoundsthatSMPSsmake.
SMPSfailinmanywaysbutthefollowingarecommon:
Faultyprimarysidecomponents.Rectifierdiodes,filtercapacitor(s),MOVs,andotherpartslocated
beforetheswitchmode(chopper)transistor(s)mayshortduetoasurgeorlightning,orfornoapparent
reason.Mainfusewillblowinstantly.
Symptoms:Totallydeadsupply,fuseblowsinstantly(vaporizesorexplodes)evenifswitchmodetransistor
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isremovedunlessafusableresistorhasblowntoprotectthefuse.:)Testallcomponentsonlinesideof
highfrequencytransformerforshortcircuitfailureswithamultimeter.
Shortedswitchmodetransistormaytakeoutadditionalpartssuchasfusableflameproofresistorsin
collectororemittercircuitsofbipolartransistorsorsourceordraincircuitsforMOSFETsaswellasgate
componentslikethe15or18Vprotectionzener.Mainfusewillblowunlessprotectedbyfusable
resistorsandoneormoreofthemblowsfirst.
Symptoms:Totallydeadsupply,fuseblowsinstantly(vaporizesorexplodesunlessfusableresistorhas
opened).MeasuringacrossCEorDSofswitchmodetransistoryieldsnearzeroohmsevenwhen
removedfromcircuit.
Shortedrectifierdiodesinsecondarycircuitsthesearehighfrequencyhighefficiencydiodesunderafair
amountofstress.
Symptoms:Inaverybasicsupplywithoutovercurrentprotection,thefailureofoneormoreofthese
diodesmaythenoverloadthesupplyandcauseacatastrophicfailureoftheswitchmodepowertransistor
(seeabove)andrelatedcomponents.Thus,theseshouldbecheckedbeforereapplyingpowertoasupply
thathadashortedswitchmodetransistor.
Onshortcircuitprotectedsupplies,thesymptommaybeaperiodictweettweettweetorflubflubflubas
thesupplyattemptstorestartandthenshutsdown.Anypowerorindicatorlightsmaybeblinkingatthis
rateaswell.
Testwithanohmmeteralowreadinginbothdirectionsindicatesabaddiode.Sometimesthesewilltest
OKbutfailunderloadoratoperatingvoltage.Easiesttoreplacewithknowngooddiodestoverify
diagnosis.Rectifierseitherlooklike1N400Xtypeonsteroidscylindersabout1/4"x1/2"(example:
HFR854)orTO220packages(example:C92M)withdualdiodesconnectedatthecathodeforpositive
suppliesortheanodefornegativesupplies(thepackagemayincludealittlediagramaswell).Thesemay
eitherbeusedwithacentertappedtransformer,orsimplyparallelforhighcurrentcapacity.Ifindoubt,
removefromthecircuitandtestwiththeohmmeteragain.Ifnottheoutputusedforregulationfeedback,
trythesupplywiththerectifierremoved.Asnoted,atestwithanohmmetermaybemisleadingasthese
rectifierscanfailatfullvoltage.Whenindoubt,substituteaknowngoodrectifier(onehalfofapairwillbe
goodenoughforatest).
Badstartupcircuitinitialbase(gate)driveisoftenprovidedbyahighvalue,highpowerresistoror
resistorsfromtherectifiedACvoltage.Thesecansimplyopenfornogoodreason.
Symptoms:Inthiscasethesupplywillappeartotallydeadbutallthesemiconductorswillcheckoutand
nofuseswillblow.CheckthestartupresistorswithanohmmeterpowerresistorsintheAClineinput
section.WARNING:therewillbefullvoltageonthemainfiltercapacitor(s)1Xor2Xpeakoraround
160or320VDCdependingondesign.Dischargebeforeprobing.
Driedupcapacitorseitherinputoroutputside.
Symptoms:Themainfiltercapacitormaydryuporopenandcausetheoutputtobepulsingat60(50)or
120(100)Hzandallkindsofregulationproblems.Measurevoltageacrossmainfiltercapacitor(s).Ifthe
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readingislowanddropstoamuchlowervalueor0instantlyuponpullingtheplug,thenoneofthese
capacitorsmaybeopenordriedup.Ifyouhaveanoscilloscope,monitorforripple(useanisolation
transformer!!).Excessrippleundermoderateloadisanindicationofadrieduporopencapacitor.
Inextremecases,amainfiltercapacitorwithgreatlyreducecapacityorthatistotallyopenmayresultin
failureoftheswitchmodetransistorandadeadsupplythatblowsfusesorfusableresistors.Therefore,itis
alwaysagoodideatotesttheelectrolyticcapacitorswheneverrepairingaSMPSthathasblownits
switchmodetransistor.
Capacitorsinthelowvoltagesectionmayfailcausingregulationproblems.Sometimesthereareslewrate
limitingcapacitorswhichfeedfromtheprimaryoutputtotheregulatorcontrollertolimitinitialinrushand
overshoot.Afailureofoneofthesemaymessupregulationattheveryleast.Forexample,excessleakage
mayreducetheoutputofthemainoutput(andasaconsequence,alltheothersaswell).
WhereacontrollerlikeaUC3842isused,afailureofthecapacitoronitsVccpinmayresultinaaborted
startuporcyclingbehaviorasitisstarvedforjuiceeachtimeitpulsestheswitchmodepowertransistor:
(From:JohnHopkins(bugs71@ptdprolog.net).)
"Ihaveencounteredabadcap(10uf35v)ontheVccinputofaUC3842ICinthepower
supply.Turnuniton,getveryshortburstofpowersupplyoutput,thennothing.Everytime
the3842outputapulse,itranoutofVCC.Smallpart,bigproblem."
Inalmostallcases,whenindoubtparallelaknowngoodcapacitorofsimilarcapacitanceandatleast
equalvoltagerating(exceptfortheseslewratelimitingcapacitorswheresubstitutionistheonlysuretest).
ForPanasonic(andother)VCRpowersupplies,itiscommonalmostassuredafterafewyearsthat
oneormoretheoutputfiltercapacitorscommonlyfailandreplacingallofthem,whileperhapsabrute
forcesolution,willfixawhiningsupplyoronehavingbadregulationornoise.However,checkthe
semiconductorsaswellbeforeapplyingpower.Seethesection:PanasonicVCRSMPS.
Badconnection/coldsolderjointsaswithallothermassproducedpowersystems(includingTVsand
monitors),crackedordefectivesolderconnectionsareverycommonespeciallyaroundthepinsofhigh
powercomponentsliketransformers,powerresistorsandtransistors,andconnectors.
Theseareparticularlycommonwithportableequipment.UniversalACadaptersforcamcordersand
laptopcomputersareoftenabusedtothepointoffailure.Largecomponentslikethelinefilterchokeand
highfrequencytransformerarepronetocrackthesolderbondattheirpinsorevenbreakloosefromthe
circuitboard.
Symptoms:almostanykindofbehaviorispossible.Theunitmaybeerratic,intermittent,ortotallydead.
Visuallyinspectthesoldersideofthecircuitboardwithabrightlightandmagnifyingglassifnecessary.
Gentlyprodortwistthecircuitboardwithaninsulatingsticktoseeiftheproblemcanbemadetochange.
Notethataonetimeintermittentcanblowmanycomponentssoinspectingforintermittentsisareally
goodideaevenyoubelievethatallbadcomponentshavebeenreplaced.
Regulationproblemsoutputshighorlow.
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Symptoms:voltagehaschangedandadjustmentpotifoneexistshasnoeffectorisunabletosetvoltage
topropervalue.Checkcomponentsinthefeedbackregulator,particularlytheoptoisolatorandits
associatedcircuitry.Aweakoptoisolatormayallowforexcessiveoutputvoltage.Ashortedphotodiode
intheoptoisolatormaypreventstartup.Anopenphotodiodemayleadtoarunawaycondition.
WARNING:probethesecircuitswithcarebothbecauseofthesafetyissuesbutalsosinceanyslipofthe
probemayleadtoarunawayconditionandcatastrophicfailureoftheswitchmodetransistorandits
relatedpartsaswellasdamagetoanyattachedequipment.
Notethatthehighfrequencytransformerdoesnotmakethetop10listfailureratesforthesecomponentsare
relativelylow.Youbetterhopesoinanycasereplacementsareusuallyonlyavailablefromtheoriginal
manufactureratoutrageouscost.
MostotherpartsarereadilyavailablefromplacesservicepartsdistributorslikeMCMElectronicsaswellas
generalelectronicsdistributorslikeDigiKeyandMouser.
RebuildkitsareavailableformanycommonsuppliesusedinVCRs,monitors,terminals.Seethesection:Repair
partssources.
Also,whileitistemptingtosuspectanyICsorhybridcontrollerssinceitisthoughtthatreplacementsaredifficult
andexpensivetoobtain,thesepartsareprettyrobustunlessacatastrophicfailureelsewheresentcurrentwhereit
shouldnothavegone.And,ICsatleast,areusuallyreadilyavailable.
SoundsthatSMPSsmake
Mostswitchmodepowersupplieswhenoperatingnormallyproducelittleornodetectablesound.Theswitching
frequenciesareusuallywellabovetherangeofhumanhearing,butyourdogorpetdolphinmightbedrivennuts!
However,undervariousfaultconditions,andsometimeswhenlightlyloaded,theremaybetelltailaudible
indicationsoftheSMPS'sstateofhappiness.ThecausemaybeintheSMPSitselforitsload.
1.Tweettweettweetorchirpchirpchirp(sometimesflubflubflub)Shortcircuitorcurrentoverload.
Thisisusuallyanindicationofashortedsecondarysiderectifierand/orifinaTVormonitorusingan
SMPS,ashortedhorizontaloutputtransistor.Thepowersupplyisinarepeatingcycleattemptingtostart
up,beingdraggeddownbytheoverload,andshuttingdown.
2.Highpitched,butaudible,whineExcessiveload.Like(1),thismaybecausedbyshortedcomponents.
Forexample,acommonfailureaPanasonicVCRpowersupplyisforthe18Vzenerdiodeacrossthe15
Voutputtoshortduetodriedupelectrolyticcapacitors.Theresultinanoverloadandwhine,butusually
notacatastrophicfailureofanythingelse.
Whichof(1)or(2)actuallypresentwilldependontheparticulardesignoftheSMPSandtheseverityofthe
overload.IfthedesignusesahardSCRcrowbar,anovervoltageconditionmaytriggeroneofthesymptoms!
3.TickticktickToolittleornoload.InaTVormonitorusinganSMPS,thisislikelyduetoalackof
horizontaldriveorablownfuseorfusableresistorinthehorizontaldeflectionsystem.Thepowersupplyis
inarepeatingcycleofstartingup,beingunabletolimittheregulatedvoltagetoasafevalue,andshutting
down.AttemptingtopowerupanSMPSwithoutanadequatedummyloadmayresultinthesesymptoms.
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4.Hissingorwhitenoisepossiblyfrominductorsthismaybenormalundercertainconditions:
(From:CharlieAllen(charlie.allen@usa.net).)
"Someswitchmodepowersupplyinductorswillmakeahissingorwhitenoisesound,
typicallywhenthecircuitislightlyloadedandrunningina"pulseskip"orPFMmode.Ihave
hearditonmanyDC/DCcircuits.Youcouldtryremovingthecoilandpouringinsome
epoxy."
GeneralSMPStroubleshootingapproach
ThefollowingsectionsprovideasetofguidelinesforattackingSMPSproblems.Thoseinthenext5paragraphs
arecommontoSMPSusingbothdiscreteandintegratedcontrollers:
1.First,determinethatitisnotsomethingtriviallikeablownfuseduetoalegitimateoverload(thathassince
beenremoved).IhaveaSCSIperipheralboxthatwillblowitsSMPSfuseiftheSCSIcableisinserted
live.
2.Categorizetheprobleminto:startupproblem,catastrophicfailure,incorrectoutputs,orexcessiverippleor
noise.
3.Determinewhattheproperoutputvoltagesshouldbe.Identifythemain(regulated)output.
4.Disconnectthesupplyfromtheequipmentitispoweringifpossible.Thiswillpreventthepossibilityof
expensivedamageshouldtheoutputvoltagessoartostratosphericlevelsforsomereason.Ifthisisnot
possible,youwillneedtobeextracarefulalwaysuseaVariactobringuptheinputslowlyandmonitor
themainoutputatalltimes.
Note:SomeSMPSdesignsrequirepowertobeappliedinstantlytoprovidethestartupvoltagetothe
controller.Ifthisisthecasewithyours,itwon'tbepossibletobringupthevoltageslowly(unlessyou
powerthatchipseparately).However,itshouldstillbepossibletoruntheunitsomewhatreducedline
voltage.
CAUTION:RunninganySMPSatgreatlyreducedlinevoltagewillbestressfulforit,especiallyifthe
outputloadisasignificantfractionofitsfullloadratings.Inaddition,atsomerangeoflinevoltage,the
outputregulationmaynotworkproperlyandtheoutput(s)maygomuchhigherthanexpected.Use
dummyloadsinplaceofthevaluableequipmentifpossiblewhendoingsuchtesting!
5.Determineanappropriateloadfortheoutputs(ifnotconnectedtotheequipment).AtypicalSMPSwill
wantaminimumof5%to20%offullloadcurrentatleastonthemainoutputtoregulateproperly.Others
maynotneedanyloaditdependsonthedesignortheymayhaveaninternalload.Herearesometypical
loadcurrents:
VCR0.2Aon+5Vand+12Voutputs.
PC2Aon+5V,1Aon+12V.Adualbeamautoheadlightworkswell.
Monitor0.2Aon+60Vto+120Voutput.
Typical40Wswitcher=1Aon+5Vand+12V.
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TroubleshootingSMPSsusingdiscretecontrollers
ThefollowingparagraphsapplymainlytoSMPSsusingdiscretecircuitry(noICs)forpulsewidthcontrol.For
thoseusingintegratedcontrollerchips,seethenextsection:TroubleshootingSMPSsusingintegratedcontrollers.
Startupproblemscheckthepowerontheswitchmodetransistorandworkbackfromthereifthereis
none.Checkforopenfusableresistorsinthereturnaswell.Determineifthereisstartupbase/gatedrive.
Checkforopenstartupresistors,badconnections,blownpartsinthecontrollercircuitry.
Blowsfusescheckprimarysidecomponents,switchmodetransistor(s),andallothersemiconductorsfor
shorts.Thencheckforopenfusableresistorsandbadconnections.Finally,checktheelectrolytic
capacitorsforreducedcapacityandleakage.
Powercyclingmonitorcurrentandvoltagesensingsignalstodetermineiftheyareactuallysignalinga
fault.Openoroutoftoleranceresistorsmayresultinincorrectsensing.Withtheserieslightbulband/or
Variac,disableeachoftheseinputsbybypassingtheappropriatecomponents.Ifoneoftheseexperiments
preventsthecyclingbehavior,eitherthatcircuithasafaultycomponentorthecontrollercircuitisnot
functioningproperly.
Regulationorripple/noiseproblemscheckmainHVfiltercapacitorandotherfiltercapacitorsfor
decreasedvalueoropens.Checkregulationcomponentsincludingshuntregulatorsandzenerdiodes.
TroubleshootingSMPSsusingintegratedcontrollers
Sincethereareusuallyseveralfaultconditionsthatcanresultinanabortedstartuporcyclingbehavior,thebasic
troubleshootingprocedureneedstobemodifiedwhendealingwithSMPSusingcontrollerICsliketheUC3840
orUC3842.
Alsoseethesection:TypicalcontrollerICsfoundinsmallswitchmodepowersuppliesfordescriptionsoftwo
commonintegratedcontrollerICs.
ThefollowingparagraphsapplytoSMPSsusingintegratedcontrollers.Forthoseusingdiscretecomponentsonly
(noICs),seetheprevioussection:TroubleshootingSMPSsusingdiscretecontrollers.
Startupproblemscheckthepowerontheswitchmodetransistorandworkbackfromthereifthereis
none.Checkforopenfusableresistorsinthereturnaswell.Checkforpowertothecontroller.Determine
thatnofaultconditioninputshaveabnormalvoltagesduringstartup.Checkfordriveoutofthecontroller
ICandseeifitreachestheswitchmodetransistor.Youwillprobablyneedtopowercyclethelineinput
andmonitoreachoftherelevantsignalsasyoudoso.(Itmaynotbepossibletobringupthevoltage
slowlywithaVariacifthestartupcircuitusescapacitiveorinductivecouplingtogeneratetheintialsupply
voltageforthecontrollerchip.However,aVariaccanstillbeusedtorunitatreducedvoltageifthisisthe
case.)Determineifthesupplyisshuttingdownabnormallyduetoalegitimateorbogusovercurrentor
overvoltageconditionorisneveractuallystartingupduetoalackofavoltageorastuckatfaultona
senseline.Monitoritspowertodetermineifitisstableduringstartupabadcapacitorordiodecould
resultininsufficientordecreasingvoltagewhichcausesthecontrollertogiveup.
CAUTION:RunninganySMPSatgreatlyreducedlinevoltagewillbestressfulforit,especiallyifthe
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outputloadisasignificantfractionofitsfullloadratings.Inaddition,atsomerangeoflinevoltage,the
outputregulationmaynotworkproperlyandtheoutput(s)maygomuchhigherthanexpected.Use
dummyloadsinplaceofthevaluableequipmentifpossiblewhendoingsuchtesting!
Poweringthecontrollerseparatelymayaidintroubleshootingoftheseandrelatedproblems.Thiswill
decouplethechopperdrivefromthevoltageusuallyderivedviaawindingonthehighfrequency
transformertopowerthecontrolleroncethesupplyisrunning.
Blowsfusescheckprimarysidecomponents,switchmodetransistor(s),andallothersemiconductorsfor
shorts.Thencheckforopenfusableresistorsandbadconnections.Thereisachancethatablown
transistortookoutthecontrollerchipaswell.Undernormalconditions,controllersliketheUC3840or
UC3842shouldcurrentlimitonaPWMcyclebycyclebasis.Therefore,ablownfuseindicatesafailure
ofeithertheswitchmodetransistor,controllerorboth.
PowercyclingFirstmakesureyouareprovidingtheminimumloadifoneisrequired.ManySMPSswill
cycleonovervoltageifthereisnone.Somemayblowup!Assumingtheloadconditionsarenormal,
monitorcurrentandvoltagesensingandVccinputstocontrollertodeterminewhich,ifany,areatfault.
Openoroutoftoleranceresistorsmayresultinincorrectsensing.Checkforfaultyreferencesetting
componentslikezenerdiodes.Withtheserieslightbulband/orVariac,disableeachofthesenseinputsby
bypassingtheappropriatecomponents.Ifoneoftheseexperimentspreventsthecyclingbehavior,either
thatcircuithasafaultycomponentorthecontrollerIC'sinputcharacteristicshavechangedanditwillneed
tobereplaced.Itshouldbepossibletodetermineifthesesensingreferencelevelsarecorrectfromthe
controllerspecificationsandthusshouldbeignoredbythecontrolleraswithinnormallimits.
Regulationorripple/noiseproblemscheckmainHVfiltercapacitorandotherfiltercapacitorsfor
decreasedvalueoropens.Checkregulationfeedbackcomponentstocontrollerincludinganyreference
voltageoutputandzenerdiodes.Determineifthecontrollerisrespondingtoerrorvoltage.Ifpossible,
monitorbotherrorandPWMdrivesignalsonadualtracescope.
Initialpostrepairtesting
Oncedefectivepartshavebeenreplaced,ifpossibleremovethenormalloadfromthesupplyifyouhavenot
alreadydonesojustincaseitdecidestoputexcessivevoltageonitsoutputsandreplacewithadummyload.
Foramultipleoutputsupply,themostimportantoutputtohavealoadonistheonethatisusedforregulationbut
somemodestloadonalltheoutputsispreferred.Youshouldbeabletodetermineasuitablevalueby
consideringtheapplication.ForsomethinglikeaVCR,afewhundredmAonthemainoutputisprobably
enough.Thiswouldrequiresomethinglikea25ohm2Wresistorfora5or6voltoutputor50ohm5W
resistorfora12voltoutput(dependingonwhichistheprimaryoutput).ForaPCpowersupply,acoupleof
ampsmaybeneededa2or3ohm15Wresistoronthe+5output.Theminimumloadissometimesindicated
onthespecificationsticker.InthecaseofaTVormonitor,disconnectingtheloadmaynotbepossible(orat
least,easy).
Ifavailable,useaVariactobringuptheinputvoltageslowlywhileobservingthemainoutput.Youshouldsee
somethingatabout50%ofnormalinputvoltage50or60Vforanormal115VACsupply.Withasmallload,
theoutputshouldveryquicklyreachorevenexceeditsnormalvalue.Regulationatverylowlinevoltagemaybe
faroffthisisoftennormal.Justmakesureyou'reusingdummyloadssoyourequipmentcan'tbedamaged.
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Note:SomeSMPSdesignsrequirepowertobeappliedinstantlytoprovidethestartupvoltagetothecontroller.
Ifthisisthecasewithyours,itwon'tbepossibletobringupthevoltageslowly(unlessyoupowerthatchip
separately.So,ifnothinghappenswhendoingthis,don'tpanicitmaybeafeature,notabug.:)Itshouldstillbe
possibletoruntheunitsomewhatreducedlinevoltageontheVariac.
IfyoudonothaveaVariac,putalightbulbinserieswiththeline(thisisdesirableinanycase).Usea100W
bulbforaTVorPC,40WforaVCRtypical.Thelightbulbshouldlimitthecurrenttoanondestructivevalue
longenoughtodeterminewhethereverythingisOK.Itmaynotpermitnormaloperationunderfullload,
however.Whenpowerisfirstapplied,thelightbulbwillflashbrieflybutmayjustbarelybeglowingoncethe
outputhasstabilized.Ifitisfairlybrightcontinuously,thereislikelystillaprobleminthesupply.Seethesection:
Theserieslightbulbtrick.
Onceyouarefinished,saveyourschematicandnotesforthefuture.Forexample,multiplemodelsofVCRs
evenfromdifferentmanufacturersusethesamebasicdesign,maybeeventhesamesupply.
Somegeneralswitchmodepowersupplyrepaircomments
Anytimetheswitchmodetransistorrequiresreplacement,checkallsemiconductorsforshortsandfusable
resistorsforopens.evenifyoulocatewhatisthoughttobe**the**problemearlyon.Multiplepartsoftenfail
andjustreplacingthetransistormaycauseittofailasaresultofsomethingelsestillbeingbad.Inparticular,
checkprimarysideelectrolyticcapacitorsforreducedcapacityoropens.Theseconditionscanresultinablown
switchmodetransistorasitattempttosupplyadequatecurrentduringthetroughsoftherectifiedhighvoltage
DC.Itonlytakesafewmoreminutes.Forotherproblemslikeanopenstartupresistorthisexcessivecautionis
unnecessaryastheseareusuallyisolatedfailures.However,ifanydriedupelectrolyticsarefound,itisgood
practicetotestthemallorjustreplacethemallsincethecostandtimewillbeminimal.Astheysay,'peasina
podfailatnearlythesametime'.
Itisoftenhelpfultotracethecircuitbyhandifaservicemanualisnotavailable.Youwillgainabetter
understandingofthissupplyandbeabletoputtheknowledgetousewhenthenextoneshowsuponyourbench
thereisalotofsimilarityevenbetweendifferentmanufacturers.Abrightlightbehindthecircuitboardmayhelp
tomakethefoilrunsandjumpersmorevisible.Theonlydifficultpartwillbedetermininghowthetransformer
windingsarehookedup.Anohmmeterwillhelpbutevenifyoucannotentirelydeterminethis,justmakeanote.
Formostpurposes,theexacttopologyofthewindingsisnotcriticalfordiagnosticprocedures.
Periodicpowercyclingproblems
Theseareoftheform:tweettweettweetorflubflubfluborsomeothersimilarvariation.AnyLEDsmaybe
flashingaswellandinthecaseofsomethinglikeamonitororTV,theremaybeHVstaticorevenapartialraster
insynchronywiththesounds.Thesetypesofproblemsaremorecommonwithsophisticatedimplementations
thesimpleonesjustblowup!
Asnotedelsewhere,shortedsecondarycomponentsareaverylikelycauseofthisbehavior.Theseinclude
diodes,capacitors,andovervoltageSCRs.Thefactthatthereissomeoutputsuggeststhatthemainswitchmode
(chopper)transistorisworking.Therewouldlikelybenooutputatallifitwerebad.
Notethatanunderloadedsupplymaybecyclingduetoovervoltageandtheremayactuallybenothingwrong!
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ManySMPSsrequireaminimumloadtomaintainstabilityandtoprovideproperregulation.Thisistypically20
percentofmaximumontheprimaryoutput(theonewhichdrivesthefeedbackloop).However,minimumloads
mayalsobeneededonotheroutputsdependingondesign.Theonlywaytobesureistocheckthe
manufacturer'sspecs.
Otherpossibilitiesforperiodicorpulsingoutputs:
1.Oneofthediodesisfailingatvolagequitepossible.Aslongasyoudonotremovebothfromtheoutput
thatisusedforfeeback,itshouldbesafetotakethemoutoneatatimeandthensubstitutefortheone
remaininginthefeedbackvoltage.UseaVariacandserieslightbulbwhentestinginthismannerand
constantlymonitorthemainoutput.
2.Someothercauseofexcessivecurrentshortedcapacitor,transformer(thoughnotlikely),etc.
3.Faultycurrentsensecircuitopenorincreasedvalueresistor.
4.Faultyvoltagesensecircuitdetectingovervoltageorregulationdefectiveanditisshuttingdown
(correctly).
5.Faultycomponentinthestartupcircuit.Thiscouldbeabaddiode,resistor,orevenanelectrolytic
capacitorthathaschangedvalueorisopenatlowvoltage(whenthecontrollerisjustwakingup).
6.FaultycontrollerIC(ifapplicable).
TestingaSMPSwithoutstartupdrive
WhereanSMPSdoesn'tstartanditisn'tobviouswhy,itmighthelptodrivethechopperfromanexternalsignal
sourcetoseewhatthenworks.TheonlytimethisisreallypracticaliswhereasingletransistororMOSFETis
usedgeneratingapushpullwaveformprobablyisn'tworthit.
Thiswillalwaysbeariskyprocedurebothforyouandthepowersupply.Theswitchingfrequencyislikely
unknownbutforthesetestsyoucanassumeitisinthe10tokHzrange.Youcanreducetherisksomewhat(to
thesupplyatleast)byusingaserieslightbulbloadand/orrunningonreducedlinevoltage.Themostimportant
thingtoavoidisputtinginanexcessivelylongdrivepulsewhichwillresultinthehighfrequencytransformer
saturating,hugeamountsofcurrent,andlikelyadeadtransistorandpossiblyotherpartsifthereisnothingtolimit
thecurrent.Ifyouhavetheoption,startwithanarrowpulsewaveformtominimizeontimeanddon'tpushyour
luck!:)
Similarly,whereapowersupplyattemptstostartbutcyclesorshutsdown,considerpoweringthecontroller
chipfromaseparatesupplytoeliminateanyissuesofthetransformerderivedvoltagethatnormallyrunsitafter
startup.
ComponentsFoundinSwitchmodePowerSupplies
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Common,unusual,andstrange
Mostofthecomponentsusedinswitchmodepowersuppliesarecommonandeasilyidentified.However,some
maybeunfamiliarandunrecognizable.OtherscouldbetotallycustompartsASICsorhybridcircuits
developedspecificallyforaparticularmodelorproductline.However,theserarelyfaildespiteyourtemptation
toblamethemspecifically*because*locatingareplacementisdifficultandmostlikelyexpensive.
Commoncomponentsliketransistors,diodes,capacitors,andresistors,canusuallybetestedwithamultimeter
atleastfortotalfailure.Alsoseethedocuments:"TestingofBipolarTransistorswithaVOMorDMM"and
"TestingCapacitorswithaMultimeterandSafeDischarging".
Ofcourse,withcatastrophicfailures,noequipmentbeyondyoureyeballsandnosemaybeneeded.
Switchmode(chopper)transistorsandothersemiconductors
Alsoseethedocument:BasicTestingofSemiconductorDevices.
Bipolarpowertransistors(oftenBUor2SC/2SDnumbers)highvoltagepowertypesareusedforthe
mainswitchmode(chopper)transistor.
Testforshortedandopenjunctions.Thesearethemostcommonfailuresforthepowertransistors.Partial
failurewherethereissomeleakageorvariousparameterschangevalueareunlikely.
Substitutionofatransistorwithatleastequalvoltageandcurrentratingsshouldbefinefortestingaslong
asyouuseaserieslightbulbtolimitthecurrentshouldsomethingstillbewrongelsewhereinthecircuit.A
notexactmatchmayrunhotterthannormal.Alwaysuseaheatsink.
PowerMOSFETs(2SKnumbers)manynewersuppliesareusingtheseratherthanthebipolartype.In
somewaystheyaremorerobustbuttestingismoredifficult.
Testingforshortsisstillpossiblebutanythingbeyondthe"moistfingertest"requiresadditionalequipment
thanamultimeter.However,theoriginalproblemdidnotblowafuseorfusableresistor,iftheMOSFET
isnotshorted,thereisangoodchancethatitisstillfineandyoushouldlookelsewherefortheproblem.It
maybeaproblemwiththestartupcircuitorcontroller.Thereisalsousuallya15or18VzeneracrossG
Sforprotection.ThismayblowwhentheMOSFETdies.
Note:ifyoursupplyproducesanyoutput(say,morethan10%ofratedvoltage),itisunlikelythatthechopper
transistorisbadasitmustbeworkingtosomeextentand,asnoted,theseusuallyblowtotally.
Smallbipolartransistorsthesemaybefoundinfeedbackandcontrolfunctions.
Testforshortedandopenjunctionswithamultimeter.Substitutewithsimilarknowngoodtransistoris
best,however.Ihaveseenlittlesilicontransistorsthathaddevelopedenoughleakagetopreventa400W
supplyfromcomingup!
Diodesandrectifiersabridgeorsetof2or4discretediodesisusuallyusedfortheAClinerectification
and/ordoubling.Highefficiencyand/orfastrecoverytypesareusedinthesecondarysideforrectification
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ofthevariousoutputvoltages.Thesemaylooklikenormalaxialleaddiodesormaybecombinedinpairs
insideTO220typepackages.
Testforshortedandopenjunctions.However,sometimes,diodeswillonlyfailwithfullvoltageincircuit
buttestgoodwithamultimeter.
Replacementsfortheprimarysiderectifiersareveryinexpensiveandreadilyavailable.Iftheunitblows
fuseswiththeswitchmodetransistorandmainfiltercapacitorspulled,therectifiersmayindeedbebad.
Itisusuallysafetoremovesecondaryrectifiersoneatatimetoseeifthesupplywillcomeup.Aslongas
youdonotremovealldiodesfortheoutputthatprovidesthefeedbackfortheregulation,thisshouldbe
relativelylowrisk.(However,dothiswithadummyloadnotyourexpensivelaptopcomputerjustin
case.)EvenremovingthosediodesisusuallysafeifyoucanpowerthesupplyusingaVariacsinceyouwill
beabletolimittheinput(whilemonitoringthemainoutput)shouldtheoutputsgoovervoltage.
SCRssmallSCRsmaybefoundintheovervoltageprotectioncircuitryofsomesupplies.NotethatSCR
typeofcrowbarsareusedacrosstheoutputasawaytoguaranteethatanovervoltageconditionwillkill
theoutputregardlessofthereasonfortheovervoltagecondition.Hopefully,thesupply'sovercurrent
protectionwillkickinratherthanhavingthesupplyblowup.Thisisnotalwaysthecase,unfortunately.
TestforshortsifoutputonwhichSCRisconnectedisnotcomingup.RemovetheSCR.Now,usinga
Variactobringupthevoltageslowly,seeiftherelevantoutputisgoingovervoltage,isstillclampedata
lowlevel,oristhecorrectvoltage(underload).Amomentaryovervoltagespikeatturnoncouldalsotrip
thecrowbar.Thiscouldbeduetoafaultyinrush/slewratelimitingcircuit.
TL431orsimilarshuntregulatorICeitheraTO92or8pinDIP.Has3activeterminalsA,C,andR.
CurrentwillflowfromCtoAifRAisgreaterthan2.5V.
Testforshortsbutsubstitutionisbest.However,withcare(usingaVariacANDserieslightbulbtolimit
theinputcurrent,itispossibletodetermineifthecircuitinwhichtheseareconnectedisworking.Short
acrossTL431supplyshouldeitherturnofforrunatgreatlyreducedoutput.RemovetheTL431there
shouldbenoregulationoutputsshouldcontinuetoclimbasVariacisincreased.Bymonitoringinputto
TL431itshouldbepossibletodetermineifitisdoingitsjob.
Optoisolatoreithera4or6pinDIPora4pincylindricalobject.Thisprovidestheregulatorfeedback
acrosstheisolationbarrier.Replacementsarereadilyavailable.
Testbyputting1020mAthroughLEDandmeasuringdecreaseinresistanceofreversebiased
photodiode.However,thiswillnotidentifyaweakoptoisolator.Swappingisbest.
Capacitors(filterandbypass)
Filtercapacitorselectrolytictypeareusedforfilteringoftherectified(possiblydoubled)AClineinput
andforfilteringofthevariousoutputsofthepowersupply.
Ifnocapacitorcheckerisavailable,testforopens,shorts,andleakagewithamultimeter.For
electrolytics,thisisstraightforward.Inspectthecapacitorforanydiscoloration,abulgingcase,orother
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evidenceoftrauma.
AnESRmeterisaconvenientdeviceforrapidlycheckingthehealthofelectrolyticcapacitors.TheESR
(EffectiveSeriesResistance)ofacapacitorincreasesasthecapacitordeteriorates('driesup').Evena
capacitorthattestsgoodonacapacitorcheckermaynotworkproperlyduetoexcessiveESR.
Whenindoubt,thebestapproachistosubstituteaknowngoodcapacitorofatleastequalworking
voltageandsimilaruFrating.
Alsoseethedocument:CapacitorTesting,SafeDischargingandOtherRelatedInformation.
(From:Steve(libertytek@aol.com).)
"Whenyoufindapositionthateatselectrolyticcaps,replacethembutaddaparallel.22to
.47uFceramicmonolithic.
Wheneverthesecrappycapsareusedwithevensmallhighfrequencycurrentspassing
throughthem,theybreakdownchemicallycausingotherfailuresalso.Eventhe"highripple
current"ratedcapswon'ttoleratewhattheyshouldandareoftenratedat1,0002,000
hours.
Ialsooftenfindtoolittleheatsinkingandwilladdmoresurfacetoimprovecooling."
BypassCapacitorshighqualityplasticdippedorrectangularmoldedcapacitorsaspartofRFIfilter.
Theserarelyfail.
Testforshortsyourmultimeterwillprobablynotbeabletodetectthesmallcapacitance.Substituteifin
doubt.
Notethatmanyofthesearespecialhighqualitylowlosstypeswithregulatoryapprovalforuseacrossthe
powerlineinthelinefilter.Exactreplacementsarerequiredforsafety.
Resistors(normalandflameproof),NTCthermistors,MOVs
Resistorstestforcorrectvaluewithamultimeter.Ifmeasuredincircuit,valuemayreadlowifshunted
byothercomponents.Ifahigherthannormalreadingisobtainedincircuit,theresistorisbad.Metalfilm
typesliketogoopencircuitespeciallyveryhighvalueresistors.
Startupresistorsinparticulartendtogoopencircuitresultinginadeadsupplybutnoblownfusesor
fusableresistors.Theseareusuallyhighvalue(100Ktypical)mediumwattageandrunhotsincetheyare
acrossthefullrectifiedlinevoltage.
Flameprooforfusableresistors(Theyarethesame)theseareoftendesignated'FR'.Theywilllooklike
powerresistorsbutwillbecoloredblueorgray,ormayberectangularceramicblocks.Theyshouldonly
bereplacedwithflameproofresistorswithidenticalratings.Theyserveaveryimportantsafetyfunction:
theycannotcatchfirewhenoverheatedandwillopenratherthanchangingvaluewhichimplementsan
overloadprotectionfunction.
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Theseusuallyserveasfusesinadditiontoanyotherfusesthatmaybepresent(andinadditiontotheir
functionasaresistor,thoughthisisn'talwaysneeded).IfanFRtyperesistorhasblown,youprobably
haveshortedsemiconductorsthatwillneedtobereplacedaswell.Checkallthetransistorsanddiodesin
thepowersupplywithanohmmeter.Youmayfindthatthemainswitchmodetransistorhasdecidedto
turnintoablobofsolderdeadshort.Checkeverythingoutevenifyoufindonebadpartmany
componentscanfailorcauseothercomponentstofailifyoudon'tlocatethemall.Checkresistorsaswell,
eveniftheylookOK.
ThemostcommonlocationfortheseinasmallSMPSisinthereturncircuitofatheswitchmode
transistor.However,theymaybeinthepowerfeedaswell.Thevaluemaybeafractionofanohmbut
canbelarger.
InTVsandmonitors,theseareoftenfoundinthehotpowerfeedtothemainlowvoltagepowersupply
andinvarioussecondarysupplyfeedsaswell.Forthemainsupply,theywillbe525Wrectangular
ceramicpowerresistors.Forthesecondarysupplies,theymaybethe1/22Wblueorbrowntubular
variety.
Testforopens.Thoseinthereturncircuitsareusuallyverylowvalueafractionofanohmtoafewohms
ifinthereturnoftheswitchmode(chopper)transistor.Thetypeinthepowerfeedsmaybeanywhere
fromafractionofanohmtoseveralKohmsdependingonthecircuitload.
FortestingONLY,anormalresistormaybesubstitutedbuttheproperreplacementMUSTbeinstalled
beforereturningthesupplytoservice.
Sincetheyfunctionasfuses,flameproofresistorsshouldnotbereplacedwithhigherwattagetypesunless
specificallyallowedbythemanufacturer.Thesewouldnotblowatthesamelevelofoverloadpossibly
resultingindamagetootherpartsofthecircuitryandincreasingtheriskoffire.
MOVsMetalOxideVaristorslooklikebrightlycoloredplasticcoateddiskcapacitorsbutnotmarked
withcapacitance.Thesearesurgesuppressors.Aseveresurgeorlightningstrikemayobliterateoneor
moreofthese.Therewillusuallybeeither1betweentheHotandNeutralor3acrossH,N,andsafety
ground.
Iftheyarevisiblydamagedinanyway,justremove(fornow)orreplace.Testwithanohmmeter
resistanceshouldbenearlyinfinite.
NTCresistors(thermistors)NegativeTemperatureCoefficientresistorsactasinrushsurgelimiters.
TheremaybeoneortwooftheseinserieswiththeACinput.Theseareahighvaluewhencoldbutdrop
toalowvalueoncetheyheatupduetocurrentflowintothesupply.Theseoftenlooklikefatblackdisk
capacitors.
Testwhencoldandhot(useahotairgunorhairdryerifnotincircuit).Resistanceshoulddropfrom10s
ofohmstoaverylowvalue.
Transformersandinductors
Highfrequencytransformerstheseincludetheswitchmodepowertransformerandanyfeedback
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(toroidalorEIcoretype)transformers.
Themaintransformerwhichprovideslineisolationandgeneratesthemultipleoutputvoltagesfromthe
150320VDCinputrail.Theseareusuallycustomwoundforeachmodelpowersupplyand
replacementsareonlyavailablefromthemanufacturer.However,somedistributorswillstock
replacementsforafewTVsandcomputermonitors.
Testingforopensisusuallyeasysinceconnectionstotheinput(chopper)andoutputrectifiersarefairly
obvious.However,feedbackwindingsmaybeinvolvedandthesearenotreadilydeterminedwithouta
schematicortracingthecircuit(and,possiblynoteventhen.)Thegoodnewsisthatfailuresofthese
transformersislesscommonthanonemightfear.
Somesuppliesusesmalltransformersforfeedbackratherthanoptoisolators.Thesecanbetestedfor
opensbutrarelycauseproblems.Theremayalsobetransformersinserieswiththeinputthatcanbe
similarytested.
Identifyingshortedturnsrequiresa'ringtest'ormeasurementoftheQ.Seethedocument:Testingof
Flyback(LOPT)Transformers.
Control/standbypowertransformersusedtoprovidepowertothecontrollerofsomeunitswhenthe
mainchopperisidle.Thesemaybedamagedbyapowersurge,usuallywithanopenprimarywinding.
Testwithanohmmeter.Ashortedwindingwillresultinoverheating.
Inductorstestforopens.Identifyingshortedturnsrequiresa'ringtest'ormeasurementoftheQ.Seethe
document:TestingofFlyback(LOPT)Transformers.
AClineinputinductorscanjustbebypassediftheytestopen.
Output'pi'filterinductorsrarelyfailbutifyoususpectone,justremoveitandjumperacrossthepadsfor
testingripplejustwon'tbequiteasgood.
CoupledInductorsusedaspartofthePitypeRFIfilterintheACinputcircuit.Theselooklikesmall
transformersbutthewindingsareinserieswiththeACline.Thereareusually1or2oftheseonbetter
suppliesandtheyareveryreliable.
Testforopens.Identifyingshortedturnsrequiresa'ringtest'ormeasurementoftheQ.Seethedocument:
TestingofFlyback(LOPT)Transformers.Theseinductorscanjustberemovedandbypassedduring
testingiftheyareopensincetheyonlyaffectinputlinenoisefiltering.
Fans
ManysmallSMPSsdon'thaveanyfansbuiltinbutexpecttheretobeafanorfanselsewhereintheequipment
designeddrawairoverthepowersupply.Mostcomputerpowersuppliesdohaveafaninsideandtheseare
highfailureitemsduetohowcheaplytheyaremade.
Abadortiredfan,orevencloggedairfilters,canresultinoverheatingandoutrightfailure,orattheveryleast,
increasedstressoncomponentsandreducedlifeexpectancy.Thus,periodicmaintenanceishighly
recommended.Inspectionofthefan(s)andfilter(s)shouldbeoneofthefirststepsinanytestingprocedure.
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Themostcommonproblemwithfansisdry/gummedup/wornbearings.BallbearingsarerarelyfoundinPC
powersupplies(themanufacturersaved25cents).Evenonexpensiveworkstationcomputers,mediocrefans
maybeused(SunMicrosystemshadtoreplaceawholebunchoffansonstateoftheartUltraSparcsystems
becauseofbadbearings).Quicktest:Withthepoweroff,givethefanaspin.Ifitcontinuestocoastforatleasta
coupleofseconds,thebearingsareprobablygood.Ifitstopsinstantly,theyaregummedup.Ifindoubt,replace
thefanwithagoodqualityballbearingtype.It'sreallynotworthattemptingtodisassembleandoilthebearings
unlessyouhavenothingbettertodo.
Fanmotorsdogobadbutthisismuchlesscommonthanbadbearings.WithmodernbrushlessDCmotors,one
phasecouldbedefectiveresultinginsluggishoperationand/orfailuretostartifstoppedinjustthewrong
position.
Onmoresophisticatedequipmentwithtemperaturesensingtoadjustfanspeed,thespeedcontrolcircuitrycould
alsobebad.
WARNING:ReplacementofthefanonSMPSsrequiresaccesstotheinterior.Makesuretheequipmentis
unpluggedandthelargefiltercapacitorsarefullydischargedbeforedoinganythinginsidethecasebothforyour
safetyandtopreventdamagetothesupply.
Formoreonfans,fanmotors,andlubrication,seethedocument:NotesontheTroubleshootingandRepairof
SmallHouseholdApplianceandPowertools.
(From:CliveCooper(clpc@cooperware.com).)
Ispent3dayssearchingforaproblemonaSMPS.Itturnedouttobeasimplefaultthateludedmeforsome
time.
TheSMPSworkedfineforabout10minutesandthentheoutputvoltagesdroppedslowlyandeventuallythe
supplywentdead.
Itturnedoutthatthefan,althoughitappearedtobeworkingfinewasonlygetting60%ofthesupplyvoltageit
needed.Thiswasduetoafaultytemperaturesensorthatjusttoldthefanthatthesupplywascoldevenwhenit
washot.
Conclusions:Afanthatisblowingisnotnecessarilyblowingwhatitshouldbeblowingandthefactthatitseems
tobeworkingdoesn'tmeanitsworkingatmaximumefficiency.
ItemsofInterest
PanasonicVCRSMPS
ThesamepowersupplydesignisusedwithminorvariationsinawidevarietyofPanasonic(andclone)VCRs
fromthe1980sand1990s(andmaycontinuetothisday).Dependingonthespecificmodel,theremayslightly
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differentoutputvoltagesandnumberofoutputsbutthegeneralorganizationisidentical.Theseusediscrete
componentsthroughoutwithfeedbackfromtheprimaryoutput(5to5.2Vdependingonmodel)usingan
optoisolatortoessentiallyshortoutthedrivetothemainchoppertransistor(Q1)whentheoutputequalsthe
desiredvoltage.Themostcommonproblemsfoundwithanyofthesesuppliesisdriedupelectrolyticcapacitors.
Generally,thefirsttogowillbeC16andC17onthe+5.1VDClineand/orC21inthefeedbackpath(actual
parttypeandnumbermayvaryslightlywithmodel).Symptomswillbeeitherthattheprimaryoutputissomewhat
low(4to4.5VDC)orthatthesupplyhasgoneovervoltageandblowntheprotectionzener(D15)resultingina
highpitchedwhineasthechopperstrugglestodrivecurrentintoashortcircuit(thisusuallydoesn'tdamageany
otherpartsifcaughtinareasonablytimelymanner).Ifanycapacitorrelatedproblemsarefound,itisagoodidea
toreplacealltheelectrolyticsinthesupply.Modelspecificcapacitorkitsaswellastotalrebuildkitsareavailable
fromplaceslikeStudioSoundServiceandMCMElectronics.
ThePanasonicVCRpowersupplyschematicisavailableinbothPDFandGIFformat:
GetVCRPS:vcrps.pdforvcrps.gif.
TypicalcontrollerICsfoundinsmallswitchmodepowersupplies
HereissomeinformationontheUnitrodeUC3840programmableofflinePWMcontrolleranditssimplified
cousin,theUC3842.ThesearetypicalofthetypesofsophisticatedinexpensiveintegratedSMPScontrollerICs
thatarenowreadilyavailable.
UnitrodeDatasheetsgetsyouUnitrode'spowerconversioncontrollers(morethan40differentdevices!).
AWebsearchshouldeasilyturnupothersources.
Theinformationbelowisjustasummary.
ThesedevicesgeneratethePWMpulsecontroltotheswitchmode(chopper)transistoraswellasvariousfault
sensingandothercontrolfunctions.
Partssuchasthesearenowfoundinmanysmallswitchmodepowersuppliesandprovidemuchmoreprecise
controlduringstartupandnormaloperation,andbetterhandlingoffaultconditionscomparedtomost
implementationsusingdiscretecircuitry.
However,theyalsoresultinadditionalheadscratchingwhentroubleshootingsincemanyfaultsorincorrectly
detectedfaultscanshutdowntheunitorcauseapowercyclingtypeofbehavior.Therefore,adatasheetforthe
controllerchipwillproveessential.Inmanycasesascopewillbeneededtomonitorthevarioussense,control,
anddrivesignals.Asystematictroubleshootingapproachmustbeusedtoeliminatepower,startup,sensing,and
controlcomponentsoneatatimeonceobviousshortedoropenpartsorbadconnectionshavebeeneliminated
fromconsideration.
UnitrodeUC3840programmableofflinePWMcontroller
FeaturesoftheUnitrodeUC3840include:
1.Fixedfrequencyoperationsetbyuserselectedcomponents.
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2.Avariablesloperampgeneratorforconstantvoltsecondoperation.providingopenlooplineregulation
andminimizingorinsomecases,eveneliminatingtheneedforfeedbackcontrol.
3.Adriveswitchforlowcurrentstartupoffofthehighvoltageline.
4.Aprecisionreferencegeneratorwithinternalovervoltageprotection.
5.Completeovervoltage,undervoltage,andovercurrentprotectionincludingprogrammableshutdown
andrestart.
6.AhighcurrentsingleendedPWMoutputoptimizedforfastturnoffofanexternalpowerswitch.
ThefollowingpindescriptionsfortheUnitrodeUC3840werederivedfromaUnitrodeapplicationnote.Errors
ininterpretationarequitepossible.
Pin1:CompensationErroramplifier(opamp)compensationnetwork.
Pin2:Start/U.V.lockoutThiscomparatorperformsthreefunctions.With
anincreasingvoltage,itgeneratesaturnon
signalatastartthreshold.Withadecreasing
voltage,itgeneratesanundervoltagefault
signalatalowerlevelseparatedbya200uA
hysteresiscurrent.Attheundervoltage
threshold,italsoresetstheErrorLatchif
theResetLatchhasbeenset.
Pin3:OVsenseOvervoltageinputfrompowersupplyoutput(s).
Pin4:Stop(Extstop)Externallogicsignaltoinhibitpower.
Pin5:ResetExternallogicsignaltoreseterrorcondition
causedby(1)overvoltage,(2)overcurrent,(3)
inputundervoltagedetect,(4)externalstop.
Pin6:CurrentthresholdThisvoltageinputsetstheovercurrenttrigger
levelsfortheinternalcomparators.
Pin7:CurrentsenseThisisthepulsebypulsePWMcurrentcontrol.
Theinputisavoltagetakenacrossaseries
resistorintheswitchmodetransistor'sreturn.
Therearetwointernalcomparatorswitha
differenceinthresholdof400mV.Theone
withthelowerthresholdlimitsthecurrent
foreachPWMcycle.Theonewiththehigher
thresholdsetstheerrorflopflopandshuts
downthesupplyifitsthresholdisever
exceeded.
Pin8:SlowstartThisinputlimitsthemaximumPWMdutycycle.
Duringpoweron,anRCdelaycantherefore
controltherateatwhichtheoutputrampsup.
ThefinalvaluelimitsthemaximumPWMdutycycle
duringnormaloperation.
Pin9:Rt/CtRandCdeterminetheconstantPWMoscillator
frequency.
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Pin10:RampRampgeneratoroutput.
Pin11:VisenseThisvoltageisnormallyderivedfromtheDC
inputandcontrolstheslopeoftheramp.
Pin12:PWMoutputThisisthedrivesignaltotheswitchmode
transistor.Thisisanopencollectoroutput
andwillnormallybeusedinconjunctionwith
theDriverbias(Pin14)signaltoprovide
totaldrivetotheswitchmodetransistor.
Pin13:GroundSignalanddrivecommon.
Pin14:DriverbiasSuppliesdrivecurrenttoexternalpowerswitch
toprovideturnonbiasandpullupduringnormal
operation.DisabledforshutdowniftheError
Latchisset.
Pin15:VccUC3840chipsupplyderivedfromtheDCinputrail
duringstartupandsecondarywindingonhigh
frequencytransformerduringnormaloperation.
Pin16:5VreferenceStablevoltagereference(output)forregulation
control.
Pin17:InvinputErroramplifierinvertinginput.
Pin18:NoninvinputErroramplifiernoninvertinginput.
ThedifferencebetweentheinputsonPins17and
18controlPWMdutycycle.Thesewillgenerally
bederivedbycomparingthemainoutputwith
thedesiredvoltagereference.
UnitrodeUC3842offlinePWMcontroller
TheUC3842providesthenecessaryfunctionstoimplementanofflinefixedfrequencycurrentmodecontrol
schemeswithaminimalexternalpartscount.Notehowmostofthepinfunctionsaresubsetsofthosefoundin
themoresophisticatedUC3840.TheUC3842retainsmostofthefeaturesoftheUC3840butrequiresfewer
externalcomponentsandcomesinamuchsmallerpackage(8vs.18pins).
ThefollowingpindescriptionsfortheUnitrodeUC3842werederivedfromaUnitrodeapplicationnote.Errors
ininterpretationarequitepossible.
Pin1:CompensationErroramplifier(opamp)compensationnetwork.
Pin2:VfbErroramplifier(noninverting)inputfor
regulationfeedback.
ThisinputisusedtocontrolPWMdutycycle
andisnormallyderivedfromthemainregulated
outputvoltage.Itissimilarinfunctionto
Thenoninvertinginput,Pin18,oftheUC3840.
Pin3:CurrentsenseThisisthepulsebypulsePWMcurrentcontrol.
Theinputisavoltagetakenacrossaseries
resistorintheswitchmodetransistor'sreturn.
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Pin4:Rt/CtRandCdeterminetheconstantPWMoscillator
frequency.
Pin5:GroundSignalanddrivecommon.
Pin6:PWMoutputThisisthedrivesignaltotheswitchmode
transistor.Itusesatotempoleoutputwhich
hasahighcurrentdrivecapabilitybothhigh
andlow.
Pin7:VccUC3842chipsupplyderivedfromtheDCinputrail
duringstartupandsecondarywindingonhigh
frequencytransformerduringnormaloperation.
Pin8:5VreferenceStablevoltagereference(output)forregulation
control.
DescriptionofUC3842startupoperationandcyclingproblems
Dependingontheparticularcircuitdesign,avarietyoffaultconditionscanresultincyclingorshutdownofan
SMPScontrolledbyachipliketheUC3842.And,anunderloadedsupplymaybecyclingduetoovervoltage!
Inadditiontotheoverloadconditiondescribedbelow,adriedupelectrolyticcapacitorontheVcclinecanalso
resultinthiscyclingbehaviorsinceitisunabletoholdupthevoltagebetweenoutputpulses.Inaddition,the
senseinputscantriggershutdown.Inall,anoftencomplexdifficulttounderstandandtroubleshootsituation
sometimestoomuchsoforitsowngood!
(Portionsfrom:YvesHoubion(yves.houbion@fundp.ac.be).)
Pin7isthepowersupply(Vcc).Theoscillatorinsidethe3842beginstoworkabove16VonVccandstops
workingwhenthisvoltagedropsbelow11V.Withastoppedoscillator,thecurrentconsumptionisverylow,
around1mAwithaworkingoscillator,thecurrentismuchhigher,about12mA.(Thespecificvoltagesand
currentsaretypicalvaluesforoneparticularversionofthe3842andcanvaryfromdevicetodeviceand
dependingonmodel.)
Vccisgenerallypoweredintwoways:ahighvaluepower(startup)resistorconnectedtothemainbridge(e.g.,
+300V)andafromawindingoffthetransformer(viaarectifier/filtercapacitor).Thevalueofthestartupresistor
isselectedsuchthatthereismorethan16Vwith1mAbutlessthan11Vat12mA.Sotheoscillatorcan't
continuetoworkwithonlythestartupresistorsupplyingpower.
SupposeweapplyACpowertothesupply.The+300Vcomeson.First,the3842consumesonly1mA,Vcc
reaches16V,andtheoscillatorstartsup.Ifalliswell(nooverloads),thetransformerprovidesthenecessary12
mAcurrenttomaintainVccatmorethan11V.
However,ifthetransformerisoverloaded,Vccfallsunder11Vandtheoscillatorstopsworking.Thecurrent
decreasesto3mA,thevoltageincrease(comingfromthe+300V)theoscillatorstartagain,adinfinitum.
Tweettweettweet....
Switchingbetween115VACand230VACinput
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Assumingitisnotawidecompliance'universaltype',acommonwaytodothisiswithajumper(orswitch)inthe
lineinputcircuitrybelow(alsoshowninTypicalSMPSInputVoltageSelectCircuit):
D1
ACo+|>|++oDC(+)
~|D2|+|
+|<|+|+_|_
D3||C1
+|>||+|
|D4|+oo++320VDCtochopper
ACo++|<|+|J1|
|~||+_|_
+|+C2
||
++oDC()
Withthejumper,J1,installed,thecircuitisavoltagedoublerforuseon115VAC.(D3andD4never
actuallyconductbecausetheyarealwaysreversebiased.)
Withthejumper,J1,removed,thecircuitisasimplebridgerectifierforuseon230VAC.
Changingtheinputvoltageofaswitchmodepowersupply
Woulditbepossibletomodifyapowersupplydesignedforoperationon120VACforuseoverseaswherethe
poweris240VAC?
Idon'tadviseit.Therearemanyfactorsinvolvedinchangingapowersupplyunlessitisdesignedfordual
voltageorautoswitching.Theysavedafewcentsifitisnoteasilyswitched,whatcanIsay?
Theproblemisthatitisprobablyaflybackconverterandtheseareprettyfinickyaboutchanges.Inadditionto
thecaps,andswitchingtransistor,thetransformerwouldprobablysaturateatthehighervoltageunlessthe
switchingfrequencywerealsodoubled.Gettingthesethingstoworknormallywithoutblowingupistouchy
enough.Tochangeonewithoutathoroughunderstandingofallthedesignparameterswouldbereallyrisky.
Goingtheotherwaymaybemorerealisticif(andthisisabigif)youwillnotberunningatanywherenearfull
capacity.Manyswitchmodepowersupplieswillrunonmuchlowerthantheirratedinputvoltage.However,
regulationmaybepoorandtheswitchmodetransistorwillneedtobepassingmuchhighercurrenttomaintainthe
samepoweroutput.Tomaintainspecificationscouldrequireextensivechangestothecircuitryandreplacement
oftheswitchmodetransistorandpossiblytransformerandotherpartsaswell.Again,Idonotrecommendthis.
Useasmallstepuporstepdowntransformerinstead.Theonlyexceptionsare:
Ifthereareclearlymarkedjumperstoselecttheinputvoltage.
Youcanreverseengineerenoughoftheinputcircuitrytoadd/removetheneededconnectionwith
confidence.
CAUTION:Astheysayinwoodworking:"Measuretwice,cutonce".Makesureyouaredealingwith
thecorrectjumperANDyouaregoingtherightway(increasingordecreasingasneeded).Ifthe
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manufacturerdidn'tincludethisfeature,theremaybeagoodreason!
Thesupplyisclearlymarkedasbeingautoswitchingorhavinguniversalpowerinput.
Alsoseethesecton:"Switchingbetween115VACand230VACinput".
SlightlymodifyingtheoutputvoltageofaPCpowersupply
SurplusPCpowersuppliesarewidelyavailableandinexpensive.However,whatdoyoudoif5Visn'texactly
whatyouneedforaproject?
(From:WinfieldHill(hill@rowland.org).)
SomeofthePCpowersuppliesI'vedissecteddohavepots,bytheyhavealimitedvoltageadjustmentrange.
Oneinterestingthing,everydesignusedaTL431chip,whichisa3pinTO92regulatingIC,asthevoltage
referenceandoptofeedbackcomponent.Findthischipandtraceouttheresistorsconnectedtoittodetermine
whichparttochangetomakeahighervoltage.
But,watchoutfortheSCRovervoltagecircuitinsomesupplies.Thisisusuallysettotriparound6to6.5volts,
anditstrippointwouldneedtobemodifiedaswell.
Asfarasthestepdowntransformerturnsratio,there'slittletroubleonewillencounterhere,becausethepower
supplyisnodoubtdesignedtofunctionproperlywithreducedAClinevoltages.Thepenaltyonewillpayfor
turninguptheoutputvoltageisahigherminimumACvoltage.
Inmostdesigns,the+12and12Vsuppliesmerelytrackthe5Vsupply,andarenotseparatelyregulated.They
maysoartohighervoltagesanywayifunloaded,butwillbeadditionallyincreasedinvoltagebytheratioof5V
outputincrease.Eventhoughtheratingofthe5Velectrolyticmaynotbeexceeded,andstillhaveasufficient
safetymargin,thismaynotbethecaseforthe12Voutputs.Sothatissueshouldbeexaminedaswell.
Finally,areminderforanyreadertemptedtobreakopentheboxandstartexperimenting.Voltagesofupto320
Varepresent,sobecareful.Knowwhatyou'redoing.Forsafety,stayawayfromopensupplieswhenplugged
in,oralwayskeeponehandbehindyourbackwhenprobing.RememberatheACbridgeandHVDCand
flybacktransformerportionofallthesesuppliesisoperatingstraightfromtheACline,sodon'tconnectthe
groundofyouroscilloscopetoanyofthatcircuitry.Abatteryoperatedmultimeterisbest.
Useofsurgesuppressorsandlinefilters
Shouldyoualwaysuseasurgesuppressoroutletstriporlinecircuit?Sure,itshouldn'thurt.Justdon'tdependon
thesetoprovideprotectionunderallcircumstances.Somearebetterthanothersandthemarketingblurbisat
bestoflittlehelpinmakinganinformedselection.Productliteratureunlessitisbackedupbytestingfroma
reputablelabisusuallyprettyuselessandoftenconfusing.
Linefilterscanalsobeusefulifpowerinyouareaisnoisyorpronetospikesordips.
However,keepinmindthatmostwelldesignedelectronicequipmentalreadyincludesbothsurgesuppressors
likeMOVsaswellasLClinefilters.Moreisnotnecessarilybetterbutmaymovethepointoffailuretoa
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readilyaccessibleoutletstripratherthantheinnardsofyourequipmentifdamageoccurs.
VeryeffectiveprotectionispossiblethroughtheuseofaUPS(UninterruptiblePowerSupply)whichalwaysruns
theequipmentoffitsbatteryfromtheinternalinverter(notalldo).Thisprovidesveryeffectiveisolationpower
lineproblemsasthebatteryactsasahugecapacitor.Ifsomethingisdamaged,itwilllikelybetheUPSandnot
yourexpensiveequipment.Anotheroptionistouseaconstantvoltagetransformer(SOLA)whichprovides
voltageregulation,lineconditioning,andisolationfrompowerspikesandsurges.Manufacturersofthese
productsmayevenprovideequipmentdamagewarrantieswhichwillreimburseforsurgedamagetothepowered
equipmentwhileusingtheirproducts.IamnotsurehowoneprovesthattheUPSwasbeingusedatthetime,
however!
Itisstillbesttounplugeverythingiftheairraidsirensgoofforyouseeanelephantwearingthickglassesrunning
throughtheneighborhood(oranimpendinglightningstorm).
GFCItrippingwithmonitor(orotherhightechequipment)
GroundFaultCircuitInterrupters(GFCIs)areveryimportantforminimizingshockhazardsinkitchens,
bathrooms,outdoorsandotherpotentiallywetareas.TheyarenowgenerallyrequiredbytheNECCodein
theselocations.However,whattheGFCIdetectstoprotectpeopleanimbalanceinthecurrentsintheHotand
Neutralwirescausedpossiblybysomeonetouchingaliveconductormayexistsafelybydesignin3wire
groundedelectronicequipmentandresultinfalsetrippingoftheGFCI.Thereasonisthatthereareusuallysmall
capacitorsbetweenallthreewireHot,Neutral,andGroundintheRFIlinefiltersofcomputermonitors,PCs,
andprinters.Atpoweronandevenwhileoperating,theremaybeenoughleakagecurrentthroughthecapacitors
betweenHotandGroundinparticulartotriptheGFCI.Evenforungrounded2wiredevices,thepoweron
surgeintoinductiveorcapacitiveloadslikeswitchingpowersuppliesmayfalselytriptheGFCI.Thisismore
likelytohappenwithmultipledevicespluggedintothesameGFCIprotectedoutletespeciallyiftheyare
controlledbyacommonpowerswitch.
Therefore,IdonotrecommendtheuseofaGFCIforcomputerequipmentaslongasall3wiredevicesare
connectedtoproperlygroundedcircuits.Thesafetygroundprovidesalltheprotectionthatisneeded.
Whydopowersuppliesseemtofailafterapoweroutage?
Startupisthemoststressfultimeforatypicalswitchmodepowersupply.Theoutputfiltercapacitorsaswellas
theloadmustbedrivenwhiletheinputvoltageischangingpossiblywildly.Withcarefuldesign,thesefactors
canbetakenintoconsideration.Notallpowersuppliesaredesignedcarefullyorthoroughlytestedunderall
conditions.Whenpowerisrestored,surges,dips,brownouts,andmultipleonoffcyclesarepossible.Thisis
whyitisalwaysrecommendedthatelectronicequipmentbeunpluggeduntilpowerhasbeenrestoredandis
stable.
Suppliesthatareautoselectingwithrespecttoinputpowerarevulnerabletovoltagesatanintermediatevalue
betweentheirlowandhighranges.Atsomevalues,theymayautoselecttheincorrectinputrange:
(From:MikeDiack(moby@kcbbs.gen.nz).)
AsubjectdeartomyheartduetoarecentunpleasantexperienceWasusingaPicturelelvideoconference
ISDNcodeconajobwhen,becauseofapowerlinefault,thelinevoltagedroppedto170volts.ThePicTelhas
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abigOnanswitchmodePSUwhichisautoswitchingbetween100120and200240volts.Itgotconfused,and
(regrettably)chosetheformer....withverysmellyresults.
Moral:turnoffthingswithcunningPSUswhenbrownoutsoccur(ohyestheairconditionerunitsgotveryhotand
trippedout,too)
BuzzingorothersoundsfromSMPSs
Twocommoncausesare(1)loosetransformer(orothercores)vibratingatasubharmonicoftheswitching
frequencyand(2)driedupelectrolyticcapacitors(primaryside)introducing120Hzhumunderload.
(From:RayHackney(rhackney@unicomp.net).)
Simplisticallyspeaking,thesoundcomesfromsomethingmoving.
Withnonswitchmodepowersupplies(SMPS),itmaybeferrousmaterial(likeametalcover)beingdrawn
towardthepowertransformer.That'sobvioussincepushingonthecoverwillsoftenthehum.Thefrequencyis
usually60Hzor120Hz.
Theonlytimeyoushouldheara"noise"fromaSMPSisduringaperiodof"unstable"operation(i.e.their"loop"
isn'tstableandinregulation.)That'swhyyoumayhearthem"chirp"orwhistlewhenyoufirstturnthemonoroff.
ItmayalsoindicateaPCtypepowersupplythat'soverloaded.Inyearsgoneby,I'veseenaquietPCbecomea
whistlerafterhavinganew,big(30meg,fullheight!)harddiskadded.Sometimesthepitchofthewhistlewould
changedependingonwhatpartsofthesystemwerebeingaccessedorwhatsoftwarewasbeingexecuted.
(Usually,whentheoldIntelAboveBoardwasbeingaccessedinthis'286,theaudiblepitchwaslowerindicating
greatercurrentdraw.)
Forallpowersupplies,itmaybethewindingsonthe"magnetics"(inductorortransformer).Ifthey'renotwound
tightlyandsecuredtheycanvibrate.Manyvideomonitorsexhibitthisproblemwhentheirflybacktransformer
emitsawhistle.Itmaybethewindingsthemselvesmovingorthewindingassemblymaybelooseonthecore.
SometimesthecapacitorsinaSMPSwillemitsound.CapsinSMPS'frequentlyhavehighACcurrentlevels.If
thesupplyissupposedtohavewhat'sknownas"continuouscurrent"andgoesinto"discontinuouscurrent"
mode,thecapacitorplatesgetstressedprettyheavilyandmoveinthecapacitorbody(butonlywithsome
types).SincetheSMPSwillgointoandoutofdiscontinuousmodeatarate<10kHz,it'saudible.I'veruninto
thisonbreadboardsI'vebuiltfor200Wand2.5kWSMPS'.
CoolelectrolyticstemperatureratingversusESR
(From:JeroenH.Stessen(Jeroen.Stessen@philips.com).)
Electrolyticcapacitorsliketobekeptcool!Ifthere'sanythingthatthesecapacitorscan'tstand,it'sheat.Itcauses
themtodryout.
Electrolyticcapacitorsexistin(atleast)twodifferenttemperatureratings:85Cand105C.Thelatterare
obviouslymoretemperatureresistant.UnfortunatelytheyalsotendtohaveahigherESRthantheir85C
counterparts.SoinanapplicationwheretheheatisduetoI^2*ESRdissipation,the105Ctypemayactually
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bea*worse*choice!Iftheheatisduetoanearbyhotheatsinkthen105Cisindeedabetterchoice.
Whenbettermaybeworse
ESRisusuallysomethingtobeminimizedinacapacitor.However,wheretheoriginaldesigndepended
(probablybyaccident)onacertainESR,thismaynotalwaysbethecase:
(From:LeeDunbar(dunbar@unitrode.com).)
SubstitutionsoflowESRcapsintocircuitswhichhadlousycapsisnotalwaysthegoodideathatitappearsto
be....Cautionisadvised,aslowESRcapswillnotlimitsurgecurrents.
Thecircuits'seriesimpedancedrops(comparesubstitutedcapacitorsESRwhennewwiththeoriginal
capacitor'sESRwaswhenitwasanewcapacitor),which,inturn,letsthesurgemagnituderise,thehigher
currentsdestroycansemiconductorsandothercomponents.
Iguesswhattheindustryneedsisagoodcapacitorcrossreferenceguideforaluminumelectrolytics!
Alan'sSMPStroubleshootingtechnique
(From:AlanLiefting(aliefting@ihug.co.nz).)
1.Replaceallfaultycomponentsandcheckallsemiconductorsandresistors.
2.RemoveswitchingMOSFETordisconnectitssupplyvoltage.
3.ConnectvariableDCPSUtomainsecondaryvoltage(onewhichismonitored).
4.ConnectanoscilloscopetothegateoftheswitchingMOSFET.AstheDCvoltagefromtheexternalPSU
isincreasedtothevalueofwhattheSMPSoutputshouldbe,achangeinthemarkspaceratioofthe
PWMwaveformcanbeobserved.OnlyasmallchangeinthesuppliedvoltagearoundtheSMPSoutput
voltageisrequiredtoobservetheeffectasthepowersupplyattemptstoregulate.
IfthesuppliedvoltageisincreasedfurtherthePWMwaveformwillceaseasthecontrolcircuitwilldetect
anovervoltage.
WiththistechniquethewholepowersupplycanbetestedwithoutfearofdestroyingMOSFETsanditcanbe
determinediftheSMPSisregulatingtothecorrectvoltage(ifknown!).
ThiswillnotworkwithallSMPS's.Itdependsonthedesign.
John'snotesonSMPSrepair
(From:JohnCroteau(croteau@erols.com).).
Switchmodepowersupplyrepairscanbedifficult.Theproblemismanufacturersdon'tusuallygiveyouaneasy
testsetup.Theyshouldtellyouifitwillrunatnoloadorwhatdummyloadtouse.Secondlytheyshouldtellyou
whatvoltageorresistancetousetoreplacetheoptoisolator(ortransformer)forthatload.TheSMPShotside
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isahighfrequencyoscillatorwhose'ontime'isvariedbyfeedbacksuppliedthroughtheoptoisolator.The
troubleshootingprocedureshouldnormallybeinthisorder.
1.Firsteliminateexternalcausessuchasshortsornoloadasthecauseoftheshutdown.
2.Eliminatethesecondarysideshorteddiodes,capacitors,etc.
3.AftereliminatingoverloadsontheoutputschecktheDCsupplytothepowerdevice.
4.Checkthebiascomingfromthefeedback.Tracethebiassuppliedbythefeedbackandtrytodetermine
whatisthecorrectbiasforthatsituation(usuallynopowersameasstartup).
Ifthebiasisasontheschematicthentroubleshootthehot(primary)sideasanyoscillator.
Ifthebiasiswrongandthereisnoshortontheoutputthenconcentrateonwhythefeedback
doesn'tsupplytheexpectedvoltagetobiasthescillatoron.
5.IfyouworkonmanyofthesametypeSMPS:
Determinethenormalloadandmakeadummyload.
Determinethevalueofresistancethatiscreatedattheoutputoftheoptoisolator(hint:useOhm's
law).Thenremoveonelegoftheoutputoftheoptoisolatorandreplaceitwitharesistoras
calculated.
Byusingafixedloadandcuttingoutthefeedbackitisveryeasytotroubleshoot.Don'tforgettocheckthe
voltagesandwaveformsinyourtestsetupandrecordthemforfuturereference.
Russell'scommentsonSMPSrepair
(From:RussellHoulton(71101.2454@CompuServe.com))
Iwantedtopassonsomecommentsonrepairofswitchmodepowersupplies.I'vefixedafewmyself.
1.Iseequiteafewwherethefiltercapacitorshavefailed.Notallelectrolyticcapacitorsarethesame.You
shouldgetcapacitorsthatareratedforhighfrequencyservice.Useof"normal"capsthatonefindsinthe
localelectronicsstoresarelikelytogobadinaboutayear.Notsomethingaprofessionalwhovalueshis
reputationwantstoseehappen.Infact,Isuspectthatsomemanufacturerfailtounderstandthisanduse
thewrongcapscausingcommonfailuresintheirunits.Especiallyunitsthatmaybesubjectedtousein
warmerareas.Iseethismostlywithspecializeddevicesratherthenmassconsumeritems.
IhighlyrecommendthePanasonicHFSseriescapthatcanbeboughtfromDigiKey(andotherplacesI'm
sure).Theseunitarespeciallydesignedforgoodsizeaswellasuseinswitchingsupplies.Theyarealso
ratedfor105degreesCasopposedtothemorecommon85degreesCtemperaturerating.Ihavenever
hadtoreplaceaHFScapIinstalled,whereI'vehadtoreplace"common"capsinrepairsituations.(NoI
don'tselltheHFSorhavestockinDigiKey,I'mjustpassingsomeinfothathasworkedwellforme.)
(Note:TheHFSseriescapshavebeendiscontinuedbyPanasonic.TheyrecommendedusingtheEEU
FC(FCseries)asareplacment.Sam.)
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2.SMPSusuallytrytoregulateoneoftheoutputvoltagesbyusingtheswitcher,usuallyit'stheoutputwith
themostpower,butmightbetheonethat'smostvoltagecritical.Ifthefiltercapsgobadinthemain
outputvoltage,theauxiliaryoutputvoltageswillgohigh.TheSMPSmayalsostarttomakehighpitched
soundsastheripplemesseswiththefeedbacksystem.Theauxoutputvoltagesmaygosohighthatthe
secondaryregulatormaygointofoldbacktoprotectitself.Ifoundthisoutthehardway.It'sreally
somethingthatcankickyouinthepantsbecausenormallyonewouldnotcheckthe5Vsupplyifthe
problemseemstobeabad23.5Vregulator.
3.Noisy(whiningorbuzzing)SMPSsthatstillworktendtobeeitherbadmainoutputvoltagecapacitorsor
badelectrolyticsinthepoweroscillatorcircuit.Seethesection:BuzzingorothersoundsfromSMPSs.
4.MostSMPSshavealsohavea*minimum*powerdrawrequirementfromtheirloads.Thisisespecially
trueofthemainoutputvoltage.Ifnotenoughpowerisdrawnfromthesupply,thesupplymaynotbe
stableandcannotsupplyfullpowerontheauxiliaryvoltages.Anexampleofthisisusinga250WPC
powersupplyjusttodriveadiskdrive.Withouttheheavy5Vpowerdrawofamotherboard,thesupply
maynotstartupreliableorprovidetheneeded12Vpowerfortheharddrives.
5.I'vealsoseencaseswhereoneofthevoltagedoublercapswillopenupcausingfailureinoneofthe
switchingtransistor(s).Itwillshortoutasingletransistorunit,butinadualswitchingunit,thetransistor
associatedwiththegoodcapwilloverworkitselfandopen.Aneasywaytotestistoremovetheother
switchingtransistor(inadualunit)andapplypowerfor2seconds.(Takeallprudentprecautionsfor
workingaroundaliveandopenunit!)Disconnectpoweranduseyourvoltmetertocheckthevoltage
acrosseachofthecaps.Theyshoulddischargeataroughlyequalrate.Abadcapwillloseallit'svoltage
inlessthen2seconds.Agoodcapwillholdit'schargemuchlonger.
6.Lastly,someunitthathavetheswitchmodepowersupplyinthesameenclosureastheCRTwillhavea
syncsignalthatcomesfromthehorizontalflybacktransformer.ThiskeepstheSMPSinsyncwiththe
displaysothatthesmallmagneticfieldsthatarecreatedbytheSMPSdon'tcreateawavypatternonthe
screen.Somethingtorememberifanewlyreassembledunitshowsawindowscreenlikeinterference
patternonthedisplay.
Bob'sdescriptionofhowatypicalPCpowersupplyworks
(From:BobWilson(rfwilson@intergate.bc.ca).)
Ireallysuggestyourefertoahandbookonbasicswitchmodepowersupplydesignforthenittygritty.
Ihaveaschematicofa200WattPCpowersupply,andIassureyouthatthereareenoughcostsavingclever
shortcutsinthedesign,thatunlessyouknowafairamountaboutthedesignofswitchers,itwilljusttotallyand
completelybaffleyou.
Nearlyall200WPCpowersuppliesare*identical*knockoffsofoneanother(exceptforthepowergood
comparatorsection).Thetransformerhasa+5Voutputwhichiswhatisregulated.Italsohasa+12Voutput
anda12Voutput.The5Voutputisderivedfromthe12Voutputusinga7905regulator.Alltransformer
outputsarerelatedinvoltagebythetransformerturnsratio.ThepowersupplytopologyisaHalfBridge,which
normallyrequiresa"bucksection"ineachoutput(namelyaninductor,catchdiodeandcapacitor).Tovastly
improvethecrossregulationbetweenwindings,acommoncoreisusedtowindallthe3outputinductorson.
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Basically,however,a200WPCpowersupplyisahalfbridgedesign,withabridgetypevoltagedoublerin
frontwhichsimplyrectifies220V,ordoubles110Vto220V.Sothethingisbasicallya220Voltdesign.
ThecontrolleristypicallyaTITL494thatoperatesofftheoutputofthesupply.Thismeansthatinordertostart,
theremustalreadybeanoutputvoltagepresent!Howtheydothisisreallyreallyclever,andalsoextremely
confusing.Thepowertransformerisitself,selfoscillating.Thisgeneratesarudimentaryoutputvoltagethatallows
thethingtobootstrapuptonormaloperation,andthecontrollerchiptotakeover.
The+12VoltoutputiswhatisusedtopowerthePWMchip.Thus,thesupplyrunsoffitsownoutput.Thisis
donetoeliminatetheneedfortroublesomeoptocouplerfeedback.Tobootitselfup(afterall,thereisnoinitial
+12Vtoallowitselftostart),thedrivertransformerismodified(verycleverly)toformpartofablocking
oscillator.Thustheunitinitiallyselfoscillatesinacrudefashionuntilthereisenoughvoltageonthe+12Voutput
toallowthePWMtostart,whichthenswampsouttheselfoscillationandnormaloperationcommences.
Sincethecontrollerresidesontheoutputsideofthetransformer,thedrivetothe2halfbridgeNPNbipolar
transistorsisbyadrivertransformer(adirectconnectioncannotbemadebecausethetransistorsareonthe
primaryside).
Frequencyofoperationis50kHz,whichislowbytoday'sstandards,butthismeanslowercosttransformer
winding(Litzwireisnotneeded,forexample).
Steve'scommentsonPCpowersupplyoperationandrepair
(From:SteveBell(service@bellelectronics.freeserve.co.uk).)
TherearenotnormallyschematicsavailableforPCpowersupplies.
IfthePC'sareveryold,someservicemanualsincludedthePSUschematicsbutthesewillbeveryveryold,
liketheearlyApricotthatusedtheAstecAC9335,theOlivettiXT,andsomePC'sthatranCPMliketheLSI
Octopus.
MostATclasscomputersneverhadschematicsavailablefortheirpowersupplies,themanufacturerssimply
intendedthemtobeswappedout.Schematicswereproducedbythepowersupplymanufacturersforcompanies
suchasCompaq,SunMicrosystemsetc,butthesewhereonlyreleasedtotheirauthorizedservicecentres.These
arefarandfewbetweenandsignnondisclosureagreements,soschematicsarenotavailabletoanyoneelse.I
usedtoworkforonesuchcompany,theyrepairedallofSun'spowersuppliesfromthroughoutEurope.
HereintheUK,andalsointheUSA,ifa'standard'ATorATXpowersupplyfailsit'softencheapertoreplace.
ManyPCpowersuppliesaren'tstandardwerepairmanyfromCompaq,Elonex,HP,Apple,Sunetcthatare
nonstandardandcanberepairedfarcheaperthanthemanufacturersexchangeunit.Alsoinmanycountriesa
swapoutisn'tavailableorcanbecostly.
Evenwithoutschematicspowersuppliescanberepaired.Thesametypeofcircuitryrepeatsitself.Olderpower
suppliesoftenusedtheTL494CpwmIC,newerusetheUC3842/3/4/5seriesdrivingMOSFETs.Someolder
stillusedtheNE5560,SG3524etc.,manydidn'tuseaPWMIC,butinsteaddiscretecomponents.Datasheets
ontheIC'susedareveryuseful.
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Consideringthe'standard'200WATPSU,theseusuallyuse2T0220powertransistors,andatpowerona
resistor,usuallyaround270330Kturnonthetoptransistor,andcurrentflowsintheinvertertransformer.A
windingonthesecondarysuppliesavoltagethatisrectifiedandsmoothedtofeedthePWMICanditsdrivers.
Thesethendrivethe2transistorsviaatransformerandthepowersupplyisrunning.The5Voutputvoltageis
thensensedandfedbacktothePWMICtomaintainregulation.Mostfaultsonthesetypesofpowersupplies
involvethehighvalueresistorsfailingassociatedwiththeinvertertransistors,thetransistorsandassociated
components,bridgerectifiershortedalsocheckinrushthermistorforcracksorpinholes.Secondaryrectifiers
canfail,andelectrolyticcapscanfailifthefanstops.ThePWMcircuitrycanalwaysbefedwithanexternalDC
supplyandcheckedindependently.
Theothertypeofpowersupply,lesscommoninolderpowersupplies,usestheUC3842seriesPWMIC
drivingasingleMOSFET.ThisICsitsontheprimaryside,soitsgroundisfloatinghigh.Anisolatingtransformer
isneededwhenscopinganythingontheprimary,withthescopegroundcliptoprimaryground.
Sourcingsubstitutecomponentsisn'tnormallydifficult.I'dstartbyobtainingsomedecenttransistor,diodeand
MOSFETdatabookssoyoucanrelatefaultypartstowhat'savailablelocally.
Ifthepowersuppliesareall200W,asimpleresistiveloadwillsufficefortestingmadefromlargeallyclad
resistorsonasubstantialheatsink.Thesewilltoastwhenrunningforlonger,sowillneedfancoolingacheap
deskfanissufficient.Ifyouaregoingtoberepairingalotofvaryingpowerandtypeoveraprolongedperiod,it
maybebettertobuildanactiveload.Thisisbasicallybanksof2N3055's(for5V&3.3V)and2N3773(for12
Vupwards)inserieswithlowvaluepowerresistorsthancanhavetheirconductionvariedandcurrentmonitored
byothercircuitry.Yousimplyhavealeadforeachpowersupplytypeyoutest/repair.Alsodon'tforgettocheck
thePGo/ponthepowersupply.
PCpowersupplyinformation(pinouts,testingandnonstandarduses)
WhentestingoroperatingacommonPC(computer)powersupplywithoutbeingconnectedtoitsmainboard
andperipherals,asubstituteloadmustbeprovided.Thiswouldbethecaseifyouwantedtodeterminewhether
asupplywasgoodorwantedtousethesupplyforotherpurposes.
Totestthesupply,youwantto:
Removeallofthe(expensive)stuffmainboard,drives,etc.Unplugallofthepowersupplyconnectors.
Provideadummyloadto+5and+12outputs.
Typical(butnotalways)colorcodesforPCpowersupplies:
Red:+5,Yellow:+12,Black:Gnd(Probablycaseaswell).
White:5,Blue:12,Orange:Power_good(output).
(Somenewersuppliesmayhavea+3.3outputaswellwhichmaybegreen).
PCpowersupplies(aswellasmostotherswitchers)needaminimumloadon+5andpossiblyon+12as
well.Anamp(e.g.,5ohmson+5)shouldbeenough.
Iuseanolddualbeamautoheadlight.Itaddsatouchofclassaswelltoanotherwisetotallyboringsetup.
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:)Youcanalsouseautotaillightbulbsorsuitablepowerresistorsorolddiskdrivesyoudon'treallycare
about(youknow,thoseboatanchors).
Therearenosenselines.Thereisa'Power_Good'linewhichisanoutputfromthepowersupplytothe
mainboardandcanbeignoredunlessyouwanttoconnectittoanindicatortoletyouknowalltheoutputs
arewithinspecs(itmayneedapullupandIdon'tknowitsdrivecapability).
PinoutforthestandardPCandcloneconnector(somecompanieslikeCompaqdoNOTusethistypeof
connector,however.).Black(Gnd)wirestogetherfortheP8andP9connectorswheninstalledto
mainboard.
J8:Pin1=Power_GoodJ9:Pin1=Gnd
Pin2=+5Pin2=Gnd
Pin3=+12Pin3=5
Pin4=12Pin4=+5
Pin5=GndPin5=+5
Pin6=GndPin6=+5
Note:foranXTonly,J8Pin1isGnd,J8Pin2isnoconnect.
Theperipheralconnectorsare:Pin1:+12,Pin2and3:Gnd,Pin4=+5.
SafePCpowersupplyloading
PCpowersuppliesareoftenidealforotherpurposesbuttherequiredloadsrepresentwastedpower.So,it
wouldbenicetobeabletoeliminatethem.Unfortunately,itprobablyisn'teasytomodifyaPCpowersupplyso
less/noloadisneededforregulation.However,itisworthtestingasupplytoseehowlowyoucanactuallygoon
theloadsmanyWILLregulatethe+5withnoloadonthe+12butprobablynotthereverse.While20percent
loadisoftenrecommended,5percentorlessmayworkjustfine.And,somedon'tneedanyadditionalloadson
eitheroutput(theywillprobablyincludeaminimalloadresistorinternally).
CAUTION:Usually,aPCpowersupplywilljustshutdownwithtoolittleload.However,somemaybemuch
moreunhappy.Thusattemptingtodetermineasafeminimumloaddoesentailsomeriskoflettingthesmokeout.
ThereasonthatyouneedaloadisthatthePWMcontrollercan'tdodowntoreallysmalldutycyclesneededfor
lowloading.Thedesignwouldneedtobechangedanddiffersfromunittounit.
TypicalPCandATXpowersupplyschematic
DomaciStranka'sWebSitehasareverseengineered200WATXPCPowerSupply.(Localcopyof
diagram:SchematicofTypicalATXPowerSupply.)Note:Thereareerrorsinthisschematic.For
example,oneoftheinputstotheovervoltagecircuit(middleleft)shouldbe+12VDC,not+5VDC.So,
useitasaguideonly.
NotesonATXpowersupplytesting
Youdon'tneedafancy"mainboardsimulator"or"specialATXtesttool"torunanATXpowersupplyonthe
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bench.
(From:StefanKrommes(stkro@gmx.net).)
Thereisawire(Power_Supply_On)ontheATXconnectorthatwillturnonthemainsupplywhenpulledlow.
Thiscolorofthatwireismostlylabeledonthesideofthesupplyor(aswithfortronsupplies)itistheonethatis
notlabeled(green).IfyoulookontopoftheATXconnectorasifitwaspluggedintotheboardthewirein
questionisthe4thfromtherighthandsideonthetoprow(wherethereistheclip)alookintoyourmainboard
manualmightgiveyouavisualideasincetheATXconnectorisoftendepictedtherewithpinslabeled.
Assaidifyoufireupyoursupplyitwouldbewisetoloadit.Checkthelabelonthesupplyandloadthemain
+5Vand+12Vlinetoabout1520%oftheirmax.currentcapability.Someautomotivebulbs(headlight,
brakelight,etc.)comehandynotonlyforthe12Vbutforthemain5Vlinetoo.Belowabout20%loadthereis
thechanceofthesupplynotregulatingthevoltageproperlybutitshouldstart.
The5Vstandbylinedoesnotneedanyloaditshouldreadaclean5VDCassoonasthesupplyispluggedin
andthemainspowerswitchisswitchedon.
ThemainsupplyshouldgetonlineassoonasthePower_Supply_Onwiregetspulledtogroundandthe
voltagesshouldmeasurewithin5%ifloadedtoabout20%ofmaximumpower.
(From:Sam.)
CAUTION:IhaveseenonecasewhereanATXsupplyactuallyblewupwithoutaloadusingthis"hotwire"
technique.Idon'tknowiftherewasalreadyaproblemwiththeunitoritreallyabsolutelyrequiredaload.But
almostimmediatelyaftergroundingthegreenwire,multipleelectrolyticcapsonthesecondarysideexplodedand
spilledtheirguts,oneoftheMOSFETSshorted,andthenthepowerfuseblew.:(Itmaybethatthedesignersof
thissupplyintheirinfinitewisdomassumedthatsincepowerisenabledviathemainboard,therewouldneverbe
acircumstancewheretherewouldn'tbeatthisthatasaload!
(From:Tom(w_tom1@usa.net).)
Youmighttrythisandtrythatand....Wellthatlistislongandstilldoesnotsaywhatiswrong.Youwantto
identifytheproblemnow,andthenfixit.Inbutminuteswitha3.5digitmultimeter,wecanidentifytheproblem
ANDthenreplacethesuspect.Donotattachordisconnectanything.Changingthingsmayevenexponentially
complicatetheproblem.That3.5digitmeterisavailableforlessthan$20inSears,Lowes,Kmart,Radio
Shack,andHomeDepot.That'sthecomplexpart.
WithcomputerpluggedintoACreceptacle,usemetertomeasurevoltageonpurplewirebetweenpowersupply
andmotherboard(connectprobestopurplewirebypushingintonylonconnectorandotherprobetochassis).
Thatvoltagemustbemorethan4.87VDC.Ifnot,powersupplycontrollerwillnottellpowersupplytopower
on.Nextmeasurevoltageongreenwire.Itmustbemorethan2voltsbeforeswitchispressedandmustdrop
immediatelytolessthan0.8voltswhenswitchispressed.Thistellspowersupplytoturnon.
Nextmeasurevoltageongraywire.Itmustrisetomorethan2.4voltswithinsecondsafterpowerswitchis
pressed.Again,youwanttoseewhathappenswhenswitchispressednotjustlongafterswitchispressed.
ThissignaltellsmotherboardthatpowersupplyisOK.
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Ifgraywireisgoodorbad,thenmoveontoonered,orange,andyellowwires.Measureeachasswitchis
pressed.Withinonesecond,eachshouldexceed3.23,4.87,or11.7voltsDC.Ifanydoesnotrise,thenfind
whateveronmotherboardorperipheralsisexcessivelyloadingthatvoltage.
Notonlydonumbershelpyoutofindathesuspect.Thosenumbers,ifposted,meanthatyourrepliescan
includeusefulinformation.Withoutnumbers,theneveryreplywillbeonly'trythisandtrythat'alsocalled
shotgunning.Thesenumberscanalsoidentifyanintermittentfailurebeforethatfailureoccurs.Usefulnumbers
obtainedinbuttwominutesmeansausefulreplyandnoshotgunning.
(From:ArthurJernberg(stubbie45@hotmail.com).)
HereisthepinoutforanATXmainboard:
Lefttoright:FirstrowvoltageSecondrowcurrent/color:
[+3.3V][+5V][+12V][12V][5V][+5VSB][COM][PON][PG]
[14A][22A][9A][1A][.5A][PUR][BLK][GRN][GRY]
(From:ClaudioLima(claudio.jc.lima@bol.com.br).)
ThefollowingprocedureisintendedforthenewerATXv.2.xpowersuppliesusinga24pinconnector,asall
pinoutreferencesweremadeaccordingtothatstandard.
1.Ifyoufireupyoursupplyitwouldbewisetoloadit.Checkthelabelonthesupplyandloadthemain+5
VDCand+12VDClinetoabout15to20%oftheirmaximumcurrentcapability,typically:2.2ohms,15
W:pin4(+5VDC)topin7(GND)33ohms,5W:pin10(+12VDC)topin24(GND).
2.WithpowersupplypluggedintoACreceptacle,usemetertomeasurevoltagebetweenthepurplewire
(pin95VSB)andpin24(GND).Thatvoltagemustbemorethan4.87VDC.Ifnot,powersupply
controllerwillnottellpowersupplytopoweron.
3.Nextmeasurevoltageongreenwire(pin16,PS_ON).Itmustbemorethan2voltsbeforepulledto
groundandmustdropimmediatelytolessthan0.8voltswhenpulledtoground.Thistellspowersupplyto
turnon.
4.Nextmeasurevoltageongraywire(pin8,PWR_GOOD).Itmustrisetomorethan2.4voltswithin
secondsafterPS_ONispulledtoground.Again,youwanttoseewhathappenswhenPS_ONispulled
togroundnotjustlongafter.ThissignaltellsmotherboardthatpowersupplyisOK.
5.Ifgraywireisgoodorbad,thenmoveontooneorange(pins121213),red(pins46212223),
andyellow(pins1011)wires.MeasureeachasPS_ONispulledtoground.Withinonesecond,each
shouldexceed3.23,4.87,or11.7VDC.
(From:Sam.)
IMPORTANTCAUTION:Apparently,Dell,whohasfollowedindustrystandardsinmostrespects,changed
theATXpowersupplypinoutontheirPCssometimein1998andmaystillbeusingthisproprietarypinout.See:
DellProprietary(NonStandard)ATXDesign.Sincethereisabsolutelynovalidtechnicalreasonfordoingthis,
onecanonlyassumeitisduetosome,shallwesay,shadybusinessdecisiontopreventpeoplefromgoingtoa
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thirdpartyforupgradesorreplacementmainboardsorpowersupplies.Worse,installinganonDellpower
supplywithaDellmainboardwillresultinadestroyedpowersupplyandpossibledamagetothemainboard.
ThanksDell.:(It'sstraightforwardthoughnottrivialtochangethepowersupplypinoutbacktostandard(butit
isn'tamatterofjustmovingpinsaroundintheconnectorsincethenumberofwiresforsomesignalshasalso
changed).Butthereshouldbenoneed.Companiesshouldcompetebysellingabetterproduct,notaclosed
system.
DetailedProcedureforATXPowerSupplyFaultDiagnosis
Beforeblamingthepowersupply,makesuretheoutletislive,themainpowerswitch(ifany)ison,andthatany
linevoltageselectswitchhasn'tchangedpositionorshiftedtoanintermediatepositionaccidentally(possibly
whenmovingthePC).
(From:PetrusBitbyter(p.kralt@hccnet.nl).)
IhavewrittenasetofnotesonrepairingATXpowersupplies.Itfollowsbelowandshouldcontainallyouneed
(andmore)todecidewhetheryourpowersupplyhasgoneornot.
Firstofallreadthedocument:SAFETYandthegeneralinformationonSMPSrepairelsewhereinthis
document.
Mostofthetimesthefaultisfoundbetweenthemainsconnectionandthetransformer(s).
1.Inthemostsimplecasesonlythefuseisblown.Afterreplacingthisfuse,connectthePStothemainsusing
theserieslightbulbtrick.
Ifthebulbburnsbrightly,youknowthattheoldfusehadagoodreasontoquit,sothecaseisnot
simpleanymore.Thefirstthingyouhavetodonowistofindtheshortcircuit.Themostsuspected
componentsarethemainsrectifier,thefiltercapacitorsandoneormoreofthepowertransistors.
Useeyes,noseandanohmmetertofindsceneofthecrime.Removeandcheckthesuspected
components.Replacedefectivecomponentsexceptforthepowertransistorsatthistime.Itmakes
nosensetocontinueuntilyoufixedtheshortcircuit
IfthefuseisgoodbutthePSstilldead,youcanstarttocheckthevoltages.
2.Checkthevoltagebetweenpin3andpin9oftheATXtomainboardconnector.Thisshouldbe+5VDC.
Ifnotyouhavetocheckthevoltagesonthemainsside.Otherwiseitwillbewisetocheckthevoltageson
themainssideaswell(Steps3to5).ThencontinuereadinguptoStep12,nottomisssomeexplanation.
ContinueatStep12.
3.TheACpinsofthemainsrectifiershouldshowthemainsACvoltage.Ifnotyoumayhaveaninterrupted
traceormainsfilter.
4.Betweenplusandminusofthisrectifieryoushouldfindabout+310VDCor+325VDCdependingon
yourmainsvoltage.Icallittheprimarypowervoltage.
5.Ifnotyoumayhaveafaultymainsrectifier.
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6.Ifthevoltageismuchlower(analogmeter)orjumpingaround(digitalmeter),thelargefiltercapacitors
(e.g.,470uF,200V)arealsosuspected.
7.Bothfiltercapacitorsmentionedaboveareinseries.Themidpointshouldbeathalftheprimarypower
voltage.Ifitisnot,themainsrectifier,thefiltercapacitorsandtheparallelresistors(paralleltothe
capacitors)maybedefective.Anothersuspectisathirdcapacitor(typically1uF,250V)thatleadsfrom
themidpointtoatransformer.
Explanation:ATXPSsusuallyhasthreepowertransistorsatthemainsside.Oneisconnectedtoasmall
transformer,theothertwoconnectedtoalargertransformer.Youcanrecognizethepairoftransistorsbestby
findingtheemitterofoneofthemconnectedtothecollectoroftheother.Firstyouhavetodealwiththeone
transistorandthesmalltransformer.(GotoStep8ifyouremovedthistransistoralready.)
6.Checkthevoltageonthecollectorofthetransistor.
Ifthisvoltageiszeroorverylowtheremaybeaninterruptionbetweenthecollectorandthe
primarypowervoltage.
Ifthisvoltageisbelowtheprimarypowervoltageorjumping,thereseemstobeswitchingactivity.
YoucancheckthiswithanACvoltmeteronasecondarycoilofthetransformer.Thereadingwill
notbecorrect,butifyoufindanACvoltageyouhavetocontinuecheckingthesecondaryrectifier
andregulator.
Ifthisvoltageistheprimarypowervoltagethetransistorisnotconducting(openornotbeing
driven).
7.Checkthevoltageonthebaseofthetransistor.Ifthisvoltageislessthan0.6V,thestartupresistormay
bedefective.Otherwise,thetransistormaybegone(mostlikely.)
8.DisconnectthePSfromthemainsandtakethesafetyprecautionstodischargethecapacitors.
9.Removethesuspectedtransistorandcheckitwithanohmmeteroratransistorchecker.Mostofthetimes
youwillhavetoprovideanewtransistor.(Beware!Evenatransistorthatlooksgoodundertest
conditionsmaymalfunctionintheactualcircuit.)Thisisalsothetimetoremove,checkandreplaceother
fried,explodedordiscoloredcomponentsnearthetransistor/transformercombination.
10.RepowerthePSusingtheserieslightbulb.
IfthelampisburningbrightlyyouhaveashortcircuitinyourPS.Mostlikelyyour(new)power
transistorisconductingduetotoohighacontinuousbasecurrent.Youhavetodivedeeperintothis
partofthecircuituntilyoufindthecauseofthisproblem.
Ifthelampisdimornotburningatallyoucanrecheckthevoltagebetweenpin3andpin9ofthe
mainboardconnector.Finding+5VDC,youcancontinue.Otherwiseyouhavetorestartyour
investigationofthesmalltransformer/onepowertransistorpartofthecircuit.(Step6.)Itmakesno
sensetocontinueuntilthispartofthePSfunctionscorrectly.
11.DisconnectthePSfromthemainswhenyouaredonesofar.
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Explanation:ForthenextpartoftherepairprocedureyouhavetoprovidesomeloadtothePS.Thisissimply
becauseofsomePSswillnotfunctionwellwithoutload.Youmayusean(old)mainboard.Someoneevertold
meheuses12Vcarbulbs,oneonthe+5VDCandanotheronthe+12VDCoutputs.Ipreferahugeand
heavyoldharddrive.Thoseoldbasaltblocks(weusetostrengthenourdikes)consumealotofenergy.Theone
Iuse,providedenoughloadforallthePSsIeverrepaired.
12.Replacethepowertransistorsyoumayhaveremovedearlier.ReconnectthePStothemainsusingthe
serieslightbulb.Checkthevoltagebetweenpin3andpin9ofthemainboardconnector.Connectpin14
ofthemainboardconnectortopin13.ThiswillswitchonthemainpartofthePS,thepartwiththetwo
powertransistorsandthelargetransformer.
Ifyourloadsstarttowork,checkthevoltagesoftheseveralpowerconnectors.Whentheyhave
thecorrectvaluesyourPSisonairagain.Checkitoutbyremovingtheserieslightbulb.
If(evenafterremovingtheserieslightbulb)somebutnotallofthevaluesarecorrect,youhavea
problem.Youhavetoinvestigatethefailingvoltagesfromthesecondarycoilofthetransformertill
theconnector.Quiteachallenge.
Ifthelightbulbisburningbrightlyyouhaveashortcircuit.Mostlikelyyourpowertransistorsare
gonesoyouhavetocheck(andalmostsurereplace)themandtheirsurroundingcomponents,
especiallythestartresistors.Payspecialattentiontothefreewheeldiodes(betweenthecollector
andtheemitterofthepowertransistors.)Don'tforgettodisconnectthePSandtodischargethe
filtercapacitorsfirst!Whenyouaredone,restartatStep12.
Ifyourlampisdimordarkbutyourloaddoesnotworkyoumayhavedefectiveorblockingpower
transistors.Afaultonthesecondarysideofthetransformerisanotherpossibility.
13.SearchforswitchingactivityonthesecondarycoilsofthetransformerusinganACmeter.
Ifyoudon'tfindACvoltageyouhavetocheckthevoltagesonthepowertransistors.
IfyoufindanACvoltageyoumostlikelyhaveadefectiverectifier,filtercapacitororregulatorat
thesecondaryside.Disconnectfromthemains,dischargethefiltercapacitorsandtrytofindthe
failingcomponentswithanohmmeter.Youwillhavetoremovetherectifiersfromtheboardpriorto
testingbecauseofthesecondarycoilshaveonlyfewwindingsofthickwiresotheyaretheshortest
shortcutsasfarasyourohmmeterconcerns.Anothertrickistouseacontrollablepowersupply.
Connectittothepointwheretheremovedrectifierwasconnectedtoitsfiltercapacitor.Bewareof
thepolarity!PoweronbothPSsandincreasethevoltageofyourcontrollablePStothelevelof
normaloperatingofyourdefectivePS.Theregulatorthatsuckstomuchcurrentwithrespecttothe
lightloadwillbethemainsuspect.Youhavetogodeeperintothecircuitofthisregulatorifyou
wanttorepairit.Anotherchallenge.
14.Checkthevoltagesonthepowertransistors.Thecollectorofoneofthemshouldbeattheprimarypower
voltage,theemitteroftheothershouldbeatthecommon.Theremainingcollectorandemitteraretied
togetherandshouldbeathalftheprimarypowervoltage.
Ifyoucan'tfindtheprimarypowervoltageatacollectoryouhaveaninterruption.Maybeabad
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solderingorthelike.
Ifnoemitterisconnectedtocommonyoualsohaveaninterruption.
Ifthetiedcollectoremitterisnotathalftheprimarypowervoltageyoumostlikelyhavedefective
powertransistors.(Inmyexperiencetheyalwaysdietogether.)Disconnect,dischargeandremove,
checkandreplacethepowertransistorsandtheirsurroundingcomponents.RestartatStep12.
Ifthetiedcollectoremitterisathalftheprimarypowervoltageyoucancheckthebaseemitter
voltageofthepowertransistors.Iftheyarelessthan0.6Vyoumaybeluckyandfindonly
defectivestartresistor(s)and/orotherbasecircuitcomponents.Butmostofthetimesadefective
basecircuitwillkillitstransistorwhichinturnwillkillitsneighbor.Soyouwillhavetoreplacethem
all.
Ofcourse,thisstorydoesnotcoverallpossiblefaultsofPCpowersupplies,butIonlyoncefailedtorepaira
PSusingthisscheme.
WarstoriestheBoschert2stageSMPSU
(From:TonyDuell(ard@p850ug1.demon.co.ku).)
Incaseyouhavebeenluckyenoughnottohavecomeacrossthebeast,thebasicideais:
1.Rectify/smoothmains,giving340VDC.
2.Putthatintoanonisolatedstepdownswitchingconverterusingafatpowertransistor,afreewheeldiode
andaninductor.ThecontrolICforthisisa723(!)withfeedbackappliedviaanoptocouplerfromthe
secondaryside.Oh,andthere'sacurrentlimitshutdownfroma0R15resistorinserieswiththe'load'
(section3,etc).Theoutputofthisstageisabout150V
3.Theoutputofthatfeedsapairoftransistorsthatrunasafreerunningpush/pulloscillator.Thatdrivesthe
primaryofthemainchoppertransformer(whichprovidesisolationfromthemains).
4.Thesecondariesofthattransformerarerectifiedtoprovideoutputvoltages.There'safeedbackto(2)as
described,andalsoacrowbar.
Nowforthefailuremode(seenithappen):
1.Thefirstchoppergoesshortcircuitbecauseitfeelslikeit.The150VDClinejumpsto340VDC
(remember,noisolation,andtheinductor/transistorareinseriesfromthe340VDClinetothe150Vline).
2.Thecrowbarfires,shortingtheoutput.Theprimarysidecurrentgoesupaswell.
3.Theovercurrenttripoperates,andthe723triestoshutdown.Itremovesthedrivefromthe*first*
chopper.Butthat'sshorted,soremovingthedrivedoesn'tdoadarnthing.
4.The2transistorsinthepush/pullcircuitshortaswell.
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5.Rectifiedmainsisnowconnectedacros:3shortedtransistors,afewsmallwindings(oscillatorfeedback
transformer,inductor,etc),andthe0R15resistor.Thelatterexplodes.
6.340VDCisnowappliedacrosstheconnectionsoftheex0R15resistor.Afewsmalltransistorsandthe
723expire,alongwithsomePCBtracks.
7.Thefuse(10A,FFblow)fails.
Repairingthatwasanentertainment.Istillhavemyphotocopyoftheschematicwithallthedudcomponents
circled!
Capacitors,startup,andlowvoltagetesting
(From:KevinBeeden(kevin.beeden@rrl.co.uk).)
IwasfightingwithaHitachiPSU(SP13AunitfromUKVTF860EVCR).
Symptoms:Followinglinepowerdisconnect,wouldn'tstartup.Tracedcircuit,foundbrokenTrinLVside,
replaced,nogood.Nogatedrive.Troublefiguringgatedrivecct.Applied30VDCtoHVsideanddrovegate
from10kHzsignalgenerator(5Vsquarewavevia1Kresistor).TheMOSFETswitcherwasokay,output
activebutwon'tstart.Startupdriveisviaa1uF,250Vcap.Can'tseeanydriveongatewhenpowerapplied
fromcold.Readthesenotes.Doh!Capacitorgoneopencircuit.Replacecapandnowgetgatedriveuntiloutput
settles.
Iwashappilysurprisedtofindthatthecircuitworkedoffof30VDC,asI'mnotkeenondebugginglivemainsor
400VDC!Thismaybeatoptipforfellowdebuggers.Isimplyconnected30VDCtothepostrectification
smoothingcap,hitthegatewiththesignalgenerator,andawayitwent.Note:thisisundernoloadconditionsthe
PSUwasremovedfromtheVCR.
Ialsofoundadeviouslittlecomponentmasqueradingasaresistor.Itappearstoactuallybebacktoback
(Schottky?1V3)diodesanda220ohmresistorinsomeseriesorparallelarrangement.Markedexternallyas
220R,identicalappearancetootherresistors.
Whyisthemainfuseratingsobig?
OnatypicalSMPS(orpieceofequipmentlikeaTV,monitor,orVCRusinganSMPS),thenameplatecurrent
ratingmaybemuchmuchsmallerthanthefuserating(orequivalently,thenameplatepowerratingmayimplya
muchsmallercurrent).Whyisthisthecase?
Thereareactuallymanyreasonsforthefusetobemuchlargerthanthemaximumcurrentspecifiedonthe
nameplate.Someoftheseinclude:
1.Thepeakcurrentduringpoweronisactuallymuchhigherduetothedegausscoilandchargingofthe
SMPScaps.
2.?ThepowerfactorismuchsmallerthanunityforatypicalSMPSandthisincreasetheaveragecurrent
whichiswhatthefusesees.
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3.ThefusefortheSMPSisreallytheretoprotectagainstcatastrophicfailuresoitcanbemuchlargerthan
theaverageexpectedcurrent.Ifthatfuseblows,it'susuallytheresultofthefailureofthemainchopper
transistor,notaslightoverload(forwhichtheSMPSshouldshutdown).
Replacingthefusewithasmalleronereallywon'tmaketheequipmentanysaferbutmayresultinnuisance
blowing.
ServiceInformation
Advancedtroubleshooting
Ifthesolutionstoyourproblemshavenotbeencoveredinthisdocument,youstillhavesomeoptionsotherthan
replacement.
(Alsoseetherelateddocument:TroubleshootingandRepairofConsumerElectronicEquipment.
Manufacturer'sserviceliterature:Servicemanualsmaybeavailableforforyourequipment.Onceyouhave
exhaustedotherobviouspossibilities,thecostmaybewellworthit.Dependingonthetypeofequipment,these
canrangeinpricefrom$5100ormore.Sometimes,thesemayevenbefree(yes,eveninthisdayandage
whereyouhavetopayforfreeairatyourlocalgasstation!)Somearemoreusefulthanothers.However,notall
includetheschematicssoifyouarehopingtorepairanelectronicproblemtrytocheckbeforebuying.
Insidecoveroftheequipment:TVsoftenhavesomekindofcircuitdiagrampastedinsidethebackcover.Inthe
olddays,thiswasacompleteschematic.Now,ifoneexistsatallforamonitor,itjustshowspartnumbersand
locationforkeycomponentsstillveryuseful.
SamsPhotofacts:Thesehavebeenpublishedforover45yearsmostlyforTVsandradios.Therearesomefor
VCRsandafewforsomeearlyPCmonitorsandotherpreJurassiccomputers.However,forthepower
suppliesinTVs,therewillnearlyalwaysbeaSamswithcompleteschematics.
Whatevertheultimateoutcome,youwillhavelearnedagreatdeal.Havefundon'tthinkofthisasachore.
Electronictroubleshootingrepresentsadetective'schallengeofthetypehatSherlockHolmescouldnothave
resisted.Youatleasthavetheadvantagethattheelectronicsdonotlieorattempttodeceiveyou(thoughyou
maybegtodifferattimes).So,whatareyouwaitingfor?
SMPSinfoanddatasheetsonline
ManycompaniesnowhaveveryextensiveinformationavailableviatheWorldWideWeb.Hereareafew
companysites:
InternationalRectifier
LambdaSemiconductors
MaximIntegratedProducts
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SGSThomson
UnitrodeCorporation
ThefollowingsitehasavarietyofinformationandlinkstoSMPSrelatedsites:
SMPSDesignbyJerroldFoutz.
ReferencesonSMPStechnologyandtroubleshooting
ThereisanicedetailedarticleonPCpowersupplyrepairfromNutsandVoltsMagazineonlineat:PCPower
SupplyRepairbyT.J.Byers.Thisisprobablyagoodplacetostartifyouarespecificallyinterestedinthe
commonPCpowersupply.ItlookslikethisarticleispreATXbutmostoftheinformationstillapplies.
SMPSPowerSupply.comhasextensiveinformationincludingagreatdealonPCpowersuppliesincluding
explanationsofhowtheywork,schematics,standards,andmore.
Alsoseethedocument:PCSwitchmodePowerSupplies.
TexasInstrumentshasanapplicationnotewhichissortofthe"short"versionofSMPSrepair.See:OffLine
SMPSFailureModesPWMSwitchersandDCDCConverters.
HerearesomesuggestedbookswithinformationrelatingtoSMPSandDCDCconverterdesign,testing,
troubleshooting,repair,etc.:
1.PowerSupplies,SwitchingRegulators,Inverters&Converters,2ndEdition.
IrvingGottleib
TABBooks,1994
ISBN0830644040
2.ModernDCtoDCSwitchmodePowerConverterCircuit
RudolfP.SevernsandGordonE.Bloom
VanNostrandReinhold
ISBN0442213964
3.PrinciplesofSolidStatePowerConversion
RalphE.Tarter
HowardW.Sams&Co.,Inc.
ISBN0672220180
4.AdvancesinSwitchedModePowerConversion
R.D.Middlebrook&SlobodanCuk
Contact:TeslaCo,Pasadena,CA91107(lastknownaddress)
5.SimplifiedDesignofSwitchingPowerSupplies
JohnD.Lenk
ButterworthHeinemann
ISBN0750698217.
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6.PowerElectronics,2nded.
B.W.Williams
McGrawHill,1992
ISBN0070704392
7.SwitchingPowerSupplyDesign
AbrahamPressman,SecondEdition
McGrawHill,1998
ISBN0070522367.
ISBN0070508062(FirstEdition,1991).
8.SwitchModePowerConversion
K.KitSum
9.SwitchmodePowerSupplyHandbook
KeithBillings
McGrawHill,1989
ISBN0070053308
10.PowerSupplyCookbook
MartyBrown
ISBN0750694424
11.TransformerandInductorDesignHandbook
ColonelWm.T.McLyman(yes,his1stnameis"Colonel"notmilitary)
MarcelDekker,Inc.
ISBN0824768019
12.MagneticCoreSelectionforTransformers&Inductors
ColonelWm.T.McLyman
MarcelDekker,Inc.
ISBN0824718739
13.MagneticComponents,DesignandApplications
SteveSmith
ISBN0442203977.
14.SoftFerrites,2nded.
E.C.Snelling
Butterworth,1988
ISBN0408027606
15.HighFrequencySwitchingPowerSupplies,TheoryandDesign
GeorgeChryssis
McGrawHillCo.,1984
16.SwitchedModePowerSuppliesDesignandConstruction
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Whittington,FlynnandMacphersonpublished
ResearchStudiesPress,Ltd.
ISBN0863802036
Inaddition,manysmeiconductormanufacturerspublishextensiveinformationonswitchmodetechnology.
Mostly,thisisinconnectionwiththeirproductlinesbutwillalsocontainalotofgeneralinformation.Muchofthis
isavailableonInternetviatheWorldWideWeb.Companiesinclude:Maxim,LinearTechnology,andUnitrode.
(From:OneStone(OneStone@bigpond.com).)
"TrytheLinearTechnologiesWebsite.
LookfortheirAppnotes:
AN25SwitchingregulatorsforPoets.
AN19LT1070Designmanual
AN29SomethoughtsonDCDCconverters
AN30Switchingregulatorcircuitcollection.
AN31LinearCircuitsfordigitalsystems.
Thentryoneoftheirnewdatasheets,suchastheLT1370,forsomemoderncircuitconfigurations,
suchasSEPICconverters.TheaboveAPPnotesareallcontainedintheirLinearApplications
handbook,Volume1,1990.IfyouareadesignertheyalsohaveaCDROMavailable,which
includessomeswitcherandfilterdesignsoftware.It'sabitlimited,butagreatstartingpointifyou
don'tneedtostretchtheboundaries."
FordiagnosingpowerproblemsinTVsandComputerorVideomonitors,hereisonebookthatincludesmany
illustrationsandcasehistories.
17.TroubleshootingandRepairingSolidStateTVs
HomerL.Davidson
2ndEdition,1992
TABBooks,Inc.
BlueRidgeSummit,PA17214
(From:ErnstC.Land,Jr.(a6mech@ionet.net)andMarkZenier(mzenier@eskimo.comor
mzenier@netcom.com).)
TheSeptember1996(VOL.17NO.9)issueofNuts&VoltsMagazinehasagreatarticleontheory,
troubleshooting,andrepairofPCpowersupplies.Theirwebsiteis:http://www.nutsvolts.com/.
Whenyougetthere,clickon[more],then[backissues]
Partsinformation
IhavefoundoneofthemostusefulsinglesourcesforgeneralinformationonsemiconductorstobetheECG
SemiconductorsMasterReplacementGuide,about$6fromyourlocalPhilipsdistributor.STK,NTE,and
othershavesimilarmanuals.TheECGmanualwillenableyoutolookupU.S.,foreign,andmanufacturer'house'
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numbersandidentifydevicetype,pinout,andotherinformation.NotethatIamnotnecessarilyrecommending
usingECG(orothergeneric)replacementsiftheoriginalreplacementsare(1)readilyavailableand(2)
reasonablypriced.However,thecrossreferencecansavecountlesshourssearchingthroughdatabooksor
contactingthemanufacturers.Evenifyouhaveawallofdatabooks,thissourceisinvaluable.Acoupleof
caveats:(1)ECGcrosseshavebeenknowntobeincorrectthespecificationsoftheECGreplacementpart
wereinferiortotheoriginal.(2)Don'tassumethatthespecificationsprovidedfortheECGpartareidenticalto
theoriginaltheymaybebetterinsomeways.Thus,usingtheECGtodeterminethespecificationsoftheparts
inyourjunkbincanberisky.
Othercrossreferenceguidesareavailablefromthepartssourcelistedbelow.
InformationsourcesontheInternet
ManymanufacturersarenowprovidingextensiveinformationviatheWorldWideWeb.Theanswertoyou
questionmaybeamouseclickaway.Performanetsearchorjusttrytoguessthemanufacturer'shomepage
address.Themostobviousisoftencorrect.Itwillusuallybeoftheform"http://www.xxx.com"wherexxxisthe
manufacturers'name,abbreviation,oracronym.Forexample,HewlettPackardishp,SunMicrosystemsissun,
WesternDigitalCorp.iswdc.NECis,youguessedit,nec.Itisamazingwhatisappearingfreelyaccessiblevia
theWWW.Forexample,monitormanufacturersoftenhavecompleteinformationincludingdetailed
specificationsforallcurrentandolderproducts.Electronicpartsmanufacturersoftenhavedetaileddatasheets
andapplicationnotesfortheirproductofferings.
Interchangeabilityofcomponents
Thequestionoftenarises:IfIcannotobtainanexactreplacementorifIhaveamonitor,TV,orotherequipment
carcassgatheringdust,canIsubstituteapartthatisnotaprecisematch?Sometimes,thisissimplydesiredto
confirmadiagnosisandavoidtheriskoforderinganexpensivereplacementand/orhavingtowaituntilitarrives.
Forsafetyrelateditems,theanswerisgenerallyNOanexactreplacementpartisneededtomaintainthe
specificationswithinacceptablelimitswithrespecttolineisolation,Xrayprotectionandtominimizefirehazards.
Typicalpartsofthistypeincludeflameproofresistors,sometypesofcapacitors,andspecificpartsdealingwith
CRThighvoltageregulation.However,duringtesting,itisusuallyacceptabletosubstituteelectricallyequivalent
partsonatemporarybasis.Forexample,anordinary1ohmresistorcanbesubstitutedforanopen1ohm
flameproofresistortodetermineifthereareotherproblemsinthetheSMPSchopperbeforeplacinganorderas
longasyoudon'tgetlazyandneglecttoinstallthepropertypebeforeconsideringtherepaircomplete.
Forothercomponents,whetheranotquiteidenticalsubstitutewillworkreliablyoratalldependsonmany
factors.Somedeflectioncircuitsaresocarefullymatchedtoaspecifichorizontaloutputtransistorthatno
substitutewillbereliable.
Herearesomeguidelines:
1.Fusessametype(usuallynormalorfastblow),exactsamecurrentratingandatleastequalvoltage
rating.Ihaveoftensolderedanormal3AGsizefuseontoasmallerblown20mmlongfuseasasubstitute.
2.Resistors,capacitors,inductors,diodes,switches,potentiometers,LEDs,andothercommonparts
exceptforthosespecificallymarkedassafetycriticalsubstitutionaslongasthereplacementpartfitsand
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specificationsshouldbefine.Itisbesttousethesametypemetalfilmresistor,forexample.Butfor
testing,eventhisisnotahardandfastruleandacarbonresistorshouldworkjustfine.
3.Rectifiersmanyofthesearehighefficiencyand/orfastrecoverytypes.Replacementsshouldhaveequal
orbetterPRV,Imax,andTrspecifications.However,theACinputbridgecanusuallybereplacedwith
anythingwithatleastequalvoltageandcurrentratings.
4.Mainfiltercapacitor(s)usereplacementswithatleastequalworkingvoltageandsimilaruFrating.For
testing,evensomethingwithhalfthecapacitywillbefine.Forthefinalreplacementbiggerisnotalways
betterandevenusingasmallerone(uF)willbefineaslongasyouarenotrunningthesupplynearfullload
capacity.Useofahighertemperatureratedcapacitorthantheoriginalmaybedesirableasitslifemay
havebeenshortededbyahotenvironment.Thispracticewillneverhurt.
5.Transistorsandthyristors(exceptSMPSchoppersorHOTs)substituteswillgenerallyworkaslongas
theirspecificationsmeetorexceedthoseoftheoriginal.Fortesting,itisusuallyOKtousetypesthatdo
notquitemeetalloftheseaslongasthebreakdownvoltageandmaximumcurrentspecificationsarenot
exceeded.However,performance(likeregulationspecifications)maynotbequiteasgood.Forpower
types,makesuretouseaheatsink.
6.SMPSchopper(orhorizontaloutput)transistorsexactreplacementisgenerallybestbutexceptforvery
highperformancemonitors,genericHOTsthathavespecificationsthatareatleastasgoodwillworkin
manycases.Makesurethereplacementtransistorhasaninternaldamperdiodeiftheoriginalhadone.
Fortestingwithaserieslightbulb,evenatransistorthatdoesn'tquitemeetspecificationsshouldworkwell
enough(andnotblowup)toenableyoutodeterminewhatelsemaybefaulty.Themostcritical
parametersareVceo/Vcbo,Ic,andHfewhichshouldallbeatleastequaltotheoriginaltransistor.Ihave
oftenusedbyfavoriteBU208DasatemporarysubstituteforotherHOTsandSMPS(chopper)
transistors.Makesureyouuseaheatsink(withinsulatingwasherifapplicable)andthermalgreaseinany
caseevenifyouhavetohangtheassemblywithacabletietomakeitfit.
Alsoseethesection:Replacementpowertransistorswhiletesting.
Thefollowingareusuallycustompartsandsubstitutionofsomethingfromyourjunkboxisunlikelytobe
successfulevenfortesting:flyback(LOPT)andSMPStransformers,interstagecoilsortransformers,
microcontrollers,andothercustomprogrammedchips.
Substitutingentirecircuitboardsandothermodulesfromidenticalmodelsis,ofcourse,possibleandanexcellent
troubleshootingaidevenifitisonlyusedtoconfirmoridentifyabadpart.However,iftheoriginalfailurewas
catastrophic,youdorunsomeriskofdamagingcomponentsonthesubstitutecircuitboardaswell.
Replacementpowertransistorswhiletesting
Duringtestingofhorizontaldeflectioncircuitsorswitchmodepowersupplies,particularlywheretheoriginal
failureresultedinthedeathoftheHOTorchopper,overstressonreplacementtransistorsisalwaysapossibility
ifalldefectivecomponentshavenotbeidentified.
Therefore,usingapartwithbetterspecificationsmaysaveyouinthelongrunbyreducingthenumberof
expensiveblownparts.Onceallotherproblemshavebeenlocatedandrepaired,theproperpartcanbe
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installed.
However,thisisnotalwaysgoingtowork.InaTVandespeciallyahighperformancemonitor,theHOTmaybe
closelymatchedtothedriveandoutputcomponentsofthedeflectioncircuits.PuttinginonewithhigherVce,I,
orPspecificationsmayresultinoverheatingandfailureduetolowerHfe.
Wherepossible,aseriesloadlikealightbulbcanbeusedlimitthemaximumcurrenttothedeviceandwillallow
youtopowertheequipmentwhilecheckingforotherfaults.Somedesigns,unfortunately,willnotstartupunder
theseconditions.Insuchcases,substitutinga'better'devicemaybethebestchoicefortesting.
(From:GlennAllen(glenn@manawatu.gen.nz).)
IbeenrepairingSMPSofalltypesbutwhenIstartedonthoseusingMOSFETsIwasblowningafewofthem
whenreplacedbecausesomethingelsewasfaulty.
EversinceIhavebeenusingaBUZ355onaheatsinkIhaven'tblownit.Itisratedat800V,6A,and220W.
itisaTO218casebiggerthanaT0220.Itseemsthehigherratingsallowsyoutodorepairwhereasasomething
likea2SK1117orMTP6N60willjustblow.
Testingofreplacementchoppertransistors
Thefollowingisusefulbothtoconfirmthatasubstitutereplacementchoppertransistorissuitableandthatno
othercircuitproblemsarestillpresent.However,thiswillnotcatchsingleshoteventsthatmayblowthe
transistorinstantlywithoutanyincreaseintemperature.
ItwaswrittenwithTVandmonitorhorizontaloutputtransistorsinmindbutappliestotheswitchmode/chopper
transistorsfoundinlinepoweredSMPSsaswell.
(From:RaymondCarlsen(rrcc@u.washington.edu).)
AfterinstallingareplacementHOTinaTVsetormonitor,Iliketocheckthetemperatureforawhiletomake
surethesubstituteisagoodmatchandthattherearenootherproblemssuchasaweakHdrivesignal.Theinput
currentisjustnotagoodenoughindicator.IhavebeenusingaWCF(wellcalibratedfinger)foryears.Forme,
theruleofthumb,quiteliterally,is:ifyoucannotholdyourfingeronit,it'srunningtoohot,andwillprobablyfail
prematurely.Touchingthecaseofthetransistororheatsinkistricky....
Metalcasetransistorswillbeconnectedtothecollectorandhaveahealthypulse(>1,200Vpeak!)andeven
withplasticcasetabtransistors,thetabwillbeatthispotential.Itisbesttodothisonlyafterthepowerisoffand
theB+hasdischarged.Inaddition,theHOTmaybehotenoughtoburnyou.
Abettermethodistheuseofanindoor/outdoorthermometer.IboughtonerecentlyfromRadioShackforabout
$15(631009).Ithasaplastic'probe'ontheendofa10'cableastheoutdoorsensor.Withalargealligator
clip,IjustclampthesensortotheheatsinknearthetransistorandsetupthedigitaldisplayneartheTVsetto
monitorthetemperature.ThelastTVIuseditonwasa27"SanyothathadashortedH.outputandanopenB+
resistor.ReplacementpartsbroughtthesetbacktolifeandtheflybackpulselookedOK,butthetransistorwas
gettinghotwithin5minutes...upto130degreesbeforeIshutitdownandstartedlookingforthecause.Ifound
a1uF160voltcapinthedrivercircuitthatwasopen.Afterreplacingthecap,Ifiredupthesetagainand
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monitoredtheheatsinkasbefore.Thistime,thetemperatureslowlyrosetoabout115degreesandstayedthere.
Iranthesetalldayandnoticedlittlevariationinthemeasurement.Testequipmentdoesn'thavetocostafortune.
Repairpartssources
Forgeneralelectroniccomponentslikeresistorsandcapacitors,mostelectronicsdistributorswillhavea
sufficientvarietyatreasonablecost.EvenRadioShackcanbeconsideredinapinch.
However,formodernelectronicequipmentrepairs,placeslikeDigikey,Allied,andNewarkdonothavethea
varietyofJapanesesemiconductorslikeICsandtransistorsoranycomponentslikeflybacktransformersor
degaussPosistors.
Seethedocument:MajorServicePartsSuppliersforsomecompaniesthatIhaveusedinthepastandothers
thathavebeenrecommended.
Inaddition,specificallyforVCRSMPSrepair:
StudioSoundService
Fax:18129497743
Email:studio.sound@datacom.iglou.com.
RebuildkitsformanypopularVCRswitchmodepowersupplies,VCRparts,somecomponents.They
willbehappytoidentifyspecificVCRpartnumbersaswellbasedonmodelanddescriptionaswell.
endV2.86
63/63

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