13.8 V / 15 A from a PC Power Supply

From: "Saved by Internet Explorer 11" Subject: 13.8 V / 15 A from a PC Power Supply Date: Mon, 20 Jan 2014 10:22:42 -0800 MIME-Version: 1.0 Content-Type: multipart/related; type="text/html"; boundary="----=_NextPart_000_00B1_01CF15C9.8DD610E0" X-MimeOLE: Produced By Microsoft MimeOLE V6.1.7601.17609 This is a multi-part message in MIME format. ------=_NextPart_000_00B1_01CF15C9.8DD610E0 Content-Type: text/html; charset="iso-8859-1" Content-Transfer-Encoding: quoted-printable Content-Location: file://C:\Users\R&D 1\Documents\Research\Power Supplies\13_8 V - 15 A from a PC Power Supply.htm 13.8 V / 15 A from a PC Power Supply=20 =20 =20 =20 =20 =20 =20 =20 =20 =20 =20

I would be grateful for a professional translation = or=20 correction of the following text. Please E-Mail to DL2YEO@qrp4u.de =

13.8 V / 15 A from a PC Power Supply =

Safety = Instructions

Caution mortal danger: The following = circuit=20 operates at a mains voltage of 230 Vac. Because of rectification some = of the=20 components conduct dc voltage of more than 322 V. Work has to be = carried out=20 only if the circuit is disconnected from the mains and de-energized. = Note that=20 capacitors located to the primary side can be charged with high voltage = for=20 several seconds even after switching of the mains = voltage.

The major disadvantages of usual linear power supplies are high power = dissipation, the size and the appropriated weight. When looking for an=20 alternative solution, I decided to use a switch mode power supply = (SMPS). The=20 efficiency of such power supplies is around 70 % to 90 % at a power = density of=20 0.2 W / cm=B3. Because homebrewing was out of the question due to lack = of time, I=20 tried the modification of a PC switch mode power supply. The later are=20 mass-produced goods and available for less than 50 DM.

Fig.1: Block diagram of a primary switching = power supply =20
3D"{short

Brief description of PC SMPS Features

Depending on the PC model, these are rated anywhere between 150 and = 240 W.=20 For supplying socket 7 main boards they have four different output = voltages of=20 +5 V, +12 V, -12 V and -5 V. They are mainly primary switching power = supplies=20 with power switches arranged in a half-bridge configuration. The = outputs can=20 drive the usual 20 A (+5 V), 8 A (+12 V) and 0,5 A (-12 V, -5 V). At = approx.=20 205 W output power and a typical efficiency of 75 % this means a = dissipation of=20 only 68 W. I had acquired an unbranded PC power supply, measuring 140 x = 100 x=20 50 mm (W, D, H) and weighing 350 g. Most power supply units are = designed=20 according to the same principle (half-bridge configuration) and hence = the=20 following described modification should be applicable also to power = supplies=20 from other producers.

Fig.2: Half-bridge configuration of power switches
3D"{short

Regulation

After switching on the mains voltage the circuit = operates for=20 a short duration as a free-running oscillator. This behavior is caused = by a=20 feedback winding at the output transformer T2. As soon as the auxiliary = voltage=20 Uaux is present the pulse width modulator IC TL494CN from = Texas-Instruments=20 takes over the control function and synchronizes the "oscillator". =
The=20 error amplifier in the TL494 compares the voltage at the +5 V output = (actual=20 value) with a reference voltage (set value), calculates the analogue = control=20 variable according to the PI algorithm and adjusts the pulse width = modulator=20 (see Fig. 6). The modulator sends alternate pulses to the driver = transistors Q5=20 and Q6. The pulse duration is reverse proportional to the control = variable=20 rating. Increasing loading on the +5 V output makes for wider pulses, = lighter=20 loading causes narrower pulses. As there is a finite minimum pulse = width, a=20 minimum load of 0.1 A is required. Without this load the power supply = may be=20 destroyed. The switching frequency is approx. 33 kHz as usual for PC = power=20 supplies. It is defined by a resistor and a capacitor located at pin 5 = and 6 of=20 IC1.

Fig. 3: Primary side mains filter, rectifier, = power=20 switches and drivers
3D"{short

Monitoring Circuit

Several protection circuits are included in the original power = supply.=20 Excessive primary current due to a very high secondary current leads to = a high=20 alternating voltage at the T3 output. If this voltage is above a fixed=20 threshold the TL494 stops immediately generating cyclically pulses and = changes=20 to the intermitted mode (on / off). The circuit and the load are = protected=20 likewise against over-voltage at the +5 V output or short-circuit at = the -12 V=20 and -5 V outputs. Switching off is executed via H-signal to the IC1 = protection=20 input (pin 4) too.
If you see a KA7500 or IR3MO2 PWM regulator IC on = the=20 board, each one is a pin compatible second source to the TL494CN. IC3 = is a dual=20 comparator from LM339 type. Some power supplies are not equipped with = this IC,=20 but with a two transistor discrete monitoring circuit, offering the = same=20 functionality.

Mods to the Secondary Rectification

The intent is for all of the available power at the = 12 V=20 secondary of T1 to be rectified, regulated, protected and filtered to = provide a=20 single output of 13.8 V DC at 205 W, or more if possible. A first check = indicates that the +12 V wire was of the same diameter as the +5 V = wire. =20
First unsolder and remove all components on the secondary side of T1 = which=20 are provided for rectification, filtering and regulation of the four = output=20 voltages. On that part of the board are only remaining three RC members = RC1 to=20 RC3 and the components for providing the auxiliary power supply Uaux. =

Fig.4: Secondary rectification as found in the original PC power=20 supply
3D"Rx/Tx-Steuerung"

Reconstruction of the secondary side.

Break the PCB tracks between the RC members RC1 / RC2 and both 5 = V =20 taps of the T1 secondary winding.

Modify L4 for 12 V at 20 A. Remove windings L4a, L4b and L4c = from the =20 toroid (counting turns of L4c). Rewind the toroid L4* with a = single =20 winding, turn count as old L4c but with 2.5 times the = thickness. Take=20 two wires with 1 mm diameter each, bifilar = wounded.

Install two low ESR electrolytic capacitors of 2200 uF each and = the =20 100 Ohm bleeder resistor as permanent load.

Use the old PCB tracks from the +5 V section and GND tracks as = =20 terminals for L4* , the 100 Ohm resistor and the two 2200 uF = capacitors. =20 Insert L4* at the same place onto the PCB component side where = the L4b=20 winding was connected before.

The original cooling of the rectifier diode D5 is insufficient. = =20 Adequate cooling is achieved by a finned heat sink measuring 70 x = 50 x 30 =20 mm (W, D, H) instead of the old aluminium sheet metal. =

Fasten D5 to the heat sink and extend the three leads by 40 mm = long =20 wires. Use isolation material and thermal compound. D5 carries = on some =20 boards the abbreviation SKD.

Place the finned heat sink approx. 40 mm above the "stripped" = =20 secondary (see photo) with plastic spacers and long M3 screws = (avoid =20 short-circuit to common).

Connect the anode leads of D5a and D5b with one RC member RC1 / = RC2 =20 each. The cathodes have to be connected to the nodal point of = RC1, RC2=20 and L4.

Establish two links between the 12 V terminals of T1 and the RC = =20 members by two thick wires. D5 will be fed from the 12 V winding. = =20

A simple and clear structure of the secondary rectification was = achieved=20 after "stripping" and "reconstruction".

Fig. 5: New designed secondary for = Ua =3D 13,8 V =20
3D"{short

Mods to the Regulation and Protection Circuit

The part of the circuit responsible for regulation and monitoring has = to be=20 modified at three places. Arrange additional components free standing = onto the=20 component side of the PCB.

R24* is calculated for 13.8 V output voltage. The voltage at the = (+) =20 input of the error amplifier must be equal to 2.5 V after = control loop=20 stabilization, i.e. half the 5 V reference voltage when the = output=20 is at 13.8 V.

R24* =3D 20 = kOhm =3D 2 x 10=20 kOhm in series

Arrange a second universal diode 1N4148 and a 8,2 V Zener diode = in =20 series to D16.

Usum =3D 8,2 V + 2=20 x 0,7 V =3D 9,6 V

Simplify the voltage divider (R36, R42, R45 and D14) in the = =20 short-circuit protection circuit. For this remove R36 and D14. = Connect the=20 free end of R42 to common (GND) and replace R45 with one of = higher=20 value to ensure no shut-down at normal operation. The = voltage across=20 R42 must be less than 1,7 V (I chose 1,2 V).=20

R45* =3D 15 kOhm

The areas marked with dotted frames, show the modified or additional=20 components that are necessary for 13.8 V output voltage.

Fig. 6: Regulation and protection circuits incl. all = modifications=20
3D"{short

Further Modifications

After commissioning the modified board, the situation regarding to=20 interferences looks very bad. The whole reception range from 3,5 MHz to = 30 MHz=20 was disturbed by harmonics of the 33 kHz switching frequency. S-meter = readings=20 showed S5 on 80 m down to S2 on 10 m. As I was testing the board in a = metal=20 box, the HF radiation could only get out on the mains cable and/or DC = output=20 leads. The insertion of an additional standard 230 VAC mains filter and = a=20 home-brewed pi-filter in the output rendered the interference = inaudible.

Insert an additional 230V / 2A mains filter to the primary side, = close=20 to the place where the mains cable enters the enclosure rear = wall.=20

Insert a 20 A pi-filter to the DC output , behind the +/- DC = terminals=20 at the rear wall.

The power supply enclosure must absolutely consist of iron sheet = metal=20 to screen magnetic fields. Aluminum plates protect only = against=20 electrical fields.

Optional on the primary: Replace the 220 uF smoothing capacitors = C1 =20 and C2 by 470 uF capacitors. This reduces primary ripple, which = helps =20 output regulation at full load.

Testing the Power Supply

Phase 1: These tests have to be carried out at a = low DC=20 supply voltage in order to avoid component destruction in case of = possible=20 errors. The 13.8 V output is loaded with a 12 V / 50 W car headlight = bulb and a=20 15 V / 1 A lab power supply is connected to GND and Uaux. The TL494 IC = gets its=20 operating voltage and generates control pulses with maximum pulse = duration.=20 Check the signals at Q5 and Q6.

Phase 2: During the second test phase the galvanic = isolated=20 primary side of the circuit is supplied by the lab supply too. For this = purpose=20 make a short cable link between Uaux and U+ as well as between GND and = U-. The=20 PWM controller tries to offer 13.8 V at the output at maximum pulse = duration.=20 The later cannot be successful due to the low 15 Vdc input voltage and = the=20 present transformer ratio. With an oscilloscope measured signals at the = measuring points TP1 (emitter Q1 against emitter Q2) and TP2 (cathode = D5=20 against GND) must look like as shown in figure 7.

Fig. 7: Signal shape at TP1 and TP2
3D"{short

Phase 3: Nor disconnect the lab supply from the primary side only. = Instead=20 connect a 48 V / 1 A mains transformer to the L1 and N terminal in = order to=20 feed the board with a galvanic isolated Ac voltage. 60 Vdc at C1 and C2 = is in=20 Europe defined as a non-dangerous voltage rate. 48 VAC at the input = causes a=20 rise of the output voltage up to +6 V.

If everything is all right up to now, one can proceed with the = exciting test=20 at 230 Vac. The laboratory power supply, the 48 V transformer, the = measuring=20 instruments and all provisional cable links attached for the test etc. = must=20 obviously be removed. The car bulb are further needed as a load and for = the=20 functional checks. If after applying of the 230 Vac mains voltage the = lamps=20 light up brightly, the output voltage amounts to 13.8 V and no = undefined noises=20 or smells are noticeable one has won the first round. If a non = recognizable=20 error has passed the pre-testing the two switching transistors and = copper=20 tracks say good-bye with a more or less loud bang.

For the following load test some high power resistors with resistance = 1 Ohm=20 and sufficent power rating are required. The current flowing with this = load=20 should not cause excessive heating of the rectifier diode and the = switching=20 transistors during a 5 minutes test periode.

Warning: Check temperature of components only = if the=20 mains voltage is switched off

Cooling of the switching transistors Q1 and Q 2 at a continuos = current of 15=20 A has to be improved in any case. When exchanging the small heat sinks, = note=20 that they form an electrical connection between coper tracks on some = boards.=20 Replace the missing connection by wire links. As one can see on the = photo, I=20 did not taken this measures for further power improvement.

Operation Experience

The modified board was permanently installed in the = speaker=20 cabinet SP120 that matches my transceiver. The mains lead exit from its = back,=20 which also carries the DC terminals, an on-off switch, the additional = mains=20 filter and a small 12 V blower. A green LED power-on indicator was = inserted in=20 the front panel into a 5 mm hole drill. I had installed the small = blower just=20 in case, but found it superfluous; at the low duty cycle of CW and SSB, = none of=20 the components is getting hot. The power supply has been used for = several years=20 and has given no problems.

Fig. 8: Modified power supply board in the SP120 = speaker=20 cabinet

3D"{short

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