Inside the Power Supply

With the Desktop PC Supply as an Example

Charles E. Mullett, P.E.

ON Semiconductor
[email protected]
(805 933-4607)

Outline

Introduction, Technical Overview & Objectives

Simplified Block Diagram
Typical Specifications
Regulatory Issues
Functional Block Diagram
Electronic Components
Switched-Mode Basics
Operation of Each Functional Block
Inside the ATX12V Box
Summary and Open Discussion
2

Simplified Block Diagram

Input
Filter

Rectifier

PFC

Power
Stage

Transformer

Output
Circuits

Specifications (Abbreviated)
Input Voltage:
Input Current:
Input Harmonics:

90 265 Vac, 47-63 Hz

5 A maximum.
Meets IEC1000-3-2
for all load conditions.
Hold-up Time:
20 ms minimum.
Inrush Current:
Usually, must be less than the
ratings of input components.
Outputs (example of 250 W ATX power supply):
OUTPUT
VOLTAGE (V)
+12
+5
+3.3
-5
-12
+5 SB

OUTPUT CURRENT (A)

MIN.

MAX.

0
0.3
0.3
0
0
0

10
25
16
0.3
0.8
1.5

PEAK
CURRENT
(A)
12

2.5

RIPPLE &
NOISE (mVpp)
120
50
50
100
120
50

Specifications (contd.)
Some Power Supply Specs. Contain:
Efficiency:

75% minimum at full load, 120 Vac input

Temperature:
Storage

Operating: See derating curve below

-40 oC to +85 oC

100 W
200 LFM FORCED AIR COOLING

80 W

NATURAL CONVECTION
COOLING

0 oC

10 oC

20 oC

30 oC

50 W
40 W

40 oC

50 oC

60 oC

70 oC

Temperature Derating
5

Leakage Current
Without insulation in the appliance, the user provides a
path for the electrical current to return to ground! Even
with insulation, some small leakage current flows.
The dotted line shows the third wire ground, not present
in 2-wire (Class 2) appliances.
Nurse
(CPR Trained)

Victim

120 Vac
Ground

Power Box
(circuit breakers)

Power From Utility

Safety Standards (Non-Medical)

IEC950 (now IEC60950) and its derivatives
(UL1950 --- now UL60950, CSA 22.2 No. 950)
Primary-secondary spacings increase smoothly as
voltage increases.
Leakage current to earth (maximum limits, ac):
Double-insulated appliances: 250 uA
Grounded, hand-held products: 750 uA
Others: 3.5 mA
At 230 Vac, 60 Hz, this limits the total capacitance from line to
ground to a value of C = I / (2 f V) = 0.04 uF.

Medical designs require larger spacings, lower leakage.

7

UL1950 (Contd.)
Clearance: The shortest distance between two
conductive parts, through air.
Depends on temperature, humidity and pollution level.

Creepage: The shortest distance between two

conductive parts, measured along the surface of the
insulation.
Depends on temperature, humidity, pollution level, and the
insulators comparative tracking index (CTI).

Typical practice in PC power supplies:

4 mm spacing between primary conductors and safety ground.
8 mm spacing between primary and secondary conductors.
8

UL1950 (Contd.)
Creepage distance is very important on
circuit boards and in transformers.
Most insulation material on components, including the
varnish on magnet wire, is not recognized as insulation.
Therefore, the body of a resistor is considered an
uninsulated live part.
Inside a transformer that crosses the primary-tosecondary safety barrier, creepage distances force
margins at the edges of windings, thereby increasing
the size of the transformer.
Magnet wire is available with multi-layer Teflon or
Kapton, which can be considered insulated, but the
wire is expensive.
9

UL1950 (Contd.)
Ground bonding
Connection from the ground terminal to the
chassis must be less than 0.1 ohm, measured
with twice the rated current applied for 120 s.

Component temperatures
Components, including transformer and
inductor insulation systems, must operate
within their ratings.

Electric Strength (Hipot tests)

Primary-ground, primary-secondary: 1500 Vac
Secondary-ground: 500 Vac
10

Input Harmonics, per EN61000-3-2 (Class D)

Amplitude, mA per W

10.000
1.000
EN61000-3-2 Limit
Power Win (No PFC)

0.100

Seasonic, Passive PFC

Seasonic, Active PFC

0.010
0.001
3

13

23

33

Harmonic Number

Without PFC, limits are exceeded.

Passive PFC is almost at limit for 3rd harmonic.
Note logarithmic scale for amplitude.
11

CISPR 22 Class B Limits

for

Conducted and Radiated Emissions

CISPR 22 Conducted Emissions Limits
Frequency
Range (MHz)
0.15 - 0.50
0.5 - 5
5 - 30

CISPR Class B Limit (dBuV)

Quasi-Peak
Average
66-56
56-46
56
46
60
50

CISPR 22 Radiated Emissions Limits

Frequency
Range (MHz)
30 - 88
88 - 216
216 - 230
230 - 960
960 - 1000
Above 1000

CISPR Class B Limit

at 10 m (dBuV)
30
30
30
37
37
-

12

The Energy Conservation Scene

Standby Power Reduction
25% of total energy consumption is in low power/sleep/standby
mode
Concerted effort by CECP, Energy Star, IEA and other
international agencies to limit standby power

Active Mode Efficiency Improvement

75% of total energy consumption is in active mode
Changing efficiency from 60% to 75% can result in 15% energy
savings

Power Factor Correction (or Harmonic Reduction)

Applicable with IEC 1000-3-2 (Europe, Japan)
Some efficiency specifications also require >0.9 PF
13

Active Efficiency Certification Programs

(External Power Supplies)
Code

Region/Country & Timing

CUC1 CECP (China) & Energy Star (US)

CE2
CE1

From January, 2005 (Tier 1)

Europe (EC Code of Conduct)
From January 1, 2007
Europe (EC Code of Conduct)
From January 1, 2005

CUC2 CECP and Energy Star (Tier 2)

Active Mode Efficiency

0.49*Pno for 0-1 W
[0.09*Ln(Pno)]+0.49 for 1-49 W
0.84 for >49 W
0.70 for 6-10 W
0.75 for 10-25 W
0.80 for 25-150 W
TBD (More stringent than Tier 1)

From July, 2006

CA1

Australia (High Efficiency)

From April, 2006

0.48*Pno for 0-1 W

[0.089*Ln(Pno)]+0.48 for 1-60
W
0.84 for >60 W

Note: Pno is defined as the nameplate output power.

14

Functional Block Diagram

Input Filter

Rectifier

PFC

+ Bus

PFC
Control

Power Stage

Xfmr

+ Bus
Return

Output Circuits
+
12 V, 3 A
+

+ Bus

5 V, 10 A
PWM
Control

+
3.3 V, 5 A
-

+ Bus
Return

Mag
Amp
Reset

15

Resistor
Ohm's Law :

R=

V
I

I=

V
R

Where:
VB

R = Resistance (ohms)
V = Voltage (volts)
I = Current (amperes)

SW
2

IR

VB

I=

dQ Q
=
dT
t

Where:
I = Current (amperes)
t = Time (seconds)
Q = Charge (coulombs)

1
0
2

VB
0
VB / R

IR
0

16

Capacitor
C=

V=

Q
C

SW

2
IR

Where:

R
3

VB

C = Capacitance (farads)
Q = Charge (coulombs)
V = Voltage (volts)

VB
1

Q = I t

Where:

0
VB
0
VB / R

I = Current (amperes)
t = Time (seconds)

IR

37.2% of final value

0
VB

So: Voltage on a capacitor

cant change instantaneously!

t=0

62.8% of final value

t=

= R C = time constant
17

Inductor
SW

V
L=
dI / dt = rate of change of current

VB

Where:

2
IR

L = Inductance (henries)
I = Current (amperes)
t = Time (seconds)
dI/dt = I / t, if I is constant

dI V
=
dt L
So: Current in an inductor cant
change instantaneously! (unless V
is infinite or L is zero OR there
are multiple windings or taps)!

3
L

VB
1
0
2

VB
0
VB / R
62.8% of final value

IR
0
VB
3

t=0

t=

=L/R
= R C = time constant
37.2% of final value

18

Diode
Diodes purpose is to rectify
(conduct current in only one
direction).
Nobodys perfect:
In the forward direction, there is a
small voltage drop of 0.3 to 1.2 volts,
depending on the material and
amount of current.
In the reverse direction, there is a
small leakage current of a few
nanoamperes (silicon) to a few
milliamperes (Schottky-barrier
types).
FETs are sometimes used in place of
diodes for lower forward voltage.

I
VF

+
I

ILEAKAGE

VBREAKDOWN
1
IR

R
2

Vs

CR

VF

IR

19

Field Effect Transistor (FET)

A FETs primary purpose is to amplify.
In the linear mode (as a linear amplifier),
the output is a faithful replica of the input
waveform.
In the switched mode (operating as a
switch), the output is driven from cutoff to
saturation.
Nobodys perfect.
While off, theres leakage current.
While on, theres the on resistance.
No matter how well you drive it, the turn-on and
turn-off times arent zero.
Theres capacitance from each terminal to the
others, and it must be charged and discharged
every time the FET is switched.

Drain
Gate
Source

Output is amplified and inverted

Output goes from cutoff to saturation

20

Optocouplers/Optoisolators
1
2
3

5
4

Output (transistor)
Current (mA)

Typical Optocoupler Transfer Characteristics

(On Semiconductor MCT2)
10
1
0.1
0.01
0.1

10

100

Input (diode) Current (mA)

Optocouplers (synonymously optoisolators) couple a signal

across an isolation barrier. Current in the diode causes it to emit
light, which falls on the transistor and causes it to conduct.
Optocouplers provide a high degree of electrical isolation from
the mains (primary side) to the output circuits. Most are rated
to withstand 7500 volts peak.
21

Basic Switched-Mode Toolkit

Source

Load

By arranging the three elements, one can

build each of the three most fundamental
switched-mode converter topologies.
22

Buck Converter
Source

Load

Output must be less than the input.

Input current is discontinuous; output
current is smooth.
23

Boost Converter
Source

Output must be greater than the input.

Input current is smooth; output is discontinuous.
24

Buck-Boost Converter
Source

Load

Output is inverted from the input.

Magnitude of the output can be less or greater than
the input. Both the input and output currents are
discontinuous.
By substituting a transformer (two windings) this
becomes a flyback.
25

Single-Ended Primary Inductance Converter

(SEPIC)

An inductor has been added, but it can be

combined with the first to form a single inductor
with two windings.
+ The input can be above or below the output.
- All energy passes through a capacitor.
26

Input Filter
F1

Input Filter

L
T1
G

F1
F2
RV1
T1
C1, C2
C3

L1
C3

RV1
N

C1

AC
TO
RECTIFIER

C2

F2

Usual input fuse

2nd fuse for medical
MOV transient suppressor
Common-mode choke
Y capacitors (1 nF)
X capacitor (1 uF)
27

Input Rectifier
Rectifier
Fairly simple when used with a PFC
stage, due to good current waveshape
Current rating of the bridge is just the
input current of the power supply.
Diodes tend to snap off when there is no PFC
stage, since they turn off abruptly at the end of
each charging peak. With PFC, the current
decreases sinusoidally to zero at the end of each
half cycle of the input voltage.

28

PFC Stage
Boost topology is by far the most
popular.
Continuous input current
High output voltage for efficient
energy storage (holdup time)

PFC
CR1

L2

+ Bus

FROM
RECTIFIER

PFC
Control

Q1

TYPICALLY
400 VDC

C4

Bus
Return

Two popular types of boost converters:

Continuous conduction mode
Ripple current in L2 is small

Critical conduction (or transition) mode

Ripple current in L2 is huge; peaks are 2x the sine shape
Controller ICs are simple and cheap, but the inductor design can be a
serious challenge.
29

Power Stage
Single-ended forward converter
There are many variations:
Clamped reset (another pri. wdg.)
Resonant reset

Power Stage

+ Bus

Q2

Control types

Current-mode control
Voltage-mode control
Hysteretic (variable freq.)
And more

PWM
Control
Bus
Return

30

Other Popular Topologies

Flyback
Single-Transistor Forward
Two-Transistor Forward
Half-Bridge
Full-Bridge
Push-Pull
All are transformer-coupled, so here are the
fundamentals
31

Right-Hand Rule

According to Amperes Law, current causes a

magnetic field. Its direction is easily remembered
via the right-hand rule.
32

Transformer (No Energy Storage)

IN

OUT

Ampere-turns of all windings sum to zero.

Right-hand rule applies to the applied current and the
resulting flux. The opposite occurs on the output
winding.

33

Transformer (Energy Storage)

+15

Voltage

IN

i pri.

0
-5

Current (ipri )

Voltage

OUT

+5
0

i sec.

-15

Current (isec )
4.5
0

This is a conventional flyback transformer.

Energy is delivered to the magnetic core during the positive
pulse applied to the primary.
Energy is transferred from the core to the load during the
remaining portion of the cycle.
Ampere-turns of all windings still sum to zero over each cycle.
34

Flyback
Transformer stores
energy
Designed like an inductor
Causes it to be larger
Really an integrated
magnetic, because it
combines the transformer
and inductor functions in
one core

+ Bus

Q2
PWM
Control
Bus
Return

35

Single-Transistor Forward
Single-transistor forward
converter
+ Bus

PWM
Control

Gate
Drive

Bus Return

With equal turns on both primary windings, the

FET drain and diode anode move together.
Adding the capacitor between them eliminates the
decoupling due to leakage inductance.
36

Two-Transistor Forward
+ Bus

Gate
Drive

PWM
Control

(IC
or
Transformer)

Bus
Return

Although there are two FETs, the circuit is

desirable, because the maximum voltage on either
one is never more than the input bus voltage.
37

Half Bridge
+ Bus

Gate
Drive

PWM
Control

(IC
or
Transformer)

Bus
Return

Maximum voltage on each FET is the bus voltage.

Major advantage is in the transformer. It can be
smaller, since it transfers energy on both halfcycles.
38

Full-Bridge
+ Bus

PWM
Control

Gate
Drive

Gate
Drive

(IC
or
Transformer)

(IC
or
Transformer)

Bus
Return

Compared to a half-bridge, each FET operates at

the same voltage (+Bus), but half the current.
Good for FETs, where loss is proportional to I2.
Therefore, power handling capability is higher.
39

Push-Pull
+ Bus

PWM
Control
Bus
Return

Gate
Drive
(IC
or
Transformer)

Another full-wave topology, but this ones

FETs are subjected to twice the bus voltage.
40

Transformer
Xfmr

CR2
CR3

L3a

CR4

+ Bus

Q2

CR5

+
12 V, 3 A
-

C5
L3b
C6

+
5 V, 10 A
-

+ Bus
Return

In forward converters, as in most topologies, the

transformer simply transmits energy from primary
to secondary, with no intent of energy storage.
Core area must support the flux, and window area
must accommodate the current. => Area product.
41

Transformer (contd)
Xfmr

Note the polarity dots.

Outputs conduct while Q2 is on.
Secondary Vpeaks = +Bus Ns/Np

CR2
CR3

L3a

CR4

+ Bus

Q2

CR5

+
12 V, 3 A
-

C5
L3b
C6

+
5 V, 10 A
-

+ Bus
Return

With output chokes in continuous conduction, each output

voltage is the average of its secondary voltage (neglecting
diode drops).
Therefore, each output voltage is its secondary peak voltage
times the duty ratio of the primary bus voltage, +Bus,
(neglecting diode drops and Q2s ON voltage).
42

Transformer (contd)
Note the coupled output
choke, L3.

Xfmr

CR2

L3a

CR3

Windings must have same turns

ratios as transformer, which is
the same as output voltages plus
diode drops of CR3 and CR5.

CR4

+ Bus

L3b
C6

CR5

Q2

+
12 V, 3 A
-

C5

+
5 V, 10 A
-

+ Bus
Return

With output chokes in continuous conduction, each output

voltage is the average of its secondary voltage (neglecting
diode drops).
Therefore, each output voltage is its secondary peak voltage
times the duty ratio of the primary bus voltage, +Bus,
(neglecting diode drops and Q2s conduction voltage).
43

Output Circuits
Popular configuration for
these voltages---two
secondaries, with a lower
voltage output derived
from the 5 V output using
a mag amp postregulator.

CR2
From 12 V
secondary

CR3
CR4

From 5 V
secondary

CR5
SR1
CR8

CR6
CR7

L3a
+
C5
L3b
C6
L4
C7

12 V, 3 A
+
5 V, 10 A
+
3.3 V, 5 A
-

Mag
Amp
Reset

Feedback to primary PWM is usually from the 5 V

output, leaving the +12 V output quasi-regulated.
44

Review of Some Magnetic

Concepts

45

Material Characteristics
B
flux density in tesla (1 tesla = 10,000 gauss)
Slope = B/H = = permeability

H
magnetic field strength in ampere turns / meter

Bulk property of the material

H = NI/le = ampere turns per meter
Classic definition is amperes per meter (assumes only one
turn)
le = magnetic path length

= permeability, usually relative to air (air = 4

10-7 H/m)

46

Core Characteristics

flux in webers (1 weber = 1 tesla square meter)

Slope = /F = P = permeance
"Inductance Factor" in H / t 2

F
magnetomotive force in ampere turns

Core with no winding (but has physical size).

Material characteristics, with Ae and le added.
Ae = core area, le = effective magnetic path length
Common unit for the slope is Inductance Factor, usually given in
nH / t2
47

Wound Coil Characteristics

flux turns in weber turns = volt seconds

Slope = L = inductance (henries)

I
current in amperes

Using volt-seconds and amperes, the wound

component can be analyzed easily by circuit
engineers using time-domain analysis.
48

The Transformer Equation

E
= 4 B Ae f
N
Bmax in tesla, Ae in m2, f in Hz
Modern SI units

OR:

E
= 4 B Ae f 10 8
N
Bmax in gauss, Ae in cm2, f in Hz
Medieval cgs units

Where did this mess come from, anyway?

49

Watch closely, now:

Transformer Equation from Faradays Law
E=N
B
B

= B Ae

t
= B Ae = 2 B Ae

1
1 1
t = T =
2
2 f

Finally:

E
1
=
= 2 B Ae 1 = 4 B Ae f
N
t
2f

50

An Extremely Important Fact

E
= 4 B Ae f
=
N
t
Unless the flux is changing, there will be no voltage.
If the flux swings back and forth, so will the voltage.
In order for there to be a net dc voltage, the flux must
be continually increasing.
Therefore, our chances of inventing a magnetic rectifier
are ZERO.
The average voltage (dc) across a winding (neglecting
winding resistance) is ALWAYS ZERO. This is one of
the most useful facts in our bag of tools.
51

Input Filter Design

Beginning at the input (left) side:
F2 required for many medical designs

Input Filter
F1
L
T1

C1

L1

AC
TO
RECTIFIER

RV1 is an MOV transient

suppressor
T1 design follows:
T1 is the common-mode inductor (note the polarity marks)
Theoretically, no amount of input current should saturate it,
because the ampere-turns cancel. Not entirely true!
G

RV1

C3

C2

F2

Coupling isnt perfect, so expect around 1% leakage inductance

(depends on the winding structure).

C1 and C2 are the capacitors to ground (Y capacitors), and

their value is limited by the allowable input leakage current
per the safety standard for the product.
52

Common-Mode Filter Section

Each coil has N turns
T1

L = N2 AL

C1

C1 // C2

C2
LISN
50

I IN

Z1

Z2

I1

SMPS
NOISE

I2

View this as a single-stage LC

filter

I1 Z 2
=
I 2 Z1

Noise current will divide per Z1 & Z2

Z2 is constrained by allowable leakage
current

(assumes Z1 >> Z2)

53

Differential-Mode Filter Section

Each coil has N turns
L = 4 N2 AL

L1

C1

C3

C3

C2

LISN
50

I IN

Z1

I1

Z2

SMPS
NOISE

I2

As before, view this as a single-stage LC filter

Noise current will divide:
(assumes Z1 >> Z2)
Z2 is not constrained by allowable leakage current.
54

Power Factor Correction

Power Factor (PF) is a term describing the input
characteristic of an electrical appliance that is powered by
alternating current (ac).
It is the ratio of real power to apparent power or:

PF =

Preal
(v i )averaged over one cycle
=
Papparent
Vrms Irms

Where v and i are instantaneous values of voltage and

current, and rms indicates the root-mean-squared value of
the voltage or current. The apparent power (Vrms x Irms),
in effect, limits the available output power.
55

What About IEC 1000-3-2?

It applies in most European countries (CENELEC members),
and was modified in January, 2001, by Amendment 14.
It poses limits on the harmonic content of input current of
various classes of electrical equipment with input power of 75 W
or greater.
Class D, which contains stringent limits for low-power
equipment (75 W and greater) no longer applies to anything
except personal computers, monitors, and TV receivers, per
Amendment 14. This is good news for many manufacturers!
Most of our applications are regulated by Class A, which applies
between 75 W and 16 A. Its limits are fixed, with the values that
applied in Class D at 600 W. Below 600 W, were getting a
break!
Bottom line: It may turn out that non-PFC-input power supplies
are now in conformance, where in the past they werent.
56

Power Factor Correction

Ideally, power factor is 1.00; the input current
waveshape (lower trace) matches the voltage
waveshape (upper trace) and is in phase with it
(not displaced to the left or right).
100%
80%
60%
40%
20%
0%

1>

9 11 13 15 17 19 21

Harmonic Number
2>

1) CH1:
2) CH2:

1 00 V 5 ms
2 A 5 ms

Also, the input current harmonics

are near zero (harmonic #1 is the
Fundamental frequency).
57

Power Factor Correction

In order to meet international standards, and from
a practical standpoint, it isnt necessary to do a
perfect job of shaping the input current. Quasi
PFC (found in some present products in the 60 to
120 watt range) meets the standards without the
cost of near-perfect PFC.
100.00%
80.00%
60.00%
40.00%
20.00%
0.00%

1>

9 11 13 15 17 19 21

Harmonic Number

2>

1) CH1:
2) CH2:

2 00 V 5 ms
1 A 5 ms

Here, the 3rd and 5th harmonics are

noticeable, but well within limits.
58

Power Factor Correction

Heres the input current of a power supply without
PFC. The current is concentrated at the peak of the
voltage waveform, where the input rectifier conducts
to charge the input energy-storage capacitor.
100.00%
80.00%
60.00%
40.00%
20.00%
0.00%

1>

2>

9 11 13 15 17 19 21

Harmonic Number

1) CH1:
2) CH2:

2 00 V 5 ms
2 A 5 ms

In this case the harmonics are huge,

because much of the power is concentrated
in a short period of time in each cycle.
59

Power Factor Correction

The rms value of this current is much higher than that
of a pure sine wave with the same average value, due to
the instantaneous value for each small element is
squared before the result is averaged and the square
root is taken. The rms value is what heats up the wiring
to the power supply and is what the power generation
plant must be designed for.
Because power factor and
input harmonics are closely
related, the harmonic content
is a common way to express
these limits. The power factor
of this power supply is about
0.6. This is acceptable in
low-power applications.

1>

2>

1) CH1:
2) CH2:

1) CH1:
2) CH2:

2 00 V 5 ms
2 A 5 ms

2 00 V 5 ms
2 A 5 ms

60

The Mag Amp Output

L3a

CR2
From 12 V
secondary

CR3
From 5 V
secondary CR4

20 V
0
d = 0.27

20 V
0

L3b

CR5

Leading edge
delayed by
SR1

SR1
CR8

12 V, 3 A
-

C5

L4

CR6
CR7

+
5 V, 10 A
-

C6

+
3.3 V, 5 A
-

C7

Mag
Amp
Reset

d = 0.185

Saturable reactor SR1 has very high impedance until

it saturates; then it is practically a short circuit.
The time it takes to saturate after the input pulse is
applied depends on the amount of reset volt-seconds
61
applied during the previous half-cycle.

More Details of the Mag Amp

d = 0.27

(volt-seconds)

20 V
0

SR1
L4

CR6
CR8

20 V
0
d = 0.185

CR7 C7

+
3.3 V, 5 A
-

Mag
Amp
Reset

The mag amp reset circuit compares the output to a reference,

then delivers current (or voltage) to SR1 via CR8.
The reset current pulls up on the output side of SR1, inducing
a reset voltage across it. This voltage, multiplied by the width
of the negative pulse, is the volt-second reset, (lambda), that
is blocked at the beginning of the next pulse.
62

The Reset Circuit

SR1
L4

CR6
CR8

CR7 C7

+
3.3 V, 5 A
-

Mag
Amp
Reset

The reset circuit can provide either voltage reset or

current reset. The only difference is the output of
the reset block, either a voltage source or a current
source (most popular and easiest to implement).
This example shows reset being accomplished on
the only winding of the reactor. However, an
additional winding can be used for reset. This
allows many other circuit configurations.

63

Reset Circuit (contd.)

3.3 V Output

CR8

R1
24

R2
620

R4
2.05 k

R3
1.3 k

CR9

TLV431
(1.25 V)

R5
1.25 k
3.3 V Return

These are typical circuit values of the reset circuit.

The purpose of CR9 is to keep the reset transistor from
saturating when CR8 is not conducting.
R24 is added to make the circuit more independent of the
transistor characteristics.
64

Typical PS With Active PFC

Output Capacitors
Output Smoothing Chokes

5 & 12 V Choke

3.3 V Choke
Bias
Transformer
(+5 V SB)

Output Heat Sink

3.3 V
Mag Amp

Bus Capacitor

Main
Transformer
PFC Heat Sink

Diff.-Mode
Choke

Common-Mode
Choke

Rectifier
PFC Inductor

PFC & Converter

Controller
65

Fan & Input Filter

Input EMI Filter

(First Stage)
Safety Ground
Connections to
Chassis

Ac Input
Connector
66

EMI Filter, Rectifier, PFC Choke

Input Rectifier

PFC & Forward

Converter
Control Board

Input
DifferentialMode Choke

PFC Choke

Input CommonMode Choke

Y Capacitors
From Each Side of
Line to Chassis

Bus Capacitor
(Film)

67

Side View
Bias Transformer in Front
+12 V & +5 V
Output Choke

Input Rectifier
Bridge
Input CommonMode Choke

Input
DifferentialMode choke
Bias
Transformer

Inrush Current Limiting

Thermistor

68

Side View
PFC & PFC Controller at Left
Main Transformer in Center

PFC & PWM

Combo
Controller
Main (Forward
Converter) FET

Output
Smoothing
Choke
Main
Transformer

3.3 V Mag Amp

3.3 V Choke
69

Passive PFC

Here, the PFC circuit has been replaced by a linefrequency inductor. Its big, heavy, and cheap.
70

Passive PFC Circuit Details

.01
.0047

Inrush Current
Limiter
(Thermistor)

PFC Inductor
470
.022

0.1
1M

DifferentialMode
Inductor
(L2)

325 Vdc
to
Forward
Converter

230 Vac
0.22

CommonMode
Inductor
(L3)

115 Vac

.022

470

.0047

PFC inductor smoothes the input current, reducing harmonics.

On the 115 Vac range the right side of the PFC inductor and the left side of
the bridge rectifier carry no current, and the right side of the bridge functions
as a half-wave doubler to produce 325 Vdc.
On the 230 Vac range the entire PFC inductor conducts, and the four-diode
bridge functions as a full-wave rectifier, again producing 325 Vdc.
71

Printed Wiring Board (PWB)

Typical ATX supply with Active PFC
Primary-Secondary
Safety spacing (8 mm).
Slots to increase
creepage distance.
Surface-mount resistors
Surface-mount capacitors
Copper reinforced with
solder to carry more
current.
Chassis ground
connection (here and at
opposite corner).
Primary side

Secondary side
72

Input Current Shaping

4>

1>

2>
3>

CH1:
CH2:
CH3:
CH4:

5A 2.5 ms
5 A 2.5 ms
5 A 2.5 ms
200 Volt 2.5 ms

Top (Ch 4): Input voltage, 230 Vac (325 Vpk)

Ch 1: Input current, Power Win (no PFC)
Ch 2: Input current, Seasonic with passive PFC
Ch 3. Input current, Seasonic with active PFC
73

Boost PFC Circuit Performance

1>

2>

1) Rectifier Output: 50 Volt 2.5 ms

2) PFC Output: 50 Volt 2.5 ms

Rectifier output is fed to the input of the PFC Inductor.

Output (380 Vdc) is fed to the power converter.
Note minor ripple on the 380 V at 120 Hz.
74

PFC Voltage and Current

2>

1>

1) Voltage on PFC Cur. Sense Resistor: 500 mVolt 2.5 us

2) PFC FET Drain Voltage: 100 Volt 2.5 us

Upper trace shows PFC boost FET voltage.

Lower trace is current in return (same as current in
the PFC inductor). Downslope indicates
increasing current, due to the polarity of sensing.
75

Standby Power Converter

2>

1) CH1:
1 > 2) CH2:

100 Volt 2.5 us

10 Volt 2.5 us

Ch. 1 (lower trace) is FET drain voltage.

Ch. 2 (upper trace) is secondary waveform.
This is a flyback converter to provide +5 VSB @ 1.5 A.
When FET is on (voltage is near zero), Secondary is off.
When FET is off, secondary is approx. +6 V.
76

Main Converter FET Waveforms

1>

2>

1) FET current (0.22 ohm sense res.): 500 mVolt 2.5 us

2) FET drain voltage: 200 Volt 2.5 us

Top trace is FET current, measured across the 0.22

ohm source resistor.
Lower trace is the FET drain voltage at 200 V/div.
This is a single-FET forward converter.

77

Main Converter Waveforms

1>

2>

1) 5 V secondary: 20 Volt 2.5 us

2) Primary FET drain voltage: 200 Volt 2.5 us

Operation of the forward converter transformer:

Lower trace is FET drain voltage (800 V peak).
Upper trace is 5 V secondary (approx. 22 V peak).
78

5 V Rectifier Waveforms
2>

1>

1) 5 V secondary voltage: 20 Volt 2.5 us

2) 5 V rectifier output: 20 Volt 2.5 us

Lower trace is the secondary voltage, appearing at the

input to the series rectifier diode.
Upper trace is at the diodes cathodes (input to the filter
inductor). The average of this waveform is 5 Vdc.
79

3.3 V Mag Amp Waveforms

3>

2>

1>

1) 5 V secondary voltage: 20 Volt 2.5 us

2) 3.3 V mag amp inductor (output side): 20 Volt 2.5 us
3) 3.3 V mag amp rectifier output: 20 Volt 2.5 us

Lower trace is the 5 V secondary. This is connected to the input

of the 3.3 V mag amp.
Center trace is the output side of the mag amp. Note the reduced
negative amplitude, due to the applied reset.
Top trace is the output of the 3.3 V rectifier. Average is 3.3 Vdc.
80

Review (PS With Active PFC)

Output Capacitors
Output Smoothing Chokes

5 & 12 V Choke

3.3 V Choke
Bias
Transformer
(+5 V SB)

Output Heat Sink

3.3 V
Mag Amp

Bus Capacitor

Main
Transformer
PFC Heat Sink

Diff.-Mode
Choke

Common-Mode
Choke

Rectifier
PFC Inductor

PFC & Converter

Controller
81

I hope youve enjoyed

Inside the Power Supply!

Chuck Mullett
ON Semiconductor
[email protected]
(805 933-4607)
82