I would be grateful for a professional translation or correction of the following text.

Please E-Mail
to Delta Lima 2 Yankie Echo Oscar @ Queen Romeo Papa 4 Uniform .Delta Echo

13.8 V / 15 A from a PC Power Supply

Safety Instructions

Caution mortal danger: The following circuit operates at a mains voltage of 230
Vac. Because of rectification some of the components conduct dc voltage of
more than 322 V. Work has to be carried out only if the circuit is disconnected
from the mains and de-energized. Note that capacitors located to the primary
side can be charged with high voltage for 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 alternative
solution, I decided to use a switch mode power supply (SMPS). The efficiency of
such power supplies is around 70 % to 90 % at a power density of 0.2 W / cm³.
Because homebrewing was out of the question due to lack of time, I tried the
modification of a PC switch mode power supply. The later are mass-produced
goods and available for less than 50 DM.

Fig.1: Block diagram of a primary switching power supply

Brief description of PC SMPS Features

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

Fig.2: Half-bridge configuration of power switches

Regulation

After switching on the mains voltage the circuit operates for a short duration as a
free-running oscillator. This behavior is caused by a feedback winding at the
output transformer T2. As soon as the auxiliary voltage Uaux is present the pulse
width modulator IC TL494CN from Texas-Instruments takes over the control
function and synchronizes the "oscillator".
The error amplifier in the TL494 compares the voltage at the +5 V output (actual
value) with a reference voltage (set value), calculates the analogue control
variable according to the PI algorithm and adjusts the pulse width modulator (see
Fig. 6). The modulator sends alternate pulses to the driver transistors Q5 and
Q6. The pulse duration is reverse proportional to the control variable rating.
Increasing loading on the +5 V output makes for wider pulses, lighter loading
causes narrower pulses. As there is a finite minimum pulse width, a minimum
load of 0.1 A is required. Without this load the power supply may be destroyed.
The switching frequency is approx. 33 kHz as usual for PC power supplies. It is
defined by a resistor and a capacitor located at pin 5 and 6 of IC1.
Fig. 3: Primary side mains filter, rectifier, power switches and drivers

Monitoring Circuit

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

Mods to the Secondary Rectification

The intent is for all of the available power at the 12 V secondary of T1 to be

rectified, regulated, protected and filtered to provide a 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.
First unsolder and remove all components on the secondary side of T1 which are
provided for rectification, filtering and regulation of the four output voltages. On
that part of the board are only remaining three RC members RC1 to RC3 and the
components for providing the auxiliary power supply Uaux.
Fig.4: Secondary rectification as found in the original PC power supply

Reconstruction of the secondary side.

Break the PCB tracks between the RC members RC1 / RC2

and both 5 V taps of the T1 secondary winding.
Modify L4 for 12 V at 20 A. Remove windings L4a, L4b and
L4c from the toroid (counting turns of L4c). Rewind the toroid
L4* with a single winding, turn count as old L4c but with 2.5
times the thickness. Take two wires with 1 mm diameter
each, bifilar wounded.
Install two low ESR electrolytic capacitors of 2200 uF each
and the 100 Ohm bleeder resistor as permanent load.
Use the old PCB tracks from the +5 V section and GND
tracks as terminals for L4* , the 100 Ohm resistor and the two
2200 uF capacitors. Insert L4* at the same place onto the
PCB component side where the L4b winding was connected
before.
The original cooling of the rectifier diode D5 is insufficient.
Adequate cooling is achieved by a finned heat sink
measuring 70 x 50 x 30 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 wires. Use isolation material and thermal
compound. D5 carries on some boards the abbreviation SKD.
Place the finned heat sink approx. 40 mm above the
"stripped" secondary (see photo) with plastic spacers and
long M3 screws (avoid short-circuit to common).
Connect the anode leads of D5a and D5b with one RC
member RC1 / RC2 each. The cathodes have to be
connected to the nodal point of RC1, RC2 and L4.
Establish two links between the 12 V terminals of T1 and the
RC members by two thick wires. D5 will be fed from the 12 V
winding.

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

Fig. 5: New designed secondary for Ua = 13,8 V

Mods to the Regulation and Protection Circuit

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

R24* is calculated for 13.8 V output voltage. The voltage at

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

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

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

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

Simplify the voltage divider (R36, R42, R45 and D14) in the
short-circuit protection circuit. For this remove R36 and D14.
Connect the free end of R42 to common (GND) and replace
R45 with one of higher value to ensure no shut-down at
normal operation. The voltage across R42 must be less than
1,7 V (I chose 1,2 V).
R45* = 15 kOhm

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

Fig. 6: Regulation and protection circuits incl. all modifications

Further Modifications

After commissioning the modified board, the situation regarding to interferences

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

Insert an additional 230V / 2A mains filter to the primary side,

close to the place where the mains cable enters the
enclosure rear wall.
Insert a 20 A pi-filter to the DC output , behind the +/- DC
terminals at the rear wall.
The power supply enclosure must absolutely consist of iron
sheet metal to screen magnetic fields. Aluminum plates
protect only against electrical fields.
Optional on the primary: Replace the 220 uF smoothing
capacitors C1 and C2 by 470 uF capacitors. This reduces
primary ripple, which helps output regulation at full load.

Testing the Power Supply

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

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

Fig. 7: Signal shape at TP1 and TP2

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

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

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

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

off

Cooling of the switching transistors Q1 and Q 2 at a continuos current of 15 A

has to be improved in any case. When exchanging the small heat sinks, note that
they form an electrical connection between coper tracks on some boards.
Replace the missing connection by wire links. As one can see on the photo, I did
not taken this measures for further power improvement.

Operation Experience

The modified board was permanently installed in the speaker cabinet SP120 that
matches my transceiver. The mains lead exit from its back, which also carries the
DC terminals, an on-off switch, the additional mains filter and a small 12 V
blower. A green LED power-on indicator was inserted in the front panel into a 5
mm hole drill. I had installed the small blower just in case, but found it
superfluous; at the low duty cycle of CW and SSB, none of the components is
getting hot. The power supply has been used for several years and has given no
problems.
Fig. 8: Modified power supply board in the SP120 speaker cabinet

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I would be grateful for a professional translation or correction of the following text. Please E-Mail
to Delta Lima 2 Yankie Echo Oscar @ Queen Romeo Papa 4 Uniform .Delta Echo

250 W S.M.P.S. with Power FETs

Safety Instructions

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

Experiments with the PC power supply encouraged me to an "advancement "

design. The new power supply is also a forward converter with a half-bridge
topology. The difference to the modified PC power supply consists in the
following items: Two power FETs instead of bipolar transistors used as power
switches, a synchronous rectifier on the secondary side instead of power diodes,
the lack of a driver stage (current-proportional control) and a more simple over-
current and over-voltage monitor. With the magnetic components (output
transformer, driver transformer, chokes...) stripped from a PC power supply, the
new power supply delivers a max. power output of 250 W, whereby the efficiency
amounts up to 90 %. The power supply can handle 20 % over-load for a short
duration.

Magnetic components from a PC power supply

The magnetic components of PC power supplies for AT boards do not indicate

large differences. They are usually designed for a switching frequency of 25... 40
kHz and a power output of 200... 240 W. The transformers on the S.M.P.S circuit
boards are to be found often in a small or somewhat larger size. I am not able to
say, whether the larger size brings more power or if it is only an older design. For
the new power supply I preferred the larger transformers, because of more space
for additional turns available at all three transformers. The smaller transformers
are completely filled with copper and isolation material and therefore only
conditionally suitable for a modification.

Fig. 1: Transformers from the PC power supply

Mains rectifier and filter

This circuit section is uncomplicated. The current compensated choke Dr1

(mains filter) is followed by a NTC resistor for limiting the inrush current. Its cold
resistance amounts to 5 ohms and after few minutes the warm resistance is less
than one ohm. The 230 Vac rectifier is generously dimensioned with 4 A and
hence no cooling is necessary. A criterion for the selection of the capacity of C3
and C4 is the height of the admissible ripple voltage Ubr and the number of
mains voltage half waves to be bridged. For Ubr = 25 V and zero half waves two
470 uF capacitors in series are sufficient. This specification applies to maximum
load during low mains voltage Umin = 230 Vac - 15%
Fig. 2: Filter, rectifier and power switches

Power switches

As power switches FETs were used due to their short rise and fall times and the
easy, component-saving driver circuit. If one is content with switching times of
100 ns, a small driver transformer and two gate resistances are sufficient for
triggering the FETs. Re-dimensioning of the secondary winding for the supply of
the gate voltage is not to be gone around unfortunately. The single turn and 2 x 8
turns must be removed from transformer Tr4. Instead of this 2 x 16 turns (bifilar)
have to be applied. With a winding ratio of 16 : 26 and a 20 Vs control signal from
IC1 the FETs gate voltage is up to 10 V high. With this voltage one achieves the
indicated FETs Ron of 0,75 ohms and thus very small conduction losses.
Dynamic (switching) losses at 50 kHz and the before mentioned switching times
assume negligible. The PWM IC drives enough current for fast on /off switching
the FETs. Increasing the switching frequency from before 33 kHz (PC power
supply) to 50 kHz (new power supply) allows to transfer more energy via the
transformer. You can not increase the latter with a given transformer whatever
you like, since the transformer is usable for a certain frequency range only.
Attempts showed that the transformer can cope with the factor 1.5 without
problems (overheating).

Control circuit

After switching on the 230 Vac mains voltage an auxiliary voltage is available
from the small 50 Hz transformer Tr1 for starting up the PWM controller SG3525.
The P acting operation amplifiers in the SG3525 compares a portion of the 13,8
output voltage (actual value) with the internal +5,1 V reference voltage (set value)
and forms from it the correction variable for the pulse width modulator. The
modulator sends alternate control pulses via its two outputs to the transformer
Tr4. The pulse duration is reciprocal to the correcting variable. Increased loading
to the +13.8 V output makes for wider pulses, lighter loading causes narrower
pulses. The switching frequency of the power switches is 50 kHz. For higher
frequencies the FETs are usable but not the magnetic components that were
taken over by the PC power supply. The oscillator frequency is determined by the
components attached to pin 5 and 6. R14 determines the dead time, which is
absolutely necessary to avoid two switching transistors conduct at the same time.
Due to the not present storage time for FETs a very small value could be set.
With 1 us deadtime and 20 us period duration the FETs can theoretically lead
current for 95 % of the time and thus deliver energy to the output. Charging C13
after switching on causes a soft start with narrow pulse first and wider control
pulses afterwards. Terminal (a) of the driver transformer Tr4 remains free. Only
one half (26 t) of the primary turns (b - c) and the 16 turns of the secondary
winding are sufficient to form the necessary ratio of 0,6.

Fig. 3: PWM control and monitoring

Monitoring functions

Two protection circuits are included in the new power supply. The transformer Tr2
is used as current detector and produces at R16 a voltage that is proportional to
the current flow through the power switches. If the voltage at the shutdown pin 10
exceeds the limit value adjustable with P1, the control IC switches off
immediately and restarts after a short duration. The reason for this is usually a
too high current at the secondary side of the power transformer, caused by a
short-circuit or an overload to the output. The load and the circuit itself are
likewise protected from overvoltage at the Vo output. The SG3525 switches off at
Vo > 15 V. Note: Both protection circuits are ineffective if the slider of P1 is
adjusted to Gnd potential.

Synchronous rectifier

One must deal with a power dissipation up to 17 W at 18 A output current when

using a rectifier with fast recovery diodes. With a 30 A / 45 V Schottky diode the
looses are 12 W nevertheless. This rate forms the highest proportion referring of
the total losses. The losses at the mains rectifier, power switches, transformers
and the output choke are together below this value.

An improvement brings here a semi synchronous rectifier with two low

impedance power FETs. FETs with a low Ron of e.g. 15 mOhm have only a
voltage drop of 0,3 V at 18 A during the conduction phase. Good Schottky diodes
are rated at 0,6 V. In the literature however with push-pull topology such circuits
are advised against. As reason it is indicated that the choke current flows in
opposite direction (revers mode) through the parasitical body diodes of the FETs
as long as they are in the off state. High switching losses occur due to the
storage charge of the body diodes which has to be removed first during the
transition to the normal operation. This looses destroy the benefits achieved
during the conduction phase.

The following circuit avoids this disadvantage, since the body diodes do not
operate in the reverse mode. The free wheeling diode D3 takes over choke
current since it has a substantially smaller forward on voltage Uf compared to the
FETs body diode. D3 is from Schottky type and is arranged before the choke Dr2.
The diode does not have a storage charge and thus switching on/off is extremely
fast combined with low losses. It was removed once for by way of trial. The FETs
heat sink warmed up thereupon by around +10 °C, although the body diode of
the used IRFZ44 has already a very good trr (reverse recovery time) of 47 ns.

With a typical duty cycle of 57 % the losses in the two FETs make together 3.6
W. The free wheeling diode D3 is conducting for the remaining time and
produces 4.6 W. Less than 8.2 W can only be attained, if one replaces the free
wheeling diode also by a FET. Since triggering this FET is more complex than
from VT3 and VT4, I did without this measure. A second reason is that with mains
undervoltage or high output current the switch-on time of VT3/4 and not the
switch-on time of D3 rise.
Fig. 4: Synchronous rectifier

Construction and alignment

For the power supply assembly a glass epoxy circuit board with the dimensions
82 x 122 mm is needed. One should not use another material. It applies to fasten
relatively heavy components and realize copper tracks that are able to carry high
current. The components for regulation and monitoring are mounted on a small
strip board. Sorry, but I was too lazy to design a PCB layout for this circuit part.
Fig.5: PCB layout (1:1) and assembly

For the interconnection of the components for regulation and monitoring a 40 x

45 mm small strip-board is sufficient. The copper tracks (pink) are to be removed
in the indicated places. A wood or a metal drill with a diameter from 3 to 4 mm is
suited best tool for this work. Cable links are drawn in as broken lines. They are
forgotten fast with the assembly. The same applies to the horizontal ground
potential bar within the upper area of the strip-board that distributes Gnd potential
onto the vertical copper tracks.
Fig.6: View to the strip-board soldering side (2:1)
Fig. 7: View to the strip-board component side (2:1)

Transformers

The following drawing shows the transformers stripped from a PC switching

power supply. The data were determined so far as possible by measurements,
counting turns and calculations.

Before using the transformers it has to be checked exactly whether the size,
number of layers, wire size, number of turns and phasing correspond to the
specification in the drawing and the photos. If doubts exist in the matching, the
transformers should better not be used.
Fig. 8: PC transformers and modifications

Heat sinks

At the heat sinks is nothing special. They are manufactured from an approx. 1
mm thick aluminum plate. VT1 and VT2 are to be fastened isolated on the first
heat sink. The FETs may not have a electrical connection against each other and
against the heat sink. With professional assembling of the transistors touching
the heat sink is without danger. On the secondary side it is somewhat simpler.
VT3, VT4 and D3 carry no dangerous voltage and need thus no isolation for this
reason. Because of the FETs case and the Schottky diodes case have the same
potential, there is no objection against mounting all three components directly
onto the second heat sink. It is to be made certain however that there is not
electrical connection between the heat sink itself and the power supply housing
or electrical components.

Fig.9: Heat sink drawings

Parts list (1)

Resistors, capacitors and semi conductors

Parts No. Value

R1, 2 120 kOhm, 0,5 W
R3 100 Ohm , 2 W
R4, 5, 9 1 kOhm
R6 10 Ohm, 2 W
R7, 10 10 kOhm
R8 1,5 KOhm + 150 Ohm
R11 5,6 kOhm
R12, 13, 14 47 Ohm
R15, 16 150 Ohm
P1 10 kOhm trimming pot, 10 turns
NTC Heissleiter, 5 Ohm at 25 °C
C1, 2 0,1 uF 250 Vac
C3, 4 470 uF 200 V, 22 x 36 mm (diam. , H)
C5, 15 2,2 nF
C6 1 uF, 250 Vac
C9, 10 2200 uF, 35 V low ESR, 16 x 34 mm (Diam., H)
C7 100 µF, 35 V
C8, C20 10 nF
C11,12 0,22 µF
C13 10 uF, 25 V
C14 2,2 nF Styroflex
C16 2,2 uF
C17, 18, 19 0,047 uF
D1, 2 PXPR1507 etc. fast 200 V / 1A diode
D3 MBR3045, 30 A / 45 V Schottky diode
D4, 5, 6 BAT 46
D7 Zener diode, 13 V / 0,5 W
D8 1N4148
VT1, 2 IRF730
VT3, 4 IRFZ44N
IC1 SG3525A
Gl1 Rectifier bridge, dual in-line B40C800 DIP
Gl2 Rectifier bridge 400 V / 4 A

Parts list (2)

Transformers, chokes and miscellaneous

Parts No. Value

0,5 W print transformer EE20/10, 15 Vac at 34
Tr1 mA,
24 x 32 mm (Reichelt/Conrad)
16 x 15 x 5 mm (W,H,D)
Tr2 1 Wdg. prim.
2x 100 turns sec.
 40 x 35 x 12 mm (W,H,D) e.g. Tokin 25812 or.
25801
2x 20 turns prim. (L = 7 mH between a <=> c)
Tr3 2x (3 + 4) turns sec. (L = 200 uH between d <=>
f or d* <=> f*)
2x 4 turns sec. auxiliary winding for driving
VT3/4
22 x 19 x 6 mm (W,H,D)
Tr4 2x 26 turns. prim.
2x 16 turns. sec.
Dr1 current compensated 2A mains voltage choke
20 uH, T26-106 (yel. / white), 16 turns. 2x 1 mm
Cu wires in parallel
Dr2
better Magnetics Kool 259-77934-A7, 20 turns.
2x1 mm Cu wires in parallel
Additional
general purpose 230 V / 2 A
mains filter
Si 3,15 AT fuse, slow blow
PS Two pole mains switch
PCB, heat sinks, isolation material, heat sink
Miscellaneous
compounder etc.

The grey marked cells indicate the components, which can be taken over by a
PC power supply. The electrical data must be compared before using them and
the indicated modifications have to be executed.

Testing the power supply

I urgently advise against immediate connection to 230 Vac. Testing of the new
power supply should take place in several test phases for safety reasons and for
the avoidance of component destruction. The high voltage causes an immediate
destruction of the components in the case of an error in the circuit.

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

off.

Phase 1:The first test applies to the PWM-IC and the power switch control. For
running the PWM-IC a lab power supply adjusted to 24 Vdc must be attached to
Gnd and the positive plate of C7 (Vx). After switching on the the IC generates
sharply rising and falling control pulses with maximum pulse duration at the
output pins 11 and 14. With an oscilloscope measured signals at the gate of VT2
(VT1) must look like the one shown in figure 9. It is very important that the
signals have the indicated shape, voltage and frequency. The signals at the gates
must be further in opposite phase against each other. Otherwise, both FETs
would conduct at the same time and produce a short-circuit when later applying
supply voltage .

Fig. 9: VT2 (VT1) gate-source voltage

Phase 2: Now, connect three car light bulbs (12 V / 21 W) to the 13,8 V output
terminals. A 48 V / 1 A mains transformer feeds the S.M.P.S. via the L1 and N
terminal with a galvanical isolated Ac voltage. The + 24 Vdc lab supply is still
connected during this test. 60 Vdc at C3 / C4 is in Europe defined as a non-
dangerous voltage rate. At this voltage rate the switching transistors can start
operating and one can perform test without danger. For measurements with a
dual-channel oscilloscope Gnd from the secondary section has to be connected
temporary to the (Y) test point of the primary section with a wire link. The bulbs
glow at Vout = 4,3 Vdc if everything is right. Rectification is executed by the FETs
body diodes only, because the VT3 and VT4 gate-source voltage is not high
enough to switch on the FET. The PWM controller tries to offer 13,8 V at the
output at maximum pulse duration. The later cannot be successful due to the low
60 Vdc input voltage and the present transformer ratio.
Fig. 10: Voltage at test point (X) against (Y) und cathode D3 against Gnd

Phase 3: If everything is all right up to now, one can proceed with the exciting
test at 230 Vac. The laboratory power supply, the 48 V transformer, the
measuring instruments and all provisional cable links attached for the test etc.
must obviously be removed. The three car bulbs are further needed as a load
and for the functional checks. If after applying of the 230 Vac mains voltage the
lamps light up brightly, the output voltage amounts to 13.8 V and no undefined
noises or smells are noticeable one has won the first round. If a non recognizable
error has passed the pre-testing the two switching transistors and copper tracks
say good-bye with a more or less loud bang. With 5,7 A the duty cycle D = tp /
T = 5 us / 10 us is approximately 50 %.

Phase 4: For the following load test a dummy load is needed that can handle up
to 300 W. Because such high power resistors are not laying in the junk box and
purchasing them is very expensive, I took instead a 50 m a ring installation cable
(3 x 1.5 mm2) . An individual wire has a resistance 0.6 ohms and can dissipate
the mentioned watts without problems. Depending upon interconnection of the
three wires, load resistances of 0,6 / 1,2 and 1.8 ohms are realizable. By the
ampmeter impedance, including the appropriate measuring wires positioned in
series, the resistance value increases by approx. 0.1 ohms. At Vo = 13,8 V the
following table indicates the power output Po and the current Io as a function of
the loading.

Rl [Ohm] car bulbs Io [A] Po [W]

1x 12 V / 21
-/- 1,9 26
W
-/- 2x 12 V / 21 3,8 52
 W
3x 12 V / 21
-/- 5,7 78
W
1,8 + 0,1 -/- 7,26 100
1,2 + 0,1 -/- 10,6 146
2x 12V / 21 10,6 +
1,2 + 0,1 198
W 3,8
3x 12V / 21 10,6 +
1,2 + 0,1 224
W 5,7
0,6 + 0,1 -/- 19,7 270

Additional measures for RFI noise reduction

Experience during the PC power supply modification have shown that the filtering
on the PCB is not sufficient for amateur radio application. A pre-arranged general
purpose mains filter and a home made Pi filter direct to the 13,8 V output are
used for improved RF noise reduction. To favor of the control loop stability the PI
filter voltage drop is not eliminated. Output voltage changes of several ten
millivolts at load changes have no importance for running a 100 W transceiver.
The additional filter have to be mounted inside the S.M.P.S. case very close to
the cable inlet and outlet.

Fig. 11: External components for RF noise reduction

Operation experiences

Up to 10 A continuous output current or operation with 50 % ESD and 18 A peek

current one can do without a fan if sufficient natural air flow is present and the
ambient temperature does not exceed 30 °C. A small CPU fan (40 x 40 mm)
should be used for more than 10 A continuous current. The heatsink surface is
not large enough to keep the FETs junction temperature below the limit value ( Tj
< 100 °C). With a CPU fan the heat sink temperature remains below 28 °C
(Tu = 20 °C). The following table shows the measured and calculated power
dissipation Pv of the basic components at 250 W output power.

Abbr. Parts Pv [W]

Gl2, Dr1 Mains rectifier and filter 2,5
VT1 4,0
Switching transistors
VT2 4,0
R3 / C5 Snubbers 1,5
Tr3 Output transformer 2,0
VT3 1,8
Synchronous rectifier
VT4 1,8
D3 Free wheeling diode 4,6
Dr2 Choke 2,0
IC1 PWM control circuit 1,0

Sum 25,2

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