Contents
- 1Introduction
- 1.1Packaging and accessories
- 2Connectors & cabling
- 2.1Casing & cooling
- 3Input filtering
- 4Primary side
- 4.1+5 V stand-by rail
- 5Secondary side
- 5.1Build quality
- 6Load testing
- 6.1Loading +5 V SB
- 6.2Combined loading
- 6.3Combined loading ripple
- 6.4Crossloading, overloading
- 6.5Crossloading, overloading ripple
- 7Conclusion and evaluation
- 7.1Thanks
Primary side
The primary side begins, as always, with a bridge rectifier, the GBU1006. It handles current of 10 A continuously/220 A surge (for 8.3 ms) at 800 V and 100 °C. Voltage drop is 1.1 V per diode (at 10 A). The rectifier also has its own small heatsink with some fins, black-coated aluminium. The transistors in PFC (boost-type) circuit are Infineon IPA50R190CE (18.5/63 A at 25 °C and 500 V, on resistance (Rds(On)) is 190 mΩ at 7.8 A and 25°C, 0.45 Ω at 150 °C) in TO-220F package. The power diode in PFC is an Infineon IDH06G65C5 (6 A continuously at 650 V and 145 °C, 48 A pulsed at 150 °C, voltage drop of 2.1 V at 6 A and 150 °C) in TO-220AC package. PFC coil has adequate size with thick enough wire used for winding. The component overrating is just about enough here though could be better for sure.
The capacitor charged by PFC circuit is Rubycon USG 390 μF/400 V for 85 °C (measures 344 μF). While 420V and 105°C part would be preferred, it at least has specified lifetime of 3000 hours at 85 °C. Switching transistors are two IPA50R280CE (13/42.9 A at 25 °C and 500 V, Rds(On) 280 mΩ at 4.2 A and 25 °C, 660 mΩ at 150 °C), mounted on the other side of common primary black heatsink in half-bridge configuration The PFC circuitry is driven by Infineon ICE3PCS01G controller located on the bottom side of the PCB, switching transistors by ICE2HS01G resonant LLC controller on a small daughterboard located on secondary side, in front of its heatsink. The supply for PFC controller is filtered by Chemi-Con KY 22/50 capacitor. The main transformer has 35mm wide core.
+5 V stand-by rail
The stand-by rail uses Sanken Electric STR-A6069H PWM controller with integrated transistor for 700 V. It is rated only for 10 W while the unit’s specification says 15 W output power so I am curious about the result. Its supply rail is filtered by another Chemi-Con KY 22/50.
Behind the 20mm transformer is a single rectifying diode in DO package and a filter consisting of two NCC KY 1000/10 capacitors. We’ll see if it can handle 15 watts…
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