Power supply build quality pictorial. part 2

[momaka]

Re: Zumax ZU550W (X3)

As you can imagine, the MOV is bad it reads 9.2Ω both ways. Looks like it did its job though. Safe to assume the BR is okay?

Now isn't that a relieve?
Personally, I dislike MOVs, especially in extension cords/surge protector combos - they can short out and start a fire, especially if your breaker doesn't trip.

As for the bridge rectifier - check it with a multimeter. In diode test mode, there should be a high voltage drop (or out-of-range) reading between the two AC legs. Same with (+) and (-) legs on the bridge rectifier.
...
Or just use the bulb trick - if something is wrong, it will stay lit.

[PeteS in CA]

Re: Power supply build quality pictorial. part 2

Boschert PS-9165 (from a Unisys S40DISK unit):

2x 220uF 200V Panasonic primary units.
2x 2200uF 16V Chemi-Con SXC before +5V inductor and 1000uF 25V Chemi-Con SXC after it.
680uF 16V Chemi-Con RX before +12V inductor and 470uF 25V Chemi-Con SXC after it.
220uF 25V Jamicon WG on -5V and -12V regulator inputs and 100uF 25V Jamicon WG at each negative regulator output.
Other electrolytic capacitors not mentioned are Nichicon and Chemi-Con.

MBR1645 +5V rectifer.
BYW29-150 +12V rectifier
1N5822 rectifier each before -5V and -12V regulators.
KBL04 input bridge rectifier
BUW12 primary switcher.

Boschert's mechanical designs and board layouts qualify as what Mrs. S in CA calls "Power Supply Porn" (what she says when she sees me looking at pix here). That looks like an XL5x variant, designed in the late 70s and early 80s. The basic design was used for models ranging from 20W up to 165W. BTW the topology is discontinuous flyback - the two-transistor design much disliked here - except Boschert's engineer did it well. I worked at the bench next to his, and did some performance verification testing for him.

[Pentium4]

Advanced electronics fx 500 lpz12-50

Came across an interesting PSU so I decided to post it. I think it's made by XHY Power? http://www.xhy-power.com.cn/ But it looks so similar to a KME I have. It uses PFC (kinda) for full range, I recapped that part first. That bigger caps' value is 4.7uF 400V originally Canicon, replaced with nichicon VC. No input filtering was installed except for those lousy "Y" caps that look damaged from the factory. I assume normal input filtering won't mess with that PFC circuit?
As you can see, it was designed for a normal PFC circuit

10A bridge, the two FET's on the primary are HFA9N90 rated for 9A each @ 25C and 5.7A @ 100C, combined with a TL3843P. The input caps are 1000uF 200V Fuhjyyu, they read 904uF and 909uF. 5VSB transistor is a Toshiba C5353 rated at 3A

The secondary looks pretty decent, with a huge heatsink, 30A (MOSPEC) schottky for 3.3V, two 40A (ST) schottky in parallel for 5V, and 30A (MOSPEC) schottky for 12V (All TO-247) Each rail has CLC, and the toroids look big. There are actually two 12V rails with OCP shunts, only the 12V CPU connector is on the first rail, and towards the end of the 4 pin plug, one of the wires is split into two wires going into the same pin. Controller is a PS222S https://cdn.badcaps-static.com/pdfs/...ec01b02f46.pdf

Soldering looks pretty good except for some big blobs.

Definitely going to fix this!


Let me know what you guys think.
EDIT: Cap brands used: Canicon, Fuhjyyu, Jun Fu, Forever, JUNZL, Asia'X, and EU CAP

[goodpsusearch]

Re: Power supply build quality pictorial. part 2

Wow! Definitely a keeper!

Soldering looks nice. Toroid coils are good.

The add on board could be automatic voltage selector pcb. If it were APFC it would have a toroid coil, a mosfet and a diode.

[Pentium4]

Re: Power supply build quality pictorial. part 2

Wow! Definitely a keeper!

Soldering looks nice. Toroid coils are good.

The add on board could be automatic voltage selector pcb. If it were APFC it would have a toroid coil, a mosfet and a diode.

It's definitely unique Yeah I didn't know what to refer to it as since it's not even like some of the piggyback PFC circuits you've posted here.

I looked at the soldering more carefully and even the -12V rail has a CLC filter. But here's the strange thing...see that little cap I circled? That's being used to filter the 5VSB!!!! It's branded Forever (no series) and only 100uF 16V. It read 108uF and 0.46Ω ESR. Seems perfectly in spec to me.

[c_hegge]

Re: Power supply build quality pictorial. part 2

Nice. Looks like it even has multi-rail OCP on the 12V side. I would use a larger 5vsb output cap than that if you can get one to fit, though.

[Pentium4]

Re: Power supply build quality pictorial. part 2

Nice. Looks like it even has multi-rail OCP on the 12V side. I would use a larger 5vsb output cap than that if you can get one to fit, though.

Awesome. I was thinking about adding another rectifier on the 12V but it looks like it'd be a tight squeeze between the transformer. Plus, what I'm probably going to use this for I doubt I'll need more than 30A on the 12V.

Yeah I'm going to try and fit a 1000uF 8mm Panny FR in there. I try to use lower ESR for the 5VSB

[Pentium4]

Re: Power supply build quality pictorial. part 2

I ended up replacing that 100uF 16V Forever cap with a 470uF 6.3V Chemi-con KZH. It's the best specced cap I could get to fit in that small space. I also did a full recap, fixed blobby/weak joints, and added a useful input filter consisting of two coils, 0.1uF & 0.47uF X caps, and two Y caps. I also made use of a crappy Leadman heatsink by cutting it and using it as a heatsink for the bridge rectifier I like how the BR is positioned because it allows for a decent sized heatsink. The thing seems to be efficient, testing with a 100W load it's kicking out room temperature air, and the fan is spinning very slow. I'm sure double forward and the huge heasinks have something to do with that.

I first tested this thing using a paperclip and since there are no minimum load resistors except on the 5VSB, every main rail was out of spec except the 3.3V (Which read 3.36V). The 5V read 5.73V, 12V read 13.33V

[Wester547]

Re: Power supply build quality pictorial. part 2

You can feel airflow from it when it's spinning that slowly? Looking at the HFA9N90 datasheet, they ("SemiHow" .... "Know-How for Semiconductor" ... ) seemed to have lifted the specifications straight from FQA9N90C's datasheet excepting the power dissipation limit (110W vs. 280W @ 25*C). Rather impressed that the bulk Fuhjyyu capacitors are in spec.

[Per Hansson]

Re: Power supply build quality pictorial. part 2

The add on board could be automatic voltage selector pcb. If it were APFC it would have a toroid coil, a mosfet and a diode.

That's the most beautiful thing I've seen!
Why has it not been a standard component in powersupplies for the last 50 years untill APFC was invented!?
I did not know that a relay like that even existed, never seen it before!

In 230v land the most fun thing for students in school has been to set the voltage doubler switch on "115v" when the machine is running.
I can tell you it is spectacular!

Pretty easy to see why: √2 * 230VAC = 325VDC
Now put that through the voltage doubler circuit by flipping the switch and you are feeding the main filter caps 650VDC!

[Behemot]

Re: Power supply build quality pictorial. part 2

Not only the caps, the whole primary side

[Per Hansson]

Re: Power supply build quality pictorial. part 2

Yes, but the capacitor is the most spectacular when it explodes from the high voltage

[Pentium4]

Re: Power supply build quality pictorial. part 2

You can feel airflow from it when it's spinning that slowly? Looking at the HFA9N90 datasheet, they ("SemiHow" .... "Know-How for Semiconductor" ... ) seemed to have lifted the specifications straight from FQA9N90C's datasheet excepting the power dissipation limit (110W vs. 280W @ 25*C). Rather impressed that the bulk Fuhjyyu capacitors are in spec.

Yeah I could feel the air coming out, barely. It has a restrictive exhaust grille compared to some, but has nice intake vents on the back.

That's the most beautiful thing I've seen!
Why has it not been a standard component in powersupplies for the last 50 years untill APFC was invented!?
I did not know that a relay like that even existed, never seen it before!

In 230v land the most fun thing for students in school has been to set the voltage doubler switch on "115v" when the machine is running.
I can tell you it is spectacular!

Pretty easy to see why: √2 * 230VAC = 325VDC
Now put that through the voltage doubler circuit by flipping the switch and you are feeding the main filter caps 650VDC!

I agree, mainly for the sake of people who don't know squat about PSU's

[momaka]

Re: Power supply build quality pictorial. part 2

But here's the strange thing...see that little cap I circled? That's being used to filter the 5VSB!!!! It's branded Forever (no series) and only 100uF 16V. It read 108uF and 0.46Ω ESR. Seems perfectly in spec to me.

Wow, only a 100 uF cap to filter the 5VSB rail?! Shame they did this on an otherwise such nice PSU. What is the bigger cap next to it for?

Glad you recapped it, it looks like a trustworthy PSU. Although, I should note that those twisted series resistors on the voltage switch board look funny. I wonder why they did it this way. Perhaps to use lower-wattage resistors in place of a bigger one? I only did that once in a CRT monitor when I just couldn't get the right resistance. Other than the looks, I guess it works fine .

That's the most beautiful thing I've seen!
Why has it not been a standard component in powersupplies for the last 50 years untill APFC was invented!?

Probably because it's more expensive.
Computers also weren't so user-friendly back in the days, so I guess no one cared.

In 230v land the most fun thing for students in school has been to set the voltage doubler switch on "115v" when the machine is running.

This couldn't happen if you bought cheap L&C, Hyena, and Premier PSUs with a "AC 230V only" sticker, though . Because, you know... a voltage selector switch costs money and ain't nobody got time to put that .

[kaboom]

Re: Power supply build quality pictorial. part 2

This couldn't happen if you bought cheap L&C, Hyena, and Premier PSUs with a "AC 230V only" sticker, though . Because, you know... a voltage selector switch costs money and ain't nobody got time to put that .

Or there's only a single cap after the rectifier taking the full ~340V, meaning no mid-point to even connect a voltage doubler selector switch.

I mean, if they're gonna be cheep, why stop at that switch?

Stickers are expen$ive, too- better to "be cheap" and leave the hole open. Shocks? Well, learn to keep ya fingers out!

[japlytic]

Re: Power supply build quality pictorial. part 2

Fuji Elecromechanical PTA465-00 (from an Advantest R4131A spectrum analyser - 1988 manufacture)

All electrolytic capacitors not specified are Nichicon VT.
220uF 50V Nichicon VT auxiliary supply filter.
470uF 200V Nichicon GK primary pair.
3300uF 10V Nichicon PF on +5V rail.
470uF 16V Nichicon PF (between +12V and +5V) and 470uF 25V Nichicon PF on +12V rail.
470uF 25V Nichicon PF on -15V rail.
680uF 25V Nichicon PF on +15V rail.
330uF 50V Nichicon PF before +15V and -15V regultor transistors.
47uF 63V Nichicon VT for soft starting/bypass on +15V and -15V regulators.

C6P20F rectifiers for +15V and -15V rails before regulators.
C10P040 rectifiers for +5V and +12V rails.
D5SB60 input bridge rectifier.
2SD717 regulators for +15V and -15V rails.
2SK794 primary switcher with 2SC3160 auxiliary supply switcher.

Just about all of the electrolytic capcitors were bulging and/or leaking, and it appears that this unit has had a hard life.

[japlytic]

Re: Power supply build quality pictorial. part 2

Seasonic SSA-4065K

1000uF 10V Rubycon YXB x3 before +5V output inductor and 470uF 16V Rubycon CE-W after it.
1000uF 10V Rubycon YXB between +12V and +5V rails before +12V output inductor with 470uF 16V Rubycon CE-W on after it.
100uF 16V CE-THR unit before -12V and -5V regulators.
150uF 400V Hitachi HP3 primary unit.
All other electrolytics Rubycon general purpose units.

YTF830 primary switcher with PBP205 input rectifier.
C65-004 rectifier for +5V 7.5A rail and UF3003 rectifier for +12V 2A rail.

[Wester547]

Re: Power supply build quality pictorial. part 2

CE-W and CE-THR are certifications I believe rather than series. All I can figure out about those old, blue 85*C Rubycons is that they are bipolar? (or rather not) and general purpose. I've also seen some 85*C, 7mm tall Nichicons on old Sound Blaster sound cards without a series printed on the sleeve. I wonder what condition those Rubycons are in and if they'll fail and/or leak like the Nichicon PFs and VTs in the other unit. I understand that the Fuji is very old and was worked very hard but IIRC PF and VT were problem series (PF and PR were observed to have leaked in some CRT monitors and motherboards over time for an example), especially in old ECUs in older automobiles from the 1980s-1990s where they would eventually leak.

I'm not sure why, though. I can't figure out if it's because they're (possibly) improperly sealed (problems with the bungs as moisture would eventually get in and "attack" the bungs and electrolyte... I believe that is exactly what causes those older Fujitsu RE functional polymers with vents to fail, not being properly sealed) or if it's because of the "quaternary ammonium salts compound" issue, though those are still used in double layer capacitors.

Edit: Nevermind, they are non polar.... I thought I read somewhere once that they are bipolar but I didn't think that made sense based upon the cathode marked into the sleeve.

[Behemot]

Re: Power supply build quality pictorial. part 2

Those blue Rubycons are surely not bipolar, you can see cathode marking in there. As for quality, well, I have so far seen maybe two bad from tens of them, possibly it was just overstressed (and after 15 years? man like that was short life ).

[Pentium4]

Re: Power supply build quality pictorial. part 2

c_hegge will love this one. Found this beauty in the garbage. 5VSB only gave 4.11V. The person who put it in the garbage was verbally scolded by yours truly What a well built unit. Too bad the glue person at the factory went buck wild on this thing, most of it is still white though. The caps that went bad are Ltec LZG and LTG (The brown one) The Taicon on the 12V appear to be fine. This thing did get over 6 years of 24/7 use, and I don't think a single top mounted 92mm fan is adequate enough for this PSU, so the Ltec did good. There are some CapXon in there too, they might be out of spec. The bulk ones are good sized at least. The switchers are two W9NK90Z rated at 9A. Seems plenty for 460W although I'm not a fan of that heatsink, especially with how slow the fan spins. The fan is a death Adda but it still spins very well even though it's pretty dry. It has two bridge rectifiers that share a heatsink, and each is rated for 8A. It has a nice input filter, with huge MOV's. Is there any benefit to having two NTC thermistors in parallel? They're both SCK 058. There's actually three 12V rails with OCP. Rail A is for CPU, Rail B is for mainboard connector + peripheral. Rail C is for the PCI-E connector. They all share two MBR20H100CT's. 5V uses two 20A schottky's as well. 3.3V uses one 20A schottky. 5VSB and -12V both have rectifiers on the secondary heatsink as well. 2A for 5VSB and 1.5A for -12V. Soldering looks excellent, oh yeah, cause it's Delta! Also love the mostly 16AWG wiring. Gonna recap it.