TED : Sharing of Knowledge

Module 1: SMPS Basic Operation and

related ATE Test
Prepared by: Leonel Calderon
Test Engineer – Test Engineering Department
 Scope of this Module 1:
1. Basic Block Diagram of a Switch Mode Power
Supply
2. ATE Test

Following might be mentioned but will not be covered :

1. Different Converter Topologies
2. Detailed Operation of each block
 Switch Mode
Power Supply

1. Servers
AC - DC 2. Telecommunications Equipment
3. Medical Equipments

DC - DC 4. Driver (LED , Motor, Etc)

5. Embedded System
 Common Parameters
needed to design a PSU

1. Input and Output Voltage

Standard 2. Maximum Output Power
3. Power Factor and Efficiency

Custom 4. Output Regulation

5. Circuit Protection and Communications
 Simple Block Diagram of a Switched Mode Power Supply

Output
Filter
Input Rectifier
Protection
EMI Filter Section PFC Boost DC-DC Output
And Protection
Auxiliary

Control and Communications Section

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Block diagram of a Custom PSU
for Server with Battery Back Up
INPUT and EMI Section
BRIDGE RECTIFIER
ACTIVE PFC (Interleaved)
BULK CAP
INTERNAL BIAS (AUXILIARY)
CONTROL AND COMMS SECTION
DC-DC BUCK
DC-DC 2 FET FWD (PRIMARY)
DC-DC SYNC REC (SECONDARY)
OUTPUT SECTION
NEXT MODULE
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 Input Fan Tray
Block Diagram of Custom PSU for OCP
24V Boost
Connector
Telecommunications Equipment Converter
Switch 24V/1.25A

RS485 APC RS485

Primary Secondary Transceiver FAN RS485
1&2
Input
100 –

SPD
Fan Present
EMI Filter
Interleave Main Board
DC-DC Sync Output OCP
Boost
250

Inrush Ckt LLC Rectifier filter Switch Connector

PFC
12V/26.67A
VAC

Bridge
Rectifier
SEC
PFC Gate Drive LLC µC
Controller Transformer Controller
Other signals Other signals

UART UART
PRI OPTO
µC Coupler
AC_IN_I_ADC
AC_IN_I_DAC
Power AC_IN_U_ADC
OPTO AC_IN_U_DAC
Monitoring
IC
Coupler

Aux Ext. Alarm

Transformer SPD Connector
(Bias Supplies) (Alarm 0 & 1)

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 For this module, we will focused on this simplified block
diagram of a standard SMPS. Controller and Controller and Communications
Protection Protection

DC-DC
DC-DC
Controller and
Protection Converter (Output
Converter/
Secondary Protection
(Input Active PFC Primary Side and Filter)
– Boost
Side
Protection Bridge
Converter
and EMI Rectifier and Bulk
Filter Cap DC-DC Feedback
Converter
(Auxiliary)

Input Section Controller and

Protection

Rectifier Section DC-DC Block

(Pri – Sec) Output Section
Bias Supply

PFC – Boost and

Bulk Cap
 (Input
Protection
and EMI
Filter
1. INPUT SECTION

PROTECTION EMI FILTER

a. Fuse

b. Input Varistor 1. Common Mode Noise

2. Differential Mode Noise

c. Thermistor (NTC)

How to use NTC Thermistor as Inrush

Current Limiter?

It will be discussed on the following slide.

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 Bridge
Rectifier
2. Rectifier Section

Bridge Rectifier

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 Bridge
Rectifier
2. Rectifier Section

Bridge Rectifier

Blue – Voltage on Capacitor

Yellow – Voltage on Load R

Transient Response :18A at 500ohms Load

Blue – Current on Capacitor
Yellow – Current on Load R

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 Bridge
Rectifier
2. Rectifier Section

Bridge Rectifier

Blue – Voltage on Capacitor

Yellow – Voltage on Load R

Transient Response :18A at 2Kohms Load

Blue – Current on Capacitor
Yellow – Current on Load R

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 Bridge
Rectifier
2. Rectifier Section

Bridge Rectifier
How to use NTC
Thermistor as Current Inrush
Protection?

Blue – Voltage on Capacitor

Yellow – Voltage on Load R

Transient Response :70A at 500ohms Load

Blue – Current on Capacitor
Yellow – Current on Load R

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• Inrush Current and Input Current Measurement
3. PFC-Boost Section

Power Factor
Correction and PFC - Boost
Boost Converter

1. What is Power Factor and why do we need PFC?

2. Why do we need to boost the input voltage
before the bulk cap?

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3. PFC-Boost Section

But first what is Harmonics?

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3. PFC-Boost Section

Comparison of Input Current with and without PFC

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3. PFC-Boost Section

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3. PFC-Boost Section

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3. PFC-Boost Section
3. PFC-Boost Section

Controller tracks Input Voltage and Current, as well

as the rectified voltage.

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3. PFC-Boost Section

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3. PFC-Boost Section

Every region/country has a standard AC Output voltage level.

Table 1 : Sample Computation fn a certain controller

for expected output voltage per line

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 • Brown – In and
• Power Factor Brown - Out

• General Power On
General Power Off
Hold-up Time, AC Surge – Sag and Line Transient

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• Hold-up Time • Line Transient

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4. Auxiliary (Bias Supply)

DC-DC
Converter
(Auxiliary)

IC Controllers and Bias for

Circuit Protections

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5. DC – DC Converters (Primary and Secondary)

DC-DC
DC-DC
Converter
Converter/
Secondary
Primary Side
Side

DC - DC Output
Buck to Step
Primary Side Secondary
Down at a
(FRC, LLC, Side (Sync
constant level
TFF, others) Rec)

Control
Feedback
System

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5. DC – DC Converters (Primary and Secondary)

DC - DC Output
Buck to Step
Primary Side Secondary
Down at a
(FRC, LLC, Side (Sync
constant level
TFF, others) Rec)

Control
Feedback
System

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5. DC – DC Converters (Primary and Secondary)

DC-DC
DC-DC
Converter
Converter/
Secondary
Primary Side
Side

DC - DC Output
Buck to Step
Primary Side Secondary
Down at a
(FRC, LLC, Side (Sync
constant level
TFF, others) Rec)

Control Keeping the

Feedback
System Output at
Regulation
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5. DC – DC Converters (Primary and Secondary)

PWM SIGNAL AT HIGH FREQUENCY TO

TURN ON AND TURN OFF A SWITCH

DC - DC Output
Buck to Step
Primary Side Secondary
Down at a
(FRC, LLC, Side (Sync
constant level
TFF, others) Rec)

Control
Feedback
System

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5. DC – DC Converters (Primary and Secondary)

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5. DC – DC Converters (Primary and Secondary)

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• Dynamic Loading • Output Load Regulation

• Load Step (Step Up or Step Down)

6. Output Section (Filters and Protection)

(Output
Protection
and Filter)

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6. Output Section (Filters and Protection)

Second Order 40dB Attenuation = 100

(Output
Protection
and Filter)

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• Output Votalge Ripple Measurement
 Protection

• Output Over Current Protection

• Output Over Voltage Protection

• Output Over Power Protection

• Short Circuit Protection

Discussion of these protections will not • Over Temperature Protection

be covered by this Module.
• Input Over Voltage Protection
• Input Under Voltage Protection
Start Up Short Over Current Load Change

Running Short Over Current Ramp Up

 Communications
and Signals

• PMBus and SMBus – I2C

• UART, CAN, MODBUS

• Fault and Timing Signals

Discussion of these will not

be covered by this Module.
Thank You for listening.