SWITCHING POWER SUPPLY ATX (2009)

How to build a laboratory SPS.

How to Convert a Computer ATX Power Supply
to a Laboratory Power Supply
From 0.1V to 16V (30V) and 0.15A to 16A (30A)

"Electronics design" R.Chirio

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2008-2011
After the switching power supply of a TV, the ATX power supply is undoubtedly the electronic power supply, most popular in the
world, over the past 10 years were produced millions of pieces.
The average lifespan of a PC does not exceed 3-5 years, so there are many PCs are scrapped or updated, and a component
that is often replaced even if it still works it is the ATX power supply, replaced by a more powerful model.
As is known the ATX power supply is used to convert the energy of 220V alternating current, separate from the network and of
low value such as 3.3 V 5V and 12V, voltages necessary for the operation of microprocessor cards.
For laboratory use of electronics in most cases it is necessary to have values of voltage adjustable in continuity, to perform all
the appropriate tests. A power supply with these characteristics is expensive, especially if capable of delivering even 20A.
With relative simplicity you can edit an ATX for him to vary the output voltage and also to limit and regulate the current.
Let's say that the input to 220V should not be touched and changed. The changes should be made only on the secondary circuit
as indicated. Opening the cover of 'ATX should never be connected to 220V mains and then plug and screw always put the
metal cover.
Changing the Switching Power Supply ATX involves having a good knowledge of electronics,
equipment is required and experience in electronic assembly.
And a clear competence in the use of devices to 220V.

Not liable for damages to persons and improper implementation.

ATX 350W modified to make laboratory power supply, the potentiometer to the right (blue knob) for regulating the output voltage
from 1 to 15V (20V in this case) and the yellow potentiometer for adjusting the current from 0.15 to 15A . The voltage is read
with a digital voltmeter LED, powered by internal section named +5 V StandBy that has not been modified.
With models for over 450W, and depending on the type of ATX recovered, it is possible to reach in the output 20A 20V or 30V
12A also, as a precautionary measure will be described how to realize the less powerful model.
Before you begin to modify the ATX is necessary to identify the most suitable model to implementation, the proposed amended
scheme works with most ATX containing regulator TL494 or KA7500 equivalent.
The Integrated Driver type 2003, 2005, SG6105, are not suitable to realize a Power Supply variable.
With the 'UC3843 can be done but is not suitable for the proposed scheme on this page.

PWM driver:
(Download PDF Data Sheet)

KA7500 or TL494

The TL494 is built on ATX built in China from 1997 to the present day, although the power increase, the driver is always the
same, the rest has some good features so as to use it on ATX 200W up to 600W. What changes inside the power supply is the
power components, such as ferrite transformer, power transistors and diodes as well as the value of the filter capacitors.
From model to model change the configurations of the circuit and of that of the Power Good OverVoltage, this is not a problem,
as such circuits, we do not care because they have to be isolated and disconnected, see the interruptions of the general
scheme.

Before starting the construction is good to try working in

the ATX, and make sure it works dependents. In this
case it is necessary to ground the jumper cable green
(PS-ON), present on pin 14 of the main connector, and
then give mains voltage.
OK if you hear the fan running.
Attention to the fact that the fan runs, is a good sign but
does not mean that the power function, measure the
output voltage by connecting a load.
Measure the voltage on the white connectors and check

the 5V (+ / - 0.5V) between the red and the black, and

then the 12V cable between the yellow and black. For
testing the load operation must connect a resistor power
10 ohm 20W 12V on terminals and check that the voltage
does not drop below 12V. It's okay not a light bulb 12V
20W higher power otherwise the inrush current locks the
ATX.
Leave the connected load for a while 'time and make sure
there are no problems of voltage drop or blocking the fan
or overheating.
Any noisy fan, it is good that is being replaced with a new
one, if one were to stop during operation under load, in
certain ATX without thermal protection could easily create
damage from overheating.
To know what will be the maximum current that we can
absorb, simply read the value on the nameplate of the
ATX.
In this case with the 12V maximum absorption is 14A.
Having no other loads on the outputs, it is reasonable to
think that the 12V can absorb a higher current. 15 to 20A
for no longer than 15 minutes.
We can find 480-500W power supplies that provide 1822A from the 12V.
We can find many patterns ATX this site:

http://danyk.wz.cz/s_atx_en.html

Roberto Chirio is available for advice in designing and manufacturing Switching Power Supply
Contact:

DIAGRAM 200W ATX

Diagram of an ATX 200W recovered in the network. (Please note

that the original scheme has some errors.)
Are highlighted in red points to insulate the printed circuit board
and green components to remove.
The basic pattern is always similar, change the circuitry and power
good Overvoltage (which we will not use, and we're going to
isolate) also with different powers, change the power components.
Locate replacement parts around the TL494 PWM controller
starting from the feet of the same.

DIAGRAM ATX changes to control voltage and current.

(Version 2011/03)
Diagram of changes to be made to the components around the TL494 regulator for up to 30A output.
With this scheme, there is a better stability and precision in adjustment.
The minimum and maximum voltage adjustable dropouts are less than 0.10 V
For the general pattern refer to the two published versions later.
R3 is the potentiometer which adjusts the current, the potentiometer R17 is regulating the voltage, for greater accuracy must be
wire 10 turns.

This is the scheme more stable, suitable for the various currents available in function to ATX chosen. Use the value of R11 as a
function of the maximum current obtainable in output.
The legs refer all'integrato TL494 soldered on the printed circuit. For convenience, the legs 15:16 should be isolated from the
original scheme, the chip can be desoldered and before inserting it again, fold up the 15 and 16, by doing so you avoid
interrupting the slopes of CS.
The resistors R1, R4, R9 and R15 must be of the type to 2% metal layer, while the resistance R11 must be a power wire with a
total power of 10W. The value should be chosen according to the maximum current obtainable in output. The thermal stability
of the current value is a function of the quality of resistance used. Place the R11 as much as possible on her fan flow.
The resistor R11, the capacitor C5 and the two potentiometers R3 and R17 are to be placed outside of the printed circuit.
The R10 is used to adjust the maximum full scale for voltage (eg 16.0 V compensating for tolerances range).
The R16 is used to adjust the maximum full scale value for the current (for example 16.0 A compensating the tolerance range).
The inductors L1 and L2 are the original on the CS, make sure that they can keep up to 30A.
The capacitors C3 and C4 by replacing the original 1000uF 16V, not sufficient to withstand over-voltage and higher current.
The RC C6 R12 serves to stabilize the adjustment, eliminating the problems of return terminals for output voltages greater than
9-10V.
Should we isolate the slopes of the CS that lead to the negative mass, instead connect a capacitor of 0.1 uF 400V, this to avoid
ground loops on the current adjustment.

ATX 300/500W changes for output from 0.6V to 20V and the current from 0.15 to 20A
Complete schema changes, eliminating the parts no longer
used.
In red new connections and components.
To connect the fan using the recommended schedule below,
using a separate transformer.

ATX 300/500W changes for output from 0.6V to 30V and current of 0.1 to 12A

Complete schema changes, eliminating the parts no longer

used.
It 'necessary to introduce a new bridge rectifier output, placed on
a new radiator isolated.
Remove the ground connection on the output of the transformer.
To connect the fan using the recommended schedule below,
using a separate transformer.

Realization
The realization of Switching Power Supply involves having knowledge of electronic equipment is required and
experience in electronic assembly.
And a clear competence in the use of devices to 220V.

Not liable for damages to persons and improper implementation.

Photo Version 2007

- Begin by removing the CS from the metal container, unsolder
the network cables and unscrew the 4 screws.
- With a robust welder unplug all cables soldered on the PCB,
leaving only the green cable PS-ON and the cable Violet 5VSB.
- Remove unnecessary components of the various sections of +
the + 5V and 3.3V and also the various strengths that will be
replaced with the new values.
350W card ready for editing.

Interior view after mounting.

Interior view after mounting.

- Use at least 4 original cables for the power outputs, red for the positive directly to the output terminal. Black for the connection
to the resistor R11 of Current Sensing and by the resistance to the negative terminal.
- Do you see the large capacitors 35V replaced the originals alone 16V unsuitable to withstand higher voltages. In the case
materialize the battery charger 12V we can keep the capacitors from 16V original, since the same would go to work only at
14.50 V.

- The white strip is for powering the digital voltmeter to be placed outside of the container. (Inside there is no place.)
- The output terminal block must be of the type 30A so as to be able to fix cables 4/6mmq fitted with ferrules.
- The fan 12V can no longer be connected as originally output output, in this case take positive supply from pin 12 (+18 V) of
the TL494 and the negative from the negative common. With a regulator 7812 stabilize the power supply of the fan. The
controller does not need the heat sink, in this case is secured by a screw directly to the fan. (Check the tension upstream of the
regulator in that scheme, ie with fan set does not drop below 17V, otherwise, use the solution explained in more forward.)
- Detail on the current sensing resistor R11, made of constantan wire and attached to the terminal block 30A. The resistance is
cooled directly by the flow of air aspirated by the fan, this keeps the temperature low then we will have a reduced drift values
with increasing current.
The R11 is also easily accomplished with the parallel of n 3W resistors in parallel.
Are noticed the two precision potentiometers to 10 rpm, maintaining the connection cables as short as possible, close to the
metal of the container and distant from the transformers, this to avoid interference.

- You can see the resistance directly welded on the legs 13,14 and 16 and the two resistors on the CS at the place of R25 and
R31 that represent the new reference from 1.0 V to the control voltage. (Version 2007)

Ventilation at a controlled temperature.

Connect the fan to the flyback primary circuit, as described above in the main diagram, in many cases reduces the efficiency of
pilotage in conditions of maximum current out. To cool the ATX changed, you should use a circuit with a transformer.

It uses a small transformer 220V-12/14V from 5VA. Followed by a rectifying and filtering circuit.
- The LM317 regulator allows us to precisely adjust the output voltage.
- R2 determines the maximum operating voltage of 12V on the fan normally. 16V is also where strong demand ventilation.
- R5 determines the minimum voltage on the fan tip. 5.5 V.
- R4 determines the minimum temperature of intervention tip.40
Eliminating the R5 intervenes only the fan to the overcoming of the tripping temperature.
The NTC thermistor R3 must be fixed, with silicone adhesive, on the radiator of the diodes righting power.
The values may vary depending on the fan used, it is recommended to use a fan of better quality than that usually mounted
inside all'ATX.
Using a transformer with only 12V out you can omit the LM317 regulator circuit and connect the fan directly across the
capacitor C5, verify that the open circuit voltage does not exceed 16V.
Obviously, during the load operation of our ATX, hear the fan operate at different speeds, depending on the temperature
reached.

Improvements
With ATX 400-500W is possible to reach out to 20-22V and 20-25A
replacing the double rectifier diode of 12V to the 5V suitable for 30A, is
also to use the section always 5V inductor toroid filter best suited to
withstand high currents, as well as the second inductor with wire of larger
diameter.
Attention that the Schottky diode 30 A, working at 20V is at the limit of the
threshold voltage, check the voltage across, in the case burdening the RC
snubber, to reduce the spikes, or use a SBL3060PT, from 60V.
Better still use two diodes fast from 200V 16A one for each branch.
With these simple substitutions and adequate ventilation and efficient we
should be able to have available a more 20A and in continuous service,
are always to check the temperatures at regime, in particular of the power
transformer.

For the most expert advice to increase the working frequency of the
TL494, does not increase more than 20% but sufficient to squeeze
anything more from the transformer. Therefore, if the nominal frequency is
50kz bringing it to 60kHz acting on R and C present on pins 6 and 5 of the
TL494 driver. It's okay to use an oscilloscope and / or frequency to read
the values. After this change, it is conceivable to obtain an increase in
maximum power output, you must mount the output diode 16A 200V fast.
Are to treat all power connections, never less than 4mmq.
Check the efficiency of the fan, may adopt a higher load.
The addition of a digital voltmeter and an ammeter digital 20A, allows you
to finalize an excellent laboratory tool. Recommended for inclusion in a
movable metal of greater dimensions, suitable to contain the entire group
with electronic instruments.

With the same scheme is possible to realize an excellent battery charger

for the 12V or 24V also for simply by mounting within two trimmers instead
of potentiometers, and calibrating the output voltage to 14.5 volts (29V)
voltage that corresponds to a battery to End of charge.
In this case I included the adjustment of external current, from 1 to 18A,
while the voltage is fixed to 14.50 V.

Final Comments
Definitely a great and powerful power supply. The original design, strong of the millions of pieces produced, is optimized,
efficient and reliable. Under test conditions and they can easily get 20V 20A 400W equal to, not suitable for continuous duty,
but comfortable for loads of short duration.
The cost of construction can be considered very low, especially if you use the potentiometers and digital voltmeter.
The ATX changed to 13.8 V 20A was tested in connection to radio transmitters and the background noise is negligible. Good
behavior with impulsive absorption presenting the type of switching a low output impedance.

The construction is suitable for those who already is an electronics expert and practical systems that work with 220V.
............................................

Roberto Chirio is available for advice in designing and manufacturing Switching Power Supply.
Contact:

www.chirio.com
Roberto Chirio: all rights reserved.