Small switch mode power supplies modification secrets

Small Switch Mode Power Supplies Modification Secrets Brought to you by Jestine Yong SmallSwitchModePowerSuppliesModificationSecrets ImagineX ElectronicS Copyright@ All Rights Reserved Warning! This is a copyrighted material; no part of this guide may be reproduced or transmitted in any form whatsoever, electronic, or mechanical, including photocopying, printing, recording, or transmitting by any informational storage or retrieval system without expressed written, dated and signed permission from the author You cannot alter, change, or repackage this document in any manner Jestine Yong reserves the right to use the full force of the law in the protection of his intellectual property including the contents, ideas, and expressions contained herein Be aware that eBay actively cooperates in closing the account of copyright violators and assisting in the legal pursuit of violations DISCLAIMER AND/OR LEGAL NOTICES The reader is expressly warned to consider and adopt all safety precaution that might be indicated by the activities herein and to avoid all potential hazards This E-book is for informational purposes only and the author not accept any responsibilities or liabilities resulting from the use of this information While every attempt has been made to verify the information provided here, the author cannot assume any responsibility for any loss, injury, errors, inaccuracies, omissions or inconvenience sustained by anyone resulting from this information Most of the tips and secrets given should only be carried out by suitably qualified electronics engineers/technicians Please be careful as all electrical equipment is potentially dangerous when dismantled Any perceived slights of policy, specific people or organizations are unintentional Limit of Liability / Disclaimer of Warranty: The authors and publisher of this book and the accompanying materials have used their best efforts in preparing this program The authors and publisher make no representation or warranties with respect to the accuracy, applicability, fitness, or completeness of the contents of this program They disclaim any warranties (expressed or implied), merchantability, or fitness for any particular purpose The reader is expressly warned to consider and adapt all safety precautions that might be indicated by the activities here in and to avoid all potential hazards By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions The authors and publisher shall in no event be held liable for any loss or other damages, including but not limited to special, incidental, consequential, or other damages As always, the advice of a competent legal, tax, accounting or other professional should be sought This manual contains material protected under International and Federal Copyright Laws and Treaties No parts of this manual shall be reproduced or transmitted by any means, electronic, mechanical, photocopying, printing and recording or otherwise Any unauthorized use of this material is prohibited All product illustration, product names and logo are trademark of their respective manufacturers ImagineX ElectronicS Content Small Switch Mode Power Supplies Modification Secrets True Case Histories True Case Histories 17 True Case Histories 28 The Power Module can even work on 110 vac 37 supply Conclusion 38 Recommended Electronics Repairing Related 41 Information ImagineX ElectronicS Small Switch Mode Power Supplies Modification Secrets This small switch mode power supplies modification worked superb It eliminates your headache in solving many different types of power supplies problems Check out the advantages again in solving the below problems: When there is lightning strike on the power supply, usually there will be some bad components In some cases the power side components could burn beyond recognition If there is no schematic diagram or same model of power supply to compare to locate the original parts value, it would be tough to repair the power supply The power IC and power FET in power supplies come with many different types of part numbers If you can’t locate either one of the parts this mean you will not be able to repair it Save cost- In some power supplies the price of power IC and the power FET can be quite expensive You no longer have to keep stock for variety part numbers for power IC and power FET This modification method can truly save the cost Save time- Sometime we spent too much time in troubleshooting the power supplies Problems like no power, low power, too high power, power shut down, intermittent power problem and etc can be solved by using the method that I’m going to show to you as you read on Easy to follow- It can be done in less than 20 to 25 minutes if you follow my steps The most important thing is the parts are quite cheap and you can check out where to buy the parts at page 39 ImagineX ElectronicS True Case Histories A customer sent to me a 22” Benq LCD Monitor (G2220HD Model) with the complaint of no power He told me someone had tried repair it before but unsuccessful The moment I opened the cover I saw the power IC was missing and I not know what the original part number was The power FET shorted and part of the current sense resistor outer layer also came off (see the photo below and next page) Power/Inverter Board with missing Power IC- Figure ImagineX ElectronicS Missing Power IC and Current Sense Resistor Cracked- Figure Finding the original schematic in order to look for the original part (power IC) will not be easy Even if you could find the power IC you still have to proceed to buy the parts, replace the power FET and check all the primary side components and make sure they are all good This also will not guarantee the power supply will come back to life after it had been badly repaired by someone Precious time will be lost doing a repair work that had been done by others In my opinion the best solution is to modify with a universal external power module onto it How this can be done? Check the photos in the next page and read the step by step explanations ImagineX ElectronicS Universal External Power Module- Figure Universal External Power Module-Figure ImagineX ElectronicS Assuming you already have the universal external power module and before installation you need to remove the power IC and the power FET and make sure the below components are good: Main Fuse Bridge Rectifier Main Filter Capacitor Power Transformer primary winding Optoisolator IC Secondary output diodes and Secondary filter capacitors (made sure the capacitors are not bulged) Note: For main fuse, bridge rectifier, Optoisolator IC and secondary output diodes you can use a normal analogue multimeter to test Filter capacitors you can use ESR meter to test and Power transformer (primary winding) you can use Blue Ring Tester to check it If you not have a Blue Ring tester no worries because usually the primary winding of power transformers are quite robust and rarely have problem The primary winding is the pins of the drain of power FET (center leg) and the positive (+) leg of main filter capacitor and it should show LED light as shown in the photo in the next page: ImagineX ElectronicS Identifying the Power Transformer Primary Winding Legs- Figure Note: In some smaller power supplies the Blue Ring Tester only registered to LED lights on the transformer primary winding Besides the above components, you are also required to check on the corresponding components in the power supply especially the semiconductors like diode, zener diode and transistor (if have) and made sure they are good The reason to check all these components is to prevent the newly install universal external power module from not working or blowing caused by the shorted component/s I just mentioned Assuming all of the components mentioned above tested good, you now can begin to install the universal external power module Apply some heat compound to the module before fitting it to the heatsink See the photo in the next page ImagineX ElectronicS Apply heat compound before fixing the module to heatsink- Figure Since there is no extra hole for the wires from the power module to pass through, you may need to use a drill to make a hole on the circuit board as seen from the photo below: Drill a small hole so that the power module wires can be inserted- Figure Note: Make sure the drill did not break any circuit track behind the board 10 ImagineX ElectronicS Once you have tested that the power supply is working fine you can actually redo all the wires soldering and a proper wiring before closing back the cover You can refer to figure 36, 37 and 38 to see how I have properly done a nice work on a DVD player power supply There you are, simple and fast modification that always work Power supply working perfectly good- Figure 25 27 ImagineX ElectronicS True Case Histories The Akira DVD Player Internal boards Figure 26 The complaint of the AKIRA DVD player was no power but the main fuse was good This power supply design use only one power IC and the power FET is built into the Power IC 28 ImagineX ElectronicS The Akira DVD player power supply unit- Figure 27 When I checked on the output diodes there was no output voltage even after all the connectors from power supply to the mainboard were pulled out Sometimes a shorted component in the mainboard could cause no power symptom so removing all the connectors is just one of the procedures in power supply troubleshooting I did not check the bridge rectifier because the main fuse did not blow I proceeded to check on the main components The first thing I did was to discharge the main filter capacitor-see next page 29 ImagineX ElectronicS Discharging the main filter capacitor- Figure 28 The main components that I’m referring to in this power supply are main filter capacitor, power transformer primary winding, secondary output diodes and Optoisolator IC All of the main components were found to be good Even the Run DC filter capacitor (22uf 50 volt) also tested good with my Blue ESR meter The next test was voltage testing When I checked on the VCC of the power IC I found that the DC voltage fluctuates indicating either the power IC or corresponding components have problem Since many of the corresponding components checked good thus I suspect is the power IC fault The power IC part number was ICE2A165 which I not have stock with me 30 ImagineX ElectronicS Power IC, Optoisolator IC, Run DC diode and capacitor- Figure 29 Getting just a piece of power IC online or purposely go to the center of town just to buy that IC is not economical The only solution is to modify the power supply and retest Since all the below components were tested good: Main Fuse Bridge Rectifier Main Filter Capacitor Power Transformer primary winding Optoisolator IC Secondary output diodes and Secondary filter capacitors (made sure the capacitors are not bulged) So I proceeded right away to the modification work You can refer to page 17 on True case histories for reference purpose 31 ImagineX ElectronicS Basically both power supplies are using only the single power IC Below are the wires and at where you should connect the wires: Black wire- Connect to the negative leg of Main filter capacitor Green Wire- Connect to the positive leg of Main filter capacitor Red Wire- Connect to the Run DC circuit output (after the Run DC diode) White wire- Connect to pin of Optoisolator IC (make sure the circuit line is cut) In this case I removed a resistor Instead of cut the circuit track I removed the resistor- Figure 30 Yellow Wire- Connect to the drain/output pin of Power IC Note: Make sure to remove the power IC Please take a look at the photo in the next page: 32 ImagineX ElectronicS wires from Power Module were connected for testing- Figure 31 Note: For your information this is just a test and not a final fix This is to make sure the power supply works before doing a nicer wiring work As usual after the modification work, place a 100 watt bulb across the fuse (with the fuse removed) and power it On Light bulb was used on power supply before turning on the power- Figure 32 33 ImagineX ElectronicS Make sure the equipment is working before the final touch up- Figure 33 Once the power supply is working, you then can think of a way on how to secure a heatsink with the power module attached See the photo below: Use a small drill bit to make holes on circuit board- Figure 34 34 ImagineX ElectronicS The power module and heatsink is placed on a strategic location- Figure 35 This is how the wires were soldered at the back of the board- Figure 36 35 ImagineX ElectronicS This is how the wires are connected in a better way- Figure 37 Note: Make sure to apply heat compound to the back of power module and if possible find a bigger heatsink You can use hot glue gun to further strengthening (secure) the wires joints You may also use shrink tube to cover the wires- Figure 38 36 ImagineX ElectronicS A dead DVD player was brought back to life- Figure 39 From this modification it has proven that indeed the power IC was the cause of the no power symptom You have saved your time and money and no headache in fixing this power supply If you are doing the repair work full time, I suggest that you order more of this universal power module to keep it as spare for future use The Power Module can even work on 110 vac The DVD Player can even work on 110 vac- Figure 40 37 ImagineX ElectronicS Another LCD Monitor modified and run on 220 volt- Figure 41 The same LCD Monitor tested on 110 vac and worked beautifully-Figure 42 38 ImagineX ElectronicS Conclusion You can use this method to modify on DVD players, Satellite Receivers, LCD/LED Monitors or any other electronic equipment that uses the small switch mode power supplies that have similar SMPS design topologies in figure and 15 According to the supplier, the power module could withstand up to 80 watt but I personally have tested equipments up to about 40 watt only Click on this link for more information 39 ImagineX ElectronicS I strongly suggest you to reread this information for few times and start right away all of the tips and tricks you have learned from this E-book If you have questions about the small power supply modification, please not hesitate to email me at jestineyong@electronicrepairguide.com I wish you all the best and look forward to hearing your success story To your success, Jestine Yong Bsc Eng UK Author of “Small Switch Mode Power Supplies Modification Secrets” http://www.powersupplyrepairguide.com http://www.lcd-monitor-repair.com http://www.testingelectroniccomponents.com http://www.findburntresistorvalue.com http://www.electronicsrepairarticles.com http://www.bestelectronicarticles.com http://www.electronicsrepairfaq.com http://www.electronicrepairguide.com http://www.jestineyong.com http://www.noahtechelectronicstraining.com http//www.lcdmonitorcasehistories.com 40 ImagineX ElectronicS Recommended Electronics Repairing Related Information 1.Samuel M Goldwasser “Sci.Electronics.Repair FAQ” Here is the website link http://www.repairfaq.org/REPAIR/ 2.List of Electronic Spare Parts Suppliers at JestineYong.com Here is the website link http://www.jestineyong.com/category/electronic-suppliers/ 3.LCD TVs, LCD Monitors, Laptops and Plasma TVs spare part supplier: http://www.iccfl.com 4.List Of Schematic Diagram Websites: http://www.jestineyong.com/category/schematic-diagrams-website/ Electronics Repair Ebooks Power Supply Repair Testing Electronic Components Electronics Repair Articles LCD Monitor Repair Laptop Motherboard Repair Laptop Repair Video Course Basic Electronics 10) LCD TV Repair Tips Volume 11) CRT TV Repair 13) DVD Player Repair 14) Find Burnt Resistor Value 15) Plasma Television Repair 16) Basic LaserJet Printer Repair 17) Epson Dot Matrix Repair 18) Automobile Electronics Repair 19) Computer Repair Mastery Course 20) LCD TV Repair Secrets 21) LCD TV SMPS 22) LCD TV Repair Tips Volume 23) LCD TV Repair Tips Volume 24) LCD TV Mainboard 25) LCD TV SMPS 26) LCD TV Repair Secrets 41 ImagineX ElectronicS ... ElectronicS Small Switch Mode Power Supplies Modification Secrets This small switch mode power supplies modification worked superb It eliminates your headache in solving many different types of power supplies. .. manufacturers ImagineX ElectronicS Content Small Switch Mode Power Supplies Modification Secrets True Case Histories True Case Histories 17 True Case Histories 28 The Power Module can even work on 110... cost- In some power supplies the price of power IC and the power FET can be quite expensive You no longer have to keep stock for variety part numbers for power IC and power FET This modification