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CIRCUIT
ANALYSIS
SETEC MK5PFC
Circuit Analysis
R212
31
14
C59
R125
R163
R159
R195
C93
R188
R143
R189
228
C88
L8
C96
C91
R88
D19
207
C100
R245
12
R244
R87
203
R236
83
C98
F3
R242
163
161
171
R104
82
R95
159
U12
172
160
R98
C105
R89
E3
E2
227
67
X5b
62
226
D18
58
Q7
Q6
162
R102
225
169
57
C102
66
224
R217
209
63
C5
C104
56
C106
T1
R218
D42
R91
R211
223
S1
R77
R202
13
C95
D30
C101
59
Page 2
60
15
R1
L4
X6b
C99
R171
R96
17
Q5
C14
11
61
C97
L7
32
R177
R111
R142
R182
C119
R103
C89
R92
R93
R97
C94
R90
18
R197
79
C16
E1
X10
167
92
Q8
C92
19
94
Q3
E4
213
C2
Q2
98
204
C125
R23
165
D33
D6
R84
R243
24
99R130
R193
U9
69
10
4
U1
164
R181
100
168
208
R81
D38
91
R209
R183
R156
114
115
R196
R208
R172
181 146
D7
K1
72
158
U15
30
U13
D5218 138
22
157
97
217
D31
R99
R85
C57
R108
R124
111
113
H1
U7
55
44
47
D1
R126
R162
R235
R240
U4
D39
R94
R200
Q11
198
R192
110
U11
85
R173
R239
180
109
C90
C70
C108
C72
145
D8
199
Q4
148
R115
R131
144
D40
143
R141
R230
U3
178
75
R179
D11
48
D21
C68
R237
R146
R119
R238
R228
R234
R170
R178
R241
196
R231
191
R113
C73
C87
R114
187
136
156
R151
46
R123
R232
C86
C66
R222
R117
D22
D27
R157
96
R216
U5 80
74
R187
R152
95R191201R161
R190
86 Q9
87
R158
C114 90
U10
R229
188
C84
106
R150
R165
Q10
103
X9
D12
197
Q12
R204
C122
Q1
33
D4
R184
206
23
U8
176R160
D28
R176
U14
147
C61
20
R203
102
D26
R86
D3
R233
88 R194
U6
73
C67
76
139
177
D36
C116
195
R118
C82
R220
190
184
R120
D43
C58 205
34
C118
U2
R174
174
140
C79
R223
C78
D35
3
141
142
183
C117
16
C81
C56
R186
C53
211
R205
R219
C76
154
R168
175
212
173
194
193
C74
192
182
R221
35
C55
R185
R135
133
R226
131
R137
R116
130
R139
D41
185
200
R132
129
R140
D37
124
R154
R122
123
R148
128
R149
132
134
R82
R144
R136
26
L5
42
C54
R121
122
127
R133
C52
D16
D17
210
L6
38
R198
R213
121
126
R134
C63
21
29
R127
118
R214
120
125
R147
C120
27
28
R128
117
R199
119
C121
C64
R129
116
R138
25
C75
222
E5
R100
he SETEC MK5PFC
power supply is one of
the most complex
power supplies we see in
the gaming industry. It
incorporates the latest
advancements in modern
power supply design including Power Factor Correction
and DC to DC conversion.
Add to that some very gaming-oriented features such
as the ability to control the
X8
X7
SETEC MK5PFC
AC (mains) Input
Filtering and Monitor Control
Switched-mode power supplies are noisy. They generate a lot of electromagnetic
interference (EMI). Like all
modern power supplies,
this one starts off with an
EMI filter on the mains
input (Although we dont
use the term in North
America, in the rest of the
world, household AC current is referred to as the
mains.). This filter system
lives on the appropriately
named Filter Board. It is
comprised of a network of
capacitors and an inductor
(C1-C6, L1) and prevents
EMI from escaping the
power supply and taking a
free ride on the mains
where it might wreck havoc
on the rest of the system. It
doesnt actually change the
AC current in any significant way.
R8 is a varistor, the selfsacrificing surge protector
that absorbs the energy
from things like lightning
strikes and freak power
surges. If you see that it
has blown up, you will
naturally have to replace it.
The zero-crossing is the instant in time that the voltage and current are both
zero. By switching only during this time, AC loads such as the monitor can be
safely connected to the mains without excessive inrush current.
SETEC MK5PFC
Page 3
A zero-crossing circuit
assures that the only time
that the monitor will actually make the connection to
the mains is when the
instantaneous voltage of the
mains is precisely zero. At
that exact moment in time,
there is no current flowing
through the mains and the
monitor can be connected
safely without causing
excessive inrush current or
freaking out the degaussing
circuit in a CRT monitor.
Essentially, its like the
difference between hot
plugging something and not
hot plugging it. If the
monitors power is connected only when the voltage is zero, it can ramp up
slowly as the sine wave
voltage increases. Its a
much nicer and less destructive way to turn things
on and prevents things like
fuses that seem to blow for
no reason or destruction of
input rectifiers.
zero crossing.
The rest of the monitors
mains control circuit is
straightforward. The hot
side of the AC power passes
from pin 2 of the mains
switch, through fuse F1
and, when gated, through
the TRIAC to the monitor
receptacle. The neutral
connection is between pin 1
of the mains switch and the
monitor receptacle.
SETEC MK5PFC
later.
To the Bridge and Beyond
We have finally made it to
the bridge rectifier, D1. Of
course the bridge rectifies
the AC input, turning it into
full-wave, pulsating DC.
Following D1, we find a
departure from traditional
power supplies. The primary filter capacitor is not
connected immediately
following the bridge rectifier
as we have seen in all
power supply designs of the
past. Instead, a power factor correction circuit is
inserted between the output
of the bridge rectifier and
the primary filter capacitor,
C52.
Lets follow the positive
output of the bridge rectifier
and see where it leads.
There are two paths here
for the current to flow. One
path passes through diode
D43 and then to C52. But
why do we need the diode?
Its already DC, isnt it?
Sure it is. Its the output of
a bridge rectifier and bridge
rectifiers turn AC into DC.
Is the current being
double-rectified or something? Seems mysterious,
doesnt it?
The answer lies down the
other path so lets go back
to the positive output of the
bridge rectifier and follow it
straight across to coil L5.
This is a large toroidal coil.
From the right side of L5,
we can follow the current
path through diodes D12
and D11 and then to the
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SETEC MK5PFC
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SETEC MK5PFC
SETEC MK5PFC
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Page 15
internal temperature
sensor that is part of the
over-current protection
system. Its is a really
great place to see the
comparator in action. In a
nutshell, if too much
current is drawn from the
power supply for an
extended period of time
(causing the power supply
to overheat) or if the
machine is operating in an
environment that exceeds
the maximum temperature
rating (causing the power
supply to overheat) we
want to turn off the power
supply. U15 has just three
leads: a power supply
input, a ground and an
output. Want to guess how
it works? If you said the
output voltage changes
with temperature youre
right. It operates in a range
of -55 to +150 C. The higher
the temperature, the higher
the output voltage (it rises
at 10 millivolts per degree
Centigrade). You can see
the output is connected to
pin 10, the input of the
LM339, U3A.
For the other input to the
comparator, we generate a
+2.5 VDC reference voltage
using a TL431. This
reference gives us a precise
and unchanging voltage to
which we can compare
other voltages. In this case,
we set the trip level of the
circuit with a voltage
divider made from R124
and R231.
As long as things are cool,
the input voltage is lower
than the + input and the
Page 16
to which it is connected. As
you can see, if the
phototransistor in U5 is
turned on by the light from
the high temp LED half of
U5, its going to drag the +
input down to zero volts
and, since the input will
now be higher in voltage
than the + input, the
output of U2D at pin 13 will
go low. This will drag down
the gate of MOSFET Q4,
turning it off and when that
happens, finally, at long
last, we arrive at the final
goal of this circuit.
When Q4 is turned off, the
relay, K1, drops out. Do you
remember K1 from part one
of this discussion? Relay
contact K1 shorts out the
18.2 Ohms of series
resistance on the AC input.
If the temperature rises too
high, the relay drops out
and the power supply
enters an operating mode
that places resistors in
series with the AC input
once again.
Its also time to shut down
the power supply. This is
easily accomplished because U14, the UCC38503
PWM Controller has an
Enable input. Pin 4 has to
be high (typically, its
around 8 volts) for the
device to operate. All we
have to do is to drag pin 4
low and the GT2 output at
pin 10 turns off, turning off
the entire primary circuit.
Of course, the +24 VDC
output goes down as well.
As covered previously, when
an over-temperature condiSlot Tech Magazine
tance.
Naturally, putting 18 ohms
in series is going to have a
noticeable effect on things.
Specifically, the unregulated primary voltage is
going to drop. This is where
having the colored busses
really comes in handy because if you follow the sort
of pink colored primary DC
buss all the way to the left,
youll see a voltage divider
made of seven resistors,
R199, R214, R213, R121,
R122, R154 and R156. Our
divided voltage is applied to
pin 6, the inverting input of
one of the four devices
inside integrated circuit U2,
an LM339.
You can see from the fact
that these guys are all .5%
resistors that this is something important. This is
where we keep an eye on
the primary DC voltage.
This is another comparator
circuit. Our reference voltage is at pin 7, connected to
the 2.5 volt reference buss
through precisely 1000
ohms (again, .5% precision
resistors are used).
It is worthy to note that the
12 volt power supply for the
LM339 U2 and the reference voltage generated by
U8, the TL431 comes from
U13, the three-terminal
regulator we discussed in
part 1. Because the 12 volt
output of this regulator is
so low in comparison to the
+360 VDC or so that is its
input (when the mains
input is 240 VAC) the output of the regulator will
Slot Tech Magazine
circumstances of this
reassertion do not warrant
discussion in this article.
So to recap, if the primary
voltage is good, U6 LED is
on. If the primary voltage
begins to drop (whether
caused by the 18 ohms of
series resistance OR by an
actual drop in primary
voltage caused by a significant drop in the mains
voltage) U6 LED is off.
If were driving the LED half
of an opto-isolator we must
be getting ready to talk to
the outside world. We are,
but in a surprise move, all
of this primary voltage
detection that we just performed has absolutely nothing to do with the actual
power supply. That is to
say, it has nothing at all to
do with the generation of
the +24 VDC output of the
power supply. It is a detection circuit that talks to the
slot machine itself. It examines the condition of the
primary DC voltage (from
which it infers the condition
of the mains-when we add
the series resistance, we are
actually tricking the
power supply into thinking
that the mains voltage is
dropping) and signals the
CPU in the slot machine
through the status of the
Power Fail signal. You can
see it on the schematic
diagram at pin 9 of connector X9. Follow it back and
youll see its connected to
the drain of Q2 so obviously, when Q2 turns on,
the PFAIL signal will go low.
SETEC MK5PFC
Output Monitor
While were in this area,
lets take a look at another
circuit that is used to monitor something, this time the
+24 VDC output itself. We
have already seen how the
power supply will respond
(immediately) to an overvoltage condition by shutting down the power supply
before damage can occur.
On the other hand, in the
case of a loss of the +24
VDC output, we dont have
to worry about damage and
we dont have to shut down
the power supply. Its already going down! However,
if the +24 VDC output isnt
up and running (or, more
specifically, if it is in the
process of failing during
otherwise normal operation)
it would be nice to let the
CPU know about it so it can
do some housekeeping.
The output monitor uses
the remaining two sections
of U1, the LM339 Quad
Comparator. At first glance,
it may look like this is some
sort of circuit without an
input. You can see that the
non-inverting input at pin 9
is connected to the reference buss but whats up
with the - input at pin 8?
It looks like its just hooked
up to the +24 VDC buss
through some more of those
.5% precision resistors,
R173 and R208 (both 1.8 k
in series for a total of 3600
ohms) and R181 and R209,
both 2k ohms in parallel for
a total of 1000 ohms. The
use of precision resistors
tells us were monitoring
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SETEC MK5PFC
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SETEC MK5PFC