SERVICE MANUAL

SERVICE MANUAL FONT30C

INDEX

- FUNCTIONING DESCRIPTION
- SCHEMATICS
- COMPONENTS LOCATION SCHEMA
- TESTING AND QUALITY CONTROL
- TECHNICAL CHARACTERISTICS
- MECHANICAL DIAGRAM
 author: J. M. Mas 010921 FN11-01 FONT30C
ECLER approved:
date:
title:
project:

FUNCTIONING DESCRIPTION
product:

num: 52..0013 version: 01.00

FONT30C. Power supply functioning description:

1.- Power Stage.

It consists on a switching flyback-type symmetric output power supply.
The mains voltage applied to the input plug is led through NTC1 in order to reduce the inrush
current, and through a filtering network formed by C101, C102, C103, C104 and L101.
Double-wave rectifying is done by D101 to D104, as C105 is charged up to the mains voltage
peak value.
This voltage value, between 127V and 373V depending on the mains voltage, is sent to T101's
primary coil. When MosFET Q102 is conducting, current flows through the primary coil, and
T101's core gap is loaded with induced energy. When Q102 cuts off, this energy is discharged
through all of T101's three secondary coils; two of them provide the symmetric output voltages,
the third coil is used to feed the unit's control circuitry. The switching frequency is about 80KHz.
Shunted to T101's primary coil, a network is placed which limits voltage spikes and also is used to
damp ringings. Also D110 and D111 output diodes are equipped with ringing-damping circuitry.

2.- Feedback and Control.

The power supply obtains its feedback from the addition of both positive and negative output
voltage branches. When both voltages add reach a preset value around 35 volts, a voltage divider
formed by R109 and R112 pushes IC102 to conduct, and current flows through the LED of
optocoupler IC105, which transmits the signal to the unit's control circuitry, placed at the primary
coil-side.
This control circuit is a so-called current-mode type, and is based upon a UC3842A integrated
circuit. It consists on a reference voltage, an oscillator whose frequency is fixed by R115 and
C112, a driver circuit to control the gate of Q102, a comparator and an error amplifier, but which
is not used in this power supply. When the optocoupler conducts, the input voltage of the
comparator decreases (pin 1), and the pulse width of the signal sent to Q102 becomes narrower.

3.- Switching On / Current Limiting.

The controlling integrated circuit includes a hysteresis-cycled comparator, which makes the
circuitry to switch on while its supply voltage reach 16V, and remains active unless the supply
voltage drops down to 11V. When the power supply is connected to the mains, C106 is charged
through R103-R106 until its voltage reaches 16V. Due to 5V hysteresis, C106 is able to provide
enough current to the control circuitry during the first cycles of the power supply start up, and
allows the output capacitors to get charged, and meanwhile the voltage which will supply the
control circuitry reaches enough level (11V).
This voltage is close to proportional to the unit's output, so in case of shorting or extreme
overload, the unit's control circuitry will loose power feed and thus will shut down, trying to turn
on the unit until the short circuit or the overload disappear.
The current limiting is activated when pin 5 of the controlling IC receives a voltage level above 1V.
In case the output current is too high, the modulator's output pulses are narrowed enough in order
to maintain the current value below this limiting threshold, pulling down the output voltage, limiting
more or less the delivered power to a fixed value until the output voltage drops enough to activate
the shut-down and turn-on cycles as described above.
The current is sensed at the primary coil using three resistors shunted to Q102's source. A zener
diode, D108, avoids these resistors from burning in case Q102 is shorted.

52-0013-0100 FN11-01.doc 1 of 1
 PARTS LIST: C.I. 11.0864.04.04

Code Description Reference

FCCDH71150 C150n/275V X2 C101
FCCDH71150 C150n/275V X2 C102
FCCCD22250 C2n2/250V Y1 C103
FCCCD22250 C2n2/250V Y1 C104
FCCE450047 47u/400 C105
FCCE151000 100u/25 C106
FCXCN44700 470n C107
FCXCN44700 470n C108
FCXCN41000 100n C109
FCXCN40047 4n7 C110
FCXCN41000 100n C111
FCXCN40010 1n C112
FCXCN21500 150p C113
FCCDH71011 C10n/400V C114
FCCCD22250 C2n2/250V Y1 C115
FCCCD47100 C47p 3kV C116
FCXCN21000 100p C117
FCCE204700 470u/35 C118
FCCE204700 470u/35 C119
FCXCN21000 100p C120
FCCE204700 470u/35 C121
FCCE204700 470u/35 C122
FCCDH71150 C150n/275V X2 C123
FCXCN42200 220n C124
FCXCN42200 220n C125
FCCE252201 220u/50 C126
FCXCN21500 150p C127
FCXCN42200 220n C129
FCXCN42200 220n C130
FCCIFC0864 11.0864 Printed Board CI101
FCXDD40070 1N4007 D101
FCXDD40070 1N4007 D102
FCXDD40070 1N4007 D103
FCXDD40070 1N4007 D104
FCXREC0210 BYG22D D105
FCXDD40070 1N4007 D106
FCXZ000047 Z4.7V D107
FCXZ000047 Z4.7V D108
FCXREC0200 BYG20J D109
FCXREC0210 BYG22D D110
FCXREC0210 BYG22D D111
FCXDDBAT54 BAT54 D112
FCXFER0100 Ferrite BMB 2A 0060L N2 FB101
FCXFER0100 Ferrite BMB 2A 0060L N2 FB102
FCXFER0100 Ferrite BMB 2A 0060L N2 FB103
FCXFER0100 Ferrite BMB 2A 0060L N2 FB104
FCMECT0220 Heatsink f/TO220 HS100
FCIC431000 TL431AC IC102
FCIC384210 UC3842AD IC103
FCIC435100 4N35G IC105
FCCTM00030 B3B-EH-A J101
FCCTM00030 B3B-EH-A J102
FCCTJ10020 B2P-VH J103
FCBB002000 10mH L101
FCTUE00300 Nut M3 NV101
FCXTT08570 BC857B Q101
40-0087-0108 FN11-01.xls 1 of 2
 PARTS LIST: C.I. 11.0864.04.04

Code Description Reference

FCTR07NB60 STP7NB60FP Q102
FCXR143920 39k2 R103
FCXR143920 39k2 R104
FCXR143920 39k2 R105
FCXR143920 39k2 R106
FCXR001000 1 R107
FCXR134750 4k75 R108
FCXR141620 16k2 R109
FCXR135620 5k62 R110
FCXR135620 5k62 R111
FCXR131210 1k21 R112
FCXR154750 475k R113
FCXR141820 18k2 R115
FCXR111000 10.0 R116
FCXR124750 475 R117
FCXR146810 68k1 R118
FCXR146810 68k1 R119
FCXR146810 68k1 R120
FCXR004700 4.7 R121
FCXR123010 301 R122
FCXR123010 301 R123
FCXR123010 301 R124
FCXR111000 10.0 R125
FCXR111000 10.0 R126
FCXR004700 4.7 R127
FCXR001000 1 R128
FCXR004700 4.7 R129
FCXR004700 4.7 R130
FCNTC00015 B57153 R131
FCXR000000 0 RX101
FCXR000000 0 RX102
FCT7503010 Screw M3x10 SC101
FCTERMF280 Faston 2.8mm TS101
FCTERMF280 Faston 2.8mm TS102
FCPONT0300 30mm W100
FCARDE0300 Toothed Washer f/M3 WA101
FCBRID18R0 Wrap-it-ties T18 WA102

40-0087-0108 FN11-01.xls 2 of 2
 PARTS LIST: C.I. 11.0864.04.03

Code Description Reference

FCCDH71150 C150n/275V X2 C101
FCCDH71150 C150n/275V X2 C102
FCCCD22250 C2n2/250V Y1 C103
FCCCD22250 C2n2/250V Y1 C104
FCCE450047 47u/400 C105
FCCE151000 100u/25 C106
FCXCN44700 470n C107
FCXCN44700 470n C108
FCXCN41000 100n C109
FCXCN40047 4n7 C110
FCXCN41000 100n C111
FCXCN40010 1n C112
FCXCN21500 150p C113
FCCDH71011 C10n/400V C114
FCCCD22250 C2n2/250V Y1 C115
FCCCD47100 C47p 3kV C116
FCXCN21000 100p C117
FCCE204700 470u/35 C118
FCCE204700 470u/35 C119
FCXCN21000 100p C120
FCCE204700 470u/35 C121
FCCE204700 470u/35 C122
FCCDH71150 C150n/275V X2 C123
FCXCN42200 220n C124
FCXCN42200 220n C125
FCCE252201 220u/50 C126
FCXCN21500 150p C127
FCXCN42200 220n C129
FCXCN42200 220n C130
FCCIFC0864 11.0864 Printed Board CI101
FCXDD40070 1N4007 D101
FCXDD40070 1N4007 D102
FCXDD40070 1N4007 D103
FCXDD40070 1N4007 D104
FCXREC0210 BYG22D D105
FCXDD40070 1N4007 D106
FCXZ000047 Z4.7V D107
FCXZ000047 Z4.7V D108
FCXREC0200 BYG20J D109
FCXREC0210 BYG22D D110
FCXREC0210 BYG22D D111
FCXDDBAT54 BAT54 D112
FCXFER0100 Ferrite BMB 2A 0060L N2 FB101
FCXFER0100 Ferrite BMB 2A 0060L N2 FB102
FCXFER0100 Ferrite BMB 2A 0060L N2 FB103
FCXFER0100 Ferrite BMB 2A 0060L N2 FB104
FCMECT0220 Heatsink f/TO220 HS100
FCIC431000 TL431AC IC102
FCIC384210 UC3842AD IC103
FCIC435100 4N35G IC105
FCCTM00030 B3B-EH-A J101
FCCTM00030 B3B-EH-A J102
FCCTJ10020 B2P-VH J103
FCBB002000 10mH L101
FCTUE00300 Nut M3 NV101
FCXTT08570 BC857B Q101
40-0087-0105 FN11-01.xls 1 of 2
 PARTS LIST: C.I. 11.0864.04.03

Code Description Reference

FCTR07NB60 STP7NB60FP Q102
FCXR143920 39k2 R103
FCXR143920 39k2 R104
FCXR143920 39k2 R105
FCXR143920 39k2 R106
FCXR001000 1 R107
FCXR134750 4k75 R108
FCXR141620 16k2 R109
FCXR135620 5k62 R110
FCXR135620 5k62 R111
FCXR131210 1k21 R112
FCXR154750 475k R113
FCXR141820 18k2 R115
FCXR111000 10.0 R116
FCXR124750 475 R117
FCXR146810 68k1 R118
FCXR146810 68k1 R119
FCXR146810 68k1 R120
FCXR004700 4.7 R121
FCXR123010 301 R122
FCXR123010 301 R123
FCXR123010 301 R124
FCXR111000 10.0 R125
FCXR111000 10.0 R126
FCXR004700 4.7 R127
FCXR001000 1 R128
FCXR004700 4.7 R129
FCXR004700 4.7 R130
FCNTC00015 B57153 R131
FCXR000000 0 RX101
FCXR000000 0 RX102
FCT7503010 Screw M3x10 SC101
FCTERMF280 Faston 2.8mm TS101
FCTERMF280 Faston 2.8mm TS102
FCPONT0300 30mm W100
FCARDE0300 Toothed Washer f/M3 WA101

40-0087-0105 FN11-01.xls 2 of 2
 PARTS LIST: C.I. 11.0864.04.01

Code Description Reference

FCCDH71150 C150n/275V X2 C101
FCCDH71150 C150n/275V X2 C102
FCCCD22250 C2n2/250V Y1 C103
FCCCD22250 C2n2/250V Y1 C104
FCCE450047 47u/400 C105
FCCE151000 100u/25 C106
FCXCN44700 470n C107
FCXCN44700 470n C108
FCXCN41000 100n C109
FCXCN40010 1n C110
FCXCN41000 100n C111
FCXCN40010 1n C112
FCXCN21000 100p C113
FCCDH71011 C10n/400V C114
FCCCD22250 C2n2/250V Y1 C115
FCCCD47100 C47p 3kV C116
FCXCN21000 100p C117
FCCE204700 470u/35 C118
FCCE204700 470u/35 C119
FCXCN21000 100p C120
FCCE204700 470u/35 C121
FCCE204700 470u/35 C122
FCCDH71150 C150n/275V X2 C123
FCXCN42200 220n C124
FCXCN42200 220n C125
FCCE252201 220u/50 C126
FCXCN21500 150p C127
FCXCN42200 220n C129
FCXCN42200 220n C130
FCCIFC0864 11.0864 Printed Board CI101
FCXDD40070 1N4007 D101
FCXDD40070 1N4007 D102
FCXDD40070 1N4007 D103
FCXDD40070 1N4007 D104
FCXREC0210 BYG22D D105
FCXDD40070 1N4007 D106
FCXZ000047 Z4.7V D107
FCXZ000047 Z4.7V D108
FCXREC0200 BYG20J D109
FCXREC0210 BYG22D D110
FCXREC0210 BYG22D D111
FCXDDBAT54 BAT54 D112
FCXFER0100 Ferrite BMB 2A 0060L N2 FB101
FCXFER0100 Ferrite BMB 2A 0060L N2 FB102
FCXFER0100 Ferrite BMB 2A 0060L N2 FB103
FCXFER0100 Ferrite BMB 2A 0060L N2 FB104
FCMECT0220 Heatsink f/TO220 HS100
FCIC431000 TL431AC IC102
FCIC384210 UC3842AD IC103
FCIC435100 4N35G IC105
FCCTM00030 B3B-EH-A J101
FCCTM00030 B3B-EH-A J102
FCCTJ10020 B2P-VH J103
FCBB002000 10mH L101
FCTUE00300 Nut M3 NV101
FCXTT08570 BC857B Q101
40-0087-0103 FN11-01.xls 1 of 2
 PARTS LIST: C.I. 11.0864.04.01

Code Description Reference

FCTR07NB60 STP7NB60FP Q102
FCXR143920 39k2 R103
FCXR143920 39k2 R104
FCXR143920 39k2 R105
FCXR143920 39k2 R106
FCXR001000 1 R107
FCXR134750 4k75 R108
FCXR141620 16k2 R109
FCXR135620 5k62 R110
FCXR135620 5k62 R111
FCXR131210 1k21 R112
FCXR154750 475k R113
FCXR132210 2k21 R114
FCXR141820 18k2 R115
FCXR111000 10.0 R116
FCXR124750 475 R117
FCXR146810 68k1 R118
FCXR146810 68k1 R119
FCXR146810 68k1 R120
FCXR004700 4.7 R121
FCXR123010 301 R122
FCXR123010 301 R123
FCXR123010 301 R124
FCXR111000 10.0 R125
FCXR111000 10.0 R126
FCXR004700 4.7 R127
FCXR001000 1 R128
FCXR004700 4.7 R129
FCXR004700 4.7 R130
FCNTC00015 B57153 R131
FCXR000000 0 RX101
FCXR000000 0 RX102
FCT7503010 Screw M3x10 SC101
FCTERMF280 Faston 2.8mm TS101
FCTERMF280 Faston 2.8mm TS102
FCPONT0300 30mm W100
FCARDE0300 Toothed Washer f/M3 WA101

40-0087-0103 FN11-01.xls 2 of 2
 PARTS LIST: C.I. 11.0864.03

Q Code Description Reference

1 FCCDH71150 C150n/275V X2 C101
1 FCCDH71150 C150n/275V X2 C102
1 FCCCD22250 C2n2/250V Y1 C103
1 FCCCD22250 C2n2/250V Y1 C104
1 FCCE450047 47u/400 C105
1 FCCE151000 100u/25 C106
1 FCXCN44700 470n C107
1 FCXCN44700 470n C108
1 FCXCN41000 100n C109
1 FCXCN40010 1n C110
1 FCXCN41000 100n C111
1 FCXCN40010 1n C112
1 FCXCN21500 150p C113
1 FCCDH71011 C10n/400V C114
1 FCCCD22250 C2n2/250V Y1 C115
1 FCCCD47100 C47p 3kV C116
1 FCXCN21000 100p C117
1 FCCE204700 470u/35 C118
1 FCCE204700 470u/35 C119
1 FCXCN21000 100p C120
1 FCCE204700 470u/35 C121
1 FCCE204700 470u/35 C122
1 FCCDH71150 C150n/275V X2 C123
1 FCXCN42200 220n C124
1 FCXCN42200 220n C125
1 FCCE252201 220u/50 C126
1 FCXCN13300 33p C127
1 FCXCN42200 220n C129
1 FCXCN42200 220n C130
1 FCCIFC0864 11.0864 Printed Board CI101
1 FCXDD40070 1N4007 D101
1 FCXDD40070 1N4007 D102
1 FCXDD40070 1N4007 D103
1 FCXDD40070 1N4007 D104
1 FCXREC0210 BYG22D D105
1 FCXDD40070 1N4007 D106
1 FCXZ000047 Z4.7V D107
1 FCXZ000047 Z4.7V D108
1 FCXREC0200 BYG20J D109
1 FCXREC0210 BYG22D D110
1 FCXREC0210 BYG22D D111
1 FCXDDBAT54 BAT54 D112
1 FCXFER0100 Ferrite BMB 2A 0060L N2 FB101
1 FCXFER0100 Ferrite BMB 2A 0060L N2 FB102
1 FCXFER0100 Ferrite BMB 2A 0060L N2 FB103
1 FCXFER0100 Ferrite BMB 2A 0060L N2 FB104
1 FCMECT0220 Heatsink f/TO220 HS100
1 FCIC431000 TL431AC IC102
1 FCIC384210 UC3842AD IC103
1 FCIC435100 4N35G IC105
1 FCCTM00030 B3B-EH-A J101
1 FCCTM00030 B3B-EH-A J102
1 FCCTJ10020 B2P-VH J103
1 FCBB002000 10mH L101
1 FCTUE00300 Nut M3 NV101
1 FCXTT08570 BC857B Q101
40-0087-0101 FN11-01.xls 1 of 2
 PARTS LIST: C.I. 11.0864.03

Q Code Description Reference

1 FCTR07NB60 STP7NB60FP Q102
1 FCXR143920 39k2 R103
1 FCXR143920 39k2 R104
1 FCXR143920 39k2 R105
1 FCXR143920 39k2 R106
1 FCXR001000 1 R107
1 FCXR134750 4k75 R108
1 FCXR141300 13k0 R109
1 FCXR135620 5k62 R110
1 FCXR135620 5k62 R111
1 FCXR131000 1k0 R112
1 FCXR154750 475k R113
1 FCXR132210 2k21 R114
1 FCXR141820 18k2 R115
1 FCXR111000 10.0 R116
1 FCXR124750 475 R117
1 FCXR146810 68k1 R118
1 FCXR146810 68k1 R119
1 FCXR146810 68k1 R120
1 FCXR004700 4.7 R121
1 FCXR123010 301 R122
1 FCXR123010 301 R123
1 FCXR123010 301 R124
1 FCXR111000 10.0 R125
1 FCXR111000 10.0 R126
1 FCXR004700 4.7 R127
1 FCXR001000 1 R128
1 FCXR004700 4.7 R129
1 FCXR004700 4.7 R130
1 FCNTC00015 B57153 R131
1 FCXR000000 0 RX101
1 FCXR000000 0 RX102
1 FCT7503010 Screw M3x10 SC101
1 FCTERMF280 Faston 2.8mm TS101
1 FCTERMF280 Faston 2.8mm TS102
1 FCPONT0300 30mm W100
1 FCARDE0300 Toothed Washer f/M3 WA101

40-0087-0101 FN11-01.xls 2 of 2
 6 LAYERS 2,05 +/-0,15
MATERIAL THICKNESS

BASIC COPPER 0,017

PREPREG 7678(2) 0,36 +/-0,03

BASIC COPPER 0,035

FR4 0,508 0,5 +/-0,05

BASIC COPPER 0,035

PREPREG 2113(3) 0,29 +/-0,03

BASIC COPPER 0,035

FR4 0,508 0,5 +/-0,05

BASIC COPPER 0,035

PREPREG 7678(2) 0,36 +/-0,03

BASIC COPPER 0,017

PADS ONLY IN EXTERNAL LAYERS

INTERNAL EDGE RADIUS 1mm
 author: Queralt 011105 FN11-01 FONT30C
ECLER approved:
date:
title:
project:

VERIFICATION PROCESS
product:

num: 51.0058 version: 01.00

PRELIMINARY:

To allow the source to start-up, the applied mains voltage should be at least of 90Vac.
The maximum mains voltage handled by this unit is 265Vac.
The minimum current load to start-up the unit is 100mA.

VERIFICATION:

Verify that at point TP105 shown on circuit diagram 10.0555.0102 the measured waveform is more or
less like the wave shown on the figure below. The peak voltage should not rise above 600Vp, and the
running frequency is about 80kHz.

Verify that the delivered voltages at the source's outputs are approximately ±17,5V.
Short each output to power ground.
Remove the shorting and verify that each output recovers and maintains its voltage level without any
dropout.

51-0058-0100 FN11-01 Anglès.doc 1 of 1

ECLER author: Queralt
approved:
date:
title:
011105 project: FN11-01
TECHNICAL CHARACTERISTICS
product: FONT30C

num: 53.0023 version: 01.00

Minimum Maximum Frequency

Switching power supply flyback-type symmetric 80kHz

Input voltage AC 90 Vac 265 Vac 47-63 Hz

Outpup voltage +Vdc +17 Vdc +18 Vdc
Outpup voltage - Vdc -17 Vdc -18 Vdc
Output current +Idc 100 mA 400 mA
Output current - Idc 100 mA 400 mA

Power consumption 19 W

53-0023-0100 FN11-01.xls 1 de 1
 Nº Qty ECLER Code Description
1 1 FCCIFC0100 PLANAR TRANSFORMER CIRCUIT
2 12 FCTERM0100 JUMPER PIN 1u
3 1 FCNUCL0220 PLANAR CORE E22
4 1 GENERIC ADHESIVE TAPE 50u (0,022 m) FCCINTA60000
5 1 FCNUCL0230 PLANAR CORE I22 6
1
6 1 FCNUCL0225 CLAMP FOR PLANAR CORE EI-22

SOLDER THE PINS ON THIS SIDE CUT EXTRA PIN AFTER SOLDER

5
1
STICK THE TAPE
UNDER PLANAR CORE

4
1

1
PIN Nº 1 OF TRANSFORMER PIN Nº 1 MARKER 1

INSERT ON FONT30C CIRCUIT

INSERT ON FONT30C CIRCUIT

2
12

3
1

Jordi Folch 031201 FN11-01 FONT30C

ECLER drawn:
approved:
date:
title:
project:

INSERTION DIAGRAM
product:

number: 33.0641 version 01.01

 Nº Qty ECLER Code Description
1 1 FCCIFC0100 PLANAR TRANSFORMER CIRCUIT
2 12 FCTERM0100 JUMPER PIN 1u
3 1 FCNUCL0220 PLANAR CORE E22
4 1 FCSEPPOL10 POLYESTER SPACER 35u
5 1 FCNUCL0230 PLANAR CORE I22 6
1
6 1 FCNUCL0225 CLAMP FOR PLANAR CORE EI-22

SOLDER THE PINS ON THIS SIDE CUT EXTRA PIN AFTER SOLDER

5
1

4
1

1
PIN Nº 1 OF TRANSFORMER PIN Nº 1 MARKER 1

INSERT ON FONT30C CIRCUIT

INSERT ON FONT30C CIRCUIT

2
12

3
1

Jordi Folch 010528 FN11-01 FONT30C

ECLER drawn:
approved:
date:
title:
project:

INSERTION DIAGRAM
product:

number: 33.0641 version 01.00