The manufacturer that made the charger for Apple OEM, disassembled an 870W silver switching power supply from Dell

Preface

The charging head network purchased a server power supply from Dell, which was produced around 2011, with an output voltage of 12.1V and an output current of 70.4A, and a standby power output voltage of 12V and an output current of 1.5A, with a total output power of 870W. This power supply is manufactured by Yada Electronics and has passed the 80PLUS Silver standard.

This power supply is different from a conventional flat plate brick form factor server power supply, and the power supply cross-section tends to be nearly square. The power supply is equipped with a fan at the DC output end, which extracts air from the inside, flows through the power supply and blows out from the AC input wiring, taking away the internal heat of the power supply. The following charging head network will bring the dismantling of Dell's 870W silver server power supply, and take a look at the internal materials and design.

Dell 870W server power supply appearance

Compared with the flat plate brick shape of other large power supplies disassembled by the charging head network before, the cross-section of this one tends to be square, and the overall shape is more unique, which shows that the internal structure design is very different.

However, the entire power supply shell is still made of metal, and it is fixed by screws after splicing.

The front of the fuselage is equipped with input sockets, indicator lights, carry handles, and quick-release handles.

The enclosure is marked with a nameplate sticker of the power supply.

Close-up of the power supply nameplate

Model: A870P-00

输入:100-240V~50/60Hz 12A

Output:

+12V1.5A Max

+12.1V70.4A Max

Maximum output power: 870W

Manufacturer: Yada Electronics Co., Ltd

The power supply is CE, CCC certified, and 80 PLUS Silver.

There is a cooling fan at the other end of the fuselage.

The power output is slotted.

The length of the power supply body is about 22cm.

The height is 76.66mm.

The width is 67.86mm.

Feel the size of the power supply in your hand.

In addition, its weight was measured to be about 1306g.

Dell 870W server power supply teardown

After reading the appearance of Dell's 870W server power supply, let's disassemble it and take a look at the internal design and materials.

First of all, unscrew the fixing screws of the shell and disassemble the power supply shell, which is composed of two PCBA modules.

A PCB is fixed at the bottom of the shell, a PCB is fixed at the top, and an air duct is formed through the shell to dissipate heat for the internal components.

The PCBA module is fixed inside the housing by screws.

Unscrew the set screws and remove the PCBA module from the housing.

The cooling fan is from Nidec Nidec, specs 12V1.6A, made in China, and equipped with static blades.

A list of PCBA modules inside the power supply, consisting of two parts: upper and lower.

The PCBA modules are connected by wires.

Close-up of the internal connection wire.

The control board is also connected by a cable that is insulated with tape.

Disconnect the wires and split the two PCBA modules.

The large area PCBA module at the bottom is connected to the AC input, the EMI filter circuit is welded on the right, the DC output socket is welded on the left, the transformer and rectifier tube are welded to the right, and the control board is welded at the bottom.

The back of the PCBA module is slotted for primary isolation.

The side of the PCBA module is welded with power socket, Y capacitor and output lead.

Side welding communication board, control board, fuse, safety X2 capacitor.

The power input socket is connected by wire soldering.

Solder two blue Y capacitors on the back of the socket.

The input fuse specification is 16A 250V.

The safety X2 capacitor is from Xiamen Farah Electronics, and the specification is 0.56μF.

The yellow varistor model TVR14471 for input surge protection.

The common-mode inductor is magnetically wrapped.

The specifications of the second safety X2 capacitor are the same.

Close-up of the second common mode inductor with a white plastic bracket inside and a bakelite board insulation at the bottom.

Close-up of safety Y capacitors in a shell package.

Close-up of three safety Y capacitors.

Close-up of a white connector.

The other brown connector is used to connect the PFC module.

The alternating current through the EMI filter circuit is connected to the PFC boost module.

The back side is soldered with PFC controller, driver and op amp chip.

The side of the PCBA module is soldered with terminal blocks, rectifier bridges and thin film filter capacitors.

Thin-film filter capacitors, close-up of common-mode inductors.

Film capacitors are derived from EVOX.

The common mode inductor is magnetically surrounded, and the bottom is insulated with a bakelite board.

PFC boost inductors, NTC thermistors, and high-voltage filter capacitors are welded on the sides.

Close-up of PFC boost inductor with bakelite board insulation pasted on the bottom.

The green NTC thermistor is used to suppress the inrush current at power-up.

Another NTC thermistor is insulated with heat shrink tubing.

The diode is jacketed with heat shrinkable tubing insulation.

The relay is from TE Tyco, model OJE-SS-112HM2, with a coil voltage of 12V and a contact capacity of 10A.

The PFC controller from Renesas, model ISL6729, is a current-mode controller.

The PFC switch is from Infineon, model IPP60R199CP, NMOS, withstand voltage 650 V, conduction resistance 199 mΩ, and is available in a TO220 package.

Four 20mΩ resistors are used to sense the PFC switch current.

Close-up of two color ring resistors.

The SiC diode from Infineon, model IDT02S60C, withstand voltage 600V, operating current 3A at 70°C, in TO220 package.

The high-voltage filter capacitors are from Chemi-Con and are of the KMQ series with a specification of 420V560μF.

The other side is welded with a switch tube, an isolation plate, a filter film capacitor and a PFC boost inductor.

Solder two wire sockets on the control board.

Close-up of the cable socket used on the secondary side.

Close-up of the primary side cable socket.

Close-up of a feedback optocoupler.

Two optocouplers are used to drive signal isolation.

TI Texas Instruments UCC27324 for switch tube drives.

Close-up of another drive of the same model.

Fix the two switches on the side heat sinks.

The switch is from Infineon and is the same model as the PFC switch.

The film capacitor specification is 0.47μF 400V.

Cold-pressed terminals of the output wires, soldered and fixed.

The main transformer is welded in the middle of the PCBA module.

The two film capacitors are from RIFA and are 0.082μF.

Close-up of two other film capacitors of the same model.

Solder two switch tubes on a vertical PCB.

The primary winding of the transformer is wound with wires, and the secondary winding is made of copper sheets.

Close-up of the current transformer on the side of the transformer.

Close-up of a transformer used for drive isolation.

Texas Instruments UCC27324 drivers are used to isolate transformer drives.

The synchronous rectifier is from Infineon, model IPB020N04 G, NMOS, withstand voltage 40 V, conduction resistance 2 mΩ, and is available in a TO263-7 package.

The rectifier output is connected by a screwed copper bar.

The specifications of the two filtered solid-state capacitors are 180μF 16V.

The output filter capacitors are from Ruby and the two are 16V 470μF.

The other two are 16V1000μF.

A copper sheet is soldered on the PCBA for enhanced current carrying at the negative electrode.

The output control switch is from Infineon, model BSC020N03LS G, NMOS, withstand voltage 30 V, 2 mΩ conduction resistance, and is available in a PG-TDSON-8 package.

Close-up of the positive and negative output terminals of the power supply and the communication terminals.

A controller is welded to the side plate.

The STMicroelectronics L6566A is used for auxiliary power control.

LTV817A optocoupler is used for output voltage feedback.

The primary switch is from STMicroelectronics, model STP6NK90Z, NMOS, withstand voltage 900V, conduction resistance 1.56Ω, and is available in a TO220 package.

Schottky diodes are fixed to heat sinks and are used to assist in the rectification of the power supply output.

The output filter capacitor specification is 16V680μF.

Another small board is soldered with an MCU and four op amps.

The MCU is from NXP, model MC56F8027VLH, is a digital signal controller, with a built-in 16-bit 56800E core, 32KB Flash and 4KB RAM, and supports PWM model output.

The Texas Instruments LM2902 Quad Op Amp is used for signal detection amplification.

Close-up of the cable connected to the PFC module.

A list of all dismantling and a family photo.

Summary of the dismantling of the charging head network

Dell's server power supply is manufactured by Yada Electronics, with an output voltage of 12.1V and an output current of 70.4A, and a standby power output voltage of 12V and an output current of 1.5A, with a total output power of 870W. The power supply has passed the 80 PLUS Silver standard and has an unusual block shape.

Through the dismantling of the charging head network, it was learned that Dell's server power supply is composed of two PCBs connected by wires and cables

NXP's digital signal controller controls the entire machine, PFC switches, silicon carbide diodes, and switches are all from Infineon. The internal capacitors are all from Japanese brands, and there is a fan inside to dissipate heat. The internal materials of the power supply are all first-line brands, with luxurious materials and solid workmanship.