I finally solved the mystery of the random lock outs by the primary buck converter when restoring external power and the resulting false indication of a successful transfer from internal back to external power.
I tested my three modified[1] 12v 1A wallwarts and had slightly mixed results. One of them would occasionally show the same symptom when plugged into the GPSDO after being already plugged into a mains socket, the other two failing to demonstrate the problem. If they were plugged into the GPSDO before being plugged into a mains outlet, all three contrary to my expectations, would successfully power it up every time.
After choosing the most efficient of the two symptom free wallwarts, I searched for a datasheet on the 8 pin IC identified by the SMD code 'AGCE' used by the 3A version of these Mini360 DC-DC buck converters (the 1.3A version uses a slightly more diminutive 6 pin IC).
Try as I might, there was no information to be had using the many SMD code indices I checked out so I examined the datasheets I'd already downloaded for similar ICs that these Chinese clones had most likely been based on to see if I could get some sort of clue as to whether using the enable pin function would allow me to fix the issue I'd been experiencing.
This also proved to be of no further help so I sat down to closely scrutinise my circuit diagram and do a more thorough analysis of its operation. Eventually, after running through the processes involved in transitioning from internal battery power to external power several times (I had been blind sided by the fact that the 12v supply I was using as my gate drive source would already be present whilst it was still running off the LiPo cell rather than the misguided assumption I'd been making that this would be delayed - only true in the case of a stone cold, dead in the water power up sequence), it eventually dawned on me that the 06N03LA mosfet was being switched on too quickly to prevent the LiPo cell voltage being backfed to the buck converter's output before it had properly responded to the presence of the external DC supply voltage.
In this state of operation, the backfed LiPo voltage, despite being some 300mV lower than the buck converter's set output voltage, would be enough to create an overvolt error condition and lock it into a standby mode. That, at least was my best, as yet untested hypothesis that I had come up with before finally retiring to my bed last night.
I was up bright and early this morning (9:30
is bright and early by my normal standards
) to squeeze a 100nF capacitor between the source and gate (or across the emitter/collector of the 2nd BC548, if you prefer) in order to delay the shorting out of the anti backfeed SK24 diode that would otherwise lose me some 300mV of margin, critical to being able to reliably power it from a 5 volt supply (usb wallwarts and power banks).
After about an hour's worth of fiddling this capacitor add-on into the circuit, I was ready for yet another round of testing. This time, the benefit was immediately obvious and the only way I can now get it to lockout is by setting the bench supply to less than 5.3v before turning it off and on by its mains switch.
I could probably make it proof against even sub 5.3v bench supply mains power switch on events by using a 1 or 2 uF ceramic cap but I'd need to put a 1K resistor in series to protect the BC548 from the larger discharge current surges involved when transferring back to battery power - something for anyone considering this circuit for their own use if there is a need to cater for even slower input supply voltage ramp up rates.
This had initially been just a "quick 'n' dirty" test to prove that my hypothesis was correct. The limited energy storage in a 100nF cap doesn't warrant such a limiting resistor so it never got one. I might be minded at a later time to cater for even this rather artificial powering up scenario and replace the 100nF cap with a 5uF 10 or 16 volt[2] rated ceramic cap and 1K current limiting resistor to make it thoroughly proof against even the most unlikely of power up conditions but for now, I think I've neatly addressed the most glaring defect in my 'clever' power management design.
I don't think the buck converter has any problem with very slow input voltage ramp up rates, just a lock out issue when backfed from another voltage source even when that happens to be 300mV below its output voltage setting. Since I've not been able to recreate the false external power indication state due to buck converter lockout with any of my wallwart or power bank sources under any conditions of power sequencing (mains power to wallwart before or after connecting it to the GPSDO, including using those power banks as 5v UPSes), I'm quite happy to consider that my work here is indeed well and truly done.
NOTES:
[1] I'd fitted 4.7K 1/2 watt resistors between the zero volt rail and the earth pin to kill off the annoying nuisance of the half live mains voltage issue common to all of these class II smpsu based wallwarts ( the same modification I'd used with my FY6600 BTW). Most such UK wallwarts use a plastic 'earth pin' just to open the shuttered L & N sockets on all UK 13A mains sockets but I had a couple that were blessed with proper brass earth pins that were there only for that sole purpose.
These had been relatively easy to modify but with other candidate wallwarts cursed with a plastic shutter opening pin, I simply transferred their guts into previously gutted wallwarts I'd hung onto simply because they had been endowed with a functioning, if unused earth pin.
Such class II smpsu based wallwarts, endowed with a proper, though electrically isolated, earth pin are such a rarity these days that they're worth hanging onto even if they no longer work or the kit they had been supplied with used a non-standard voltage and has long since gone to landfill. It's even worth looking for 2nd hand ones in flea markets, regardless of their actual output voltage ratings just to keep a modest stock for any such future half live mains 'touch voltage' elimination modifications. Avoid the very heavy ones unless you're looking for a cheap source of 5 to 15 VA mains transformers.
[2] If you replace the 470K resistor (R3) with a 1M and shunt the CE of Q2 with another 1M resistor, you can safely use a 6.3v rated ceramic cap instead. The maximum voltage between the 12v and the 3.85v rails is just a fraction over 8 volts and the mosfet will turn on even with only a 2.5v gate to source voltage difference. Indeed, since the impedance remains the same, you'll have the same time constant but the reduced voltage will double the effective turn on delay, giving the chosen capacitor 'more bang for the buck'.