instructables

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp)

by Eric Brouwer

POWER SUPPLY CONTEST ENTRY

Please vote for me if you find this Instructable useful

One of the most useful pieces of equipment for the electronic enthusiast is a good bench power supply. Buying
one can be expensive, so most of us search the internet for circuits to copy, and just build our own.

But there is a disadvantage going this method. As the build will be just another "copy and paste" exercise, the
builder does not understand how it works, and does not gain any knowledge.

With this Instructable, I hope I will be able to teach at least one person the basic operation of a variable power
supply. I will break down the circuit, go through each step, and show how the components work, and how to
calculate their values.

So what is a Bench Power Supply?

Well, it is simple, it is a power supply with a variable output voltage, and has adjustable current limiting. No more
sparks and burned out components when used correctly on your projects.

It consists of two parts:

1 - Unregulated part

This section converts the utility AC voltage to the required DC voltage for our power supply. The transformer
perform two tasks:

It converts the utility voltage from a high voltage to a safe working voltage of your power supply
It gives electrical isolation between the utility network and your power supply output.

Rectifier DB1 converts the AC voltage to a DC voltage.

Lastly, capacitor C1 is used to filter out the 50/60Hz components present on the DC output.

See Figure 1.

Refer to this Instructable:

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 1

Design of an Unregulated Power Supply

2 - Regulated part

Two things happen in this section. The ripple factor is reduced to as low as 1%, and the output voltage will be
adjustable. Both facilities employ negative feedback. See Figure 2.

Care should be taken when designing a power supply. With the output set at it's maximum output voltage, the
output voltage must still be lower than the lowest voltage dips in the unregulated part of the supply. A good
principal is to allow for at least 3 volt play. The idea is illustrated in Figure 3.

Step 1: Unregulated Design

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 2

Lets design a 30V, 2A power supply. C = 0.044 Farad, or 4 400uF

In a moderate power supply like this, we can allow for C = 4 700uF, 63V
a 10% peak-to-peak ripple voltage across the output.
The peak voltage at the output will then be:

Vpeak = ( Vout + 3V margin + ( 0.1 x Vpeak ) ) x 1.2

safety margin The transformer output should be:

Vpeak = ( 30V + 3V + ( 0.1 x Vp) ) x 1.2* Vrms = Vpeak / 1.414 (square root of 2)

Vpeak = 45V Vrms = 45V / 1.414

* 20% was added for transformer losses and diode Vrms = 32V
forward voltage losses.
The maximum VA delivered by the transformer is:
Capacitor C1 can now be calculated
VA = Vpeak x Iout
Vripple x C = I x t, where t = 1 / (2 x line frequency)
VA = 45V x 2A
( 45 x 10/100 ) x C = 2A x 1/( 2 x 50Hz)
VA = 90VA
4.5 x C = 2 x 0.01

The diodes should be rated at 2 x Iload to make

provision for charging the capacitor.

Idiode = Iload x 2

Idiode = 2A x 2

Idiode = 4A

The minimum reverse voltage of the diodes should be

2 x Vpeak-peak

Vd_reverse = 2 x Vpeak

Vd_reverse = 2 x 45V

Vd_reverse = 90V

Vd_reverse > 100V

The fuse is specified to withstand double the rated

current:
Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 3
Ifuse = 2 x Iload x (Vlv / Vhv )

Ifuse = 2 x 2 x ( 32V / 220V )

iFuse = 0.58A

Use 220V, 0.64A slow-blow fuse

Earthing

When an electrical earthing point is available, it is

always a good idea to connect the power supply
case, as well as the core of the transformer to earth.

Depending on your requirements, you can leave the

output of the power supply floating, or connect the 0V
output to earth. I prefer to connet the 0V to earth via a
1Mohm resistor.

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 4

Step 2: Voltage Regulation Section

This section of the design is what controls the output

of the power supply. The 2N3055 transistor has a gain of typical 50.

Looking at the transistors, we need to understand that The 2N3054 transistor has a typical gain of 100.
the voltage input to the regulator will be fixed, and the
output voltage can be varied by the user. The output Calculting Transistor Bias Current
voltage is determined by the bias current to the
transistors. But there is one drawback. The input Iload max = 2A
current will be the same as the output current, and the
voltage across the transistors will be Vin - Vout. Thus, Ibase t1 = Ice t1 / gain t1
Ptransistors = ( Vin - Vout ) x I. Looking at Figure 3,
this means that the area above the maximum output Ibase t1 = 2A / 50
voltage, and below the unregulated voltage, is the
energy that will have to be dissipated by the Ibase t1 = 40mA
regulator, which is converted into heat.
Ibase t2 = Ice t2 / gain t2
Therefore, we need a decent power transistor, with a
decent heat sink to dissipate this heat. Ibase t2 = 40mA / 100

Transistor T1 will do the regulation, and must be able Ibase t2 = 0.4mA

to handle the load current. Transistor T1 & T2 are
connected as a darlington pair, and their combined So, to turn on T1 and T2 completely, we need at least
gains will allow for a smaller biasing current. For this, 0.4mA in the base of T2. T3
lets use the old time favorite 2N3055 power transistor
for T1.Transistor 2 can be a 2N3054.

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 5

Step 3: Constant Current Source

The bias current for transistor T1 and T2 need to be R4 = Vr4 / Ice t3

stable, irrespective of the input voltage to the
regulator. To do this, a constant current source can R4 = 1.1V / 1.4mA
be used.
R4 = 785 Ohm, so take next smaller value, then
R4 and zener diode ZD1 forms a constant current
source. This current source must be high enough to R4 = 680 Ohm
cater for Ibase t2, as well as the voltage regulating
circuit (not shown).. Now,

Use BC179 transistors for T3. Ice t3 = Vr4 / R4

The BC179 transistor has a typical gain of 100. Ice t3 i= 1.1V / 680

Our current source must deliver Ibase t2 as well as Ice t3 = 1.6mA

the regulation current. Lets limit the maximum
regulation current to 1mA. The regulation current will
be controlled by transistor T4, which we will discuss
in the next step.
Take current through zener diode D1 as 2mA. This
Now: will ensure good regulation by the zener diode.

Ice t3 = Ibase t2 + Iregulation R5 = ( avarage unregulated voltage - Vzener ) /

Izener
Ice t3 = 0.4mA + 1mA
R5 = ( 45V - (4.5V/2) - 1.8V ) / 2mA
Ice t3 = 1.4mA
R5 = 20.47K
Take zener diode D1 as 1.8V. Now,
R5 = 22K
Vr4 = Vbe t3 - 0.7V

Vr4 = 1.8V - 0.7V

Vr4 = 1.1V With the constant current source complete,

transistors T1 & T2 can now be switched to deliver
Now, the 2A of the power supply.

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 6

Step 4: Voltage Feedback Circuit
To be able to control the output voltage, we need a
voltage feedback circuit. This is done via resistor R6,
R7 and transistor T4. The circuit is set up as a
negative feedback loop.
As the output voltage rises, transistor T4 is turned on
harder, thus more current flows through T4. As the
current source is constant, thus will result in less
current to bias transistor T1 & T2. This results in a
lower output voltage.
The next step is to calculate the voltage feedback
components:
Use BC109 transistors for T3.
The BC109 transistor has a typical gain of 100.
Ice t4 max = Ice t3, or our maximum biasing current
available from the constant current source.
Ice t4 = 1.6mA
Ibase t4 = Ice t4 / gain t4
Ibase t4 = 1.6mA / 100
Ibase t4 = 0.016mA.
This is the minimum current into the base of T4 that
will allow the 1.6mA to flow.
This current needs to be supplied by the resistor
network R6, R7 & R8. To be safe, current through
these 3 resistors should be 10 times the base current
needed on transistor T4.
Ir6= 10 x Ibase_t4
Ir6 = 10 x 0.016mA
Ir6 = 0.16mA
Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 7
THE DRAWBACK OF THIS DESIGN:
As can be seen, there must always be an output
voltage present to keep transistor T4 biased,
Therefore, this type of power supply MUST have a
minimum output voltage. Lets make the minimum
output voltage 2V.
The minimum output voltage is 2V. Therfore, we can
calculate the combined resistance value of R6, R7
and R8 at the minumum output voltage.
R6 + R7 + R8 = Vminimum / Ir6
R6 + R7 + R8 = 2V / 0.16mA
R6 + R7 + R8 = 12.5Kohm . . . . . . ( Eq 1 )
Now, with R7 set for maximum output voltage;
Vmax = ( ( R6 + R7 + R8 ) / R8 ) x Vbe_t4
30V = ( ( R6 + R7 + R8) ) / R8 ) x 0.7V
42.8 x R8 = R6 + R7 + R8
( 42.8 x R8 ) - R8 = R6 + R7
41.8 x R8 = R6 + R7
R6 + R7 + 42.8 R8 = 0 . . . . . . . . ( Eq 2 )
and with R7 set for minimum output voltage;
Vmin = ( ( R6 + R7 + R8 ) / R8 ) x Vbe_t4
2V = ( ( R6 + R7 + R8) ) / ( R7 + R8 ) ) x 0.7V
2.857 ( R7 + R8 ) = R6 + R7 + R8
R6 + R7 - 2.857 R7 + R8 - 2.857 R8 = 0
R6 - 1.857 R7 - 1.857 R8 = 0 . . . . . . ( Eq 3 )
Now, Eq 2 = Eq 3 is R8 as 470R preset

2.857 R7 - 40.943 R8 = 0. . . . . . ( Eq 4 ) When setting up the power supply, R6 and R8 can be

adjusted to limit the minimum voltage to 2V, and
substitute Eq 1 in Eq 2 maximum voltage to 30V.

Vmax = ( ( R6 + R7 + R8 ) / R8 ) x Vbe_t4

30V = ( 14.2Kohm / R8 ) x 0.7V

42.85 R8 = 14.2Kohm

R8 = 331ohm

Substitute R8 into Eg 4

2.857 R7 - 40.943 R8 = 0

2.857 R7 = 40.943 R8

2.857 R7 = 40.943 x 331ohm

R7 = 4.748Kohm

Lastly, substitute R7 and R8 into Eq 1

R6 + R7 + R8 = 12.5Kohm

R6 + 4.748Kohm + 331ohm = 12.5Kohm

R6 = 12.5Kohm - 4.748Kohm - 331ohm

R6 = 7.42Kohm

To get realistic component values, take:

R6 as 10K preset

R7 as 4K7 linear potentiometer

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 8

Step 5: Current Limiting Circuit

The last pat of the design is a current limiting circuit, For the current limiter to ensure zero voltage output in
which can be adjusted up to 2 amps. an overcurrent condition, transistor T5 must be able
to direct all the current from the constant current
R1, R2, R3 and transistor T5 makes up this circuit. source to 0V. Thus,

Use BC109 transistors for T3. Ice_t5 = Ice_T3

The BC109 transistor has a typical gain of 100. Ice_t5 = 1.6mA

R1 must be a low value, high wattage resistor. A Then,

typical value will be:
Ib_t5 = Ice_t5 / gain_t5
R1 = 0.47ohm
Ib-t5 = 1.6mA / 100
and,
Ib_t5 = 0.016mA
Pr1 = Ir1 ^ 2 x R1
But, Ir2 = Ir3, and we want the current through them
Pr1 = 2 ^ 2 x 0.47 10 times higher than the base current for T5. Now,

Pr1 = 1.88 watt minimum. Ir2 = Ir3 = 10 x Ib_t5

Take rating of R1 at twice calculated rating, or 5W, Ir2 = Ir3 = 10 x 0.016mA

then
Ir2 = Ir3 = 0.16mA
R1 = 0.47ohm, 5W
Now, with pot R3 set to wiper of R2, voltage across
Vr1 at maximum current is R2 will be the same as transistor T5 Vbe, or 0.7V

Vr1_max = Ir1_max x R1 R2 = Vbe_t5 / Ir2

Vr1_max = 2A x 0.47 R2 = 0.7V / 0.16mA

Vr1_max = 0.94V R2 = 4.375Kohm

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 9

R2 = 4K7 preset

At maximum current of 2 amp, Vbe_t5 should still be

0.7V. Now

Vr1_max = 0.94V, and

Vr1_max = Vr2 + Vr3

Vr1_max - Vr2 = Vr3

0.94V - 0.7V = Vr3

Vr3 = 0.24V

So,

R3 = Vr3 / Ir3

R3 = 0.24V / 0.16mA

R3 = 1500ohm

R3 = 1K linear potentiometer

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 10

Step 6: Output Filtering and Stabilization
Capacitor C2
Zener diodes are likely to develop audio noise.
Capacitor C2 mainly serves as a noise filter across
this zener. The value is not critical, with a typical
value of 10uF acceptable. Voltage across capacitor
C2 is the zener voltage, so it is quite low, thus
C2 = 10uf, 16V
Capacitor C3
Transistor T4 forms the negative feedback loop used
to regulate the output voltage. As with any negative
feedback circuit, the circuit can easily go into
oscillation. We can prevent self-oscillation by adding
capacitor C3. The exact value of C3 will be
dependent on circuit board design, and specific
components used. A good value will be anything
between 10pf and 100pf. Thus,
C3 = 10pf .. 100pf
Capacitor C4
Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 11
Capacitor C4 plays an important role, and it must
cater for frequency variations in the output current.
The output impedance of the power supply is very low
for DC and low frequency current variations.
However, if the power supply is say, connected at an
audio amplifier, the amplifier might require high
current peaks at around 10KHz. This will make the
voltage regulator unstable, and cause a high
frequency ripple on the output.
C4 forms a bypass filter at high frequencies. Thus, C4
performs the same function at 10KHz, as that C1
does at 50Hz. A typical impedance for C4 can be
somewhere between 1 ohm and 2 ohm at 10KHz. So
lets make it 1.5 ohm @ 10KHz
Xc4 = 1 / ( 2 x pi x f x C)
1.5 = 1 / ( 2 x 3.14 x 10KHz x C4)
C4 = 10.61uF
Voltage across C4 is the maximum output voltage, or
30V, thus
C4 = 10uf, 50V
Step 7: Output Voltage Time Constant
We need a stable output voltage at low and high
current frequencies, and calculated all capacitor
values to make this happen. But, there is one last
issue we need to calculate. It is the output voltage
time constant. Ideal, this time constant should not
exceed 0.25 seconds.
With the introduction of capacitor C4, changes made
to the output via the resistor R7, will not appear at the
output immediately. This is due to the time constant
of the output circuit.
This can be calculated as follow:
R x C = time constant
Step 8: Additional Power Supply Protection
Diode D1
Diode D1 protects the power transistor should a
reverse voltage spike appear across transistor T1.
This can be any diode rated at around 1 .. 4 amp, and
can be the same as used in the diode bridge. Thus
D1 = 1 amp, 100V
Diode D2
This diode protects the power supply against a
reverse voltage being applied to the output. For
Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 12
where
R is the output resistance (R6 + R7 + R8) in parallel
with R9
C i is the output capacitance (C4)
Wthout R9, the time constant = R x C
t = ( 10K + 4K7+ 330R ) x 10uf
t = 0.152 seconds
Our time constant is faster than 0.25 seconds, so
resistor R9 is not required.
instance, when the power supply is being used to
charge batteries. This diode must be mounted directly
to the output terminal posts, and should not be rated
mmore than twice the output voltage, or 4A. This will
ensure that a small battery will be short-circuited,
without the power supply being damaged.
But, if a large capacity battery is connected
incorrectly, the diode must fail. Although this might
damage the power supply, high currents will only be
present for a short period of time.
Step 9: Voltage/Current Meters

Ammeter

This meter must be custom scaled. Make use of a standard 100uA meter, and add shunt resistors so that the
meter gives full scale at 2 amp.

Voltmeter

This meter must be custom scaled. Make use of a standard 100uA meter, and add series resistors so that the
meter gives full scale at 30 volt.

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 13

Step 10: Final Design and Mounting

In the final step, we must place the components.

Transformer TR1, diode bridge DB1 and capacitor C1 is mounted separately, not on the control
board.
Resistor R1 must be placed where there is good ventilation, as it will get hot at maximum current.
Ensure no wires are running nearby this resistor.
Transistor T1 must be mounted to as large as possible heat sink on the outside of the power supply
enclosure, without any air flow restrictions. Diode D1 is soldered directly onto transistor T1.
Diode D2 must be connected directly across the output terminals of the power supply.
The volt meter is connected directly onto the output terminals.
The ammeter is connected directly across resistor R1.
The rest of the components inside the dotted area are all mounted on a PC Board or veroboard,
leaving only 5 wires connecting the circuit to the high-current components.

Easy Project - Bench Power Supply (0 .. 30V, 2 Amp): Page 14