Power-Supplies (Page 3)

This is an incomplete version of the power supply used for the Alertness Monitor with hourly LED Display. This circuit used a Dual Color LED. Green meant Alert and Red meant No Alert or acknowledge press.

Power Supply with Battery Backup

I can write here only in “Electronic English”. Focus on the tech not grimmer. It may be like Pascal with a touch of Acronyms, codes and circuit axioms.

The top part is a 5V regulator with 0.7 Diode boost, means 5.7 V DC. The battery was floating on this point above the zener Z4, that connection comes from outside. A protection fuse maybe needed in case Zener draws more current. The Zeners were test selected to get above 6V along with the diode.

The second supply is to drive the LED array and Relay. This second battery supply was needed to prevent the RAM from losing data and also the CMOS logic getting reset, when the relay solenoid operates. Even when the Display Now switch is pushed, the current is large and the pulse could reset digital circuit.

The battery was used very less, it worked during the power failures for short duration between mains and generator switching. This circuit is not meant for in situations when battery drains are high.

I will just explain part of this circuit. D9 and D10 provide a low cost -1.4 from -5 V. This is needed to reach near 0.00 for LM317 Min. setting. An LED also can be used with proper bias. Note that there is a Temperature Coefficient in ppm, see The Unusual Diode FAQ. but it may not matter upto 8 bits accuracy.

TIP2955, TIP3055 (NPN), TIP2955 (PNP) Complementary Silicon Power Transistors. It is a Darlington, that means good current gain. See Darlington transistor – Wikipedia. When current in R1 10E goes more than 50mA a voltage of 50mA X 10E = 500mV is applied across Emmiter-Base junction. So lower than 500mV no bias the tap is turned off, 500mV-700mV the tap starts turning on depending on type of transistor. The transistor is like a water Tap. So TIP2955 carries the major current burden thru the load allowing LM317 to do the decision making when to turn-on or off. It is analog control, it is not On-Off but linear-proportional. The LM317 is very cool as the burden is passed off to TIP2955 who will need a heatsink to keep going and deliver the power you want.

WorkBench Dual Power SupplyPut the filter caps appropriately. The Hum-Noise will be filtered. The cap after the regulator should be a small guy. The main filter cap after the Bridge can be as big as your cabinet or budget.

If you build it and wire it without designing a PCB, then make all wiring and connection very sound. The test of this ability you can know easily, If your project stops working after the last screw of the cabinet is tightened, Then we need to improve.

This is a Regulated Power Supply based on the LM317 IC. It will need a Boost Power Transistor and heatsink for higher currents. It is a versatile building block for stable instrumentation supplies. Consumer Electronic gadgets can use a SMPS chip. In case you wish to use a SMPS for a Precision Instrumentation Block, then take extreme care on Shielding and EMI-RFI.

LM317 based Regulated Power Supply

This is a General Purpose Chip, Series Regulation. It can be varied or trimmed. There is an Internal temperature compensated reference. The minimum trim value is around 1.2. In case you want a Low value voltage like 0.5 with a good current, then use a good negative supply to offset the 1.2 V.

The transformer can be s Split Bobbin with Pri-Sec copper shield foil. This can be earthed along with the metal enclosure. C4 sends any hi-freq components to earth. It is better if you do not earth the ground but use such capacitors. A Supply should simulate a a battery with both ends floating wrt Earth. A option to eartth the ground is fine. This also helps the user to configure his own dual supplies.

Q1 and R5 form a Short Circuit OR current fold back OR constant current mechanism. TP1 can be used to vary the output voltage. Better use something like a Bourns 10T trimpot. An open preset may introduce a noise due to dust and vibration. I don’t remember why i added a zener DZ1, a diode may suffice.

PDF file is here – LM317 – Variable Power Supply

This is a SMPS Circuit application very close to the Application Note in the book SGS Motion Control Application Manual. This worked well. Read about SG2525 – SG3525 – PWM SMPS Regulator Chip.

Some Notes Related to the Project

  • In main circuit do not link different grounds.
  • Main circuit can be used both for 110 AC and 230 AC
  • Ferrites are partial conductors use proper insulation before winding.
  • For main transformer TRX2 use split bobbin for good/safe isolation.
  • Epoxy coated toroids have to be further insulated before winding.
  • Line of isolation between primary and secondary circuits should be explicit.
  • Primary components like Q1, Q2 tabs R5, R6 etc can give shock take caution.
  • Each main module is 500W and can be used in parallel for more current.
  • Q1 and Q2 should have appropriate isolated heatsinks TO220 type 50sq cm
  • Schottky diodes D5, D6 should have heatsinks TO220 type 100sq cm.
  • Diodes D5, D6 eg D83004 are TOP3 packages are used 2 in parallel.
  • For 200W and above R2=0.1e 5W in the main circuit fusible ceramic.
  • C10, C11… Add 4.7uF 100v more in parallel to reduce ripple.
  • C13, C14 can be 250V for better safety margin.
  • TRX1 SEC1 and SEC2 dot polarity is anti-phase if same phase danger!!

100kHz Half Bridge Convertor - SG3525
Zoom Image

Magnetics Design

All Transformers Isolation 1kV PRI To SEC / SEC To SEC / PRI,SEC To Core. Use Yellow Mylar Tape Insulation or better for all. Vacuum Impregnate all Magnetics in Epoxy or Varnish. All Power Tracks on PCB reinforce with Copper Braid.

TRX1 Mosfet Drive Transformer

T25.0 MGQ-5L Hitachi – Type Torroid – 100khz Signal

  • PRI1 20 Turns #22 Awg
  • SEC1 9 Turns #22 Awg
  • SEC2 9 Turns #22 Awg

486T250-3C8 Ferroxcube – SEC1 And SEC2 Antiphase

TRX2 Stepdown Invertor Transformer

EC52 Siemens/Hitachi – Can Be ETD/EER Cosmo Ferrites

  • PRI1 22 Turns 2 Layers (44 Turns) – 2* #16 Awg(18 Swg) In Parallel.
  • SEC1 4 Turns Ct Copper Strap 0.01″ * 0.8″ Copper Strap

Coper Strap/Ribbon used, cause Hi-Freq Skin Effects, PRI 2 Wires paralleled for same reason.
EC52-3C8 Ferroxcube Phillips

Trx3 Current Feedback Trx

T25.0 MGQ-5L Hitachi – Type Torroid – 100khz Signal

  • PRI1 1 Turn 4 Amps Max
  • SEC1 20 Turns #22 Awg CT.
  • Ceter Tap 10T-CT-10T

486T250-3C8 Ferroxcube

L1 Series 60A-80A Inductor

Type EC/ETD/EER EC42 Hitachi – Air Gap In Inductor Core Both Sides
100khz Power IF30-3C8 Ferroxcube – 6 Turns 4*#12 AWG In Parallel

4 Wires Of 12 AWG Twisted & Wound For 6 Turns (Use Less AWG For Less I)

TRX5 50hz Transformer Small

  • PRI1 & PRI2 115v
  • SEC1 24V 0.2A
  • JP2 2-3 Short 230V
  • PRI1 & PRI2 In Parallel For 110V
  • JP1 1-2 Short 230V 2-3 Short 110V

TRX4

This is A 10mH Common Mode Filter

The Reference Application on ST Half Bridge Convertor – SG3525

PCB Layout

The PCB of module will be added later, if i locate it. It is small and be designed easily.

When a Inverting Opamp Configuration is at a steady state, we say the Inverting Input is at a Virtual Ground. That means it is at 0V w.r.t to the dual power supply ground, but it cannot drive or draw any current. It is at a high impedance, but still at 0V. When you buffer this 0 V, you get a low signal ground for a opamp supply.

Opamp Supply on Buffered Virtual Ground

This gnd. can sink and source in a couple of mA. You can use it with low power opamp circuits for portable battery operated devices. This creates a virtual +/- 6 V dual supply from a 12V battery. This may be needed in cases where some instrumentation opamps need the negative supply or your design demands a measurement around zero. You may get a more loadable ground using a Power Opamp, i have not tried. The above circuit gnd cannot be used as a return path for LED’s or Relays. You can drive these, between VCC-VDD, but translate levels to drive them.

A Center tap 50Hz Step Down Transformer with two diodes is used to get a train of Positive Sine Pulses at 100Hz which is applied to Q6 base via R51. 2N2646 is a unijunction transistor(UJT) in a TO-18 metal package. The control voltage or voltage proportional to error is fed to R56-Q3, The UJT drives a pulse transformer which provides isolation from the Load which the SCR bridge is controlling. This phase angle control gives a near Linear closed loop control for a SCR bridge which may be used in Electroplating or a Preregulator of a big power supply.

2N2646 based Voltage controlled SCR Pulser

This is a Regulated 0-30 V DC Power Supply manufactured by me in small numbers, 0-30V 5A and 5V -5A. It had a Switching Preregulator. This keeps the Vce across Transistor Bank at the Back of Instrument, at the lowest possible level, in order to keep them Cool. When Vce and Ic both are more in a Power transistor it will get heated more, then the efficiency of power supply is low.

Variable Regulated Power Supply

The Output had both Constant Current Control and Constant Voltage Control. The CC control is also a Short circuit protection. The Output was protected from outside voltages damaging output circuits even when equipment is switched off. The back panel is a finned anodized black aluminum heat sink with many transistors.

I looked for the circuits to scan them, i could not find it. I made-n-sold quite a few of them years ago. All of them work well even today as i over-rated most components. The cabinet was Steel for EMI-RFI Immunity, it was painted with Stipple Matt Powder Coating, the Cabinet maker had just learnt to give such a finish to his boxes.

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Study these applications at IRF Applications and ST Application Segments.