Three types of multi-functional Homebrew 6/8Amps, 20- and 30 Ampere

regulatable power supplies:

RE PSR28A68, PSR30A20 and PSR30A30

RE-PSR28A6
rev4.1.1
By Guy, de ON6MU

This is an easy to make power supply which has stable, clean and regulatable output voltage. By using
two 2N3055 transistors we become more then 2 times the amount of amps then the power supply
delivers, making it real though to brake ;). Although you could use this design to deliver 20 amps (with
some modifications, see below page), I did not needed such much power. Make sure you mount them
on a huge heat sink, as the 2N3055 transistors can get very hot at full load. Also use thick wires.
Although the LM-317 power regulator will kick in on shortcircuit, overload and thermal overheating, the
fuses in the primary section of the transformer and the fuse F2 at the output will secure your power
supply. The rectified voltage of: 30 volt x SQR2 = 30 x 1.41 = 42.30 volt measured on C1. So all
capacitors should be rated at 50 volts. Caution: 42 volt is the voltage that could be on the output if one
of the transistors should blow.
P1 allows you to 'regulate' the output voltage to anything between 0 and 28 volts. The LM317 lowest
voltage is 1.2 volt. To have a zero voltage on the output I've put 3 diodes D7,D8 and D9 on the output
of the LM317 to the base of the 2N3055 transistors. The LM317 maximum output voltage is 30 volts,
but using the diodes D7,D8 & D9 the output voltage is approx 30v - (3x 0.6v) = 28.2volt.
Calibrate your build-in voltmeter using P3 and, of course, a good digital voltmeter.
P2 will allow you to set the limit of the maximum available amps at the output +Vcc. When using a 100
Ohm/1watt varistat the current is limited to approx. 3 Amps @ 47 Ohm and +- 1 Amp @ 100 Ohms.
Note:
The collectors of the finals needs to be soldered with a wire all together if the transistors even if they
are isolated from the heatsink or not. If you do not isolated the finals from the heatsink, then please
make sure the heatsink does not make contact with the chassis (metal casing where you plan to build
the PS into).
Remember to use thick wires suitable for transfering the current needed according to the power supply
you tend to build.

RE-PSR28A68 Power supply Schematic 1

Part list for 6/8 Amp regulatable power supply (PSR28A68):

2 x 15 volt (30volt total) 6+- amps

D1...D4 = four MR750 (MR7510) diodes (MR750 = 6 Ampere diode) or 2 x 4 1N5401 (1N5408)
diodes.
F1 = 1 Amp
F2 = 10 amp
R1 2k2 2,5 Watt
R2 240 ohm
R3,R4 0.1 ohm 10 watt
R7 6k8
R8 10k
R9 47 0.5 watt
R10 8k2
C1,C7,C9 47nF
C11 22nF
C2 two times 4700uF/50v
C3,C5 10uF/50v
C4,C6 100nF
C8 330uF/50v
C10 1uF/16v
D5 1N4148, 1N4448, 1N4151
D11 LED
D6, D7, D8, D9, D101N4001
IC1 LM317
Two 2N3055 transistors (or 2N3773)
P1 5k

P2 47 Ohm or 220 Ohm 1 watt *

(be sure you can reach 0 ohms as any resistance limits the current)
note:This way of limiting the current is very basic, not an accurate way. To really get an
accurate current limitter we need to modify the schematic around the LM317. P2 has been used
to show a simple way of limitting, it is not the ideal way, but it works. When I have time I will
look into this and place an update on the website.
P3 10k trimmer
Calibration:
- Get your hands on a calibrated digital meter or a good analog meter and measure the voltage
at the output of the power supply.
- Turn P1 to maximum (maximum voltage of our power supply).
- Adjust P3 till the meter needle shows maximum result (end scale)
- If you want to calibrate the scale, turn P1 to several voltages (like every volt) and confirm
each time with your calibrated voltage meter. Make a mark on your power supply meter-scale
to calibrate the meter.
- You should see equal spaced voltage marks on your home-made scale if your meter is a linear
type.

Less maximum output voltage needed?

In operation, the LM317 develops a nominal 1.25V reference voltage, VREF, between the output and
adjustment terminal.
The reference voltage is impressed across program resistor R1 and, since the voltage is constant, a
constant current I1 then flows through the output set resistor R2, giving an
output voltage of

Since the 100 uA current from the adjustment terminal represents an error term, the LM317 was
designed to minimize IADJ and make it very constant with line and load changes.
To do this, all quiescent operating current is returned to the output establishing a minimum load
current requirement. If there is insufficient load on the output, the output will rise.
Less amps needed?
Well, without much modification you can:
- only one 2N3055, will give you 5 amps and have some amps/power to spare.
- the bridge rectifier (D1...D4) only needs 4 x 1N5401 (any +/- 3 amp diodes as only halve of the max.
amp is needed, so we have some room when short-circuited)
- one 4700uF (C2) is sufficient
- F2 = 6 amp
- D5, D10 = 1N4001

The power supply insides

Heat sink
Remember to isolate the transistors from the chassis/radiator! Use a
radiator (heat sink) of appropriate size and surface area; insulating and
heat-conducting spacer or at least a thin mica; hot adhesive and thermal
paste.

Finished power supply:

Note: You can add a 3th 2N3055 and use for R9=27 Ohm, to make a 10/12 ampere power supply of
the design stated above.
This is how Oakkar7 made it (using a PC power supply chassis too!) :
Must see: http://okelectronic.wordpress.com/2011/07/08/diy-variable-workbench-power-supply/
Mark, PA4M, made a 3 ampere version by using just one 2N3055 and build into a Zetagi power supply
box.
He reported a very good linearity of the output voltage over the entire range.

Thanks Mark for the feedback and pictures!

20 ampere regulatable power supply 1...30volt

RE-PSR30A20
(total revision)
RE-PSR30A20 Schematic 2

Major revision of the entire project.

PSR30A20/30 Specs

1.35 volt ... 30 volts

20 ampere PSR30A20 (modify up to 30 amps PSR30A30)
voltage stabilisation
low ripple
short-circuit protection
option: current regulation
HF immunity

Today's highlight!

Part list PSR30A20 or PSR30A30

20/30 Ampere regulatable power supply (30 amp version values in blue):

2 x 14 volt 20+- amps (30 amps)

F1 = 2 Amp (4 amp)
F2 = 25 amp (35 amp)
R1 2k2 - 2,5 Watt
R2 240 ohm
R3,R4,R5,R6 0.1 ohm 10 watt
R7 6k8
R8 10k
optional: R9: 47 Ohm 1 watt. Higher values limits the amps even more. Experiment!
(or 4watt potentiometer for adjustable output amps, but be sure you can reach 0 ohms as any
resistance limits the max. output current)
note:The way I limit the current is just a very basic way, not really an accurate way. To really
get an accurate current limitter we need to modify the schematic around the LM317. R9 has
been used to show a simple way of limitting, it is not the ideal way but it works. When I have
time I will look into this and place an update on the website.
optional S2 mini switch (silver plated)
R10: 10
R11 4k7
C1,C7,C9 47nF
C2 five X 4700uF/50v or one 22000uF/50v
C2 seven X 4700uF/50v or one 22000uF/50 + 10000uF/50v
C3 10uF/50v
C5 1uF/50v
C4,C6,C10 100nF
C8 220uF/50v
C10 4.7uF/16v
C11 2n2
C12 22nF
(C13,C14...100nF optional when using a metal chassis where the zero volt is islolated from)
C15 100nF
C16 10nF
D1...D4= Bridge rectifier MB2504 (25 amps cooled)
or eight BYW29 8 amp diodes (TO220 pinning cooled)
or 8 x MR750 (MR7510) diodes (MR750 = 6 Ampere diode) or 16 x 1N5401 (1N5408) diodes.
D5, D8 1N4148 (1N4448, 1N4151)
D6 & D7 1N4001
D10 1N5401
D11 LED
IC1 LM317
Q1...Q4: Four 2N3055 transistors (six 2N3055) (you can also use the 2N3773 transistor)
Q5 BC338, 2N2222, BC547
P1 5k
P3 10k trimmer
optional: relay = 30 volts AC, 2x10 (3x10) amp switching

Optional (and can be left out together with R9) S2, which switches between +- 5 Amps and full output
current. R9 can be replaced by a 47 or even a 100 ohms potentiometer of 4watt for adjustable output
amps, but be sure you can reach 0 ohms as any resistance limits the max. output current!
The relay is used to switch off the power supply voltage when the mains (S1) are/is switched off. So no
delay do to the discharge of C2, and so preventing output voltages from not return to zero
immediately. You can leave it out if you do not care about slow discharge of the voltage when turned
off, or add a heavy duty secondary switch.
A MB2504 is used as it is a 25 ampere rectifier bridge which also should be cooled. Or you could use
eight BYW29 8 amp diodes (TO220 pinning) mounted on a heat sink.
Mount a little heatsink on the LM317 IC. Be sure that C3, C4, C5 and C6 are mounted as close as
possible to LM317!

Use heavy bread wires that can deliver 20/30 amps

Remember to isolate the 2N3055 transistors from the chassis!
Use a radiator (heat sink) of appropriate size and surface area; insulating and heat-conducting spacer
or at least a thin mica; hot adhesive and thermal paste.
20/30 amp needs proper large heat sink and remember to use pretty thick wires!
Note:
The collectors of the finals needs to be soldered with a wire all together if the transistors even if they
are isolated from the heatsink or not. If you do not isolated the finals from the heatsink, then please
make sure the heatsink does not make contact with the chassis (metal casing where you plan to build
the PS into).
This revision has been improved with a feedback control on the output voltage (Q5, R11,C11,D8),
giving increased stability. However, the lowest voltage is about 1.35v, while in the previous design
(schematic 1) the voltage can by zero.
When problems with spikes or irregular voltage control then try to disconnect Q5 and take it from
there.
Special thanks to Andrew B. concerning the feedback of the output voltage.
Less maximum output voltage needed?
In operation, the LM317 develops a nominal 1.25V reference voltage, VREF, between the output and
adjustment terminal.
The reference voltage is impressed across program resistor R1 and, since the voltage is constant, a
constant current I1 then flows through the output set resistor R2, giving an
output voltage of

Since the 100 uA current from the adjustment terminal represents an error term, the LM317 was
designed to minimize IADJ and make it very constant with line and load changes.
To do this, all quiescent operating current is returned to the output establishing a minimum load
current requirement. If there is insufficient load on the output, the output will rise.
More of my projects: 78h05_powersupply
This is how Ivan Lops made it:

click to enlarge
Many thanks Ivan!!

4 ampere regulatable power supply 1...18volt

RE-PSR4A18

This how Morten LA9DNA build it:

click to enlarge

Thanks Morten!

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