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DIY Small Bench Power Supply

by newtonn2 on September 16, 2014

Table of Contents
DIY Small Bench Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intro: DIY Small Bench Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 1: Materials and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 2: Design and Etching the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 3: Drilling and Fixing Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 4: Heat-sink for the DC-DC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 5: Schematic and Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 6: LEDs On/Off and Limiting Warning (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
File Downloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Step 7: Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

Author:newtonn2 http://www.newtonn2.blogspot.c
Always loved electronics. I like to reuse parts or componets and I Love to be part of the Instructable community.

Intro: DIY Small Bench Power Supply

This is a small bench power supply that I made some time ago, and because I was very busy I couldn't do the instructable for it. I do apologise for taking so long, I hope it
was worth the wait :).
After making my Mini Adjustable Power Supply I was very happy with it, but I was missing a more accurate control of the voltage and current. So I decided to make this
slightly bigger (but still small) bench power supply.
The heart of the unit is basically the same as on the other power supply. It is based on the LM2596S. This IC can handle up to 3A with a good heat sink. I would use it
only for 2A to be on the safe side.
There is a video of the unit working on the last step of this instructable.
Enough talking about it... let's make it...

Step 1: Materials and Tools

Here is a list of materials and tools I used for this project. Many of them can be replaced with other components that you may have already, but I would definitely use an
aluminium enclosure, as I used it as a heat-sink as well. I have tried to find the cheapest components, but double check that the price has not changed, you may find it
cheaper somewhere else.
MATERIALS
-Aluminium Enclosure (link)
-DC-DC Bulk Converter (LM2596S) (link)
-6 Pin Headers (link)
-10k Multi turn Potentiometer x2 (link)
-Potentiometer knobs(link)
-Volt, Amp Metter (link)
-Heat sink paste.
-Toggle Switch(link)
-Rocker Switch(link)
-Nail Polish.
-Nail Polish remover or Acetone.
-Power Panel Mount Connector (link) Check the power supply connector to get an appropriate connector.
-Banana sockets (link) (You may get cheaper ones, but I like the ones on the link because they are smaller)
-Banana test leads (You may have already one, I won't put a link as it may be worth getting a decent one)
OPTIONAL
The rest of the components are only necessary if you want to have LEDs to let you know if you limiting the current or the voltage, and to let you know if the output is set to
on.

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

-attiny85 (link)
-2x Generic PNP transistors
-500R resistor x4 (or a close one)
-10k resistor x2
-100nf ceramic capacitor x2
-5V regulator L7805CV
-Heat-sink for the voltage regulator
-3mm Red LED x2
-5mm Two Colours LED and Panel mount for it.
-Etching Solution (Ferric Chloride) It is also used for PCB etching.
-Two containers for using the etching solution. One should fit inside the other and the inner one has to be big enough so the aluminium enclosure fits inside. (See step 2
for photos). They also need to be heat resistant.
TOOLS
-Dremel
-Cutting disk
-Drill and various drill bits
-Heat glue gun
-Solder and soldering iron
For the optional upgrade of warning LED's you will also need:
Household iron
Laser Printer

Step 2: Design and Etching the Enclosure

After taking measurements of the enclosure and all the components, I designed the layout of the front of the unit with Photoshop. I added the file so you can modify it to
your needs. If you are designing it in another enclosure, just make sure you take into account what's inside the enclosure and fitting points.
Print the design on photo paper and with a good quality laser printer.
Place the front of the aluminium enclosure on top of the photo paper, printed side facing the aluminium. Use the iron to heat as evenly as you can the other side while
applying pressure. Do this for about two minutes, or when you see the back looking like the one on the photo.
Wait for it to cool down, and peel the paper off. If everything when well your design will be left on the enclosure.
Inspect the printed area to see bright spots, and paint them with nail polish. Anything that is not covered will be etched.
Use tape to protect the rest of the front of the enclosure so you don't damage it with the etching solution.
Put some hot water in the bigger container and place the other one inside.
WARNING!! Wear gloves and eye protection when handling the etching solution. Use the solution only in a well ventilated area. The etching solution will
stain yourself as well as pretty much everything it touches, and it will damage anything metal, especially be careful with the sink if is the metal type, when
washing the enclosure.
Pour some of the etching solution in the smaller container and leave for a few minutes to warm up. Place the front of the box in there. Agitate for about two minutes and a
half. (Time will depend on the temperature of the etching solution).
Once it has been etched, wash with cold water. I use some etchant neutraliser to stop the etchant reaction, but it is not necessary if you keep applying cold water for
some time. Apply nail polish and let it dry. Carefully remove the excess to leave nail polish only on the etched area. This may take a few attempts, but I didn't want to
sand the aluminium

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

File Downloads

Small Power supply.psd (1 MB)

[NOTE: When saving, if you see .tmp as the file ext, rename it to 'Small Power supply.psd']

Step 3: Drilling and Fixing Components

I always cover the enclosures with decorators tape to protect it while drilling and cutting it. It also helps the marking procedure as it is a lot easier to mark on the tape than
on the aluminium.
I measured all the components during the design process, so it was a matter of just drilling and cutting where the marks were. Just make sure your components will fit
before this step.
I placed all the components on the aluminium where they will stay so I could access everything to solder the cables.

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

Step 4: Heat-sink for the DC-DC Converter

I decided to use an aluminium enclosure so I could use it also as a heat-sink. I cut a small piece of aluminium and after applying heat paste, I glued it to the back of the
regulator. Then I applied heat paste on the back of the enclosure and hot glued the regulator to the back.

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

Step 5: Schematic and Diagrams

These schematics are self explanatory. The first one is without the LEDs, the second has the option of LEDs for the output and to let you know if you are limiting the
voltage or the current.
The colours on the voltage and current meter may change on your model, so please check your wiring with the meter provider.
Here you can see the schematic bigger.

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

Step 6: LEDs On/Off and Limiting Warning (Optional)

For the CC/CV LEDs I used the dremel to sand a bit of the top of the LED to avoid it being too bright on that area. I drilled an opening on the top of the meter and placed
both of the LEDs inside as per photo.
For the On/Off LED I used some heat shrink, but some tape will do.
Here is the code for the Attiny85, It is very simple, and I'm sure there are ways to do the same without a microcontroller, but I have a few of then around and I love to use
them.
#include
#include
int LED = 1; //LED for CC
int LED2=2; //LED for VC
int Signal=0;
int SignalYN;
void setup() {
pinMode(LED, OUTPUT);
pinMode(LED2,OUTPUT);
pinMode(Signal,INPUT);
}
void loop() {
SignalYN=digitalRead(Signal);
if (SignalYN==HIGH){ // Limiting the Current
digitalWrite(LED,HIGH);
digitalWrite(LED2,LOW);
}else {
digitalWrite(LED2,HIGH); //Limiting the Voltage
digitalWrite(LED,LOW);
}
}

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

File Downloads

powersupplyleds_ino.ino (420 bytes)

[NOTE: When saving, if you see .tmp as the file ext, rename it to 'powersupplyleds_ino.ino']

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

Step 7: Testing
Here is a video of a test of the power supply. I hope you enjoy this instructable. I will be happy to answer any questions or help you out to build your own.

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Comments
50 comments Add Comment

nunorvoliveira says:

view all 92 comments

Mar 15, 2015. 11:53 AM REPLY

Hello,
I found this to be awesome and made it but I'm running into a problem. When the output switch is off, I have about 4.15v on the output terminals when my
display reads 18v. Shouldn't that be 0v? Also, if I set the voltage to a value below 5v the output terminals have a negative voltage of (set value)-5v.
The only difference I have is using 2N3906 instead of the BC327.
Can someone give me some help, please?

DivideWorks says:

Feb 28, 2015. 4:14 PM REPLY

thanks for the awesome instructable.

s3cz0ne says:

Feb 4, 2015. 9:24 PM REPLY

Hello,
I bought a DC-DC LM2596S but stupidly did not notice it only had a pot for voltage. All of the 2596's that have 3 pots that i am finding are without headers.
Did you desolder? Also I am seeing what appear to be two larges capacitors in one of your images... Also what is your input voltage and what kind of PNPs
did you use? I'm sorry but I'm a bit new at this but it would really be great to have one of these for my arduino projects!

deneman says:

Nov 6, 2014. 2:53 PM REPLY

Hi Newton
I searched, but cannot find the dimensions of the aluminium enclosure. I cannot use your source and have to look somewhere else, but I need dimensions if
you can please?
Oh, and thanks

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

dondoerner says:

Feb 4, 2015. 2:03 PM REPLY

I CAN HELP DONDOERNER@SIMPATICO.CA

rpotts2 says:

Nov 11, 2014. 7:15 PM REPLY

102x70x64. it's buried in the link

deneman says:

Nov 12, 2014. 12:02 AM REPLY

Thanks, much appreciated

rpotts2 says:

Nov 12, 2014. 6:36 AM REPLY

NP. If you're in the U.S., the Rat Shack has a similar box. I just found them on ebay for 3.49, free shipping.

deneman says:

Nov 16, 2014. 5:02 AM REPLY

Thanks rpotts2, I am in South Africa. I will check out eBay, although I doubt they will ship to SA for free.

dondoerner says:

Feb 4, 2015. 2:00 PM REPLY

DOES THE TWO 3296 POTS ON THE AC/DC CONVERTER NEED TO BE UNSOLDERED IN ORDER TO ADD THE NEW WIRING?

jdahl2 says:

Dec 6, 2014. 1:24 PM REPLY

I made one out of an old PSU. It works perfect.

newtonn2 says:

Dec 6, 2014. 2:51 PM REPLY

Perfect! Thank you for sharing the photos.

pjkim00 says:

Nov 30, 2014. 9:12 PM REPLY

I read with interest this article when it first came out. I have finally gotten everything together to start constructing mine. Any idea what the third trimpot in the
middle is for?

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

newtonn2 says:

Nov 30, 2014. 10:31 PM REPLY

Hi there,
The third trimpot is to adjust when the middle LED will lit when using it to charge batteries. You can read more about it here:
http://circuit-diagram.hqew.net/Adjustable-LM2596-DC-DC-Step-down-Converter_12827.html
I will be happy to help in any way I can. I hope you have your own Small Bench Power Supply up an running soon.

rpotts2 says:

Nov 11, 2014. 5:23 PM REPLY

Took some searching, but I found the pos connector. for anyone confused, it is hanging out slightly below and to the right of the V/A-meter in the schematic.
this is a pretty nice looking 'ible!

MikC says:

Oct 22, 2014. 8:59 AM REPLY

Sir is this a direct AC input? Pls reply. Thanks :D

Hassanul_ says:

Oct 27, 2014. 6:52 AM REPLY

I believe he's using a DC jack in

qquuiinn says:

Oct 1, 2014. 7:36 PM REPLY

Would cooling be an issue? I have seen several builds like these that use small computer cooling fans to keep the current sink resistors cool.

newtonn2 says:

Oct 15, 2014. 11:09 AM REPLY

Good idea... there are other options... I know there is an electronic bulk converter that allows the set up of the current without a load.
I think this on will do it :
http://www.banggood.com/DC-LED-Digital-Controlled-...
And here is a video so you can see it an action
Me like it :) I will be getting one for sure!

vimajks says:

Sep 29, 2014. 10:23 PM REPLY

Hi newton vim here,

newton about the etching would not the wrinting sooner or later can be scraped off .
after all its toner right .....or does it stay on premanently.
cheers
vim

newtonn2 says:

Oct 15, 2014. 11:00 AM REPLY

Hi Vim,
After the aluminium it's etched, they are groves in the aluminium where the nail polish will be. so even if the nail polish wears off, the aluminium will still
have the "grove" or etch, so you can paint it again if you want.

yoyolo says:

Oct 14, 2014. 5:37 AM REPLY

I am confused about your schematic as to which whether i am suppose to connect each common ground together or the negative terminal on the power
source. Please and thanks

newtonn2 says:

Oct 14, 2014. 5:48 AM REPLY

Hi There
You don't need to connect it to ground. Just get the negatives together. Just keep in mind that negative out from the regulator should not be connected or
touch the input ground.

yoyolo says:

Oct 14, 2014. 6:12 AM REPLY

All right just to make sure, just connect all points with the symbol together? Sorry i do not come from an engineering background, But I really wanted
to make this!

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

newtonn2 says:

Oct 14, 2014. 7:08 AM REPLY

Hi yoyolo. No problem, ask as much as you need to make your own bench power supply. Just connect all the wires/connections with the "ground
symbol" together.

yoyolo says:

Oct 14, 2014. 3:34 PM REPLY

If I were to do the design without the LED's where would I connect the single ground wire?

tbaxter08700 says:

Oct 4, 2014. 2:07 PM REPLY

Great guide. just built it although would just like to say that for the current light you don't need all the extra stuff. Just wire a led up to the on board led that
comes on when the current needs turning up. :)

newtonn2 says:

Oct 14, 2014. 7:12 AM REPLY

Hi there! Thank you very much. You're right, you can solder another LED strait to the board, I did that on my "mini bench power supply" instructable. But
that LED will only light when you are limiting the current, and them will be off when you are limiting the voltage. I wanted to have two separate LEDs that
will let you know strait away without confusion what are you limiting. But what you said it also work, and you will save some components.

valdebenito says:

Oct 3, 2014. 12:53 PM REPLY

Great instructable.
I would like to set/review the CC limit before plugin in the load, and all that I can think is to use a dummy load, say 1R 5W.
Is there a more elegant way to do this?

glennpiercennwh says:

Sep 19, 2014. 4:04 PM REPLY

Hi just another couple of questions :)

Have you tried connecting two of these or your mini supply together to get a negative and positive rail ? Ie the pos output to negative neutral of the other
power supply .
Please could you elaborate on the section of the circuit involving switching the two colour led. May discuss the current flow through the transistors for each
switch state. I get the general idea but am having a hard time seeing how the current flows through the emitter / collector of either transistor as I don't see
how current can flow from emitter to base of either when the switch is open.
Thanks

newtonn2 says:

Sep 21, 2014. 5:47 PM

(removed by author or community request)

gdriver says:

Sep 23, 2014. 7:58 AM REPLY

Hi
Current is going in the opposite direction to the emitter arrow....

newtonn2 says:
You're right, thank you very much for letting me know. Here is how it should be.

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

Sep 23, 2014. 8:21 AM REPLY

glennpiercennwh says:

Sep 24, 2014. 1:43 AM REPLY

That makes sense now. It's funny though I simulated the last circuit and that worked as well so I thought I must be mistaken.

glennpiercennwh says:

Sep 22, 2014. 7:15 AM REPLY

Yeah think I understand that now.

Thanks.

tomatoskins says:

Sep 23, 2014. 8:23 PM REPLY

This is straing up good looking!

FoamboardRC says:

Sep 23, 2014. 10:00 AM REPLY

Very nicely done! I wish I could give it 3 votes instead of 1!

newtonn2 says:

Sep 23, 2014. 10:34 AM REPLY

LOL, Thank you very much!

FoamboardRC says:

Sep 23, 2014. 10:47 AM REPLY

:D

jumpur says:

Sep 22, 2014. 2:05 PM REPLY

nice

comeandshow says:

Sep 22, 2014. 5:54 AM REPLY

excuse if this is very silly question,but this is

i wanna know that the electricity if this power supply come from a ac or dc?

fxxxx says:

Sep 22, 2014. 2:05 AM REPLY

And what about doing short-circuit with the two wires? Is there a protection circuit?

nevils-station says:

Sep 21, 2014. 11:35 AM REPLY

Have you operated this near an AM-BC, Ham SSB, SW, and/or VHF-Aircraft receiver, please?
I'm curious about potential RFI.
Thanks, David KD4E

KROKKENOSTER says:

Sep 20, 2014. 10:07 AM REPLY

When working with power IC'S remember the power difference between input to your regulator / power transistor times the current.I had problems with
overheating and when I calculated the power consumed by the regulator I was way out.The series I.C. or power transistor act like a variable resistor
absorbing the excess power if used in a linear device.

doye says:

Sep 20, 2014. 5:32 AM REPLY

oye

doye says:

Sep 20, 2014. 5:31 AM REPLY

oye

alfplata says:

Sep 20, 2014. 2:06 AM REPLY

Hello Newtonn2,
I appreciate and envy your creativity and, consistent with your busy schedule and your ability, I make a request that I think would help quite a few people.
Are Alfio, leg amputee, Italian, and for greater autonomy, I need a system of suspension of the prosthesis with negative suction that I can not afford for the
high costs of sale.
Would you have an idea for the design and construction of a small vacuum pump with the possibility of adjusting the vacuum to be applied?
I'll send you the link of the system sold by Ottobock but not necessarily the project must be so sophisticated, it could connect to the socket via a simple tube

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

with a two-way valve.

the important thing is the adjustment of the depression with the maintenance of the value reached, all of a smaller burden.
Thank you in advance for your possible directions.
Alfio
http://www.ottobock.com/cps/rde/xchg/ob_us_en/hs.xsl/52959.html
http://www.ottobock.it/cps/rde/xchg/ob_it_it/hs.xsl/14902.html

gluvit says:

Sep 19, 2014. 2:30 PM REPLY

Great

gluvit says:

Sep 19, 2014. 2:30 PM REPLY

Great

turbiny says:
Its far from finished, but it does the job. I tried if it will work and its still in that experimental box.
I'm waiting for a aluminium box big enough to put in a fan and 40v power supply that i took out of old printer.

view all 90 comments

http://www.instructables.com/id/DIY-Small-Bench-Power-Supply/

Sep 19, 2014. 12:12 PM REPLY