ECE 322

Winnie Tafempa Messa

OREGON STATE UNIVERSITY

Variable Power Supply

Date Description Contributor
10/4/16 Initial Creation Winnie Tafempa
10/11/16 Assembly of the power supply Winnie Tafempa 1. Re
10/18/16 Brainstorming on the voltage regulators Winnie Tafempa vis
10/25/16 Assembly of the positive voltage regulator Winnie Tafempa ion
10/27/16 Assembly of the negative voltage regulator Winnie Tafempa
11/1/16 Improved project specifications Winnie Tafempa
11/8/16 Built discharge circuit Winnie Tafempa
11/22/16 Rebuilt negative voltage regulator Winnie Tafempa
11/23/2016 Rebuilt positive voltage regulator Winnie Tafempa
History

2. Introduction

TheprojectdescribedinthisdocumentisatwochannelDCvariableDCpowersupply
intendedtobeconstructedbystudentsintheECE322courseatOregonStateUniversity.This
projectwillbelooselyassociatedwiththeTekBotsprogramandshouldbebasedonprevious
studentexperience.
Theprojectneedstobethebestfitforthefollowingpriorities;EducationalMerit,Student
TimeCommitment,InstructorBuyin,FutureReusability,andcost.

CustomerRequirements&ProductBackground
TheECE322courselabcomponenthasnotbeenupdatedtoreflectnewteachingmethods
ournewcontentsince1996.Thiscourseisbadlyinneedoftheseupdates.TheTekBotsgroup
wasaskedtohelptodevelopanewlabexperiencetobetterfitmodernmethodsandinformation.
Norestrictionwasplacedonthedevelopmentotherthanthoseenforcedbythelectureportionof
the course in terms of duration, student enrollment, lab facilities, and previous student
experience.
Fromthisinformation,manypossiblethemesand/orideasweregeneratedwithaDCpower
supplybeingthebestcandidateselected.Thedeliberationsandtradeoffsmadetodecideona
DCpowersupplyareoutsidethescopeofthisdocumentandarenotcovered.
CriteriaofInterest
EducationalMeritTheprojectneedstohelpstudentslearnnewinformationasefficiently
aspossible.Themetricofeducationalmeritisasomewhatambiguousterm.Educationalmeritis
ascribedonaratingof2,1,or0points.Pointsareassignedthroughgroupdeliberationswitha
groupassignmentofmerit.Factorsthatarereviewedduringgroupdeliberationare:
ConnectiontoLecture:Ratherthanhavingalabinavacuum,itisbesttolabthelabmaterial
and tasks support the lecture material andvice versa.Students learning using multisensory
approachesandperformingtasksthatrequireknowledgesynthesisarebetterabletoretainand
useknowledge.
 Fundamentals: Projects that help to expose more fundamental knowledge rather than
specificnichetopicsgivethestudentsastrongerbasisforlatercoursework.
Sophistication:Istheprojectappropriateforthestudentlevel?Typicalstudenttranscripts
arereviewedandprojectdifficultyismatchedtostudentexperience.Howmanydifferentareas
of knowledge are required? Is the number of missing topics acceptable? Can a student be
expectedtolearnwhatismissing?
RealWorldSimilarity:Doestheprojectadequatelyshowtherealworldofengineering?Is
theprojectcontrivedortoidealizedtoshowthemessynatureofengineering?Dotheproject
forcestudentstoconnectmultipledisciplinesinsideandoutsideofelectricalengineering?
StudentTimeCommitmentThisistheexpectednumberofhoursperweekastudentwill
spendontheproject.Thistimeincludesscheduledlabtimeandtimeoutsideoflabaswell.
InstructorBuyin Iftheinstructorlikestheprojecttheyaremorelikelytoinvolvethe
projectintheirlecturematerial.Thiscreatesatighterconnectionbetweenlectureandlaband
promotesbetterstudentunderstanding.
FutureReusabilityWilltheprojectbereusablebythestudenteitherforclassesorfor
someexternalpurpose?Projectsthathaveaclearpathforreuseallowforamortizationofstudent
effortandmonetaryinvestment.Thisallowsforajustificationofmoresophistication.
CostThisistheactualcostindollarsoftheproject.

3. Product Space Analysis

DC power supplies commonly fall into one of two categories, switching and linear.
Switchingsuppliesaremoremodernandinvolvevoltageconversionthroughchargingand
discharging of capacitors and inductors. This method allows for both stepdown voltage
conversionandstepupvoltageconversion.
Linear voltage regulation allows for only stepdown conversion with excess voltage
convertedtoheatandwaste.

1. TargetFeatureSet
Twochannels,onepositiveandtheothernegativewhenreferencedground.
Eachchannelmust:
o Supplyaminimumof2voltsforallloads(lowerisbetter)
o Becapableofsupplying12voltswhileloadedto900mA.
Atanyloadlessthan900mAthepowersupplystillneedstobeabletoachieve2(or
less)and12volts(ormore)
Currentlimitingcircuitryforeachchannel,protectingabove1amp+/10%.
Voltageripplelessthan0.75Vppperchannelwithbothchannelsfullyloadedto900mA.
Externalconnectionsforleadsandvoltageadjustment.
Safelyequippedwithacoolingfanthatshouldnotnormallyberunningat70Fbutshould
reachratedspeedaround95F.
Dischargesthefiltercapacitoroneachchanneltounder3voltsin5secondsorlesswhen
themainpowerswitchisturnedtooffandthereisnoloadpresentontheoutputofthe
supply.
Maximallystudentdesigned
 Utilizesasafetyfuse.
Humansafewithshortcircuitprotection
EasilyaccessibleACpowerswitch.
Aclearlyvisiblepowerindicationlight.
CoreconceptsdrawnfromlectureportionofECE322
VoltageRegulatorsmustuseBJTs
Forcedesignspecificationskills
Introducephysicalprototypingskills
Helpstudenttounderstandvalueofsimulationbeforebuild
Motivateproperdiligencethroughstudentresponsibility
4. ArchitecturalOverview
1. ImplementationApproach
Theprojectwillbedonewithlinearvoltageregulationasitmoredirectlyreliesontheconcepts
taught in ECE322. The concept of DC analysis and input/output impedance is strongly
emphasizedinlinearregulators.Switchingsupplieswhilemoreefficientandrelyingonsimilar
conceptsintroducetransientelementsthatarenotinthescopeofthecourseandcouldneedlessly
confusestudents.
TheenforceduseofBJTsalsocausesstudentstoworkmorewiththeconceptsfromthecourse.
Whilethisisanartificialrestriction,itshouldresultinbetterpreparedstudents.
Thedesignmustbeabletosupplyratedcurrentatthespecifiedvoltagerange.Thisrestriction
willforcestudentstoexploreinputandoutputimpedancestobestdesigntheircircuits.This
approachshowstheinterconnectionofcircuits,asnocircuit(includingpowersupplies)existsin
avacuum.
ApurchasedkitwithincludedcustomPCBwhileallowingforeasystudentsuccesswouldnot
meet the goals of a student authored design. Even if many of the parts were removed and
studentsaskedtocalculatevalues,thelabwouldfeelcontrivedandveryfewsolutionswould
exist.Flexibilitywasdeemedmoreimportantthaneaseofuse.

5. Top Level Description

1. Theory of operation
ThedesignedpowersupplyconnectstoaUSstandardACwalloutletof120VAC.Itdrawsno
morethan500mAwhiledeliveringfullypowertoitstwoDCvoltageoutputs.Therearetwo
outputchannels,onepositiveandonenegative.Bothchannelsshareasinglecommonground.
Eachoutputistobeadjustablebyapotentiometer.Eachvoltageoutputwillsupplyvoltagesfrom
2to12volts.Ascurrentisdrawnfromtheoutputs,thevoltagewillremainsteadyuntil900mAis
reached.At900mAofcurrent,thepowersupplywillbecomeaconstantcurrentsourceallowing
forovercurrentprotection.OptionallytherewillbeindicatorLEDdenotingwhenthepower
supplyovercurrents.
2. Top level block diagram

Positive Voltage
Regulator +2 to 12V

17.3V
AC Rectifier
 GND
120VAC Negative Voltage
Regulator

-17.3V
-2 to -12V
1. Top level Interface Definition

Name Type Description

ACInput Input Frequency:60Hz
Voltage:120VAC
MaximumCurrent:.5Amps
PositiveVoltageOutput Output VoltageRange:
o Supplyaminimumof2volts
forallloads(lowerisbetter)
o Be capable of supplying 12
voltswhileloadedto900mA
MaxCurrent@AllVoltages:.9Amp
CurrentLimit:1Amps+/10%
MaximumRipple:.75VPP
Negative Voltage Output VoltageRange:
Output o Supply a minimum of 2
voltsforallloads(lowerisbetter)
o Becapableofsupplying12
voltswhileloadedto900mA
MaxCurrent@AllVoltages:.9Amp
CurrentLimit:1Amps+/10%
MaximumRipple:.75VPP
Positive Voltage Input AdjustmentMethod:Dial/Potentiometer
Adjustment FullScale:SingleTurn
Negative Voltage Input AdjustmentMethod:Dial/Potentiometer
Adjustment FullScale:SingleTurn
V+ InternalPower NominalVoltage:18VDC
MaxCurrent:900mA
MaximumRipple:.75VPP
V InternalPower NominalVoltage:18VDC
MaxCurrent:900mA
MaximumRipple:.75VPP
DischargeSupply InternalPower NominalVoltage:36VDC
MaxCurrent:900mA
MaximumRipple:.75VPP
DischargeSignal InternalSignal LEDturningoffafterafewseconds
6. Functional Unit Description
1. Chassis

Front Panel Sketch

Rear Panel Sketch

Transformer

Voltage AC rectifier
regulators PCB
 Approximate outline of the interior of the case

2. AC rectifier block diagram

System outputs
System inputs
Total output: 72.8 LED
Wall voltage Vrms (36.4 VrmsFull
Center Tapped whenBridge Filtering 17.3V Ripple
110-120 VAC measured
Transformer from one rectifier Capacitors voltage =
line to center)
0.75Vpp
-17.3V

1. AC rectifier interface definition

Name Type Description

AC Input Input Frequency: 60Hz
Voltage 120VAC
Maximum Current: 1A
V+ Internal Power Output Voltage Range:
~16 to 18V
V- Internal Power Output Voltage Range:
~-16 to -18V
LED Indicator ON if power supply is
ON
OFF if power supply is
OFF
Reference: Output The reference voltage
(GND)
AC rectifier Interface diagram

6.2.2 ACRectifierSchematicandTheoryofOperation
The AC rectifier is designed to convert 60Hz 120VACrms down to usable 1-12V DC, by
using a transformer. The DC output from the rectifier has a periodic ripple with maximum
peak-to-peak amplitude of less than 0.75V

3. Positive Voltage Regulator Block Diagram

16~18 Darlington Pair Current Sense

Volts Amplifier Resistor
(NPN)

GND Current
Sense
GND Transistor

Feedback
 1. Positive Voltage Regulator Interface definition

Inputs Outputs
Rectified voltage System (Positive 2~12V adjustable voltage 1A
(16~18V) adjustable Voltage current limited
regulator)

Reference voltage
(GND)
Reference voltage (GND)

positive potentiometer feedback

Name Type Description

Rectified input voltage Input Voltage Range:
~16 to 18V
Reference Input GND
Positive Regulated Output Output Voltage range: 2-12V
Voltage Max current: .9A
Current limit: 1A +/- 10%
Maximum Ripple:.75Vpp
Reference Output GND
Potentiometer feedback I/O Used internally to the voltage
regulator

2. Positive Voltage Regulator Schematic and Theory of Operation

The output voltage is set by the voltage divider that is created by the resistors in this circuit.
Thus, the output current does not affect the voltage across the load. When the Vout drops, the
feedback of it dropping increases the current going into the base of the Darlington pair, which
raises the voltage back to what it was supposed to be.
The ability of the potentiometer to change this output voltage is assimilated to changing the
characteristics of the voltage divider.
The current limiting also uses this feedback system: when the voltage across the current limiting
resistor is greater than Vbe(on) for the current limiting transistor, its feedback reduces the
voltage and consequently the current that flows through the load.
To obtain the values of R4 and R5
We know that we are supposed to get a Vregulated between 2 and 12V, so we need to calculate
R4 and R5 so that they give us those values. I calculated R4 and R5
Voltage divider between the potentiometer and R4 (when the potentiometer is at its max, R5 is
negligible).
Vregulatedmax
xR5=0.7V(VbeofQ3).BysettingVregulatedmaxto14V(abovethe
9.4 K +R 5
9.4 K0.7
maxrequired,toallowforasafetymargin),IgetR5= =494.73 ohms .I
140.7
chosetousea470ohmsresistor.
Vregulatedmin
Withtheequation xR5=0.7(andsettingVregulatedminto1.1V)Iget
R 4 +R 5
VregulatedminR 50.7R 5
R4 = =268.57 ohms , I chose to use a 220 ohms
0.7
resistor.

4. Negative Voltage Regulator Block Diagram

Adjustable
output

-16~-18 Darlington Pair Current Sense

Volts Amplifier Resistor
(PNP)

GND Current
Sense
GND Transistor

Feedback
 1. Negative Voltage Regulator Interface definition

Inputs Outputs
Rectified voltage System (Negative -2~-12V adjustable voltage
(-16~-18V) adjustable Voltage 1A current limited
regulator)

Reference voltage
(GND)
Reference voltage (GND)

negative potentiometer feedback

Name Type Description

Rectified input voltage Input Voltage Range:
~-16 to -18V
Reference Input GND
Positive Regulated Output Output Voltage range: -2~-12V
Voltage Max current: .9A
Current limit: 1A +/- 10%
Maximum Ripple:.75Vpp
Reference Output GND
Potentiometer feedback I/O Used internally to the voltage
regulator
 2. Negative Voltage Regulator Schematic and Theory of Operation

The output voltage is set by the voltage divider that is created by the resistors in this circuit.
Thus, the output current does not affect the voltage across the load. When the Vout drops, the
feedback of it dropping increases the current going into the base of the Darlington pair, which
raises the voltage back to what it was supposed to be.
The ability of the potentiometer to change this output voltage is assimilated to changing the
characteristics of the voltage divider.
The current limiting also uses this feedback system: when the voltage across the current limiting
resistor is greater than Vbe(on) for the current limiting transistor, its feedback reduces the
voltage and consequently the current that flows through the load.

To obtain the values of R4 and R5:

We know that we are supposed to get a Vregulated between 2 and 12V, so we need to calculate
R4 and R5 so that they give us those values. I calculated R4 and R5
Voltage divider between the potentiometer and R4 (when the potentiometer is at its max, R5 is
negligible).
Vregulatedmax
*R5=0.7V(VbeofQ3).BysettingVregulatedmaxto14V(abovethe
9.4 K +R 5
9.4 K0.7
maxrequired,toallowforasafetymargin),IgetR5= =494.73 ohms .I
140.7
chosetousea470ohmsresistor.
Vregulatedmin
Withtheequation *R5=0.7(andsettingVregulatedminto1.1V)Iget
R 4 +R 5
VregulatedminR 50.7R 5
R4= =268.57 ohms ,Ichosetousea220ohmsresistor.
0.7
 5. Capacitor Discharge
1. Capacitor Discharge interface definition

Name Type Description

AC Input Input Frequency: 60Hz
Voltage 120VAC
Maximum Current: 1A
V+ Internal Power Output Voltage Range:
~16 to 18V
V- Internal Power Output Voltage Range:
~-16 to -18V
LED Indicator ON if power supply is
ON
OFF if power supply is
OFF
Reference Output The reference voltage
(GND)

2. Capacitor Discharge schematic and theory of operation

The capacitor discharge circuit discharges the filter capacitor on each channel to under 3V in five
seconds or less, when the main power switch is turned to off and there is no load present on the
 output of the supply. The discharge circuit does not also increase the ripple voltage of the
capacitor when the power supply is turned on beyond 0.75 Vpp.
When the switch is ON, Vg-Vs <Vt. When the switch is off, Vg-Vs>Vt. The discharge time is
proportional to (R1*(C1//C2))+(R2*C3)). R2 and C3 should be big enough to keep the MOSFET
OFF when the switch is ON, so that it does not increase the voltage ripple of the filter capacitors.
On the other hand, R2 and C3 should be small enough to discharge the capacitors in the required
time when the switch is OFF.
To find the values of R2, C3 and R1 :
31+32< 5s 3(R2C3)+(3(C1//C2)*R1) < 5.
By choosing C3 = 10F, C1//C2 = 7500F.
To keep the ripple steady without increasing it, the following equation has to be respected, with
Vp Vp
Vth being the MOSFET threshold voltage: <Vth . <R2 ,
fR 2 C 3 fVthC 3
17.30.7
< R 2 , (Vth = 2.1V) R2> 13.17K. I chose R2 = 22K. Then by reusing the
60101062.1
above equation, , 3(R2C3)+(3(C1//C2)*R1) < 5
53 C 3R 2 531010622000
R1< . R1< . R1 < 192.88 . I chose to put a parallel
3 C 1 / C 2 37500 F
combination of three 470 resistors in series with one 100 . The first time I put one 100
resistor, and the circuit blew because there was too much power going through the resistor, so I
put the resistors in parallel to split the power and cause less damage.

7. Testing
1. BlockTests
For this project Items that fall under functional tests are listed below along with
recommendedtestingprocedures.
1. ACRectifierTwochannels,onepositiveandtheothernegativewhen
referencedtoground
1. PowertheACrectifierwithwallinput.
2. SetthemultimetertomeasureDCvoltage.
3. Connectthepowersupplysgroundtothegroundofthemultimeter.
4. ConnectoneoutputoftheACrectifiertothevoltageinputofthemultimeter.
5. Checkthereadingonthemultimeter.
6. Connecttheotheroutputoftherectifiertothevoltageinputofthemultimeter.
7. Checkthereadingonthemultimeter.
PASS:Oneoutputreadspositivevalueandtheotheronereadsnegativevaluewhen
referencedtoground.
FAIL:Bothoutputsarepositive,negative,orzerowhenreferencedtoground.

2. ACRectifierRectify60Hz,120VACrms toDC

1. PowertheACrectifierwithwallinput.
2. Connectthepowersupplysgroundtothegroundofthemultimeter.
3. ConnectoneoutputoftheACrectifiertothevoltageinputoftheoscilloscope.
4. Checktheoscilloscopeoutput.
 5. ConnecttheotheroutputoftheACrectifiertothevoltageinputofthe
oscilloscope.
6. Checktheoscilloscopeoutput.
PASS:TheoscilloscopereadsDCvoltageforbothrectifieroutputs.
FAIL:TheoscilloscopereadsACvoltageornovoltageforeitheroutput.

3. ACRectifierCapableofsupplyingatleast900mAampperchannel
continuously
1. FollowtheinstructionontheECE322teststation.
2. ConnecttheECE322teststationtotheACrectifieroutputs.
3. ConnecttheECE322teststationtoanampmeter.
4. Switchthestationtotestchannel1.
5. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast900mA
6. Switchthestationtotestchannel2.
7. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast900mA
PASS:Theampmeterforbothchannelsreadsatleast900mA.
FAIL:Theampmeterdoesnotreadatleast900mAforeitherchannel.

4. ACRectifierVoltagerippleoutofthefilterislessthan0.75Vppperchannel
withbothchannelsfullyloadedto900mA
1. FollowtheinstructiononECE322teststation.
2. ConnectECE322teststationtotheACrectifieroutputs.
3. ConnecttheECE322teststationtoanampmeter.
4. Switchthestationtotestchannel1.
5. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
900mA.
6. ConnectVOLT+oftheteststationtothevoltageinputoftheoscilloscope.
7. Checkoscilloscopewaveform.
8. Switchthestationtotestchannel2.
9. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
900mA.
10. ConnectVOLT+oftheteststationtothevoltageinputoftheoscilloscope.
11. Checkoscilloscopewaveform.
PASS:Theoscilloscopewaveformshowsvoltageripplessmallerthan0.75Vppfor
bothchannels.
FAIL:The oscilloscope waveformshows voltageripplelargerthan 0.75Vppfor
eitherchannel.

5. ACRectifierEasilyaccessibleACpowerswitch
VisualinspectionbytheTA
PASS:TheACpowerswitchismountedonthefrontorbacksideofthepower
supplyandcanturnthesystemonandoff
 FAIL:TheACpowerswitchisnotmountedonthefrontorbacksideofthepower
supplyorcannotturnthesystemonandoff

6. ACRectifierAclearlyvisiblepowerindicationlight
1. Flipthepowerswitchtoonmode.
2. Checktheindicationlight.
PASS:Thepowerindicationlightismountedonthefrontorbacksideofthepower
supplyandcanturnonandoffwiththeswitch
FAIL:Thepowerindicationlightisnotmountedonthefrontorbacksideofthe
powersupplyorcannotturnonandoffwiththeswitch

7. ACRectifierAssembledsafelyandwithnoelectricalhazardsandutilizesasafety
fuse
1. Makesurethepowersupplyisnotpluggedintothewall.
2. Openthefusesocket.
3. Checkifafuse(atleast1amp)ispresent.
PASS:Thepowersupplyisassembledsafelywithoutloosewire(s)andpotential
shortage,andafuseispresentinthefusesocket.
FAIL:Thepowersupplyisnotassembledsafelyorhasloosewire(s)orshorts,orafuse
isnotpresentinthefusesocket.
8. VoltageRegulatorsOnepositivechannelwhenreferencedtogroundis
capableofsupplyingatleast900mAcontinuously(2~12V)
1. FollowtheinstructiononECE322teststation.
2. Connectchannel1oftheECE322teststationtothepowersupplysgroundand
positivechannel.
3. ConnecttheECE322teststationtoanampmeter.
4. ConnecttheECE322teststationtoavoltmeter.
5. Switchthestationtotestchannel1.
6. Setthepowersupplytooutput12Vorhigher.
7. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
900mA.
8. Checkboththevoltmeterandtheampmeter.
9. Setthepowersupplytooutput2Vorlower.
10. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
900mA.
11. Checkboththevoltmeterandtheampmeter.
PASS:10%of12Vand10%of900mAcanbedisplayedatsametimeonthe
voltmeterandampmeterAND10%of2Vand10%of900mAcanbedisplayedat
sametimeonthevoltmeterandampmeter.
FAIL:10%of12Vand10%of900mAcannotbedisplayedatsametimeonthe
voltmeterandampmeterOR10%of2Vand10%of900mAcannotbedisplayedat
sametimeonthevoltmeterandampmeter.
9. VoltageRegulatorsOnenegativechannelwhenreferencedtogroundis
capableofsupplyingatleast900mAcontinuously(2~12V)
1. FollowtheinstructiononECE322teststation.
2. Connectchannel2oftheECE322teststationtothepowersupplysgroundand
negativechannel.
3. ConnecttheECE322teststationtoanampmeter.
4. ConnecttheECE322teststationtoavoltmeter.
5. Switchthestationtotestchannel2.
6. Setthepowersupplytooutput12Vorhighermagnitude.
7. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast900mA.
8. Checkboththevoltmeterandtheampmeter.
9. Setthepowersupplytooutput2Vorlowermagnitude.
10. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast900mA.
11. Checkboththevoltmeterandtheampmeter.
PASS:10%of12Vand10%of900mAcanbedisplayedatsametimeonthe
voltmeterandampmeterAND10%of2Vand10%of900mAcanbedisplayedat
sametimeonthevoltmeterandampmeter.
FAIL:10%of12Vand10%of900mAcannotbedisplayedatsametimeonthe
voltmeterandampmeterOR10%of2Vand10%of900mAcannotbedisplayedat
sametimeonthevoltmeterandampmeter.
10. VoltageRegulatorsMustsupplyarangeofatleast2~12Vunderallload
conditions
1. Makesurethepowersupplydoesnothaveaload.
2. Usingavoltmeterandmeasurethepositivechannelofthepowersupplywith
referencetoitsground.
3. Adjustthepositivechannelcontrolknobofthepowersupplytooutputthehighest
voltage.
4. Checkthevoltmeter.
5. Adjustthepositivechannelcontrolknobofthepowersupplytooutputthelowest
voltage.
6. Checkthevoltmeter.
7. Adjustthenegativechannelcontrolknobofthepowersupplytooutputthehighest
magnitudeofvoltage.
8. Checkthevoltmeter.
9. Adjustthenegativechannelcontrolknobofthepowersupplytooutputthelowest
magnitudeofvoltage.
10. Checkthevoltmeter.
PASS:Thepowersupplyhavepassedtheprevioustwotests,ANDcansupplyarangeof
atleast2~12Vwithnoload.
FAIL:Thepowersupplydidnotpassoneorbothoftheprevioustwotests,ORcannot
supplyarangeofatleast2~12Vwithnoload.

11. VoltageRegulatorsPositiveChannelhasoverloadprotectiontolimit
currentto1A10%
1. FollowtheinstructiononECE322teststation.
2. Connectchannel1oftheECE322teststationtothepowersupplysgroundand
positivechannel.
3. ConnecttheECE322teststationtoanampmeter.
4. Switchthestationtotestchannel1.
5. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast1A.
6. Checktheampmeter.
7. Slowlykeepondecreasingtheresistanceuntilminimumresistanceisreached.
8. Checktheampmeter.
PASS:1A10%wasobservedforpositivechannel.
FAIL:1A10%wasnotobservedforpositivechannel.
12. VoltageRegulatorsNegativeChannelhasoverloadprotectiontolimit
currentto1A10%
1. FollowtheinstructiononECE322teststation.
2. Connectchannel2oftheECE322teststationtothepowersupplysgroundand
negativechannel.
3. ConnecttheECE322teststationtoanampmeter.
4. Switchthestationtotestchannel2.
5. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast1A.
6. Checktheampmeter.
 7. Slowlykeepondecreasingtheresistanceuntilminimumresistanceisreached.
8. Checktheampmeter.
PASS:1A10%wasobservedfornegativechannel.
FAIL:1A10%wasnotobservedfornegativechannel.
13. VoltageRegulatorsPowersupplyassembledsafelyandwithnoelectrical
hazards
1. Opentheblackcoverofthepowersupply.
2. Examinetheinside.
PASS:Thepowersupplyisassembledsafelywithoutloosewire(s),looseboard(s),and
potentialshortage.
FAIL:Thepowersupplyisnotassembledsafelywithloosewire(s),orlooseboard(s),
orpotentialshortage.
14. VoltageRegulatorsBJTUsage
1. Visuallyverifycomponentsused.Allsemiconductorcomponentsusedin
constructionofvoltageregulatorblocksmustBJTcomponents.
PASS:AllsiliconcomponentsareBJTs
FAILAllsiliconcomponentsarenotBJTs

15. ThermalProtectionBlockFunctionalcoolingfan
1. Turnonthepowersupplyandwaitfor30seconds.
2. Observethefan.
3. Touchthethermistorwithtwofingers.
4. Observethefan.
PASS:Thefanisnotrunningat70oF(roomtemperature)ANDthefanstartstorunat
around95oF(whentouchedwithfingers).
Fail:Thefanisrunningatbelow70oFAND/ORthefandoesnotstarttorunatabove
95oF.

16. ThermalProtectionBlockDesignshoulduseanOPAMPandaBJTor
MOSFETtocontrolthefan.
1. Checkthefancircuitwiththedesignedschematic.
PASS:ThefancircuitwasdesignedusinganOPAMPandaBJTorMOSFET.
FAIL:ThefancircuitwasdesignedwithoutusinganOPAMPoraBJTorMOSFET.

17. ThermalProtectionBlockThefananditscontrolcircuitareassembled
safelyandwithnoelectricalhazards.
1. Shortthepowersupplyspositivechanneltoground.
2. Waitforabout20~30seconds.
3. Checkthefan.
PASS:Thefanturnsonaftershortingthepositiveoutputtoground,ANDisassembled
withoutanyloosewire(s),looseboard(s),andnopotentialshortage.
 FAIL:Thefandoesnotturnonwithin30secondsaftershortingthepositiveoutputto
ground,ORisassembledwithloosewire(s),looseboard(s),orhaspotentialshortage,OR
thepowersupplyisdamagedduetoshortage.

18. CapacitorDischargeBlockThefiltercapacitorforthepositivechannel
dischargestounder3voltsin5secondsorlesswhenthemainpowerswitchis
turnedtooffANDnoloadpresentsontheoutputofthesupply.
1. Connectavoltmetertothepowersupplyspositivechannelandground.
2. Turnonthepowersupplyandwaitfor30seconds.
3. Turnoffthepowersupplyandwaitfor5seconds.
4. Checkthevoltmeter.
PASS:Thevoltmeterdisplayslessthan3voltsafter5seconds..
FAIL:Thevoltmeterdisplaysmorethan3voltsafter5seconds.

19. CapacitorDischargeBlockThefiltercapacitorforthenegativechannel
dischargestoundermagnitudeof3voltsin5secondsorlesswhenthemainpower
switchisturnedtooffANDnoloadpresentsontheoutputofthesupply.
1. Connectavoltmetertothepowersupplysnegativechannelandground.
2. Turnonthepowersupplyandwaitfor30seconds.
3. Turnoffthepowersupplyandwaitfor5seconds.
4. Checkthevoltmeter.
PASS:Thevoltmeterdisplayslessthanmagnitudeof3voltsafter5seconds..
FAIL:Thevoltmeterdisplaysmorethanmagnitudeof3voltsafter5seconds.

20. CapacitorDischargeBlockDesignusedone(ormore)MOSFETS
1. Checkthedischargecircuitwiththedesignedschematic.
PASS:ThedischargecircuitwasdesignedusingatleastoneMOSFET.
FAIL:ThedischargecircuitwasdesignedwithoutatleastoneMOSFET.

21. CapacitorDischargeBlockCapacitorripplevoltagestillmeetsspec
outlinedinearliersections.
1. Connectthepowersupplygroundtotheoscilloscopeground.
2. Connectthepowersupplypositivechanneltotheoscilloscope
3. Checkoscilloscopewaveform.
4. Connectthepowersupplygroundtotheoscilloscopeground.
5. Connectthepowersupplynegativechanneltotheoscilloscope
6. Checkoscilloscopewaveform.
PASS:Theoscilloscopewaveformshowsvoltageripplessmallerthan0.75Vppfor
bothchannels.
FAIL:The oscilloscope waveformshows voltageripplelargerthan 0.75Vppfor
eitherchannel.

2. SystemTests
1. Eachchannelmustbecapableofsupplyingatleast900mAperchannel
continuously
1. FollowtheinstructiononECE322teststation.
2. ConnecttheECE322teststationtothepowersupplysground.
3. Connectchannel1oftheECE322teststationtothepowersupplyspositive
channel.
4. Connectchannel2oftheECE322teststationtothepowersupplysnegative
channel.
5. ConnecttheECE322teststationtoanampmeter.
6. Switchthestationtotestchannel1.
7. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
900mA.
8. Switchthestationtotestchannel2.
9. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
900mA.
PASS:900mA10%canbeoutputtedforbothchannels.
FAIL:900mA10%cannotbeoutputtedforbothchannels.
2. Voltageoutputbetween2and12voltsunder900mAload
1. FollowtheinstructiononECE322teststation.
2. ConnecttheECE322teststationtothepowersupplysground.
3. Connectchannel1oftheECE322teststationtothepowersupplyspositive
channel.
4. Connectchannel2oftheECE322teststationtothepowersupplysnegative
channel.
5. ConnecttheECE322teststationtoanampmeter.
6. ConnecttheECE322teststationtoavoltmeter.
7. Switchthestationtotestchannel1.
8. Setthepowersupplytooutput12Vorhigher.
9. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
900mA.
10. Checkboththevoltmeterandtheampmeter.
11. Switchthestationtotestchannel2.
12. Setthepowersupplytooutputmagnitudeof12Vorhigher.
13. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
magnitudeof900mA.
14. Checkboththevoltmeterandtheampmeter.
15. Setthepowersupplytooutputmagnitudeof2Vorlower.
16. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
magnitudeof900mA.
17. Checkboththevoltmeterandtheampmeter.
18. Switchthestationtotestchannel1.
19. Setthepowersupplytooutput2Vorlower.
20. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
900mA.
 21. Checkboththevoltmeterandtheampmeter.
PASS:10%of12Vand10%of900mAcanbedisplayedatsametimeonthe
voltmeterandampmeterAND10%of2Vand10%of900mAcanbedisplayedat
sametimeonthevoltmeterandampmeter.
FAIL:10%of12Vand10%of900mAcannotbedisplayedatsametimeonthe
voltmeterandampmeterOR10%of2Vand10%of900mAcannotbedisplayedat
sametimeonthevoltmeterandampmeter.
3. Anoverloadtolimitcurrentto1A10%
1. FollowtheinstructiononECE322teststation.
2. Connectchannel1oftheECE322teststationtothepowersupplysgroundand
positivechannel.
3. Connectchannel2oftheECE322teststationtothepowersupplysgroundand
negativechannel.
4. ConnecttheECE322teststationtoanampmeter.
5. Switchthestationtotestchannel1.
6. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast1A.
7. Checktheampmeter.
8. Slowlykeepondecreasingtheresistanceuntilminimumresistanceisreached.
9. Checktheampmeter.
10. Switchthestationtotestchannel2.
11. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast1A.
12. Checktheampmeter.
13. Slowlykeepondecreasingtheresistanceuntilminimumresistanceisreached.
14. Checktheampmeter.
PASS:1A10%wasobservedforbothpositiveandnegativechannels.
FAIL:1A10%wasnotobservedforeitherchannel.

4. Dischargesthefiltercapacitoroneachchanneltounder3voltsin5seconds
orlesswhenthemainpowerswitchisturnedtooffandthereisnoloadpresenton
theoutputofthesupply.
1. Connectavoltmetertothepowersupplyspositivechannelandground.
2. Turnonthepowersupplyandwaitfor30seconds.
3. Turnoffthepowersupplyandwaitfor5seconds.
4. Checkthevoltmeter.
5. Connectavoltmetertothepowersupplysnegativechannelandground.
6. Turnonthepowersupplyandwaitfor30seconds.
7. Turnoffthepowersupplyandwaitfor5seconds.
8. Checkthevoltmeter.
PASS:Thevoltmeterdisplayslessthan3voltsafter5secondsforbothchannels.
FAIL:Thevoltmeterdisplaysmorethan3voltsafter5secondsforeitherchannel.

5. Externalconnectionsforleadsandvoltageadjustment
VisualinspectionbytheTA
 PASS:Thepowersupplyhasatleastthreeexternalconnectionsandtwovoltage
adjustments.
FAIL:Thepowersupplydoesnothaveatleastthreeexternalconnectionsandtwo
voltageadjustments.

6. Assembledsafelyandwithnoelectricalhazards
1. Opentheblackcoverofthepowersupply.
2. Examinetheinside.
PASS:Thepowersupplyisassembledsafelywithoutloosewire(s),looseboard(s),and
potentialshortage.
FAIL:Thepowersupplyisnotassembledsafelywithloosewire(s),orlooseboard(s),
orpotentialshortage.
 7. Voltagerippleoutofeachchannellessthan0.75Vperchannelwithboth
channelsfullyloadedto900mA
1. FollowtheinstructiononECE322teststation.
2. ConnectECE322teststationtothepowersupplyoutputs.
3. ConnecttheECE322teststationtoanampmeter.
4. Switchthestationtotestchannel1.
5. Settheoutputvoltageto12VDCand12VDCasappropriate.
6. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
900mA.
7. ConnectVOLT+oftheteststationtothevoltageinputoftheoscilloscope.
8. Checkoscilloscopewaveform.
9. Switchthestationtotestchannel2.
10. Decreasetheresistanceoftheteststationuntiltheampmeterreadsatleast
900mA.
11. ConnectVOLT+oftheteststationtothevoltageinputoftheoscilloscope.
12. Checkoscilloscopewaveform.
PASS:Theoscilloscopewaveformshowsvoltageripplessmallerthan0.75Vppfor
bothchannels.
FAIL:The oscilloscope waveformshows voltageripplelargerthan 0.75Vppfor
eitherchannel.
8. Utilizesasafetyfuse
1. Makesurethepowersupplyisnotpluggedintothewall.
2. Openthefusesocket.
3. Checkifafuse(atleast1amp)ispresent.
PASS:Afuseispresentinthefusesocket.
FAIL:Afuseisnotpresentinthefusesocket.

9. EasilyaccessibleACpowerswitch
VisualinspectionbytheTA
PASS:TheACpowerswitchismountedonthefrontorbacksideofthepower
supplyandcanturnthesystemonandoff
FAIL:TheACpowerswitchisnotmountedonthefrontorbacksideofthepower
supplyorcannotturnthesystemonandoff.

10. Aclearlyvisiblepowerindicationlight
1. Flipthepowerswitchtoonmode.
2. Checktheindicationlight.
PASS:Thepowerindicationlightismountedonthefrontorbacksideofthepower
supplyandcanturnonandoffwiththeswitch
FAIL:Thepowerindicationlightisnotmountedonthefrontorbacksideofthepowersupply
orcannotturnonandoffwiththeswitch
 8. Parts List and Cost Analysis

Reference Qty. Common Name Manufacturer Number Supplier Supplier Number Unit Extend
Price Price
T1 1 Transformer 221373 Jameco $8.95 $8.95
R1 1 1K Resistor 29663 Jameco $0.099 $0.099
D1 4 1N4004 Diode 35991PS Jameco $0.05 $0.20
C1 2 Filter Capacitor 15000F 565-2633-ND Digikey $9.60 $20.20
M1 1 LED mount PT18H013 Jameco $0.15 $0.15
F1 1 Fuse Holder BF301-10-20-17 Jameco $0.89 $0.89
L1 1 HLMP1700 LED HLMP-1700 Mouser 630-HLMP- $0.50 $0.50
1700
Q1 3 2N4401 NPN BJT 512-2N4401BU Mouser $0.22 $0.66
Q2 1 TIP29C NPN TIP20CFS-ND Digikey $0.55 $0.55
Q3 3 2N4403 PNP BJT 38447 Jameco $0.10 $0.30
Q4 1 TIP30C 179346 Jameco $0.35 $0.35
R1 1 2.2K Resistor 29663 Jameco $0.099 $0.099
R2 2 220 Resistor 29103 Jameco $0.099 $0.198
R3 5 470 Resistor 20906 Jameco $0.099 $0.495
R4 1 100 Resistor 21880 Jameco $0.099 $0.099
C3 1 10F 94370PS Jameco $0.19 $0.19
R5 2 0.6 Resistor P0.68W-1BK-Nd Digikey $0.66 $0.66