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Improved Simple Adjustable DC Power Supply

by stuuf on August 14, 2008

Table of Contents
Improved Simple Adjustable DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Intro: Improved Simple Adjustable DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 1: Parts and Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 2: Circuit schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 3: Mounting the power jack and regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 4: Installing other components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Step 5: How to use it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

http://www.instructables.com/id/Improved-Simple-Adjustable-DC-Power-Supply/

Intro: Improved Simple Adjustable DC Power Supply

Work in progress: I'll add more text explaining how this thing actually works and a schematic image in the next few days.
There are already a few instructables about using linear voltage regulator chips to power low-voltage experiments and projects. This is my variation on those, using a low
dropout regulator to allow lower input voltages and a coarse/fine adjustment system.

Image Notes
1. Voltage Regulator
2. Input power
3. Output power
4. Coarse voltage control
5. Fine voltage control
6. o.O

Step 1: Parts and Tools

You will need the following components:
LDO voltage regulator such as MC33269
TO-220 heat sink and mounting screw
Capacitors to filter the regulator's input and output circuits
240 ohm resistor
Two potentiometers: 1Kohm or more for coarse adjustment, 100 ohm for fine
I used trimmers for both pots, since they're compact and hard to accidentally adjust
Power connectors: a PCB-mount coaxial jack for input and screw terminals for output are usually the easiest to work with
3-4 square inches of perfboard
Some hookup or bus wire
You should have these tools available:
Soldering iron
Small screwdriver
Pliers and wire cutters
A sharp knife that can carve your perfboard such as a regular #11 X-ACTO blade. (or a 1/8" drill bit)

http://www.instructables.com/id/Improved-Simple-Adjustable-DC-Power-Supply/

Step 2: Circuit schematic

Check the datasheet for your regulator for details about what capacitor values should be used and how to wire an adjustable regulator circuit. Instead of a single variable
resistor to adjust the voltage, I added a second one for fine adjustment. With the two resistors in series, the voltage depends on the sum of the two, so adjusting the fine
control (which has lower resistance) will change the output voltage slowly.

Step 3: Mounting the power jack and regulator

The most common style of DC power jacks uses two large pins that are too wide to fit in standard perfboard holes. To be able to mount the jack, you need to cut wider
holes in the board. There is also a third terminal on the jack used for a switch. Since this circuit doesn't use that terminal, and since it gets in the way, you can bend it out
of the way or cut it off.
New method: I've also discovered that it's easier to just drill three holes with a 1/8" bit, widening the existing perforations.
Medium- and high-power linear regulators use TO-220 packages that can be mounted to a heatsink to safely dissipate more heat. Heatsinks made for TO-220 devices
are usually a block of aluminum with a 4-40 threaded hole tapped near the top.

http://www.instructables.com/id/Improved-Simple-Adjustable-DC-Power-Supply/

Image Notes
1. I ended up cutting this tab completely off so i could run a piece of wire
under it without shorting

Image Notes
1. This gray sheet is an insulator, so that the heatsink won't be electrically
connected to the output voltage terminal. There's also a plastic ring under the
screw to keep it insulated from the tab. This is optional, of course.

Step 4: Installing other components

Mount the remaining components on the board and solder them together according to the schematic.

http://www.instructables.com/id/Improved-Simple-Adjustable-DC-Power-Supply/

Image Notes
1. Vin
2. Input bypass cap, as close to regulator input terminal as possible
3. Output filter
4. Output ground, connected to input ground on top side
5. Voltage control pots

Image Notes
1. Voltage Regulator
2. Input power
3. Output power
4. Coarse voltage control
5. Fine voltage control
6. o.O

Step 5: How to use it

Connect a DC power supply (AC adapter, USB cable, battery pack, generator, etc) to the input connector. Connect a voltmeter to the output and adjust the
potentiometers to select the voltage you want. Finally, connect your load circuit to the output to give it power.

Image Notes
1. Radioshack universal power supply with M adaptaplug
2. Green InGaN LED being powered by the output

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http://www.instructables.com/id/Improved-Simple-Adjustable-DC-Power-Supply/

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How Tos
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Comments
32 comments Add Comment

throbscottle says:

Apr 15, 2012. 12:13 AM REPLY

Nice! What application did you use to draw your schematic?

FreeHighFives says:

Nov 25, 2010. 12:56 PM REPLY

Does the current remain the same at the very end?

Adri3l says:

Apr 30, 2010. 3:12 AM REPLY

Is it true that the MC33269 cand only handle only 800mA max? I am looking for a replacement for a LM350T that doesn't seem to exist on the local market
here and I'm a bit stuck. I need a 1-25v regulator that can handle as many amps as possible(i was thinking at least 2 amps). Do you have any suggestions?

zack247 says:

Oct 24, 2010. 11:04 AM REPLY

hey, you wouldn't have happened to have any luck with that? i need 24v @ 2 Amps.

stuuf says:

Oct 24, 2010. 5:06 PM REPLY

2A is a little high for a linear regulator. You might be able to pull that much current from a standard LM317 (they're guaranteed to at least 1.5A), but
you'll need serious heat sinking. A switching converter will work much better.

Adri3l says:

Oct 27, 2010. 8:17 AM REPLY

Or he could try to use a LM138/338 . The datasheet also contains the schematics for using it, you just have to change the values of the two
resistors acordingly.

zack247 says:

Oct 24, 2010. 6:12 PM REPLY

a switching converter? sorry, im kind of new to voltage regulation

stuuf says:

Oct 24, 2010. 7:15 PM REPLY

http://en.wikipedia.org/wiki/Switched-mode_power_supply
Harder to design (I haven't had a chance to build one that works very well yet) but more flexible and more efficient.

qwertyboy says:

Oct 26, 2009. 1:00 PM REPLY

will the LD1084V work for this?

xiexie says:

Oct 25, 2009. 12:13 AM REPLY

I used an LM7805 to yield 5 Volt output. But the power supply didn't work. Is it possible it's due to excessive heat that I used when i solder the LM7805?
If yes, how should I plug it to the circuit?

gedion4000 says:

Jul 30, 2009. 9:27 AM REPLY

do you happen to know how to build a power supply like this with a higher output? im trying to power several circuits, each with different power requirements
ranging from 9 volts to 15 volts. if need be i would make more the one regulator but the idea is to use one battery pack to get the job done

stuuf says:

Jul 30, 2009. 10:48 AM REPLY

As long as you have a battery with a higher voltage than you need you can connect as many different regulators as you want to create different voltage
rails, just use multiple copies of this circuit with different regulators or feedback resistors in parallel with the same Vin and ground lines. If you need
regulated voltages across a wide range it might make sense to run the lower ones from a tap in the middle of your battery pack to reduce power losses
and heat. But then you also have to deal with some of your battery cells discharging faster than the others. If you need more current that your regulator
can supply, sometimes you can wire two or more in parallel, or add an external transistor (regulator datasheets usually include a "current boost"
application circuit).

gedion4000 says:
thanks, I didnt know you could use them in parallel, i will play around with that and see how it works out. thanks again

http://www.instructables.com/id/Improved-Simple-Adjustable-DC-Power-Supply/

Aug 2, 2009. 9:07 AM REPLY

12V says:

Jun 24, 2009. 12:01 PM REPLY

how much current can this cope with when connected to 18v?

silencekilla says:

Jun 23, 2009. 7:24 AM REPLY

how much do all of the supplies cost. and if possible can you make one for me and i will buy it from you

Charles IV says:

Dec 4, 2008. 6:35 PM REPLY

Would this be safe hooked up to 120v DC?

bwpatton1 says:

May 15, 2009. 8:03 PM REPLY

Where would you get 120v DC?

stuuf says:

Dec 4, 2008. 7:24 PM REPLY

With the parts I used, no. The MC33269T only handles up to 20V input, and the input cap is probably only 50V. Other regulators have different maximum
input voltages, but I've never seen one as high as 120V (not that they don't exist).

Charles IV says:

Dec 6, 2008. 3:49 PM REPLY

Alright thanks

ReCreate says:

Mar 14, 2009. 5:02 PM REPLY

whats the maximum input/output for this?

joinaqd says:

Jan 13, 2009. 5:55 PM REPLY

i made one of those just from an old headphone volume control...it started melting because the resistance made heat!!!

qwertyboy says:

Nov 17, 2008. 12:24 PM REPLY

can i use a LM317?

stuuf says:

Nov 18, 2008. 6:20 PM REPLY

An LM317 will work, but the dropout voltage will be considerably higher, which limits the output voltage you can get from a low-voltage supply. With a 5V
input, the highest output the LM317 will give you is about 3.3V compared to about 4V for LDO regulators (if you put more current on the load you'll see
an even larger dropout)

ironaxe69 says:

Nov 15, 2008. 1:20 AM REPLY

what size capacitors???

stuuf says:

Nov 15, 2008. 9:33 AM REPLY

I think I used 100?F for the output and 10?F for the input, the regulator datasheet has some information about what sizes to use

ironaxe69 says:

Nov 15, 2008. 12:35 AM REPLY

A simple question. where do you buy your parts? I started looking, and am having a hard time finding the mc33269t voltage regulator.

stuuf says:

Nov 15, 2008. 9:28 AM REPLY

I got most of those parts from http://www.allelectronics.com/

There are a lot of other regulator parts that work the same way that you could use instead, such as the LM1117

frollard says:

Aug 15, 2008. 3:03 AM REPLY

Great instructible!! Do you find that once a load is connected the voltage coming out of the regulator changes? i.e. a lot of wall-wart transformers will put out
a much higher voltage when there's no load attached.

http://www.instructables.com/id/Improved-Simple-Adjustable-DC-Power-Supply/

Sandisk1duo says:

Aug 15, 2008. 8:37 AM REPLY

well if you don't short it out, the voltage will pretty much stay the same

Derin says:

Oct 17, 2008. 11:22 PM REPLY

he is probably talking about the open circuit voltage also,if the circuit is forced to the top current(like short) it will drop

stuuf says:

Aug 15, 2008. 10:57 AM REPLY

The reason why the voltage from a simple transformer will vary depending on the load is because they don't have any kind of regulation; as you draw
more and more current, the voltage drops across the transformer windings, diodes, and wires will increase, reducing the voltage available at the end.

frollard says:
Awesome, thanks for the info.

http://www.instructables.com/id/Improved-Simple-Adjustable-DC-Power-Supply/

Aug 15, 2008. 8:24 PM REPLY