Primer on PSU design?

[Sigmoid]

Hey guys,

What resources should I read / research before designing a linear PSU from scratch? I read what I could on transformers and regulators, but I'm wondering about best practices, safety, overvoltage and overcurrent protection, and generally about designing a PCB for 120/240VAC.

[Rigby]

Older HP supplies like the 6286A have EXCELLENT manuals descriptions on the theory of operation and complete schematics.  They don't use custom parts, just transistors, transformers, resistors, caps, diodes and switches.  And a panel meter, which I guess probably would be custom if you bought it today.

I would start there and learn what can be learned.  Pretty much the entire theory of operation is written in those manuals.

[Shock]

Dave has a primer on design in his PDF here. This is on his Alternate Zone website
Obviously there is a ton of books on it as well.

It's not at all unusual to keep the primary side of the circuit totally off the main PCB.
You will need to read up on all the safety aspects.  Studying well made equipment can be a good way to learn as well.

I think if I was going to build one without following a book, magazine or kit I would do it in stages getting a basic prototype working first and then add the features.
There comes a point where you might want to simulate your circuit before you add further features to the prototype as well.
Here is a good video (if you haven't seen it) with some basic protection on the regulator. I apologize if your past this point.

[Phaedrus]

All of Jim Williams, basically:
http://www.linear.com/designtools/app_notes.php

[dentaku]

OnSemi has a good free library.

Linear & Switching Voltage Regulator Handbook & Switch-Mode Power Supply Reference Manual for starters.

Good stuff. I just downloaded Linear & Switching Voltage Regulator Handbook.