Author Topic: EEVblog #102 – DIY Constant Current Dummy Load for Power Supply and Battery Test  (Read 33217 times)

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Online EEVblog

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Dave, it there a schematic or some kind of layout of this Dummy Load PSU as you show it off.

The schematic is in the video. Nothing on paper, sorry.

Dave.
 

Offline ThunderSqueak

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because people keep asking, snapshot of the schematic from the video
Currently working with non-binary computing, no reason for it... just doing because I can ^^
 

Offline Simon

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hm did you check the terms and conditions of DaveCAD to see if reproduction of generated material is legal ?  ;D
 

Offline ThunderSqueak

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hm did you check the terms and conditions of DaveCAD to see if reproduction of generated material is legal ?  ;D

no..


hmmm, that might explain the men in black who showed up at my door this morning


 :o
Currently working with non-binary computing, no reason for it... just doing because I can ^^
 

Offline Simon

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no that must be because you have aliens in your loft but don't know it. it's ok the men in black are friend with the aliens.
 

Offline btfdev

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Just re-watched the video and got a quick question.

Noted at 2:10, Dave mentioned a LM317 could be used a constant current load when you ground the output.

So *WHY* MOSFET solution you need a power resistor going to ground but LM317 does not need one?

Any idea?

Thanks, BTFDev.
 

Offline SeanB

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With the LM317 direct to ground you are just relying on the built in current limiter, at around 1.6A or so, to provide constant current sinking provided you just ensure the voltage across the device is above about 3V and it has a big heatsink. If you use a resistor across the output to ground then it will keep the voltage across the resistor constant at 1.25V over a wide input voltage range, from about 5V to 30V in most cases. The resistor allows programming a lower current, you can go from under 1mA ( but with a slight error from adjust pin current and quiescent current of the device) to around 1A and have a pretty stable current. It does need a heatsink that will keep the device under 60C for best stability though,  especially at the higher range.

 

Offline mianchen

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Two questions:

1. What are the benefits of using a mosfet compared to a bjt transistor? I have a few 2N3055, is it a bad idea to use them? I've tested it on a bread board, and it seemed ok and worked as 'expected'. I don't have a MTP3055, but have a few P36NF06L and I managed to kill one when the set current is >2 A with a 3c/W heatsink.

2. How to calculate the heat dissipation for the transistor? The output voltage of the PSU to be tested (Vout) - Voltage  drop across the resistor (Vr) x the set current going through the resistor?

Sorry for the noob questions

Thanks
 

Offline ModernRonin

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1. What are the benefits of using a mosfet compared to a bjt transistor?
In this particular case, the major advantage is that a voltage on the gate of a MOSFET controls the current through the drain-source. With an NPN transistor, it's a current through the base that controls the current from collector to emitter. Voltage control is usually easier than current control.

In the general case, the advantage of MOSFETs is that when used as a switch, they have a lower resistance than an NPN. They are more power efficient, when used as a switch. But in this case we're not using the MOSFET as a switch. We're using it as a variable resistor. So that advantage is not useful to us here.

Also, NPNs can go into thermal runaway. NPNs conduct better the hotter they get. With MOSFETs it's the opposite, the hotter they get the worse they work. So MOSFETs can't go into thermal runaway nearly as easily.

Quote
> I have a few 2N3055, is it a bad idea to use them?
First, you need to know that there is a minimum voltage drop across an NPN transistor operating in linear mode of about 0.7 volts. This will put a limit on the maximum current that the dummy load can sink. However, the limit is pretty high. Something in the neighborhood of: (1.5 * input voltage) amps.

Second, NPN transistors can go into thermal runaway as mentioned before. This probably won't be a problem with the circuit Dave used, because the opamp will automatically throttle back the NPN if it goes over-current. But just be aware that thermal runaway can happen.

Third, it depends on how you're driving the base of the 2n3055. If there's X amount of current flowing through the collector of an NPN, then you need (X / beta) flowing through the base. The 2n3055 has a beta anywhere between 20 and 70. So in the very worst case, you will need to supply X / 20 amps of current into the base. If the opamp you use to drive the base of the 2n3055 can supply that much current, then no problem. But if it can't supply that much current...

Assuming a "typical" opamp with 20mA of output current capability, that would mean your dummy load would be able to handle a maximum of 20mA * 20 = 4000 mA = 4 amps. This is a lot less than the 15A maximum that the 2n3055 can handle.

To ensure the full 15A limit can be reached, you would need an opamp that can output 15A / 20 = 750 mA. There are opamps that can supply that much current, but they're not very common and may not be cheap.

BTW, you can go back and do all of the above math with 70 instead of 20 to see what kind of base current you would need in the "perfect world" case. But I don't recommend you count on the world being perfect.

(There's a relatively simple base driving circuit that you can make with a resistor and small MOSFET that will greatly amplify the output current of your opamp. But you're such a n00b I don't want to confuse you with it just now. It looks basically like this, except with the transistors swapped: http://www.neufeld.newton.ks.us/files/electronics/mosfet-motor/MOSFET-motor-driver.png )

Quote
> 2. How to calculate the heat dissipation for the transistor? The output voltage of the PSU to be tested (Vout) - Voltage  drop across the resistor (Vr) x the set current going through the resistor?
The usual answer is "P = IV", but in this case we should probably use the equivalent but alternate form:

P = I^2*R
or
Watts = (Current through component)^2 * Resistance of component

Now, the current you know. You just decide you want 1.3 A constant current, and that's that. The constant-current load will adjust its own resistance until that constant current is reached.

The resistance you will have to calculate, based on the input voltage and constant current. Example: You have 12V and set a constant current of 400 mA (= 0.4 A). Use V = IR to calculate the equivalent resistance:

V = IR
V/I = R
12/0.4 = R
R = 30 ohms

Now use P = I^2*R:

P = 0.4^2 * 12
P = 1.92W

This is much less than the ~100 watts than the 2n3055 is rated for.

But don't get a false sense of security. Remember that the equation depends on current squared. As the current goes up, wattage also goes up very quickly. Another example:

Constant current = 4 A; Vin = 24 volts; R = V / I so R = 6; P = I^2*R so P = 16 * 6 = 96 watts! You're getting close to the power dissipation limit of your 2n3055.
 

Offline btfdev

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Hey folks

In the winter holidays we did our own dummy load based on Dave's circuit.
http://www.binarytaskforce.com/Weblog/2013/02/08/dummy-load/]
[url]http://www.binarytaskforce.com/Weblog/2013/02/08/dummy-load/

[/url]

Sure it is a great tool!

Enjoy

Team BTF
 

Offline rodcastler

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Dave says he adds the second OpAmp because he had the dual package lying around but what is exactly the benefit of the second opamp? Apologies if this is a newbie question but I wish he had explained it a little deeper in the video.
« Last Edit: June 23, 2014, 11:45:26 am by rodcastler »
 

Offline Lee697

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Dave says he adds the second OpAmp because he had the dual package lying around but what is exactly the benefit of the second opamp? Apologies if this is a newbie question but I wish he had explained it a little deeper in the video.

Curious about that question myself - I breadboarded the dummy load yesterday, and just used the pot as Dave indicated in the video, and it works well....
 

Offline JayJones

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Reviving an old thread...

Can anyone tell what I might need to modify to run this from a 9VDC adapter, and any way to use a standard N-Channel Power mosfet?
I blew up 4 FQP50N06 mosfets already trying to figure out which parameter I'm exceeding in the datasheet :)

Thanks!
 

Offline rqsall

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At least you will need to reduce the source resistors (1 ohm in Dave's version) to something less than 0.5 ohm or so. You need more Vgs with a non-logiclevel mosfet to turn it on, and if the 1 ohm source resistor is already eating 2 volts at 2 amps, and you have 5V supply on your opamps, then there isn't much left for Vgs.

If you blew them up, however, I suspect you ran too much current through it, perhaps the gate voltage was too high due to faulty wiring?
 

Offline brutester

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Attached is even simplier way of doing it. Just use a power NPN. The one I've used was removed from old computer PSU. It is not as good as Dave,s approach, but hey - it is powered from the device and does the job :)
 


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