I get many questions about
power supplies. By the words 'power supply' it is assumed the supply is a
"linear" type; this includes a mains power transformer, diode rectifiers,
capacitors, chokes, possibly protection
circuitry and regulators. I don't
build SMPS.
In tube amps there is ac
power required for ac power to heater circuits without any rectification
and
such simple supplies are covered under the section for building a power
transformer.
For DC supplies, I should
begin to say that the basic wave forms should be well understood....
Fig 1.
Basic mains wave forms. The above sketch shows
the basic ac wave forms you should understand where ac voltage levels vary
positively and negatively when referenced to 0V, the earth or grounf reference
voltage potential.
There are two wires coming into your house from the
mains.
One is black, and called the "neutral" wire and is connected to ground
at the house circuit distribution board via an earthing to copper water pipes or
a copper clad stake buried in the ground and the voltage on the black is almost
zero volts in reference to earth. The green yellow insulated wire in the 3 wire
cables around a house are al joined to the water pipe or stake
connection.
The other wire is called the "active" because its voltage is
moves to + 340V peak to -340V peak
at a rate of 50 Hz and the graph of
such waves is shown above as approximate sine waves.
The active and neutral
wires are connected to a circuit breakers or fuses and then to the 3 wire cables
for power and lighting .
Each wire in the cable has red insulation for
active, black insulation for neutral and green+yellow for the
earth wire in
Australia. Appliances which require their cases to be connected to
earth directly can be accomodated such as washing machines, but the energy
carrying circuit is via the red and black wires.
In the US the mains active
is 117Vrms, and has F = 60Hz.
In Fig 1 the top waveform X
is the incoming mains single phase of ac wave applied to the transformer
primary.
The single secondary shown at left shows the wave form X also
occurring .
The top left transformer is supplying AC power only to the load
resistance which could be a heater
filament in a tube. No rectified dc
currents flow, only ac. It is impossible to power signal circuits with
AC
since the ac signal would swamp any signal we tried to have.
Rectified wave forms,
The middle waveform
shows the ac waveX shown again, but with the ripple wave form that appears at
the top of RL1, and C1. When the positive going voltages of the ac wave go
higher than the voltage in the cap C1,
the diode can conduct current in the
direction of the "arrow" and the the cap is charged up to the peaks
shown in
the ripple voltage wave. But no sooner does the cap get charged up and the ac
wave
potential reduces and travels negatively, and the cap tends to
discharge its store of energy
through RL1 much more slowly than the ac wave
goes negative, so then the ac wave voltage is less than the cap voltage and
current cannot flow in the diode in the opposite direction of the arrow, so
while the ac voltage is negative the cap voltage stays relatively positive with
respect to 0V.
Bath water?
Rectifying is the converting of
alternating voltage to a single polarity voltage and is like a like a guy
filling a bath with water by tipping a bucket full in at each positive wave
crest, but the bath is losing a steady flow of water out the plug hole as he
fills the bath.
The water running out is like the Resistive Load connected to
every power supply. The average bath water level is like the dc voltage level at
half way between the peaks and troughs of the ripple wave form.
And so we
have a dc voltage level in C1, but there is small ac wave as shown also
superimposed upon the dc level.
The flow in RL1 is mainly a DC flow, but
because some ripple voltage is present at the top of the capacitor,
there is
some small ac ripple current in RL1, and its frequency is the same as the ac
wave form X, or mains frequency of 50 or 60 Hz. The ripple voltage contains many
harmonics of the mains basic frequency.
The current flow in the diode is
shown in a hatched wave below +ve peaks in the ac voltage wave.
The current
only flows in the diode for a small fraction of the ac wave form; the current
flow is like bucket fulls of water being tipped into the bath, and the peak
charging current into the cap through the diode must be higher than the ripple
current measured with an rms meter, since the input charge current x time must
transfer the same energy into the cap as flows out of the cap into the load RL
in the form of Vdc x current x time.
The set up as shown in the middle
transformer with R1, C1 is a half wave rectifier, since only the positive going
1/2 of each the ac wave is converted to a DC flow.
The lowest set of waves show wave X and wave Y
with the ripple wave at C2, R2.
In the transformer at bottom left the
secondary has two windings arranged so equal turns exist each side
of where
the two windings join, which is called a centre tap. Each winding has the same
turns as the
half wave rectifier transformer winding. Wherever you have a
winding with a CT taken to 0V, the ac signals
at each free end are of
opposite phase and 180 degrees out of phase with each other.
The result is
that "balanced output voltages" exist at each free end of the two
windings.
There are also two diodes, and as each wave goes positive there are
alternating XYXYXY charging pulses at twice the mains fundamental
frequency of 50/60Hz.
This arrangement is called a full wave rectifier, and
is very common in tube amps which use a tube rectifier which contains
two
diodes with a commoned cathode.
When silicon diodes were invented, bridge
rectifiers and voltage doubler arrangements which are shown in textbooks were
rapidly adopted because they offered much greater efficiency, lower cost and far
better voltage regulation.
Diode resistance,
Tube rectifiers have
considerable series resistance usually above 50 ohms when conducting current and
thus dissipate heat during their function, so the tube gets quite hot as a
result, and there are limitations on what sized capacitor follows the rectifier
so that peak currents do not exceed the cathode current ability.
Silicon
diodes have very low "on" resistance of only about 1 ohm and a 1N5408 can easily
take 3 amps
of current, about 10 times that of a tube rectifier. So they tend
to run cool because the I squared x R power heat loss is low, and since their
series resistance is so low the power supply output voltage regulation with load
changes is far better than with any tubed rectifier power supply, and the larger
current ability allows for large value electrolytics to be used and the peak
charging currents are then limited by the winding resistances and not the diode
"on" resistance.
Beacuse peak charge currents in silicon diodes are much
larger than tube rectifiers some say that is a problem since power supply noise
can all too easily find its way into earth paths and feedback wires by magnetic
induction or other leakage or voltage generation in low impedance earth buss
wires, but I have found that with careful design and wire layouts such noise
problems never arise.
If we assume that R1 = R2,
and that C1 = C2, and that the ac voltage in the half wave rectifier
winding
is the same as the voltages in each half of the balanced winding,
then the dc output voltage
will be slightly higher with the balanced set up
because the rate of discharge of C2 is about the same as C1,
but C2 is
charged twice as often as C1, so in fact the dc voltage in C2 is slightly
higher, and
the ripple voltage is about 1/2 the value of that across
C1.
In other words, the full wave rectifier is more efficient then the half
wave.
Ripple voltage and output dc voltage vs C and
Idc.
In all the above rectifiers, the higher the value of C, the less
ripple voltage you get for a given dc current output,
and the closer the dc
voltage output becomes to the peak ac voltage at the winding.
Or you an say
the lower the dc current output for a given value of C, the less ripple voltage
is present, and the higher the dc voltage approaches to the peak ac voltage from
the winding.
The maximum dc voltage that
can exist in a cap being charged by an ac wave is the the peak
voltage of
the ac wave form when there is no load to drain out the voltage in the
cap.
So all caps in the power supply should be able to easily withstand 1.41
x the Vrms of the HT winding.
Thus where a 280Vrms secondary is used, the
actual Vrms could be +/- 10%, or between 252V and 308V due to mains voltages
variations; I have seen the mains here at 255Vrms on some days. Always design
the power supply to be able to
cope with the HT winding being 10% higher
than the actual dsign centre value.
Hence the rectified peak voltage with no
load could be 1.41 x 308 = 434V dc, so therefore caps should have a V
rating
well above 434V. 450V rated caps are easily available, but seriesed
250V rated caps would be better.
The mains ac wave is usually
a sine wave, but harmonics do exist to make the mains look like a triangular
wave with
flattened peaks. The harmonic voltages in the mains supply is
seldom more than 5% of the 50Hz or 60Hz wave.
But for practical design
purposes, the mains wave form is considered to be a sine wave and the rms
measurement of it is 240Vrms in Australia and the peak voltage value of the wave
crests is 1.414 x Vrms = 339.4V.
With a given secondary
winding for the B+ of a tube amp as we drain more and more current to a load
from the input cap the dc voltage tends to drop so that in an average power
supply, the conversion factor from Vrms to dcV reduces from a maximum of 1.4
with no load to about 1.35 when the design load is connected using well designed
PS with Si diodes.
With tube diodes
the Vdc is often only just above the Vrms value of the transformer ac rms
voltage.
To have 600mA at +480V with tube
diodes, I would have to use a full wave CT winding for the B+
with the
ac voltage at about 420V-0-420V and maybe at least a pair or quad of
GZ34.
Half wave rectifiers have
their place in all sorts of circuits where load current is low and efficiency
isn't a big problem such as deriving a grid bias voltage for output tubes.
Half wave rectifiers can use 2 diodes and two caps to make a voltage doubler
so alternatively charge one cap positively, the other negatively, and with one
transformer winding end taken to the connection of the two caps, thus giving a
dc voltage output near twice the peak ac voltage of the winding.
This
voltage doubler rectifier produces a ripple frequency same as a full wave
rectifier but is not quite as efficient as a full wave type, but with silicon
diodes and small sized large value modern capacitors, it is much more efficient than any tubed rectifier
arrangement.
The voltage doubler arrangement allows a more efficient
transformer winding with 1/2 the turns of the bridge rectifier and half the
voltage, allowing control relays meant for mains use to be used. The doubler
winding uses 1/4 of the turns needed
for the full wave CT winding so
commonly used in the past.
The design of the power
supply isn't difficult if we follow a path through a series of equations.
I
will base my mathematical processes upon an example of a power supply for the
8585 amplifier of mine:-
Fig
2.
The above looks but it
is merely repetition of basic simple ideas.
The principles in the
explanation of the above can be applied to any other tube amp supply.
B+ plate supply.
There are 8 x output tubes
and each draws about 40mA of plate and screen current with B+ at +480V.
So
we want 320mA dc at idle and and then we also want enough dc for the driver /
input stages,
so the total idle working dc output from the top of C16&C17
will be about 400mA.
But during class AB operation we must allow for the
anode and screen currents to the output stages to nearly double,
but the
increases in current demand with music is only ever temporary so
design B+ current supply = 1.5 x idle current,
which is 600mA in this example.
A voltage doubler supply was
chosen because it allowed me to wind the power transformer with just one winding
of thick wire of N turns, rather than have a winding for a bridge rectifier with
2N turns of thinner wire, or a full wave winding for two diodes with 4N turns of
even thinner wire.
The one winding of N turns can more easily be fitted into
the winding space than the higher turn windings because with more turns there is
more room needed for insulation.
The ratio of dcV/acV = about 2.65 for working
circuits with doublers, so here
Secondary Vrms = Vdc / 2.65
= 480V / 2.65 = 181Vrms.
The RL that is effectively connected to the dc supply
= Edc / ( 1.5 x idle Idc ) = 480V / 0.6A = 800 ohms.
I chose to use CLC filtered
supply supply, ie, a capacitor input plus following single LC filter to reduce
ripple voltage
to a low level. There is negligible winding resistance losses
in the choke and OPT primaries and voltage drop
is less than 10V betaeen the
C1 input resevoir cap and the output anodes.
When higher resistance in chokes
and OPT windings exist, an adjustment of the HT secondary ac voltage must be
made so
the wanted B+ appears at the anodes.
The natural regulation of a
rectifier power supply depends on the reactive value of the C
being much
lower than the RL value, both measured in ohms. Or if you like the higher the C
value, the better the regulation.
Old time wisdom suggested that the C1 cap
charged by the diodes, the resevoir cap, have a reactance at the ripple
frequency
of no more than 1/10 x RL.
Maximum reactance of capacitor, ZC, = RL / 10,
in this case ZC max = 800 / 10 = 80 ohms.
Reactance of a capacitor in ohms = ZC
=
1,000,000
6.28 x C x F
Where ZC
= reactance, or impedance of C, measured in ohms,
1,000,000 is a constant
for all equations,
6.28 = 2 x pye, a constant for all equations,
C =
capacitance in Uf,
F = frequency involved.
Therfore C =
1,000,000 = 20uF in this
case.
6.28 x ZC x F
20 uF is a low amount of capacitance which has a high reactance, and
the ripple voltage will be a fairly high figure, which may have been acceptable
in 1955 because the electrolytic caps were then not so reliable and amp makers
often used quite high inductance choke values for a CLC filter. The ratings
for peak charging current of vacuum tube diodes
is quite low so in 1955 a cap
value of 20uF for a 600mA supply may have been appropriate.
The cap values
which are allowable after a tube rectifier for a given Idc are given in
the tube data sheets.
Using a higher C1 value than allowed after a tube
rectifier will soon result result in wrecked tube.
But today we can do a lot
"better" than that because modern electrolytic caps are available cheaply which
have high ripple current ratings and low size and Si diodes allow brutish peak
charge currents up to 10 amps if we wish so let us choose C16 and C17 as 470uF
caps which in series will make C1 = 235uF
which will give over ten times
lower ripple voltage than a 20 uF cap.
So for 235uF, and 100Hz
ripple frequency for each cap in a doubler supply,
Capacitor reactance
ZC =
1,000,000 / ( 6.28 x 235 x 100 ) = 6.8 ohms.
C1 of the CLC supply
consists of two 470uF caps in series. The doubler charges each of the two caps
so that
a 50Hz ripple voltage frequency exists across each cap.
Because
the two caps are in series the ripple voltage at the top of two caps must be
twice the mains F
of 50Hz, or 100Hz because while one cap discharges energy
into RL, the other one is charged up.
So we can consider that we have 235uF
shunting the 800 ohm RL and ripple F = 100 Hz, so
therefore ZC that is
shunting RL = 1,000,000 / ( 6.28 x 235 x 100 ) = 6.8 ohms.
Ripple voltage, Vr = Idc x 2,200
C uF
where Vr is in Vrms,
Idc = dc load current in Amps,
2,200 is a constant for 100Hz ripple, but
must be 1,833 for 120Hz, 4,400 for 50Hz and 3,666 for 60Hz.
C is in uF
shunting RL.
So in this case, Vr = 0.6 x
2200 / 235 = 5.6Vrms.
Now ripple current must be
checked to make sure the ripple current is less than the maximum
rated
ripple current for the capacitors at the wanted frequency.
Ripple current, Ir = Vr / ZC
So in this case Ir = 5.6V /
6.8ohms = 0.82Amps rms.
The 470 uF caps I bought for
this amp have a have a ripple current rating = 5 Amps at least. They have 5mm
screws to
terminate the wires to them and were made for arduous
conditions.
Many 470uf caps have only a 2Amp rms rating, and in a fault
situation they could fail to a short circuit
after overheating because excess ripple current is a real killer of
electrolytic capacitors.
If double the capacitance was used, Vr would
halve to 2.8Vrms, and ZC = 3.4 ohms,
so Ir would be 2.8 / 3.4 = 0.82Arms, or
the same as with 470 uF, but the Ir could be shared
over two lots of
paralleled caps, and so each cap would have 0.41Arms instead of the full
0.82Arms.
On the other hand if C1 was
say 20uF, Vr = 66Vrms, and ZC = 80 ohms, and Ir = 66 / 80 = 0.82Arms
and we would need to find a reliable type of 20uF cap which could put up with
0.82Arms, and ripple current ratings tend to fall as C gets lower, so
using
20uF electrolytics isn't a good idea unless we decided to use some polypropylene
motor start capacitors
or paper & foil in oil caps which will be much
larger than electros. But then have a much larger ripple voltage to filter away
before connection to the amp.
Peak charge
currents.
It must be remembered that the peak input charge current can
be perhaps 10 times higher than the dc current draining out from the cap if the
power transformer and mains supply has low winding resistance and source
impedance, and we know silicon diodes are less than 1 ohm when conducting, and
we have large value electrolytics. In 8585 tube diodes could never be used
unless I had paralleled about 4 x GZ34 and used a fullwave CT winding for
HT.
Current limiting resistances.
In amps with a
large amount of class A we can cheat a little to reduce the charge current
several times
by using an R in series with the transformer winding and
diodes. Usually R = 4 x ZC is plenty, so in this case ZC = 6.8 ohms, so a
27ohm R would suffice to reduce cap charging currents.
One may say well why
not just use a tube rectifier, or paralleled tube rectifiers?
The resistance
we add almost exactly mimics the action of tube rectifiers. But we don't have to
use a heater supply for a tubed rectifier/s, nor have a tube socket/s, and a
couple of well rated resistors glued to the chassis with silicon to better
dissipate their heat is still a better option, and if a fault occurs and the
protection elsewhere fails, the resistors will fail by fusing open, and a couple
of resistors are much easier and cheaper to replace than a transformer/and or
rectifier tube. Where there is some mechanically caused mains transformer noise
due to switching currents in dc supplies vibrating the winding, the added series
resistances act to limit currents and reduce the transformer noise.
But with series R there is a
less well regulated B+ and a 5-10% lower B+, but peak charge currents and
switching transient currents around the earth paths would be much lower. The measured Vripple will not change although
the shape of the ripple wave will have more even up and down charge and
discharge strokes, so that the charging current time is about
equal to the
discharge time.
The series resistors can get scorching hot since their
dissipation can be high and related to current
squared x R, and there is a high peak AC flow, but since the Iac peak is
lowered, the dissipation is then less in the winding resistances of the P and S
windings and the series R tends to reduce heating in the transformer windings.
And if a fault happens in the amp and a larger Idc flow occurs, the current
limiting R will help prevent cap failure, because the R will fuse open. R is
cheaper than C which is cheaper than transformer replacement.
In the 8585 case I saw no
need to use charge current limiting resistors in series with high current diodes
and
caps, despite the low winding resistances of the transformer I wound
which is an 800 VA toroidal type.
The 800 VA toroid took a couple of days to
wind using a hand held shuttle but at least I was able to get a transformer
which
has an operating B at less than 0.9 Tesla which usually leads to silent
transformer operation even with a rectifier
connected. The winding
resistance is 33% higher than a transformer with the same wire size running at
1.2 Tesla.
Regulators
I built a bench top regulated
power supply about 10 years ago when I was learning.
It can provide +200V to
+500V in 50V steps and has switched
input voltages to the series pass
regulator using a 6BX6 gain pentode with 2 x 6080 pass element tubes.
The
maximum output current is about 500mA and to avoid frying the tubes at low
voltages and high output
currents the primary supply with CLC filtering can
have its C1 switched out to give an LC input network and
a much lower B+
supply ahead of the regulator.
This series reg is very
reliable but I don't use it much so it has lasted well. It becomes useful when I
want to
set up a test for some output tubes. It had a very real value
as one of the many learning exercizes
I engaged myself with for 5 years
before I started spending all this time using a PC
to explain to the world
what I find to be valid voltage/current management techniques.
It replaced my early attempt
to build a regulator with BU208A series pass elements. I fused several
bjts
in the learning process, and finally the tube regulator was far more
reliable for tests where something I did
caused an ""oops"" event and some
smoke. The tubes could take the abuse with a smile, but the solid state
just
fried.
I have since perfected the
BU208A/108A regulator for use for screen voltage regulators as seen in my 300
watt amp pages, and I have learnt how to perfect the protection of such circuits
so that for the last 5 years I have
yet to have lost a solid state high
voltage regulator.
My favourite type of regulator for tube amp B+ rails is
just to have the BU208A or BU108A with an MJE340
driver transistor connected
as a darlington pair to work as an emitter follower.
Since all tube amps have
high voltages, as long as the base voltage applied to the pass
transistor
cane be kept steady, the output emitter voltage cannot sag more
than about 1.2V between no load
and say 3 amps. Of course if there is say 50V
across the BU208A and a 3 amp flow, then you would have
3 x 50 = 150 watts
of heat in the device so the device will just fail to become a sullen short
circuit.
Its how soid state devices fail. Tubes and resistors usually fail to
an open circuit. Not bjts, unless they
explode, which isn't unusual, and
then maybe they are open.
When failing, they do so to protect a
fuse.........
So, the rule for series regulators is to always have a well rated resistor in series so
that at the wanted current
there is an equal voltage across the R and between
collector and emitter.
Thus equal idle power is
dissipated in the R and pass device. As current increases, V across the R
increases, V across the device reduces, so the R gets hotter, the active pass
device gets cooler.
When current doubles, the device is conducting, but has
only a volt across it, regulation stops and the
output voltage is allowed to
sag. But I always place some diodes around the regulator to prevent
excess
output currents and backward flows of currents which are truly sudden death for
any bjt.
A good example of a solid
state regulator is at my page '300watt amplifier power supplies,
sheets3,4&8'.
Fig 3.
.
Notice the BU108A and MJE340
solid state screen voltage regulator in the centre of the schematic.
The two
easily available discrete BJT devices are connected as a simple darlington
emitter follower pair.
BU208 is ideal. Should excessive screen currents ever
flow, R5 will develop a voltage across it reducing the collector-emitter voltage
to 1V across the BU108, and it will stop regulation and allow the screen voltage
to fall if any screen decides to conduct way too much current in a fault
condition.
Excessive output currents are also limited by R6, so that if too
much emitter current should suddenly flow in R6,
then the 4 diodes from the
top of C5 to MJE340 base will conduct and the base voltage
reduced quickly,
and thus output voltage. The circuit is protected against reverse flow of supply
voltage applications by the diode from the output to collectors. But under
normal operation, the screen voltages held very steady between low and clipping
when dc screen currents vary considerably with signal levels.
The supply to the input
stage is shunt regulated by the string of zeners near C1.
The parts shown on this
schematic are all included on the 300watt amplifier chassis which is separate to
the power supply enclosure, connected to the amp chassis with umbilical
cable. If the cable is removed from the power supply with the amp turned
on, the pins of the plug of the cable carrying high dcV levels
become exposed
and could make skin contact so to minimize any risk of shock a fast B+ discharge
path
has been established via R9 to 0V through the action of the relay if the
'red' cable is disconnected
from the PS.
Switch Mode Power Supply?
I do not make
switch mode power supplies. I would like to use them since they would save a lot
of weight,
but there are problems such as RF noise, reliability and
complexity which need to be addressed, and so far, I have yet to see any
commercially or privately made tube amps with high voltage B+ and low voltage
heater dc derived from SMPS.
The reason probably is that if you have heavy
output transformers in a tube amp one may as well have a heavy power transformer
and chokes. The problems of having a
switchmode supply producing +500V at 1
amp mean that the HF energy is considerable, and requires some
careful
engineering which probably would end up being more costly to produce even though
lighter.
And all the heater voltages also add to the problem.