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.