High Power regulated power supply - 60V - 50A Circuit
Build a high power regulated 60V 50A power supply circuit for electronics projects. Step-by-step DIY guide with components, working, and troubleshooting tips in...
What Is a High Power Regulated Power Supply?
A high-power regulated power supply offers a stable, controlled power supply is able to deliver high-current voltage and current that can drive high-current loads. The regulation makes the output voltage remain constant regardless of the variations in load.
60v 50a adjustable power supply project
It is an advanced electronics project that aims to provide stable current and high voltage with high current capability to be used with heavy-duty devices. This type of power supply is essential when performing testing of the industrial devices, operating high-current electronics, or performing lab experiments that require the control of the voltage to a high degree of accuracy.
High-power controlled power supply 60V 50A circuit consists of a high-current transformer, a bridge rectifier, filter capacitors, pass transistors or MOSFETs, and a voltage regulator, which is controlled by the feedback to keep a constant 60V output at 50A or less. It has an in-built current limiting and safety protection to eliminate overloading or short-circuiting. The design is based on high-current power design, voltage regulation, thermal management, and protection circuitry, and is ideal for electronics engineering work, hobby work, and laboratories.
DIY 60V 50A Regulated Power Supply
Build a high-current, stable 60V power supply suitable for industrial electronics, motors, and electronics labs with overcurrent and thermal protection.
Advantages
- High Current Output: Suitable for motors, industrial electronics, and heavy loads.
- Voltage Regulation: Maintains 60V output even with changing loads.
- Safety Features: Overcurrent and thermal protection prevent damage.
- Precision Testing: Ideal for electronics labs and power testing.
- Versatility: Can drive multiple parallel loads or high-power circuits.
Components Required
| Component | Quantity | Purpose |
|---|---|---|
| High-current Transformer (AC 70V–0–70V, 60A) | 1 | Step-down AC mains |
| Bridge Rectifier (High current, 100A diodes) | 1 | Converts AC to DC |
| Filter Capacitors (≥10,000uF, 100V rated) | Multiple | Smooth DC output |
| Voltage Regulator Circuit (Discrete MOSFET/BJT) | 1 | Maintains 60V output |
| High-current MOSFETs / BJTs (IRFP460 / TIP3055) | Several | Pass elements for current |
| Resistors | Various | Voltage sensing and current limiting |
| Potentiometer | 1 | Adjusts output voltage |
| Heat Sinks & Cooling Fans | As needed | Thermal management |
| Output Fuse / Circuit Breaker | 1 | Overcurrent protection |
| LED Indicators | 2 | Power ON / Overcurrent indication |
| PCB / Bus Bars | 1 | Connect components and conduct high current |
| Enclosure | 1 | Safe housing for high-power components |
Working Principle
AC Input & Transformer: High-current AC enters the transformer, reducing voltage to the desired level (~60V DC after rectification).
Rectification & Filtering: Bridge rectifier converts AC to pulsating DC; large capacitors smooth the output.
Voltage Regulation: Feedback-controlled pass MOSFETs/BJTs maintain 60V output; voltage sensed via resistor network.
Current Limiting & Protection: Sense resistors detect >50A; overcurrent triggers shutdown or reduction; fuse/breaker provides backup protection.
Output Stage & Cooling: Regulated DC delivered through thick bus bars; MOSFETs/BJTs mounted on heat sinks with fans; LEDs indicate power and overload.
Circuit Diagram (Text)
Transformer Secondary → Bridge Rectifier → Filter Capacitors → Voltage Regulation Circuit → Output Terminals Current Sense Resistor → Feedback to regulate voltage/current Pass Elements → High-power MOSFETs/BJTs conduct high current Cooling Fans → Thermal management LED Indicators → Power and overcurrent status Fuse/Circuit Breaker → Safety
Step-by-Step Construction Guide
- Mount transformer and connect primary to mains; ensure insulation for 60V/50A operation.
- Connect high-current diodes in bridge configuration; smooth DC with large electrolytic capacitors.
- Connect pass transistors/MOSFETs with heat sinks; set up a feedback network with voltage sense resistors; adjust the potentiometer for a 60V output.
- Install a sense resistor in series with the load; connect overcurrent detection to shutdown or current reduction.
- Attach heat sinks and cooling fans to pass elements; ensure good airflow and thermal protection.
- Connect thick wires or bus bars to the output; connect LED indicators; install a fuse/circuit breaker in series.
- Test initially with resistive load; gradually increase load while monitoring voltage, current, and temperature; verify regulation at full load.
Applications
- Industrial equipment testing
- High-power LED or motor drives
- Electronics lab power supply
- Battery charging for large banks
- High-current experiments and prototyping
Troubleshooting Tips
| Problem | Solution |
|---|---|
| Voltage drops under load | Check transformer rating and pass element wiring. |
| Overheating | Improve cooling and add thermal sensors. |
| Fuse blows frequently | Verify current rating and wiring. |
| Unstable output | Check feedback network and capacitor values. |
| LED indicators not working | Verify connections and polarity. |
Frequently Asked Questions - High Power regulated power supply - 60V - 50A Circuit:
What is a high power regulated power supply?
A circuit that provides stable voltage and high current output with safety features.
What voltage and current can it deliver?
This design provides 60V DC at up to 50A.
Which components handle high current?
High-power MOSFETs or BJTs with heat sinks and fans.
How is voltage regulated?
Using feedback from output voltage to control pass elements.
How is overcurrent protection achieved?
Via sense resistors, shutdown circuits, and fuses or breakers.
What cooling is required?
Heat sinks and cooling fans for MOSFETs/BJTs.
Can it power motors?
Yes, suitable for motors and high-current devices up to 50A.
Is it safe to build?
Yes, with proper insulation, enclosures, fuses, and thermal management.
What type of transformer is needed?
High-current transformer capable of 60V DC after rectification.
Can it be used in labs?
Yes, ideal for lab experiments, industrial testing, and prototyping.
