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030VDCStabilizedPowerSupplywithCurrentControl0.0023A

Home Projects Power 030VDCStabilizedPowerSupplywithCurrentControl0.0023A

030VDCStabilizedPowerSupplywithCurrentControl0.0023A
more info / buy kit :www.smartkit.gr

Copyrightofthiscircuitbelongstosmartkitelectronics.Inthispagewewillusethiscircuittodiscussfor
improvementsandwewillintroducesomechangesbasedonoriginalschematic.

GeneralDescription

This is a high quality power supply with a continuously variable stabilised output adjustable at any value
between 0 and 30VDC. The circuit also incorporates an electronic output current limiter that effectively controls
the output current from a few milliamperes (2 mA) to the maximum output of three amperes that the circuit can
deliver.Thisfeaturemakesthispowersupplyindispensableintheexperimenterslaboratoryasitispossibletolimit
the current to the typical maximum that a circuit under test may require, and power it up then, without any fear
that it may be damaged if something goes wrong. There is also a visual indication that the current limiter is in
operationsothatyoucanseeataglancethatyourcircuitisexceedingornotitspresetlimits.

TechnicalSpecificationsCharacteristics

TechnicalSpecifications
InputVoltage:................24VAC
InputCurrent:................3A(max)
OutputVoltage:.............030Vadjustable
OutputCurrent:.............2mA3Aadjustable
OutputVoltageRipple:....0.01%maximum

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Features
Reduceddimensions,easyconstruction,simpleoperation.
Outputvoltageeasilyadjustable.
Outputcurrentlimitingwithvisualindication.
Completeprotectionofthesupplieddeviceagainstoverloadsandmalfunction.

HowitWorks

To start with, there is a stepdown mains transformer with a secondary winding rated at 24 V/3 A, which is
connected across the input points of the circuit at pins 1 & 2. (the quality of the supplies output will be directly
proportionaltothequalityofthetransformer).TheACvoltageofthetransformerssecondarywindingisrectifiedby
thebridgeformedbythefourdiodesD1D4.TheDCvoltagetakenacrosstheoutputofthebridgeissmoothedby
the filter formed by the reservoir capacitor C1 and the resistor R1. The circuit incorporates some unique features
which make it quite different from other power supplies of its class. Instead of using a variable feedback
arrangement to control the output voltage, our circuit uses a constant gain amplifier to provide the reference
voltagenecessaryforitsstableoperation.ThereferencevoltageisgeneratedattheoutputofU1.
The circuit operates as follows: The diode D8 is a 5.6 V zener, which here operates at its zero temperature
coefficient current. The voltage in the output of U1 gradually increases till the diode D8 is turned on. When this
happensthecircuitstabilisesandtheZenerreferencevoltage(5.6V)appearsacrosstheresistorR5.Thecurrent
whichflowsthroughthenoninvertinginputoftheopampisnegligible,thereforethesamecurrentflowsthroughR5
andR6,andasthetworesistorshavethesamevaluethevoltageacrossthetwooftheminserieswillbeexactly
twicethevoltageacrosseachone.Thusthevoltagepresentattheoutputoftheopamp(pin6ofU1)is11.2V,
twicethezenersreferencevoltage.TheintegratedcircuitU2hasaconstantamplificationfactorofapproximately3
X,accordingtotheformulaA=(R11+R12)/R11,andraisesthe11.2Vreferencevoltagetoapproximately33V.The
trimmer RV1 and the resistor R10 are used for the adjustment of the output voltages limits so that it can be
reducedto0V,despiteanyvaluetolerancesoftheothercomponentsinthecircuit.

Schematicdiagramm

clickforhigherresolution

Anotherveryimportantfeatureofthecircuit,isthepossibilitytopresetthemaximumoutputcurrentwhichcan
be drawn from the p.s.u., effectively converting it from a constant voltage source to a constant current one. To
makethispossiblethecircuitdetectsthevoltagedropacrossaresistor(R7)whichisconnectedinserieswiththe
load.TheICresponsibleforthisfunctionofthecircuitisU3.TheinvertinginputofU3isbiasedat0VviaR21.At
thesametimethenoninvertinginputofthesameICcanbeadjustedtoanyvoltagebymeansofP2.
Letusassumethatforagivenoutputofseveralvolts,P2issetsothattheinputoftheICiskeptat1V.Ifthe
load is increased the output voltage will be kept constant by the voltage amplifier section of the circuit and the
presence of R7 in series with the output will have a negligible effect because of its low value and because of its
locationoutside the feedback loop of the voltage control circuit. While the load is kept constant and the output
voltageisnotchangedthecircuitis stable. If the load is increased so that the voltage drop across R7 is greater
than 1 V, IC3 is forced into action and the circuit is shifted into the constant current mode. The output of U3 is
coupledtothenoninvertinginputofU2byD9.U2isresponsibleforthevoltagecontrolandasU3iscoupledtoits
inputthelattercaneffectivelyoverrideitsfunction.WhathappensisthatthevoltageacrossR7ismonitoredandis
notallowedtoincreaseabovethepresetvalue(1Vinourexample)byreducingtheoutputvoltageofthecircuit.
This is in effect a means of maintaining the output current constant and is so accurate that it is possible to
presetthecurrentlimittoaslowas2mA.ThecapacitorC8istheretoincreasethestabilityofthecircuit.Q3is
usedtodrivetheLEDwheneverthecurrentlimiterisactivatedinordertoprovideavisualindicationofthelimiters
operation.InordertomakeitpossibleforU2tocontroltheoutputvoltagedownto0V,itisnecessarytoprovidea
negativesupplyrailandthisisdonebymeansofthecircuitaroundC2&C3.Thesamenegativesupplyisalsoused
forU3.AsU1isworkingunderfixedconditionsitcanberunfromtheunregulatedpositivesupplyrailandtheearth.

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ThenegativesupplyrailisproducedbyasimplevoltagepumpcircuitwhichisstabilisedbymeansofR3andD7.
InordertoavoiduncontrolledsituationsatshutdownthereisaprotectioncircuitbuiltaroundQ1.Assoonasthe
negativesupplyrailcollapsesQ1removesalldrivetotheoutputstage.Thisineffectbringstheoutputvoltageto
zeroassoonastheACisremovedprotectingthecircuitandtheappliancesconnectedtoitsoutput.Duringnormal
operationQ1iskeptoffbymeansofR14butwhenthenegativesupplyrailcollapsesthetransistoristurnedonand
bringstheoutputofU2low.TheIChasinternalprotectionandcannotbedamagedbecauseofthiseffectiveshort
circuitingofitsoutput.Itisagreatadvantageinexperimentalworktobeabletokilltheoutputofapowersupply
withouthavingtowaitforthecapacitorstodischargeandthereisalsoanaddedprotectionbecausetheoutputof
manystabilisedpowersuppliestendstoriseinstantaneouslyatswitchoffwithdisastrousresults.

Construction

Firstofallletusconsiderafewbasicsinbuildingelectroniccircuitsonaprintedcircuitboard.Theboardismadeof
a thin insulating material clad with a thin layer of conductive copper that is shaped in such a way as to form the
necessaryconductorsbetweenthevariouscomponentsofthecircuit.Theuseofaproperlydesignedprintedcircuit
board is very desirable as it speeds construction up considerably and reduces the possibility of making errors. To
protecttheboardduringstoragefromoxidationandassureitgetstoyouinperfectconditionthecopperistinned
during manufacturing and covered with a special varnish that protects it from getting oxidised and also makes
solderingeasier.
Solderingthecomponentstotheboardistheonlywaytobuildyourcircuitandfromthewayyoudoitdepends
greatly your success or failure. This work is not very difficult and if you stick to a few rules you should have no
problems. The soldering iron that you use must be light and its power should not exceed the 25 Watts. The tip
shouldbefineandmustbekeptcleanatalltimes.Forthispurposecomeveryhandyspeciallymadespongesthat
are kept wet and from time to time you can wipe the hot tip on them to remove all the residues that tend to
accumulateonit.
DO NOT file or sandpaper a dirty or worn out tip. If the tip cannot be cleaned, replace it. There are many
differenttypesofsolderinthemarketandyoushouldchooseagoodqualityonethatcontainsthenecessaryfluxin
itscore,toassureaperfectjointeverytime.
DONOTusesolderingfluxapartfromthatwhichisalreadyincludedinyoursolder.Toomuchfluxcancausemany
problemsandisoneofthe main causes of circuit malfunction. If nevertheless you have to use extra flux, as it is
thecasewhenyouhavetotincopperwires,cleanitverythoroughlyafteryoufinishyourwork.

Inordertosolderacomponentcorrectlyyoushoulddothefollowing:

Cleanthecomponentleadswithasmallpieceofemerypaper.
Bend them at the correct distance from the components body and insert he component in its place on the
board.
Youmayfindsometimesacomponentwithheaviergaugeleadsthanusual,thataretoothicktoenterinthe
holesofthep.c.board.Inthiscaseuseaminidrilltoenlargetheholesslightly.Donotmaketheholestoo
largeasthisisgoingtomakesolderingdifficultafterwards.
Takethehotironandplaceitstiponthecomponentleadwhileholdingtheendofthesolderwireatthepoint
wheretheleademergesfromtheboard.Theirontipmusttouchtheleadslightlyabovethep.c.board.
Whenthesolderstartstomeltandflowwaittillitcoversevenlytheareaaroundtheholeandthefluxboils
andgetsoutfromunderneaththesolder.
The whole operation should not take more than 5 seconds. Remove the iron and allow the solder to cool
naturallywithoutblowingonitormovingthecomponent.Ifeverythingwasdoneproperlythesurfaceofthe
joint must have a bright metallic finish and its edges should be smoothly ended on the component lead and
theboardtrack.Ifthesolderlooksdull,cracked,orhastheshapeofablobthenyouhavemadeadryjoint
andyoushouldremovethesolder(withapump,orasolderwick)andredoit.Takecarenottooverheatthe
tracksasitisveryeasytoliftthemfromtheboardandbreakthem.
Whenyouaresolderingasensitivecomponentitisgoodpracticetoholdtheleadfromthecomponentsideof
theboardwithapairoflongnoseplierstodivertanyheatthatcouldpossiblydamagethecomponent.
Makesurethatyoudonotusemoresolderthanitisnecessaryasyouarerunningtheriskofshortcircuiting
adjacenttracksontheboard,especiallyiftheyareveryclosetogether.
Whenyoufinishyourwork,cutofftheexcessofthecomponentleadsandcleantheboardthoroughlywitha
suitablesolventtoremoveallfluxresiduesthatmaystillremainonit.

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PCBConnections

pcb.gif(60KB)(12,5cmx8,7cm)

connections.gif(17,8KB)

layout.gif(92KB)

Construction(...continued)

Asitisrecommendedstartworkingbyidentifyingthecomponentsandseparatingthemingroups.Placefirstof
allthesocketsfortheICsandthepinsfortheexternalconnectionsandsolderthemintheirplaces.Continuewith
the resistors. Remember to mound R7 at a certain distance from the printed circuit board as it tends to become
quite hot, especially when the circuit is supplying heavy currents, and this could possibly damage the board. It is
alsoadvisabletomountR1atacertaindistancefromthesurfaceofthePCBaswell.Continuewiththecapacitors
observingthepolarityoftheelectrolyticandfinallysolderinplacethediodesandthetransistorstakingcarenotto
overheatthemandbeingatthesametimeverycarefultoalignthemcorrectly.
Mount the power transistor on the heatsink. To do this follow the diagram and remember to use the mica
insulatorbetweenthetransistorbodyandtheheatsinkandthespecialfibberwasherstoinsulatethescrewsfrom
theheatsink.Remembertoplacethesolderingtagononeofthescrewsfromthesideofthetransistorbody,thisis
going to be used as the collector lead of the transistor. Use a little amount of Heat Transfer Compound between
thetransistorandtheheatsinktoensurethemaximumtransferofheatbetweenthem,andtightenthescrewsas
farastheywillgo.
Attachapieceofinsulatedwiretoeachleadtakingcaretomakeverygoodjointsasthecurrentthatflowsin
thispartofthecircuitisquiteheavy,especiallybetweentheemitterandthecollectorofthetransistor.
It is convenient to know where you are going to place every thing inside the case that is going to accommodate
yourpowersupply,inordertocalculate the length of the wires to use between the PCB and the potentiometers,
thepowertransistorandfortheinputandoutputconnectionstothecircuit.(Itdoesnotreallymatterifthewires
arelongerbutitmakesamuchneaterprojectifthewiresaretrimmedatexactlythelengthnecessary).
Connect the potentiometers, the LED and the power transistor and attach two pairs of leads for the input and
output connections. Make sure that you follow the circuit diagram very care fully for these connections as there
are 15 external connections to the circuit in total and if you make a mistake it may be very difficult to find it
afterwards.Itisagoodideatousecablesofdifferentcoloursinordertomaketroubleshootingeasier.

Theexternalconnectionsare:

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1&2ACinput,thesecondaryofthetransformer.
3(+)&4()DCoutput.
5,10&12toP1.
6,11&13toP2.
7(E),8(B),9(E)tothepowertransistorQ4.
The LED should also be placed on the front panel of the case where it is always visible but the pins where it is
connectedatarenotnumbered.
Whenalltheexternalconnectionshavebeenfinishedmakeaverycarefulinspectionoftheboardandcleanitto
remove soldering flux residues. Make sure that there are no bridges that may short circuit adjacent tracks and if
everythingseemstobeallrightconnecttheinputofthecircuitwiththesecondaryofasuitablemainstransformer.
Connectavoltmeteracrosstheoutputofthecircuitandtheprimaryofthetransformertothemains.
DONOTTOUCHANYPARTOFTHECIRCUITWHILEITISUNDERPOWER.
The voltmeter should measure a voltage between 0 and 30 VDC depending on the setting of P1, and should
follow any changes of this setting to indicate that the variable voltage control is working properly. Turning P2
counterclockwiseshouldturntheLEDon,indicatingthatthecurrentlimiterisinoperation.

Data

Adjustments

Ifyouwanttheoutputofyoursupplytobeadjustablebetween0and30VyoushouldadjustRV1tomakesure
thatwhenP1isatitsminimumsettingtheoutputofthesupplyisexactly0V.Asitisnotpossibletomeasurevery
smallvalueswithaconventionalpanelmeteritisbettertouseadigitalmeterforthisadjustment,andtosetitata
verylowscaletoincreaseitssensitivity.

Warning

Whileusingelectricalparts,handlepowersupplyandequipmentwithgreatcare,followingsafetystandardsas
describedbyinternationalspecsandregulations.
CAUTION
Thiscircuitworksoffthemainsandthereare220VACpresentinsomeofitsparts.
Voltagesabove50VareDANGEROUSandcouldevenbeLETHAL.
Inordertoavoidaccidentsthatcouldbefataltoyouormembersofyourfamilypleaseobservethefollowingrules:
DONOTworkifyouaretiredorinahurry,doublecheckeverythingbeforeconnectingyourcircuittothemains
andbeready
todisconnectitifsomethinglookswrong.
DONOTtouchanypartofthecircuitwhenitisunderpower.
DONOTleavemainsleadsexposed.Allmainsleadsshouldbewellinsulated.
DONOTchangethefuseswithothersofhigherratingorreplacethemwithwireoraluminiumfoil.
DONOTworkwithwethands.
Ifyouarewearingachain,necklaceoranythingthatmaybehangingandtouchanexposedpartofthecircuitBE
CAREFUL.
ALWAYSuseapropermainsleadwiththecorrectplugandearthyourcircuitproperly.
Ifthecaseofyourprojectismadeofmetalmakesurethatitisproperlyearthen.
Ifitispossibleuseamainstransformerwitha1:1ratiotoisolateyourcircuitfromthemains.
Whenyouaretestingacircuitthatworksoffthemainswearshoeswithrubbersoles,standondrynon
conductivefloor
andkeeponehandinyourpocketorbehindyourback.

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Ifyoutakealltheaboveprecautionsyouarereducingthe
risksyouaretakingtoaminimumandthiswayyouareprotecting
yourselfandthosearoundyou.
Acarefullybuiltandwellinsulateddevicedoesnotconstituteanydangerforitsuser.
BEWARE:ELECTRICITYCANKILLIFYOUARENOTCAREFUL.

Ifitdoesnotwork

Checkyourworkforpossibledryjoints,bridgesacrossadjacenttracksorsolderingfluxresiduesthatusuallycause
problems.
Checkagainalltheexternalconnectionstoandfromthecircuittoseeifthereisamistakethere.
Seethattherearenocomponentsmissingorinsertedinthewrongplaces.
Makesurethatallthepolarisedcomponentshavebeensolderedtherightwayround.Makesurethesupplyhas
thecorrectvoltageandisconnectedtherightwayroundtoyourcircuit.
Checkyourprojectforfaultyordamagedcomponents.

PartsList

R1=2,2KOhm1W
R2=82Ohm1/4W
R3=220Ohm1/4W
R4=4,7KOhm1/4W
R5,R6,R13,R20,R21=10KOhm1/4W
R7=0,47Ohm5W
R8,R11=27KOhm1/4W
R9,R19=2,2KOhm1/4W
R10=270KOhm1/4W
R12,R18=56KOhm1/4W
R14=1,5KOhm1/4W
R15,R16=1KOhm1/4W
R17=33Ohm1/4W
R22=3,9KOhm1/4W
RV1=100Ktrimmer
P1,P2=10KOhmlinearpontesiometer
C1=3300uF/50Velectrolytic
C2,C3=47uF/50Velectrolytic
C4=100nFpolyester
C5=200nFpolyester
C6=100pFceramic
C7=10uF/50Velectrolytic
C8=330pFceramic
C9=100pFceramic
D1,D2,D3,D4=1N5402,3,4diode2ARAXGI837U
D5,D6=1N4148
D7,D8=5,6VZener
D9,D10=1N4148
D11=1N4001diode1A
Q1=BC548,NPNtransistororBC547
Q2=2N2219NPNtransistor
Q3=BC557,PNPtransistororBC327
Q4=2N3055NPNpowertransistor
U1,U2,U3=TL081,operationalamplifier
D12=LEDdiode

Feedback

Pleasetellmeyourexperiences/thoughtsbuildingthispowersupplyhere
Alsochecktheconversationaboutthisprojectatthecommunity.Postyouquestionshere.

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hereisaboardmadebySamCarmelandworkednice

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Daniel'sbuildofPSUfrontviewwithLCDvoltmeter
Potensiometersforcoarseandfinevoltageadjustmentandcurrentregulator

Daniel'sbuildofPSUinternalview.Amobilephonechargerisusedaspowersupplyforvoltmeter

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Daniel'sbuildofPSUinternalview.Heisgoingtochange2200uFa6800uFcapacitortoreducerippleinhighload.

Daniel'sbuildofPSUinternalview.newcapacitor(6800uFx40V)toimproveripplefiltering

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Daniel'sbuildofPSUinternalview.ModificationtoprotecttheLM311

ReceivedthefollowingemailfromDanielon06/2012:
Ionlyfaceaproblemwithoneofthebiggestplaguesinelectronicsnow...Fakecomponents.Ibougthafake
2N2219anditlast100ms(orless)inmyfirsttry.AsthepiecewasnewIneversuspectedonit.Ispent2hours
lookingfortheproblemandIcouldnotbelievewhenItestit...IhadmoretwoIbougthtogeter,theyhadthesame
destiny...FormyluckyIhadaboxwitholdcomponents(somedatesfromthe70s)andthereIfoundagenuine
Motorola2N2219...Thisisrunningperfect.ThiswastheonlydifficultyIfound...

ReceivedthefollowingemailfromIvanon02/2010:
Ok.Ibulidyourprojectaboutadayago.Mountedallthepartsonthepcbandthenconcludedthatthereissome
seriousproblemsinthisschematics.First,2N3055willoverheat,soyouhavetoconnecttwooftheminparallelwith
emitterresistors0.1ohm/5w.Second,maximalvoltagebetween'+'and''ofTL081is36VDC.Ifyouconnectthem
asitisshowninthiscircuitdiagramthatvoltagewillbeabout45VDC,sotheywillburndownimmediately.Tofix
thisproblemyouhavetoreconnectallpinsnumber7ofU1,U2andU3,emitterofQ3and'upper'endofR19toout
ofan7809with18Vzenerdiodebetween'common'pinand''of3300uFcap,andinputof7809connectto'+'of
thesamecap.Now,onpinnumber7andmentionedpartsyou'llhave27VDC,andtotalvoltagewillbe32.6VDC.
Third,insteadofusing3300uF,use4700or6800uF/63VDCtoreducetherippleonhighercurrents(23A).Therest
ofthecircuitisperfect.Ilikeitcauseitissoinexpensiveandeasytomakewiththosesimplereconstructionsi
mentioned.

Upgrading

AgreatadditiontoyourPSUwouldbeaVoltmeter+AmmeterLCDpanel.Checkithere!
LCDmultimeterVolt&Ampermeter

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