• Electronic DC Load Project

    Posted in: DIY Projects

    DIY Project to build Electronic Constant Current DC Load

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        Electronic Constant Current DC Load #1 – Breadboard design and test
        1. Breadboard design and test

        Link to Kibi’s “Dave Jones’ dummy load with added features” :
        http://mjlorton.com/forum/index.php?t…

        Dave Jones / EEVblog video:
        http://www.youtube.com/watch?v=8xX2SV…

        If viewers are keen I will do a video / tutorial on how the circuit works and mention a few “tweaks” that can be made on how it operates.

        My components:

        * Infineon MOSFET N-channel 200V 13.5A TO-220 – BUZ31L H
        * Vishay 534 Series Pot with 6.34mm shaft, 50K
        * 2 x 10 k Ohm resistors
        * Arcol HS50 Al house wirewound high power resistor,1R (1 ohm) 50W – HS50 1R J
        * National Semiconductor Quad op amp,LM324N 1MHz DIP14

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        Electronic Constant Current DC Load #2 – How does the circuit work, and tweaks
        2. How does the circuit work, and tweaks

        Link to Kibi’s “Dave Jones’ dummy load with added features” :
        http://mjlorton.com/forum/index.php?t…

        Dave Jones / EEVblog video:
        http://www.youtube.com/watch?v=8xX2SV…

        WHAT IS AN OP-AMP?:
        http://talkingelectronics.com/project…

        My components:

        * Infineon MOSFET N-channel 200V 13.5A TO-220 – BUZ31L H
        * Vishay 534 Series Pot with 6.34mm shaft, 50K
        * 2 x 10 k Ohm resistors
        * Arcol HS50 Al house wirewound high power resistor,1R (1 ohm) 50W – HS50 1R J
        * National Semiconductor Quad op amp,LM324N 1MHz DIP14

        * How does an N Channel logic level MOSFET work – gate voltage, variable resistance, heat dissipation.
        * How does a LM324N Op Amp work – voltage follower, comparator, rail to rail, head room, feedback loop.

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        Electronic DC Load #3 – What is the function of the dummy load resistor?
        3. What is the function of the dummy load resistor?

        Link to Kibi’s “Dave Jones’ dummy load with added features” :
        http://mjlorton.com/forum/index.php?t…

        Dave Jones / EEVblog video:
        http://www.youtube.com/watch?v=8xX2SV…

        WHAT IS AN OP-AMP?:
        http://talkingelectronics.com/project…

        My components:

        * Infineon MOSFET N-channel 200V 13.5A TO-220 – BUZ31L H
        * Vishay 534 Series Pot with 6.34mm shaft, 50K
        * 2 x 10 k Ohm resistors
        * Arcol HS50 Al house wirewound high power resistor,1R (1 ohm) 50W – HS50 1R J
        * National Semiconductor Quad op amp,LM324N 1MHz DIP14

        * How does an N Channel logic level MOSFET work – gate voltage, variable resistance, heat dissipation.
        * How does a LM324N Op Amp work – voltage follower, comparator, rail to rail, head room, feedback loop.
        * What is the heat / power dissipation from a variable resistor?

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        Electronic DC Load #4 – Load sense feedback and oscillation
        4. Load sense feedback and oscillation

        I take a look at an oscillation problem with the oscilloscope and test to see if the load resistor acts as a sense / feedback for the op-amp to regulate the current.

        Link to Kibi’s “Dave Jones’ dummy load with added features” :
        http://mjlorton.com/forum/index.php?t…

        Dave Jones / EEVblog video:
        http://www.youtube.com/watch?v=8xX2SV…

        WHAT IS AN OP-AMP?:
        http://talkingelectronics.com/project…

        My components:

        * Infineon MOSFET N-channel 200V 13.5A TO-220 – BUZ31L H
        * Vishay 534 Series Pot with 6.34mm shaft, 50K
        * 2 x 10 k Ohm resistors
        * Arcol HS50 Al house wirewound high power resistor,1R (1 ohm) 50W – HS50 1R J
        * National Semiconductor Quad op amp,LM324N 1MHz DIP14
        * UNI-T / Trend UT81B Scopemeter / oscilloscope.

        * How does an N Channel logic level MOSFET work – gate voltage, variable resistance, heat dissipation.
        * How does a LM324N Op Amp work – voltage follower, comparator, rail to rail, head room, feedback loop.
        * What is the heat / power dissipation from a variable resistor?

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        Electronic DC Load #5 – Final circuit before build
        5. Final circuit before build

        Diagram and components on forum here:
        http://mjlorton.com/forum/index.php?t…

        Link to Kibi’s “Dave Jones’ dummy load with added features” :
        http://mjlorton.com/forum/index.php?t…

        Dave Jones / EEVblog video:
        http://www.youtube.com/watch?v=8xX2SV…

        WHAT IS AN OP-AMP?:
        http://talkingelectronics.com/project…

        My components:

        * Infineon MOSFET N-channel 200V 13.5A TO-220 – BUZ31L H (I will be using two of these in parallel)
        * Vishay 534 Series Pot with 6.34mm shaft, 50K
        * Vishay 534 Series Pot with 6.34mm shaft, 5K
        * 1 x 10 k Ohm resistor
        * 1 x 10 turn 10K trim pot
        * Arcol HS50 Al house wirewound high power resistor,1R (1 ohm) 50W – HS50 1R J
        * National Semiconductor Quad op amp,LM324N 1MHz DIP14
        * 1uF Capacitor

        * How does an N Channel logic level MOSFET work – gate voltage, variable resistance, heat dissipation.
        * How does a LM324N Op Amp work – voltage follower, comparator, rail to rail, head room, feedback loop.
        * What is the heat / power dissipation from a variable resistor?

        I talk about Joshua’s Youtube channel: https://www.youtube.com/user/jjoster
        His electronic DC load video:
        1- http://www.youtube.com/watch?v=mkymew…
        2- http://www.youtube.com/watch?v=M26jP3…
        3- http://www.youtube.com/watch?v=jXnKK5…
        4- http://www.youtube.com/watch?v=WSQeZd…

        Kickstarter Video for my Mini USB Host Board (Arduino Compatible) :
        http://www.youtube.com/watch?v=pwg39X…
        http://www.kickstarter.com/projects/9…

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        Electronic DC Load #6 – Layout and test on proto PCB / Stripboard
        6. Layout and test on proto PCB / Stripboard

        A quick look at the circuit on the stripboard PCB so that measurements can be taken to aid with completing the enclosure design.

        Dave Jones / EEVblog video:
        http://www.youtube.com/watch?v=8xX2SV…

        Veroboard Stripboard Software:

        http://www.printedcircuitsboards.com/…
        Fritzing here: http://www.fritzing.org

        My components:

        * Infineon MOSFET N-channel 200V 13.5A TO-220 – BUZ31L H
        * Vishay 534 Series Pot with 6.34mm shaft, 50K
        * 2 x 10 k Ohm resistors
        * Arcol HS50 Al house wirewound high power resistor,1R (1 ohm) 50W – HS50 1R J
        * National Semiconductor Quad op amp,LM324N 1MHz DIP14

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        Electronic DC Load #7 – Final Assembly and Build
        7. Final Assembly and Build

        It’s finally complete! Thanks to so many of you that made this happen!
        Pictures, design and CAD drawings: http://mjlorton.com/forum/index.php?t…

        A special thanks to Yves (Yttrium – forum ID) for the great the enclosure design and the time spent creating the CAD drawings and providing me with guidance.

        Link to Kibi’s “Dave Jones’ dummy load with added features” :
        http://mjlorton.com/forum/index.php?t…

        Dave Jones / EEVblog video (EEVblog #102 – DIY Constant Current Dummy Load for Power Supply and Battery Testing)
        http://www.youtube.com/watch?v=8xX2SV…

        Joshua’s Channel:
        https://www.youtube.com/user/jjoster/

        Joshua’s Constant Current Dummy Load – Completed :
        http://www.youtube.com/watch?v=WSQeZd…

        * Electronic DC load with data logging via Metrix MTX 3282 graphical multimeter
        * Energy testing, capacity and density measurements of rechargeable batteries, LiPo, LiFe, super capacitors, hybrid / ultra capacitors and more…

  • Electronic_DC_Load_transElectronic DC loads are a handy tool to have on your bench but if you priced them you may have sticker shock. I built this one and this is a great project that you can build for yourself. The maximum load on mine will is limited to 2 amp. The FETs can handle 13.5 amp as long as the total power is within 90 watt.

    The FETs are rated for 200 v but again as long as power is within 90 watt. Mine operates from about 0.5 volt to 30 volt. I have included step by step photos so you can follow along as I build the project, this give you a better look at the details. Clicking on the photos will enlarge them. You may download the Electronic DC Load Build Sheet for a list of materials and it has clickable links for more information. The parts can be found at our Amazon store. Watching the video tutorials will help you with the build. If you have trouble along the way visit our Forum to find out if others already found the solution or ask questions about new problems.

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