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We've had a few discussions about fabricating simple power supplies from eBay modules, I decided to go one step beyond.  I spotted these cool DC-DC Buck/Boost power modules with tons of features.  With an output voltage range of 0.6VDC to 36VDC, and a max output current capacity of over 5 amps, they seem to have pretty much all I'd need in a bench supply.  They do constant voltage, constant current, and have a really accurate digital display of both voltage and current.  You can also graph the voltage and current output for analyzing external circuit performance, pretty neat.

__Buck-Boost Power Module

XYS3580 DC DC Buck Boost Converter CC CV 0.6-36V 5A Power Module Adjustable Regulated Laboratory Power Supply Variable

Of course, one of the little issues is they require DC input as well.  I hunted around and found this 120W 24VDC switcher that looked like a good fit to provide the input power.  This little gem puts out 24 VDC at 5 amps with 120VAC in.

Both the buck-boost and primary switcher have a host of protection features, so I think this should be a pretty decent source of bench power.

Mean Well EPS-120-24

I shopped around and found a case on Jameco, it was a tight fit, but I managed to get all of the stuff in.  I also needed a small cooling fan if I push this unit very hard, so I added that.  Banana jacks salvaged from a dead MTH TIU and a power switch round out the picture.

If one of these nice power supply modules is good, two would obviously be better, right?  Of course, so two it is!

Dual Bench DC Power Supply N1

I actually bought two cases from Jameco, this is the smaller one, and I got a larger one as well.  Since I could squeeze all of the stuff into the smaller case, I decided that limiting the bench space it consumed would be a good idea.  As you can see, the front panel doesn't have any more room, it really is stuffed!  However, I did want to fit the dual banana jacks for ease of use, so this was the only layout that everything would fit in.

Dual Bench DC Power Supply N2

The interior is pretty straight forward.  Since I had no idea how hot the primary 120W supply might get, I added a fiberglass plate and mounted it on some standoffs to allow ventilation all around. 

Dual Bench DC Power Supply N3

An 80mm ball bearing fan blows directly on the primary supply and I provided generous exhaust vents to allow air circulation.  Since I had the grill laying around, I thought it was a nice touch.

One little disappointment in the primary power supply.  It conveniently included a 12VDC fan output, only that output didn't work!   So, I added a little regulator module to drop the 24V to 12V for my fan.  I thought of a resistor, but the fan consumes 75ma, and it was a pretty big resistor, so I just dropped in the little regulator module.

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  • __Buck-Boost Power Module
  • mceclip0
  • mceclip0
  • Dual Bench DC Power Supply N1
  • Dual Bench DC Power Supply N2
  • Dual Bench DC Power Supply N3
Last edited by gunrunnerjohn
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@PLCProf posted:

Hi John-

Looks like a useful gadget. I note that the module is rated 6 - 36 VDC out at 5A, but is also rated at only 80 watts. Did you try it near the limits to see what happens? Maybe 36A at 3A; your 120 watt DC source should be able to handle that.

Since there are two of these modules feeding off one primary supply, I figured that one would not max out the primary 120W supply.  Truthfully, it's probably going to be a very rare occasion I'm pulling 5 amps from one of these, and certainly not 5 amps from both sides.

I ran one of these up to 4 amps at 8 volts, it worked, but it was getting warm.  The input voltage at the time was from a 10A bench supply at 24 volts, I was pulling just about 2 amps from the 24V input supply.  The little fans kick on when needed, and in the case, the case fan runs whenever power is on.

@Falcon70 posted:

John, this is a cool set up!  You have too much free time!  But neat for sure; Falcon70

Actually, I have very little free time, but I needed another DC bench supply, and I figured when I found these that I could be a dual-channel model.

Rod, you are so right, but I think with four DC supplies now, I'm set.  My modification on my 10A one has been working great, so I have more faith in that one now as well.

@fastman posted:

John If you have a few minutes could you look at my MTH TIU post in electro forum would like your feedback. Thanks Charlie

A link is always useful.

@Richie C. posted:

GRJ - what do you figure your parts cost was for a complete one of these units ?

The two display modules were $21/ea, and the rest of the stuff was around 30 total, so call it $75.

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