Power Supply Unit Multimeter

www.elfly.pl
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Tachometr / Tachometer	Regulator modelarski / RC ESC	PDIP multimeter version

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MULTIMETER FOR POWER SUPPLY UNIT

This multimeter was designed to measure output voltage and current in a PSU, where the current sense shunt resistor is connected in series with load at the negative voltage rail. It needs only one supply voltage that can be acquired from main PSU. An additional function of the multimeter is that it can control (switch on and off) an electric fan used to cool the main heatsink. The power threshold at which the fan switches on can be adjusted using One Touch Button Setup.

Technical Specifications - Characteristics

single µC ATMEL ATmega8 used to handle all the multimetr functions;
voltage range 0-30V;
voltage measure resolution 10mV;
current range 0-99A;
current measure resolution 10mA (depend on current sense resistor value*);
single, non isolated voltage supply;
one side PCB;
compact construction allowed to use multimetr as panel meter;
well interaction with standard LCD based on HD44780 controller

*Internal MULTIMETR resolution is given by equatin:
resolution[mA] = 1/(R[om]*3.2)
If internal resolution is worse than 10mA, MULTIMETER displays current with internal resolution, if better - with 10mA one.
In addition voltage drop on shunt resistor musn't exceed 2.4V, so R[om] should be less than 2.4/Imax[A]

Construction

Schematic

There are elements on schematic and in the following table marked as "Do Not Assemble". That elements was needed in previous software edition. Current software version doesn't , so you just don't add them. Maybe in a future version of the multimeter there will be a simpler PCB with simpler electronic diagram too.

Part List:

Element	Value/Type	Case	Remars
R1	100k	1206
R2	100k	1206
R3	10k		Potentiometer
R4	30k	1206
R5	10k	1206
R6	10k	1206
R7	7k5	1206
R8	7k5	1206
R9	500R		Potentiometer
R10	500R		Potentiometer
R11	5k1	1206
C1	100n	1206
C2	100n	1206
C3	100n	1206
C4	100n	1206	Do Not Assemble
C5	100n	1206	Do Not Assemble
C6	100n	1206	Do Not Assemble
C7	100n	1206	Do Not Assemble
C8	100n	1206	Do Not Assemble
C9	100n	1206	Do Not Assemble
C10	22u/6V	SMD A
C11	10n	1206	Optional element - protect Q1 against voltage peek after switch off fan. Most of the computer type fans which I tested didn't produce voltage peeks dangerous for Q1
C12	10u/50V
L1	47u	1210	Do Not Assemble - cross PCB pads
D1	DIODE	SMD A	Optional element - protect Q1 against voltage peek after switch off fan. Most of the computer type fans which I tested didn't produce voltage peeks dangerous for Q1
D2	DIODE	SMD A	e.g. SK310A
U1	7805	TO-252	Voltage regulator +5V, e.g. LM7805
U2	7812	TO220	Voltage regulator +12V, e.g. LM7812
U3	ATMEGA8	TQFP32
LCD	GOLDPIN	1x16
J1	GOLDPIN	1x2	FAN_CON - fan connector
J2	GOLDPIN	1x1	+12V_CON - optional +12V supply connector
J3	GOLDPIN	1x1	+35V_CON - main supply connector
J4	GOLDPIN	1x3	ground and measured signals
S1	SWITCH
Q1	MOSFET N	SOT-23	e.g. BSS-138 (fan current lees than 200mA)

Layout - top side

Layout - bottom side

Picture of PCB is here. There are two version of PCB - normal and mirrored. I think, that anyone who makes PCBs will know, which one schould be used to produce right PCB.

After soldering all the parts on PCB:

make two cross connection on PCB (see "Layout - bottom side");
short L1 pads;
place U2 element (+12V voltage regulator) on heatsink
pay attention on right polarity D1 i D2 elements. Wider side of silk screen layout, where part number is placed, is CATHODE.

Programing

Because µC is in TQFP package, we can program it after soldering all the elements on PCB. It makes programing quite easy to perform. Programing signals are delivered through LCD connector. To make the programing cable, you can use old PC HDD cable. Picture of my programing cable is shown here.
Remember, that durring programing multimetr circuit must be supplied with +5V. Depending on your programmer, supply voltage is provided either by programmer, or from separate power supply unit.

Programing cable connection list

LCD Pin number	LCD signal	µC signal/Pin	Prog signal
1	GND	GND	GND
2	VCC	VCC	VCC
4	RS	SCK / PB.5	SCK
5	RW	MISO / PB.4	MISO
6	EN	MOSI / PB.3	MOSI
10	D3	RESET	RESET

After connecting µC to prog, you should check, if µC is "visible" for prog. When everything is fine, you can upload code to µC. The code is available here .
It is assumed here, that µC is new and works with its internal RC clock at 1MHz. If not, set apropriate fusebits to achive above mentioned conditions.
In addition Brown-out detector should be turned on by enabling BODEN fuse. Recomended Brown-out Reset Threshold Voltage is 4V.

The next thing to do is to cross LCD soldering pads number 1 and 5. It is neccesary to provide ground for LCD RW signal.
After all, connect LCD module with the multimeter PCB. It is recommended to use a detachable connector for further expandability e.g. software upgrading.

Instalation in PSU and Regulation

Mount multimeter to PSU according to the diagram below:

Connectors and regulation elements:

ELEMENT	ACTION
S1	reset/setup connector During normal work pushing S1 button cancel amount of displayed charge. In versions without charge displaying, pushing this button doesn't make any reaction. To enter setup push and hold S1 button, then power on multimeter. When "www.elfly.pl" appear on LCD, you are in setup mode. First parameter to adjust is ATMega8 voltage reference. Reference voltage inaccurracy is the main measurement error factor in previous multimeter code versions, because Vref vary from chip to chip in quite wide range . You can measure reference voltage between multimeter ground and µC pin no. 20. Measured value you should write down in setup. If you don't write anything, it will be assumed, that Vref=2.56V (due to datasheet). After Vref setup, button must not be pressed for about 5 seconds. The next parameter to set up is shunt resistor value. If the resistor value is known, repeat button pushing until correct value reached. If resistor value is unknown (e.g. self made resistor), short PSU output by ammeter, set some current by PSU current limit regulator and then, push button, lead to equal current indication on ammeter and multimeter. After shunt resistor value setup, button must not be pressed for about 5 seconds. The next parameter to set up is fan switch-on power threshold. It is the real power loosed on output transistor (transistors), because multimeter has information on voltage drop on transistor and driving current. To avoid instability switch-off threshold is automatically set to 20% less than switch-on one.
R9	Fine voltage circuit regulation potentiometer. To reduce ADC conversion errors like un-linearity, gain factor etc. measuring range is divided into two sub-ranges 0-10V and 10-30V (switch threshold can be between 7-13V depend on sourcing current and elements tolerance). To regulate fine sub-range connect voltmeter to PSU output, set up voltage at about 9V and turn R9 until voltmeter and multimeter indications are equal.
R10	Coarse voltage circuit regulation potentiometer. There is over-sampling applied in multimeter software, so measuring resolution is the same in fine and coarse circuit and is 10mV. Because of the reason described above multimeter has two measuring circuits. To regulate coarse sub-range connect voltmeter to PSU output, set up voltage at about 19V and turn R10 until voltmeter and multimeter indication are equal. (If you posses 4.5 digit voltmeter, you could regulate at voltage 30V)
R3	LCD contrast potentiometer. Turn that potentiometer first, if nothing is visible on LCD.
J1	Fan connector. Pin no. 1: Fan "+" Pin no. 2: Fan "-"
J2	+12V If +12V DC is available in your PSU, connect it to that pin. In that case you shouldn't assemble +12V voltage regulator U2 on PCB. That solution is convenient for multimeter, because eliminates U2 heating and permit to connect fan and LCD with higher current consumption. If you haven't got +12V DC in your PSU, left that pin unconnected.
J3	+35V Rectifier bridge voltage. See U2 element you used data sheet to know about maximum voltage it can work properly. On the other hand the minimum voltage on that pin mustn't drop bellow c.a. 9V, or 6.5V if low drop type U2 and U3 voltage regulators were used. That pin should be connected even if +12V DC is connected to J2 pin. Voltage from that pin deliver information for fan switching.
J4	Measuring signal connector. Multimeter is suitable for voltage and current measurement in PSU, where current sense shunt resistor is connected in series with load and is in negative rail. Pin no.1: voltage measurement U - connect to "+" PSU output, best directly to output terminal; Pin no.2: current measurement I - connect to "-" PSU output, best directly to output terminal; Pin no.3: ground - connect to shunt resistor terminal opposite to that connected to "-" PSU output.
LCD	LCD connector. Multimeter works properly with LCD's 1x16 logical controlled as 2x8 (most of LCD's available on the market). Because of linear voltage regulators used in multimeter, sourcing current is limited. Main current consumption elements are fan and LCD backlight, so: - use LCD with LED backlight (typically current consumption is less than 15mA); - use low speed, low current fan. Additional advantage of that solution will be silence.

Front panel design is HERE
Panel is suitable for Z-17 case

Remember to cut sufficient paper just after mounting and match panel with front plastic part of case.
That frame on print is only coarse outline.

Below some pictures of multimeter and PSU

PSU presented above was build acording to http://www.electronics-lab.com/projects/power/003/index.html

I prepared some multimeter code versions:

	LCD 1x16	HEX
	LCD 2x16	HEX
	LCD 2x16 Load resistance displaying	HEX
	LCD 2x16 Capacity in mAh passed to load displaying	HEX
	LCD 2x16 Load resistance and capacity in mAh passed to load displaying	HEX

Caution! Wrong code (e.g. PDIP mutlimeter version) can damage µC chip after powering up multimeter

I use MULTIMETER version with measurement of the amount of electric charge sourced from PSU to charge my RC Li-Pol cells. That PSU is very convenient for that purpose, because constant-current, constant-voltage (CC-CV) charging is easy to achive. Charged capacitance indicator give possibility to estimate cells condition and level of discharge after cells use.

CAUTION
This circuit itself doesn't work off the mains and there are not 220 VAC present, but PSU does.
Voltages above 50 V are DANGEROUS and could even be LETHAL.
In order to avoid accidents that could be fatal to you or members of your family please observe the following rules:

DO NOT work if you are tired or in a hurry, double check every thing before connecting your circuit to the mains and be ready to disconnect it if something looks wrong.
DO NOT touch any part of the circuit when it is under power.
DO NOT leave mains leads exposed. All mains leads should be well insulated.
DO NOT change the fuses with others of higher rating or replace them with wire or aluminium foil.
DO NOT work with wet hands.
If you are wearing a chain, necklace or anything that may be hanging and touch an exposed part of the circuit BE CAREFUL.
ALWAYS use a proper mains lead with the correct plug and earth your circuit properly.
If the case of your project is made of metal make sure that it is properly earthen.
If it is possible use a mains transformer with a 1:1 ratio to isolate your circuit from the mains.
When you are testing a circuit that works off the mains wear shoes with rubber soles, stand on dry non conductive floor and keep one hand in your pocket or behind your back.

If you take all the above precautions you are reducing the risks you are taking to a minimum and this way you are protecting yourself and those around you.
A carefully built and well insulated device does not constitute any danger for its user.

BEWARE: ELECTRICITY CAN KILL IF YOU ARE NOT CAREFUL

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