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Final Component Selection

A project log for Nixie Tube Power Supply

A flexible power supply for Nixie tubes. Input voltage can be from 3V to 12V. Output up to 200V. It uses commercially available transformers

paul-andrewsPaul Andrews 11/08/2017 at 15:120 Comments

I got my thermal camera, so the results are in! It looks like the peak temperature I have managed to get for the transformer is 129°F. Here are some pictures. The first shows the temperature of the transformer. This is when the power supply is producing 20mA at 200V with 12V in:

Next up, the controller:

And next the MOSFET:

Is that OK? Well the data sheet for the transformer says:

It is recommended that the temperature of the part does not exceed +125°C under worst case conditions. 

125°C is 257°F, so we are well under that. These measurements were taken with an ambient temperature of around 70°F. We could expect worse behavior in a closed case, but I think we may still have some headroom, so it could be that the current sense resistor value that I chose could be reduced some. I will try this with a 0.04Ω resistor and check the temperatures again.

I will list the final component values in a moment, but for now here are some performance results:

12V
Rload (K) Vout Iout (mA) W Vin Iin (mA) W Eff
20 199.6 10.40 2.08 11.96 238 2.85 0.73
15 199.5 13.70 2.73 11.96 298 3.56 0.77
10 199.2 20.00 3.98 11.94 415 4.96 0.80
20 177.6 9.26 1.64 11.96 195 2.33 0.71
15 177.5 12.18 2.16 11.96 243 2.91 0.74
10 177.4 17.84 3.16 11.96 347 4.15 0.76
5V
Rload (K) Vout Iout (mA) W Vin Iin (mA) W Eff
20 192.4 10.00 1.92 4.85 500 2.43 0.79
15 172.6 11.84 2.04 4.84 502 2.43 0.84
10 141.0 14.17 2.00 4.8 508 2.44 0.82
20 177.0 9.22 1.63 4.85 500 2.43 0.67
15 172.5 11.81 2.04 4.84 502 2.43 0.84
10 141.0 14.18 2.00 4.8 508 2.44 0.82
3.7V
Rload (K) Vout Iout (mA) W Vin Iin (mA) W Eff
20 174.0 8.80 1.53 3.6 373 1.34 1.14
15 154.0 10.34 1.59 3.6 370 1.33 1.20
10 130.0 12.80 1.66 3.6 364 1.31 1.27
20 172.0 8.80 1.51 3.6 380 1.37 1.11
15 153.0 10.30 1.58 3.6 373 1.34 1.17
10 129.0 12.70 1.64 3.6 370 1.33 1.23

For each input voltage, there are two sets of numbers. The first set is for a Vout limit of 200V. The second set is for a Vout limit of 177V. Here are some takeaways:

  1. My measurements for 3.7V are clearly wrong somewhere, because they give an efficiency of > 1!
  2. Ignoring that, we are hitting efficiencies of between 70% and 80%, which is pretty good!
  3. We can get 20mA out of it if we put 12V in. We could probably get more, but my test equipment (such as it is) can't go lower than a 10K load without starting a fire. In fact, the thermal camera shows that my 10K load resistor was hitting 400°F as it is! Anyone want to buy me some lab equipment? 20mA will power just about any 6 tube clock.
  4. On battery, we can get 8mA out, which is enough for 4 to 6 small tubes. Which is fine.
  5. On USB (aka 5V), we can get roughly 12mA out at a decent voltage. That is good for a lot of tube types. If I can decrease Rsense, so I can get more current flowing, we could improve these numbers.
  6. The voltage regulation starts to fail as load goes up and input voltage drops. Again, I know from experience that if I can drop Rsense, I can get a more stable output voltage

So here is the final circuit diagram:

  1. The MOSFET is an AO4294. This has a 100V Vds and a very low Rds(on). Other options I tried tended to get a bit warm.
  2. Rsen is 0.06Ω.
  3. Rfreq is 47K.
  4. Rsnub is 249Ω
  5. Csnub is 360pF.
  6. The diode is an ES1FL R3G.
  7. The transformer is a Wurth ER11/5 - order code 749196141.

Here is a picture of the board layout:

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