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Thursday, October 6, 2011

How to limit curent and monitor it with a sense resistor

It doesn't get any simpler than this. But somebody asked, so here we go!

So you have an experimental device to test (DUT). It is supposed to be supplied a voltage to turn it on (lets say: 12V). The first thing you should ask is: How much current can this draw before it blows up?
Once you know the maximum current specification (ex: 200mA), How do you ensure that it doesn't go beyond this maximum value?

Procedure to deliver 12V and a maximum of 200 mA from a DC Power Supply:
  • Find a Current Meter that can handle >200mA.
  • Find a DC Power supply that can supply 12V.
  • Place the Current Meter in series with the Power Supply (see above photo).
  • Most DC power supplies have at least 2 knobs. One labeled "voltage", and the other labeled "current". Set your voltage on the power supply (PS) to 12V.
  • Now set your current by:
    • turning your PS current knob all the way down to zero.
    • replace the DUT with a short by connecting the supply-leads together.
    • observe the current-reading on the multimeter and slowly turn the PS current-knob until it reads 200mA (voltage on your PS should read 0 V since leads are shorted together)
  • Disconnect the leads and ensure that PS voltage goes back to 12 V.
  • Re-connect your DUT and you can now monitor current via the Current Meter.

What if you cannot find a Current Meter that can handle your required current?
Say you want to deliver 10 A instead. You can still monitor the current by using a Volt-Meter and Sense resistor instead.

Choose a small resistance value for the sense resistor: 1/2 ohm. Since you expect to now deliver 10 A, the resistor must be able to handle the higher power: P=VI = 50 W... not your typical resistor found in a test kit!

Use a Voltage Meter to measure the the voltage across the sense resistor and convert voltage to current: I=V/R. Set your current limit on the PS as before.

Notes:
  • Keithley makes an all-in-one unit that supplies a voltage and measures current (or vice verse).
  • Most Current Meters also function as Voltage Meters and are called "Multi-Meters".
  • Its always smart to check the voltage at your DUT to ensure their isn't a voltage-drop over long supply-wires.

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