Electrical – Safety: Mains step down transformer vs SMPS for bench power supply

isolationmainspower supplysafety

Between a mains step down transformer and a SMPS, which would be safer for a bench power supply? I cannot look inside the transformer in either case to judge the insulation quality. But, if the insulation does fail there would be 230VAC at the secondary for the mains transformer. And, maybe 325VDC at the output of the SMPS (is that possible)? I can visually inspect the SMPS PCB to check if there is proper clearance, presence of MOVs, thermistors, fuses etc, but of course cannot see inside the transformer.

So the question is, which is easier to make safer (or screw up)? Which is easier to figure out when new, if failure will be catastrophic in future? Can SMPS transformers fail due to failing mosfets etc? I'm guessing that if a mains transformer works without issues when new (including the problem of interwinding capacitance), I can expect it to work for at least a decade without issues, right? Assuming everything will be fused properly and fan cooled.

It's one thing to get a shock from inadvertently touching bad wiring, and quite another to be exposed while clutching the wires in my hands. So I am concerned somewhat about safety. Of course, an RCD/RCCB should probably be put in, but I don't have that yet.

[PS: I'm planning to put a buck converter and then a linear regulator to drop and adjust the final output voltage, be it the SMPS, or the mains transformer.]

Best Answer

If you are making a bench supply for conducting EE design work then you need to have "extra" protection because you may well be touching 0 volts or the "hot" DC output for significant periods of time. Fusing each leg of the DC output and using a zener diode to ground is something I would consider to be safe. When I say ground I mean a proper safety ground. Normally the zeners would not be called on to do anything but, if a transformer fault occured that generated a potential over-voltage situation, the fuses should blow. Zeners and fuses need to be rated accordingly.

For higher power protection, consider using a zener with a crow bar circuit like this: -

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Here, the zener passes current to the SCR's gate when the output voltage of the regulator is exceeded. It turns on the SCR and it conducts current until the fuse blows. This is just one example of a crow bar protection circuit and please bear in mind that a lot of SMPS modules may have this feature already.

Other ideas along the same line