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The Zeus power supply is an advanced switch-mode power supply designed to step down and convert high-voltage AC mains input ranging from 85V to 250V RMS into a regulated 5V DC output capable of delivering up to 12 Amps (60W). The conversion process begins by passing the incoming AC voltage through a bridge rectifier, which converts the alternating current into a high-voltage DC bus. This primary-side DC is then switched at high frequencies using Power MOSFETs driven by a Texas Instruments UCC28740 flyback controller. A coupled transformer provides high-voltage electrical isolation between the dangerous primary AC mains and the low-voltage secondary output while transferring energy across the barrier. On the secondary side, energy extraction is optimized using a UCC24630 synchronous rectifier controller paired with low-drop Schottky diodes to maximize efficiency and handle the high 12A current demand with minimal thermal losses. Voltage regulation is tightly controlled via a feedback loop utilizing an auxiliary TL431 adjustable Zener reference and optocouplers, which safely transmit error signals across the isolation boundary back to the primary-side flyback controller to maintain a stable 5V output. Power inductors and complementary passive components are used throughout the circuit for filtering, smoothing, and reducing electromagnetic interference, ensuring a clean and reliable DC output suitable for sensitive electronics.
Why Build This
Design and analyze a high-efficiency isolated flyback converter capable of delivering high secondary currents (up to 12A) for demanding low-voltage loads.
Implement advanced power management integrated circuits, including primary-side constant-voltage/constant-current (CV/CC) controllers and secondary-side synchronous rectification.
Gain practical engineering experience in custom PCB layout, transformer coupling, and thermal management for high-wattage offline power supply units.
Real-World Application
Powering high-current LED strips, custom electronics setups, and benchtop testing equipment requiring isolated low-voltage high-current supplies.
Skills You'll Learn
Switch-mode power supply design
AC-DC power conversion
flyback transformer implementation
synchronous rectification
closed-loop voltage regulation
optocoupler feedback isolation
printed circuit board layout for high voltage and high current
Safety Precautions
Warning: This circuit deals with AC mains (High Voltage that can kill you). Take high precautions before handling or performing tests.
Technology Tags
SMPS
FLYBACK CONTROLLER
UCC28740
UCC24630
POWER MOSFET
BRIDGE RECTIFIER
EASYEDA
PCB DESIGN
AC-DC CONVERSION
Frequently Asked Questions
The coupled transformer is critical for two reasons: it steps down the high primary voltage to the low voltages required for a 5V output, and it provides galvanic isolation to protect users and low-voltage circuitry from the dangerous AC mains voltage.
At high current levels like 12 Amps, standard diodes would introduce significant forward-voltage drop and severe power losses as heat. The UCC24630 synchronous rectifier controller drives MOSFETs to act as near-ideal switches, greatly improving overall power efficiency.
No. Because this circuit connects directly to high-voltage AC mains (85V-250V RMS), it carries lethal voltages on the primary side. High precautions, such as using an isolation transformer and a current-limited variac, are mandatory, and live probing should only be done by experienced engineers.
Gallery
This page is part of Kitkraft's Project Hub — a curated collection of electronics & robotics projects gathered from the maker community to help students and hobbyists discover and learn to build. Kitkraft does not claim authorship of the original project, and makes no representation as to the accuracy, completeness or safety of third-party source material. The summary and "How It Works" explanation above are AI-generated, rewritten with reference to the original tutorial — not a reproduction of it. Full credit and a direct link to the original source are provided above. If you're the original creator and have a concern about how your work is represented here, please contact us and we'll address it promptly.
