Elliott Sound Products Project 106
hFE Tester for NPN Power Transistors
© August 2004, Geoff Moss
(with additional material from Rod Elliott)
Introduction
The design objective was to produce an hFE tester with switched collector currents for the
DUT (Device Under Test) covering a range suitable for the selection and matching of output
transistors for amplifiers such as the JLH Class-A, ESP DoZ etc.
The tester should provide a range of collector test currents from 0.05A to 3A in (roughly)
logarithmic steps.
It is important to avoid the need for high power resistors and (rotary) switches with high
current rated contacts, especially since the latter can be very difficult to obtain. It is also
important to minimise the cost.
Although the circuit may appear complex, it isn't really, but it does test devices at a specified
(and fixed) collector current - this is the way that it should be done, but most circuits don't.
It is far simpler to fix the base current and measure collector current, but matching devices
based on collector current becomes virtually impossible with the fixed base current method.
You may wish to look at Project 177, which uses the same test method, but is far more
flexible than the version. It can test both NPN and NPN transistors by simply switching the
supply polarity, and is far simpler to build.
Description
Refer to Figure 1 (below). D1 (or U2 shown in Figure 2), R3 and VR1 create an adjustable
voltage reference. Rc1-Rc7 resistor values have been selected so that the design collector
current flows in the DUT when the voltage across the resistor bank is around 1V. Q1
monitors the voltage across the resistor bank, compares it with the preset voltage reference
derived from the LED, and drives sufficient current into the base of the DUT to maintain 1V
across the current setting resistors.
Figure 1 - Circuit Diagram of hFE Tester
Note that the supply is 20V DC. The connection points shown indicate positive and
negative, and do not mean or imply a dual supply - only the polarity of the connections.
Unmarked resistors are 0.25W. Q2, a power Darlington, has been included as a buffer to
minimise voltage (and therefore current) variations when DUTs with a low hFE are being
tested. SW1 to SW7 should be rated at a minimum of 2A DC.
Fuse F1 provides protection from high collector currents and has been fitted where shown,
rather than in the supply rail, so that a 3.15A fuse can be used. If fitted in the supply rail, the
next higher standard value (4A) would be needed, thus providing reduced protection. This is
because the base current would also be passing through the fuse if it were in the supply rail.
Fuse F2 has been provided to prevent excess base current in the event of the DUT being
faulty or incorrectly connected. A resistor in the collector of Q2 could achieve a similar
effect but, if large enough to provide sufficient current limiting, the DUT collector current
variation for low gain transistors would be outside the design objective of keeping the
current constant (for different DUT hFE) to within 1%. A lower value collector resistor for Q2,
such that the DUT collector current remained constant, would not limit the DUT base current
to below 0.5A and would need to be rated at 10W to prevent failure under fault conditions.
C4 has been included to minimise the possibility of oscillation in the DUT. Because it has
been found by a constructor that C4 was not effective, C5 has been added. This makes the
circuit unconditionally stable, and oscillation (which will give very odd readings) is not
possible with C5 installed. C4 may be left out if you so desire - it is largely redundant with
the addition of the extra cap.
The DMM has been used on its current range, rather than the safer alternative of using it on
a voltage range and measuring across a series resistor, because the highest value of series
resistor (10R) that could be used in the DUT base circuit, without affecting the accuracy of
the DUT collector current, is such that some DMMs will not have sufficient sensitivity to
accurately measure the small (mV) voltage generated across the series resistor at the lower
DUT collector current settings, particularly if the DUT has a high gain. Note that the reading
on the meter is the reverse of DUT current gain - a high reading means a low gain transistor,
while a low reading means a high gain device. This is not a limitation, merely something the
user should bear in mind.
Those fortunate enough to have a DMM that will accurately resolve a reading to within
0.1mV could, if they so desired, use a 10Ω (1% or better) resistor in place of the DMM
connection shown on the schematic, with meter connection points provided on each side.
This allows the meter to be used in voltage measurement mode, with the voltage directly
proportional to base current.
Switch Settings and Circuit Notes
The switches SW1-SW7 are used to select the collector current for the DUT. The base
current drawn will always be a direct function of the DUT's hFE.
SW1 Off On On On On On On On
SW2 Off Off On On On On On On
SW3 Off Off Off On On On On On
SW4 Off Off Off Off On On On On
SW5 Off Off Off Off Off On On On
SW6 Off Off Off Off Off Off On On
SW7 Off Off Off Off Off Off Off On
IC 0A 50mA 100mA 200mA 500mA 1A 2A 3A
Table 1 - Switch Settings Vs. Collector Current
With the sequential switching shown on the schematic, the DUT collector currents are as
shown in Table 1. The 3A range can be left out, if desired by omitting SW7 and Rc7. The
0.05A range can be left out by omitting SW1 and Rc1 and changing Rc2 to 10R (0.5W).
If the 3A range is left out, the voltage regulator can probably be an LM317K since the typical
current limit for this device is 2.2A, but constructors should note that the LM317K is only
guaranteed up to 1.5A so current limiting could be experienced on the 2A range.
An LM338K could be used in place of the LM350K but then fuse F1 is (even more) essential
since the current limiting of an LM338K doesn't kick in until something over 9A compared to
4.5A for the LM350K. With any of the IC regulator options shown, you will need a good
heatsink. Power dissipation in the regulator is determined by the voltage across the IC, and
current through it. Worst case current will be a little over 3A (including base current), and
approximately 5-7V across the regulator IC itself. This represents a dissipation of up to
about 22W or so. Choose a relatively large heatsink, and watch your mounting techniques
carefully to ensure best thermal transfer. A fan may be used if desired, and is
recommended if regular use at high current is anticipated. For normal intermittent duty, a
1°C/W heatsink will probably be quite adequate.
The suggested supply voltage is 15V (to suit alternative fixed voltage regulators and cheap,
surplus power supply units). This gives a test voltage that is reasonably close to the
expected Vce in the final amplifier circuit whilst keeping the DUT power dissipation at a
reasonable level.
The supply voltage could be increased to say 21V (to give a test Vce of 20V) but the 3A
range would need to be dispensed with (IMO). Conversely, the supply voltage could be
reduced to 6V (Vce 5V) so that higher test currents could be used or to permit comparison
of measured results with data sheet figures. If the supply voltage is reduced, the value of
R3 will need to be reduced as well to maintain a suitable current through the voltage
reference and VR1. You will need to make your own calculations for regulator dissipation.
Q1 is not critical and can be any small signal PNP transistor with a specification
comparable to that of a BC560. Q2 is also not critical and can be any NPN power Darlington
with a similar specification to that of a TIP142. Note that a heatsink is highly recommended
for Q2, given that dissipation may be as high as 4.5W at maximum base current for a very
low gain device (typically 300mA, although this will blow the 160mA fuse) - see below for
more information.
Fuses F1 and F2 should be quick blow (and plenty of spares should be kept handy ).
The push switch has been positioned between the resistor bank and Q1 so that when
measurements are not being taken, there is no current flow through Q1. If the push switch
were located in the more usual position (in series with F2 and the DMM), whenever the push
switch was open (most of the time) there would be a 4mA+ current through Q1.
Initial Setup
A spare, expendable DUT (on a suitable heatsink) is connected and a link inserted in place
of the DMM. With the push switch and SW7 (only) - SW6 if the 3A range is omitted - made,
VR1 is adjusted to give 1V across Rc7 (or Rc6).
A DMM (on an appropriate current range) is inserted in the collector lead of the DUT and the
collector current measured at each of the sequential switch positions which set the
collector current. These currents are used for future hFE calculations (see below).
All switches are then returned to the open position, the DUT and DMM link are removed and
the tester is ready for use.
Using the Tester
The DUT is connected (mounted on a suitable heatsink), along with the DMM (initially set to
the 200mA current range). SW1 is closed and the push switch operated. A DMM reading is
taken when the display has stabilised (the DMM current range may need to be lowered for
this switch position). The push switch is released, SW2 is closed, the push switch is
remade and another reading is taken. Repeat until all toggle switches are closed, then reset
all of the toggle switches to open. Every attempt should be made to keep the speed at
which the toggle switches are actuated constant between tests on different DUTs, so that
the temperature rise in the DUTs is approximately the same. This is because hFE varies
according to the transistor junction temperature.
Alternatively, the push switch can be held closed whilst the toggle switches are sequentially
actuated, with readings being taken after each switch operation. If anything untoward is
observed (or smelt) during the test, release the push switch immediately.
The hFE at each of the collector currents can be calculated from the collector currents
measured during the initial setting up and the base currents measured during the test
sequence (a spreadsheet comes in handy here). The preset collector currents may not be
exactly spot on due to resistor tolerances (+/-5%) but they will remain virtually unchanged
(within about 1%) for DUT gain variations between 25 and 200.
To calculate the hFE for any collector current (Ic), use the simple formula ...
hFE = Ic / Ib (where Ib is base current)
For example, if the collector were measured at 3A, and base current measured at 83mA, hFE
is ...
hFE = 3 / 0.083 = 36
When disconnecting the DMM after completion of measurements remember to move the
leads back to the voltage measuring position.
Appendix
This section includes some additional notes that you may find useful ...
Some more information about heatsinking Q2 ... The maximum (no fault) dissipation in Q2
(DUT gain 25, DUT Ic 3A) is just over 1.5W. With a junction-air thermal resistance of 35°C/W,
and (very) intermittent operation at maximum dissipation levels, no heatsinking should be
necessary. However, it would be prudent, particularly in a totally enclosed case, to mount
the TIP142 onto a metal chassis if available. Otherwise, fit a small heatsink (say around
10°C/W, or even a small sheet of aluminium).
As regards the heatsink for the DUT, the maximum dissipation is 45W with the proposed rail
voltage and maximum Ic, though this is intermittent and of short duration. Allowing for a
maximum junction-case thermal resistance of 1.5°C/W and an isolated heatsink (so no
mica or SilPad - thermal grease is highly recommended though), under continuous 45W
dissipation a heatsink rated at better than 0.4°C/W would be necessary to keep the junction
temperature below 130°C. Obviously, the intermittent nature and short duration of the
maximum dissipation means that something smaller can be used. I was thinking of
something between 1 and 2°C/W, which would allow for an average dissipation over the
course of the tests of around 20W, even with devices having a relatively poor j-c thermal
performance.
As mentioned above, an alternative to the LED is a TL431 voltage
reference IC. The connection scheme is shown to the left, and the IC
is wired in place of the LED. No other changes to the circuit are
needed. While this is undoubtedly more accurate than the LED, the
improvement in real terms will probably not be worth the effort.
In Geoff's original circuits, the 3 electrolytic capacitors were specified
as either 1µF tantalum or 22µF aluminium electros. Regular readers
Figure 2 will be aware of my hatred of tantalum caps (the most unreliable
capacitor ever made), so I only recommend the aluminium
electrolytic option.
It is also likely that you will need a suitable power supply. This should be fairly robust, but
make sure that the loaded voltage is reasonably close to 20V (assuming the 15V supply
recommended). If the input voltage is too high, the regulator's dissipation will increase,
placing greater demands on the heatsink.
The supply will typically use a dual 15V toroidal transformer, with the windings in parallel for
maximum current. Unloaded voltage will be in the order of 25V, dropping to around 20V at
full load. The transformer should be rated for around 80-100VA, but a 160VA (typical of
toroidal transformers) will do very nicely. A 25A bridge rectifier and a minimum of 4,700µF
should be used for rectification and filtering respectively. More capacitance can be used if
you want, but will not improve the performance. Figure 3 shows a typical supply.
Figure 3 - Power Supply
There is nothing special about the supply, but the usual precautions must be taken to ensure
that no-one can make accidental contact with any mains wiring. Naturally, a 'conventional'
E-I transformer may also be used if one is to hand or can be obtained for the right price. A
secondary current rating of at least 5A is recommended to prevent the voltage from
collapsing too much when the load is applied.
As noted, this tester is designed for NPN power transistors, and it is obvious that it will be
difficult to make the unit dual polarity so that PNP devices can be tested as well.
Essentially, there are several ways to make the tester able to test both NPN and PNP
devices, but it is not an especially trivial exercise. It may be easier to duplicate the entire
tester section, using a reversed LED, and with an NPN transistor instead of PNP and vice
versa. The polarity of the DC at the regulator output needs to be reversed, and it would
probably be easiest to use relays to switch the polarity and base current driver circuits. This
is especially true because of the number of connections that must be changed. Only the
base drive circuit needs to be duplicated for the opposite polarity - the remainder of the
circuit is passive and not polarity sensitive.
Note that getting a high current version of any regulator is no longer easy. TO3 types sell for
astonishing prices, and it will almost certainly be necessary to use some other arrangement
to obtain the current needed. Probably the easiest is to use 7815 fixed regulators in parallel,
with a current balancing resistor at the output of each. These should not be less than ~0.22
ohms 1W, and I'd recommend that three 7812 regulators be used, with a maximum current
of 1A each. This distributes the heat better (each will dissipate about 5W), which is
important given the rather poor heat dissipation capabilities of the TO220 package. This
arrangement will work very well, and it will be easy to keep the regulators at a sensible
temperature. A heatsink is mandatory of course, but it need not be particularly large. 1°C/
watt allows a 15°C temperature rise for the regulators at 1A each. For intermittent
operation, the heatsink can be smaller.
It will be left as an exercise for the constructor to figure out the PNP version, based on the
description above.
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Copyright Notice.This article, including but not limited to all text and diagrams, is the intellectual property of
Geoff Moss and/or Rod Elliott, and is © 2004. Reproduction or re-publication by any means whatsoever,
whether electronic, mechanical or electro-mechanical, is strictly prohibited under International Copyright
laws. The authors (Geoff Moss & Rod Elliott) grant the reader the right to use this information for personal
use only, and further allow that one (1) copy may be made for reference while constructing the project.
Commercial use is prohibited without express written authorisation from Geoff Moss and Rod Elliott.
Page Created and Copyright © Geoff Moss & Rod Elliott 03 Aug 2004
