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An analog active load can draw a set current from a power supply while its output voltage changes. The simplest version is a feedback-controlled current sink: an op amp adjusts a power MOSFET until the voltage across a current-sense resistor matches an adjustable reference. It is useful for steady-state testing, but the MOSFET turns the source’s output power into heat, so safe operation depends on the transistor’s linear-mode safe operating area (SOA) and the complete cooling path—not its headline wattage alone.
How an analog active load holds current steady
Connect the device under test (DUT) to a low-side current sink containing a power MOSFET and a known sense resistor. The DUT supplies current through the MOSFET; the resistor develops a voltage proportional to that current. An op amp compares this voltage with a setpoint and adjusts the MOSFET gate. If the measured voltage falls below the setpoint, the op amp drives the MOSFET to conduct more; if it rises above the setpoint, it reduces conduction. This is negative feedback.
In the idealized circuit, the relationship is I ≈ Vset / Rsense. For example, with a 0.1 Ω shunt, a 0.1 V setpoint corresponds ideally to 1 A, and 1 V corresponds to 10 A. Those are circuit relationships, not a guarantee that a particular build can safely reach those currents. The op amp supplies gate control; the MOSFET provides the current-handling capability, while the sense resistor helps stabilize the loop. See Analog Devices’ explanation of electronic-load feedback and its current-sink example and op-amp considerations.
What the referenced project used—and what its ratings mean
Hackster’s project overview lists an IRFP250 MOSFET, LM358 op amp, 100 nF capacitor, 20 kΩ trimmer, 0.1 Ω 10 W shunt resistor, 1 kΩ resistor, PCB, heatsink and 12 V fan. This is the parts list reported for that project, not a universal design recipe or an independently validated bill of materials. Consult the Hackster project overview for its description.
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The same overview reports a 0–10 A adjustment range, 120 W maximum power, 200 V maximum voltage and dissipation up to 190 W. These are project-reported claims; the available description does not establish that the maxima can be used simultaneously or that they apply to a recreation with different components, layout, cooling or ambient temperature. Treat them as reported specifications, not as a safe operating envelope. The relevant operating point must be checked against the chosen transistor’s SOA and thermal limits.
Check the design before applying power
Verify MOSFET linear-mode safe operating area
An active load usually operates its MOSFET in its linear region, where the device drops voltage while carrying current. Check the selected part’s SOA for the actual drain current, drain-source voltage, mounting temperature and duration of the load. A transistor’s headline power rating alone does not show that it can safely dissipate a given amount in linear operation. Exceeding the relevant SOA can cause failure. Analog Devices discusses these limits in Part 2 of its electronic-load design guidance.
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Calculate the full thermal path
Estimate junction temperature from the heat generated and the thermal resistance from junction to case and from case through the mounting interface and heatsink to ambient. Include the effects of mounting and airflow. The MOSFET junction temperature must remain within the device’s rating; a package’s outer surface does not directly reveal junction temperature. The load’s dissipated power is approximately DUT voltage multiplied by load current, with additional heat in the shunt and other components. Fan cooling can help, but it does not replace the calculation.
Size the shunt for heat and measurement quality
The sense resistor dissipates P = I²R. With a 0.1 Ω shunt, for example, 10 A would mean 10 W dissipated in the resistor under ideal steady-state conditions. Choose a resistor with an appropriate power rating and account for precision and resistance change with temperature. A nominal 10 W rating should not be treated as permission to run continuously at that dissipation without checking the component’s conditions and thermal environment.
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Choose an op amp that fits the actual circuit
Check supply-voltage range, input common-mode range, output swing and loop stability in the circuit as built. In a low-side arrangement, the sense voltage may be close to ground; not every op amp can measure that voltage or drive the MOSFET gate appropriately from the available supply. Analog Devices’ AN-105 notes the need for a suitable single-supply or rail-to-rail type in relevant near-ground configurations. Do not assume that op amps with similar names or pinouts are interchangeable.
Keep the sense path and wiring appropriate to the test
For steady-state tests, safe current handling and thermal design are usually more important than fast response. If you need to measure rapid current changes, shunt parasitic inductance and layout can distort the sensed voltage and slow the current rise. Low-inductance construction and careful sense routing matter more in that case. At high current, wiring resistance and inductance can also affect the result, particularly with low-voltage supplies; keep the current path and sense connections appropriate to the intended measurement.
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Active sink or fixed power resistor?
| Consideration | Fixed power resistor | Analog active sink |
|---|---|---|
| Current as DUT voltage changes | Changes with voltage according to the resistor value. | Feedback adjusts MOSFET conduction to maintain the setpoint, within the circuit’s operating limits. |
| Adjustability | Requires changing the resistor or using a resistor network. | Setpoint can be adjusted by changing the reference voltage. |
| Heat distribution | Most load heat is dissipated in the power resistor. | The MOSFET dissipates substantial heat; the shunt also heats up. |
| Circuit complexity | Simple to implement. | Needs a feedback circuit, suitable MOSFET and op amp, sensing, and thermal design. |
| Transient testing | Does not actively change its draw. | Can support controlled current changes, but actual response depends on the loop and layout. |
Use a resistor when a simple, fixed load is sufficient and its current variation with DUT voltage is acceptable. An active sink is useful when you need a chosen current across a changing output voltage or controlled changes in load current. Neither approach removes the need to keep components and wiring within their ratings.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.Set up the test safely
- Define the test point. Record the DUT voltage and intended current, then calculate the approximate MOSFET dissipation as voltage multiplied by current and the shunt dissipation as current squared multiplied by resistance.
- Check component limits. Confirm the MOSFET SOA at the operating voltage, current and test duration; verify the thermal path; and check the shunt and op amp ratings for the circuit.
- Prepare the current path. Use wiring and connectors suitable for the intended current, and make sense connections that do not inadvertently include unwanted wiring drops in the measurement.
- Monitor operation. Observe current and temperature during the test. Stop if the current becomes unstable or temperatures approach component limits.
- Use added caution at high voltage. The load does not make the DUT safe to touch. High-voltage testing presents a serious shock hazard; Analog Devices’ active-load overview explains the use case and thermal considerations.
When comparing MOSFET candidates, compare linear-mode SOA at the actual operating point, thermal resistance, voltage and current limits, mounting needs and availability. The cited material does not establish a tested winner among alternative parts.
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