This is only a preview of the May 2011 issue of Silicon Chip. You can view 29 of the 104 pages in the full issue, including the advertisments. For full access, purchase the issue for $10.00 or subscribe for access to the latest issues. Items relevant to "The SportSync Audio Delay Module":
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By JOHN CLARKE
12V 100W Inverter
With Adjustable Output
Did you build the 12/24V 3-stage MPPT solar charge controller
published in the February 2011 issue? Then you will probably
want this companion 12V 100W inverter as well. It will power
laptops and other devices which require a DC voltage between
15V & 35V.
S
MALL SOLAR SYSTEMS are growing increasingly popular, whether
it is for mains power, battery charging
on boats, recreational vehicles and
remote homesteads. But was well as
needing solar panels to charge 12V or
24V batteries, you also need DC-DC
converters to obtain supplies than cannot be run direct from batteries. Laptop
computers are just one example.
We last published an adjustable DCDC converter in the June 2003 issue of
SILICON CHIP. This unit was powered
by a 12V battery and could deliver
an output voltage anywhere between
13.8V to 24V. The maximum output
current that it could deliver was 2A
at 16V, falling to 1.1A at 24V.
Unfortunately, this output current
is often not sufficient to run a laptop
computer or similar equipment. Many
78 Silicon Chip
recent laptops require a supply voltage of about 19V and a current of 4A
or more possibly more. So the June
2003 unit is simply not up to the job.
By contrast, this new design has a
much higher output current capability
and is suitable not only for powering
most laptops from a 12V supply but
for powering higher voltage equipment as well.
Fig.1 shows the output current capability of the new converter. The graph
follows a nominal 100W power curve
and as indicated, the circuit can supply just over 4A at 25V and 5A at 20V.
As well as its enhanced current
capabilities, the new converter also
boasts excellent voltage regulation at
better than 99%. This means that the
output voltage is maintained to within
±0.35V of its open-circuit voltage.
However, some additional voltage
drop can be expected in the leads running from the DC-DC Converter to the
unit being powered.
Another excellent specification is
the output ripple which is less than
200mV peak-to-peak at full power.
However, once the input current exceeds 10A, the unit’s output voltage
begins to droop.
High efficiency
As with any such circuit, there are
some power losses involved in converting from 12V to a higher output
voltage. For this DC-DC Converter,
the efficiency is well over 80% when
supplying full power. This means that
the unit only runs warm at full power,
with any heat dissipated by the diecast
box that houses it.
siliconchip.com.au
OUTPUT CURRENT (AMPS)
D2
i2
L1
7
A
+
K
+
6
5
INPUT
i1
(Q1)
C1
OUTPUT
4
–
–
3
2
0
10
15
20
25
30
Fig.2: how the DC-DC Converter operates. When Q1
closes, current i1 flows and stores energy in inductor L1.
When Q1 opens, this energy is dumped via D2 into the
capacitor C2 (via current path i2).
35
OUTPUT VOLTAGE (VOLTS)
MAXIMUM OUTPUT CURRENT VS. OUTPUT VOLTAGE
Fig.1: this graph plots the output current capability of
the 100W DC-DC Converter. It can supply just over 4A
at 25V and 5A at 20V.
This box measures 111 x 94 x 54mm
and is fitted with a power switch and
power-indicator LED at one end. Two
cable glands are fitted at the opposite
end and these clamp the figure-8
power input and output leads.
A cigarette lighter socket can be
used to make the connection to a car’s
battery. Alternatively, the unit can be
connected via 10A-rated wiring in a
solar-powered system.
How it works
Fig.2 shows the basic operating
principle of the DC-DC Converter. It
comprises an inductor (L1), a switch
(Q1), a diode (D2) and a capacitor (C1).
When the switch is closed (ie, Q1 is
on), current i1 flows through L1 (and
the switch) and so energy is stored
in the magnetic flux of the inductor.
When switch Q1 subsequently opens,
this stored energy is dumped via diode
D2 to capacitor C1 (and the load). This
is shown as current i2.
In our DC-DC Converter circuit,
switch Q1 is an N-channel Mosfet.
This Mosfet is controlled using an On
Semiconductor (previously Motorola)
MC34063 DC-DC Converter IC. This
control device varies the Mosfet’s duty
cycle (ie, its on/off ratio) to maintain
the desired output voltage.
This type of converter can only be
used to step up (boost) the input voltage. If switch Q1 is left open, then current simply flows directly through L1
and D2. The resulting output voltage
will be slightly lower than the input
voltage due to the voltage across the
inductor (due to its resistance) and the
forward voltage of the diode. It is only
when Q1 is rapidly switched on and
off that the output voltage is increased
above the input voltage.
siliconchip.com.au
Main Features
Fig.3 shows the internal arrangement of the MC34063. Its components
include a 1.25V reference, a comparator, an oscillator, an RS flipflop and
output transistors QA and QB. The
oscillator’s frequency is set by a capacitor connected to pin 3. This oscillator
drives the flipflop which in turn drives
the output transistors to control the
external Mosfet.
The comparator monitors a sample
of the output voltage at pin 5. If the
output voltage is low, the comparator’s inverting input will be below
the +1.25V reference. As a result, the
comparator’s output switches high and
sets the RS flipflop. This in turn allows
the output transistors to be toggled
(via the RS flipflop) at the rate set by
the oscillator.
The transistors are not held on
permanently. Instead, the oscillator
periodically resets the flipflop, either
after a maximum period or if the peak
inductor current, as sensed at pin 7,
reaches a certain level.
On the other hand, if the output voltage is too high, the comparator’s output
Ipk SENSE
7
V+
6
•
•
•
•
•
Steps up a 12V DC input to
between 15V and 35V DC
Maximum input current 10A
Efficient switchmode design
Fuse & reverse polarity protection
Power switch and indicator
goes low to keep the flipflop from setting. This holds transistors QA & QB
off so that the output voltage falls.
Circuit details
Take a look now at Fig.4 for the circuit details. It’s based on the MC34063
DC-DC Converter IC (IC1) but the
internal transistors are not used to
directly switch the supply current.
Instead, they are used to drive power
Mosfet Q1 which has a current rating
of 118A at 100°C (the current rating
is even higher at lower temperatures).
This rating is far more than is required for this circuit. What’s more, the
Mosfet’s low 5.3mΩ “on resistance”
with a 10V gate voltage ensures that
it runs cool, even at 10A.
Power for the circuit is applied via
DRIVER COLLECTOR
8
FLIPFLOP
S
Q
QA
R
OSCILLATOR
1 SWITCH
COLLECTOR
QB
COMPARATOR
1.25V
REFERENCE
2 SWITCH
EMITTER
5 COMP
– INPUT
3
TIMING CAPACITOR
4
GND
Fig.3: block diagram
of the MC34063 DCDC Converter IC. The
oscillator drives the
flipflop which in turn
drives transistors QA
& QB. The internal
comparator holds
the flipflop reset &
shuts down the drive
to QB & QB if the
converter’s output
goes too high.
INSIDE THE MC34063
May 2011 79
12V
INPUT
+
D1 MBR20100CT
F1 10A
CON1
L1 100 µH
3x
4700 µF
16V
OUTPUT
A1
+
K
K
A2
–
D2 MBR20100CT
R1
0.025 Ω 5W
A1
A2
S1b
S1a
–
3x
1000 µF
35V
CONVERTER
POWER
CON2
LOW ESR
LOW ESR
47Ω
7
Ips
6
Vcc
1k
POWER
A
LED1
λ
K
DrC
SwC
IC1
MC34063
100nF
GND
4
Ct
3
D
D3
1N4148
8
SwE
A
1
2
Cin5
10Ω
K
E
B
Q2
BC327
C
1k
Q1
IRF1405N
G
K
A
ZD1
18V
1W
S
22k
1nF
D3
A
K
ZD1
A
SC
2011
750Ω
VR1
2k
SET
OUTPUT
VOLTAGE
K
BC327
LED
100W DC-DC CONVERTER
B
K
A
E
MBR20100CT
A1
C
K
IRF1405N
K
G
A2
D
D
S
Fig.4: the circuit uses IC1 to drive the gate of Mosfet Q1 via diode D3, while transistor Q2 quickly discharges Q1’s
gate capacitance each time pin 2 of IC1 goes low. Voltage regulation is achieved by the feedback network connected
to pin 5 of IC1, while current monitoring is achieved by monitoring the voltage across resistor R1.
fuse F1 and double diode D1. Fuse F1
protects against excessive current being drawn by the circuit (eg, if there is a
short at the output), while D1 provides
reverse polarity protection.
D1 is necessary although it does
slightly reduce the efficiency of the
circuit due to its forward voltage drop.
However, without this diode a reverse
polarity supply connection would
cause current to flow in the reverse
direction through the integral diode
within Q1 and then through inductor
L1, resistor R1 and the fuse. As a result,
the fuse would blow.
This would not result in any damage but having the fuse blow due to a
reverse supply connection is inconvenient. D1 solves that problem.
Note that D1 is shown as two diodes
in parallel. These diodes are in the
same package and are connected in
parallel to increase the single diode
continuous current rating from 10A
to 20A.
A double diode has been specified
because parallelling diodes in separate
packages does not normally result in
even current sharing between them.
That’s because the separate diodes are
80 Silicon Chip
not matched for voltage drop and so
the diode with the lowest voltage drop
would carry most of the current. As a
result, it will heat up more than the
other diode and this then makes the
situation worse. A diode’s voltage drop
decreases with increasing temperature
and so the hotter diode will further
increase its share of the load.
With a double diode, the two diodes
are manufactured on the same silicon
die and so have the same characteristics, including a matched forward
voltage drop with current. The diodes
also operate at the same temperature
because they share the same package.
This ensures consistent and almost
equal current sharing over a wide
temperature range.
Following D1, the supply is filtered
using three parallel 4700µF low-ESR
capacitors. These provide a reservoir
of current for the following switchmode circuit which draws short highcurrent pulses.
Without the capacitors, the available
current would drop markedly due to
the inductance of the supply leads going to the 12V battery. Because of this
lead inductance, the initial current
available via the supply leads when
Q1 turns on is low (it builds up over
time). If not for the filter capacitors, the
full current capability would never be
reached due to the 30kHz switching
rate of the MC34063 DC-DC Converter
IC (IC1).
Power for IC1 is applied to pin 6
via switch S1a from the nominal 12V
supply. A 100nF capacitor filters this
supply rail, while LED1 provides
“power on” indication. The 1kΩ series
resistor limits the LED’s current to
around 10mA.
Note that the power switch (S1)
switches power to the DC-DC Converter step-up circuitry only. When
S1 is off, power is no longer applied
to IC1 but there is still a current path
from the 12V input to the output via
fuse F1, D1, R1, L1 and D2. As a result,
the output voltage sits approximately
1.2V below the input voltage (eg, if
the battery voltage is 13.8V, the DC-DC
Converter’s output will be at 12.6V).
If the laptop requires an 18V supply,
this will not be sufficient to charge the
laptop’s battery and so no current will
be drawn from the converter. However,
other loads could continue to draw
siliconchip.com.au
Parts List
1 PCB, code 11105111, 111 x 85mm
1 diecast box, 119 x 94 x 57mm
1 panel label, 79 x 103mm
1 powdered iron toroidal core, 42
x 22 x 17mm (Jaycar LO-1246
or equivalent) (L1)
4 2-way PC-mount screw terminals
with 5.08mm pin spacing
2 M205 PC-mount fuse clips
1 M205 10A fast blow fuse (F1)
2 cable glands for 3-6.5mm
diameter cable
1 DPDT toggle switch (S1) or 1 x
SPST 15A toggle switch (eg,
Jaycar SK-0976 – see text)
4 M3 x 15mm tapped Nylon spacers
4 M3 x 6m countersunk screws
4 M4 x 6mm machine screws
3 M3 x 10mm machine screws
3 M3 nuts
3 TO-220 insulating bushes
3 TO-220 silicone insulating
washers
1 150mm length of medium-duty
hookup wire
1 6.5m length of 1.25mm
enamelled copper wire
1 25mm length of 0.7mm tinned
copper wire
2 100mm cable ties
1 40mm length of 3mm
heatshrink tubing
power. If this is not desirable, then an
alternative arrangement using a 15A
switch to fully disconnect power can
be used, as described later. Of course,
if power is derived via a car’s cigarette
lighter socket, this will be switched
off when the ignition is switched off.
Current monitoring
Resistor R1 is included so that the
current into the inductor can be monitored. IC1 does this by monitoring the
voltage at pin 7. When pin 7 drops
about 300mV below pin 6, IC1 ceases
operation and current pulses cease
flowing through L1. R1 has a value
of 0.025Ω and so the peak current is
restricted to 12A.
Mosfet Q1 is driven via IC1’s transistor emitter output at pin 2 (SwE).
Each time pin 2 goes high (ie, when
the internal transistors turn on), it
drives the gate of Mosfet Q1 via diode
D3 and a 10Ω resistor. D3 is included
to ensure that transistor Q2 is off dursiliconchip.com.au
1 2kΩ horizontal trimpot
Semiconductors
1 MC34063AP DC-DC Converter
(IC1)
1 IRF1405N 169A 55V N-channel
Mosfet (Q1)
1 BC327 PNP transistor (Q2)
2 MBR20100CT 10A 100V double
diodes (D1,D2)
1 1N4148 switching diode (D3)
1 18V 1W zener diode (ZD1)
1 3mm green LED (LED1)
Capacitors
3 4700µF 16V low-ESR
electrolytic capacitors
3 1000µF 35V low-ESR
electrolytic capacitors
1 100nF MKT polyester
1 1nF MKT polyester
Resistors (0.25W 1%)
1 22kΩ
1 47Ω
2 1kΩ
1 10Ω
1 750Ω
1 0.025Ω 5W (Welwyn OAR5R025FI) (from http://au.element14.
com/ – Cat. 120-0377)
Miscellaneous
10A figure-8 wire, solder, etc
ing this time, by keeping its base 0.6V
above its emitter.
Zener diode ZD1 protects Q1’s gate
from voltage spikes above 18V which
could otherwise damage the Mosfet.
The gate rise-time for 0-10V with a
12V supply is 500ns. When Q1’s gate
is high, Q1 turns on and current flows
through Q1 and inductor L1 which
then stores energy.
When the transistors within IC1
switch off, pin 2 is pulled to 0V via
a 1kΩ resistor. Transistor Q2 now has
its base connected to 0V and so this
transistor switches on and quickly
pulls Q1’s gate voltage down to near
0V, thus switching the Mosfet off.
Q2 is necessary to ensure that Q1’s
gate capacitance quickly discharges (it
would discharge too slowly through
the 1kΩ pull-down resistor).
The gate fall time from 10V to 1V is
about 500ns and a 1V gate voltage is
sufficient to fully switch Q1 off (the
gate fall time from 10V to 0V is 1µs).
Give your lighting projects a
SEOUL
AS FEATURED IN
ZZLER
SILICON CHIP LED DA
11)
(P24, FEBRUARY 20
Acriche A4
4W Pure White AC LED
Mounted on PCB
No Electronics Needed,
Just add power
AW3231-240V $16.00 +GST
P7 Power LED
10W Pure White Emitter
Approx. 900lm <at> 2.8A
Ideal for torch applications
PCB available to suit
W724C0-D1 $16.00+GST
P4 Star 4W LEDs
Power LEDs mounted on
20mm Star PCB. Various
Colours available.
Pure White W42182 $3.90+GST
Nat. White S42182 $3.90+GST
Warm White N42182 $3.90+GST
P3-II Star 2W LEDs
Power LEDs mounted on
20mm Star PCB. Various
Colours available.
Pure White WS2182 $2.95+GST
Warm White NS2182 $2.95+GST
P5-II RGB Power LED
High power RGB LED mounted
On 20mm Star PCB
Drive each colour <at> 350mA
Ideal for wall wash applications
F50360-STAR $14.95+GST
SMD RGB LED
General purpose RGB LED
in PLCC-6 package
Drive each colour <at> 20mA
SFT722N-S $0.95ea+GST
Top View SMD White LED
High Brightness pure white
LED in small PLCC package
Great for strip lighting
Typical luminous
intensity 1600mcd
KWT803-S $0.30ea+GST
AUSTRALIAN DISTRIBUTOR
Ph. 07 3390 3302
Fx. 07 3390 3329
Email: sales<at>rmsparts.com.au
www.rmsparts.com.au
May 2011 81
MBR20100CT
D1
+
INPUT
*
+
+
+
4700 µF
16V
4700 µF
16V
4700 µF
16V
*
F1
Fig.5: follow this layout
diagram to install the parts
on the PCB. Make sure
that all polarised parts are
correctly orientated and
refer to the text for details on
installing Mosfet Q1, diodes
D1 & D2 and the LED.
–
CON1
1000 µF
+
*
S1
IC1
L1
100 µH
35V
47Ω
34063
1000 µF
1nF
1k
100nF
22k
35V
A
LED1
D2
Q1
MBR20100CT
IRF1405N
With Q1 off, the energy stored in L1
is transferred to the output via double
diode D2. This energy is then stored
in three 1000µF low-ESR electrolytic
capacitors. These reduce the ripple to
less than 200mV peak-to-peak.
The resulting output voltage is sampled using a voltage divider consisting of a 22kΩ resistor, a series 750Ω
resistor and a 2kΩ trimpot (VR1). This
provides a proportion of the output
voltage to the comparator input at pin
5 of IC1. In operation, IC1 adjusts its
duty cycle to regulate the output voltage so that the voltage at pin 5 is 1.25V.
VR1 allows the output voltage to be
adjusted between the recommended
limits of 15V and 35V. Setting the
trimpot to 64.8Ω gives a 35V output,
while a 1.25kΩ setting gives a 15V
output. A setting between these two
values gives an intermediate voltage.
Construction
The DC-DC Converter circuit is built
ZD1 D3
750Ω
K
1k
*
4148
*
CON2
18V
Q2
–
10Ω
OUTPUT
+
35V
RETREV N O C CD- CD
+
0.025 Ω 5W
1000 µF
+
BC327
11150111
VR1 2k
* USE 1.25MM ENAMELLED COPPER WIRE – SEE TEXT
* USE 10A-RATED CABLE FOR INPUT & OUTPUT LEADS
on a PCB coded 11105111 and measuring 111 x 85mm. This is mounted
inside a diecast box measuring 119 x
94 x 57mm and has cut-outs to clear
the pillars at each corner.
Fig.5 shows the assembly details
for the PCB. The first job is to check
that the indicated corner cut-outs
have been made and that the board
fits inside the case. If not, you will
have to cut and file the corner cut-outs
yourself.
That done, carefully inspect the
board for defects, such as breaks in
the copper tracks and shorts between
tracks and pads. Check also that the
hole sizes are correct by test fitting the
larger parts (fuse clips, screw terminals, Mosfet Q1, diodes D1 & D2 and
the trimpot). The screw terminal holes
must all be 1.25mm in diameter, while
1.3mm holes are required for those
wire links marked with an asterisk (*).
Larger holes again are required for the
fuse clips.
Once these checks are complete,
start the assembly by the installing
the wire links. Note that you must use
1.25mm-diameter enamelled copper
wire for the three links marked with
an asterisk, to ensure sufficient current-carrying capacity. The unmarked
link can be run using 0.7mm tinned
copper wire.
Bend each wire link so that it fits
neatly in position and be sure to scrape
away the enamel from the ends of the
enamelled wire links before soldering them.
The resistors are next. Table 1 below
shows the resistor colour codes but
it’s a good idea to also use a digital
Table 2: Capacitor Codes
Value µF Value IEC Code EIA Code
100nF 0.1µF
100n
104
1nF
0.001µF 1n
102
Table 1: Resistor Colour Codes
o
o
o
o
o
o
No.
1
2
1
1
1
82 Silicon Chip
Value
22kΩ
1kΩ
750Ω
47Ω
10Ω
4-Band Code (1%)
red red orange brown
brown black red brown
violet green brown brown
yellow violet black brown
brown black black brown
5-Band Code (1%)
red red black red brown
brown black black brown brown
violet green black black brown
yellow violet black gold brown
brown black black gold brown
siliconchip.com.au
multimeter (DMM) to check each one
before soldering it into circuit.
The 0.025Ω 5W resistor looks like a
thin U-shaped strip of metal. It can go
in after the other resistors have been
installed, after which you can install
diode D3 and zener diode ZD1. Be sure
to orientate D3 and ZD1 as shown (D1
& D2 are installed later).
IC1 can either be mounted directly
on the PCB or via a socket if you prefer.
Install it now, again making sure that
it’s correctly orientated, then install
the trimpot (VR1) and the capacitors.
Check that electrolytic capacitors go
in with the correct polarity.
Follow these with the screw terminal blocks. The 4-way terminal block is
made using two 2-way blocks that are
dovetailed together before mounting
them on the PCB. They must all go in
with their wire entry openings facing
outwards.
The fuse clips can now be fitted.
These must be mounted with their end
stops towards the outside, otherwise
you won’t be able to install the fuse
later on. The easiest way to ensure this
is to fit the fuse into the clips before installing them on the PCB. Tack solder
one leg of each clip, then remove the
fuse and complete the soldering (this
prevents the end caps from getting too
hot and possibly melting the solder
that secures the fuse wire to the caps).
Mosfet Q1 and diodes D1 & D2 are
next on the list. These should all be
mounted so that the hole centre in each
tab is 21mm above the PCB.
In practice, this means mounting
each device with 9mm lead lengths.
The easy way to do this is to cut a 9mm
cardboard spacer, insert it between the
leads and push the device down onto it
before tack soldering one of the leads.
The cardboard spacer can then be removed and the soldering completed.
LED1 must be mounted with 25mm
lead lengths, so that the top of its
lens is 30mm above the PCB. This
can also be done using a cardboard
spacer (25mm high). Take care with
the orientation – the anode lead is the
longer of the two.
Once the LED is in, it’s bent over
at 90° some 18mm above the PCB so
that it’s lens later goes into a hole in
the side of the box.
This view shows the completed PCB
assembly. The inductor is secured using
two cable ties.
The two external cables and the switch
leads must all be secured to the terminal
blocks before the PCB is slid into the case.
M3 x 10mm
SCREW
SIDE OF CASE
INSULATING WASHER
INSULATING BUSH
M3 NUT
D1, D2 OR Q1
PC BOARD
Winding L1
Inductor L1 is wound with 34 turns
of 1.25mm-diameter enamelled copper
wire (ECW). Wind each turn tightly
siliconchip.com.au
Fig.6: Mosfet Q1 and double diodes D1 & D2 must each be isolated from the
metal case using an insulating washer and insulating bush.
May 2011 83
Alternative Power Switch Arrangement
INPUT
+
*
*
+
+
+
–
OUTPUT *
+
+
+
LED1
18V
–
4148
CABLE
GLANDS
+
RETREV N O C CD- CD
*
* USE 10A-RATED CABLE FOR INPUT, OUTPUT & SWITCH LEADS
11150110
15A SWITCH
Fig.7: this diagram shows the alternative power switch arrangement.
In some cases, it may be preferable to switch the unit off completely, rather
than just switching it to standby mode using switch S1. This can be done by
wiring a 15A SPST switch in series with the incoming +12V rail and linking out
the poles for switch S1 at the 4-way screw terminal block – see Fig.7.
The 15A power switch can be mounted on one side of the case. The incoming
supply lead goes to one terminal while the other terminal is connected to the
screw terminal block. Be sure to use 10A rated leads for the switch wiring.
A suitable 15A SPST switch is available from Jaycar, Cat. SK-0976.
around the toroid, keeping each turn
alongside the previous turn. The wire
ends are terminated on the PCB as
shown. Note that one wire end passes
around the outside of the core to insert
into a hole adjacent to Q1 (see photo).
The entire toroid assembly is then
secured in place using two cable ties
that pass through the centre of the core
and through holes in the PCB.
Drilling the case
With the PCB assembly now completed, it can be installed in the box.
The first step is to temporarily place
the board inside the base and mark out
the four corner mounting holes. Drill
these holes to 3mm, then countersink
them from outside the case.
That done, the four M3 x 15mm
Nylon stand-offs can be secured in
position using M3 x 5mm countersink
Nylon screws. The PCB is then again
temporarily placed in position and
the mounting holes for Mosfet Q1 and
diodes D1 & D2 marked out. Drill these
holes to 3mm, then carefully remove
any metal swarf using an oversize
drill so that the mating areas are nice
and smooth. This is necessary to pre84 Silicon Chip
vent punch-though of the insulating
washers later on.
The next step is to drill the two
holes for the cable glands at one end
of the box (see photo). These cable
glands each require a 12.5mm hole
and should have their hole centres
some 15mm down from the top of the
base and about 20mm in from the top
edge (so that they later line up with the
2-way screw terminal blocks). A small
pilot drill should be used to start these
holes, after which they can be enlarged
to size using a tapered reamer.
Two holes are required at the other
end of the box: (1) a 4.5mm hole to accept toggle switch S1; and (2) a 3mm
hole for the LED. Position the switch
hole about 10mm down from the top
and in line with the centre of the 4-way
screw terminal block. The hole for the
LED is positioned 15mm down from
the top. As before, remove any metal
swarf from around these holes using
an oversize drill.
Final assembly
Before mounting the PCB, it’s necessary to connect the input and output
leads to the 2-way terminal blocks.
Similarly, the switch must be wired
to the 4-way terminal block.
The input and output leads must
be rated at 10A (or more). They are
installed by first sliding them though
the cable glands, then connecting them
to their respective screw terminal connectors (watch the polarity).
Switch S1 is wired using 60mm
lengths of hook-up wire and the solder
connections covered in heatshrink
tubing (this prevents the wires from
breaking). The leads are then connected to the terminal block and a small
cable tie used to further secure them.
Once the wiring is complete, the
PCB can be slid into place and secured using four M3 x 6mm screws.
It’s then simply a matter of pushing
LED1 through its hole in the case and
securing the Mosfet Q1 and diodes D1
& D2 to the side of the case as shown
in Fig.6. Note that the device tabs
must each be electrically isolated from
the case using a silicone washer and
insulating bush.
Once the devices are in place, use
a multimeter set to a high ohms range
to confirm that the device tabs are
indeed isolated from the case. If a low
ohms reading is measured, check that
relevant the silicone washer has not
been punctured.
Front panel label
Once the assembly is complete, the
front panel label can be downloaded
in PDF format from the SILICON CHIP
website. This can then be printed out,
laminated and attached to the case lid
using a smear of silicone sealant.
Testing
To test the unit, apply power to the
input and check that the output voltage can be adjusted over the range
from 15V to 35V DC using VR1. Note
that if the output is unloaded, it will
take a few seconds to drop down to
the set voltage if VR1 is adjusted for a
lower voltage.
Alternatively, if you have a 1kΩ 5W
resistor, this can be placed across the
output to hasten any changes as VR1 is
adjusted. Assuming all is well, adjust
VR1 to give the output voltage required
for your equipment.
Finally, make sure that the output
is connected to your equipment with
the correct polarity. A suitable plug
to make a power connection to your
equipment can be obtained from an
SC
electronics parts supplier.
siliconchip.com.au
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