Elenco Electronics XP-620K Guida utente

POWER SUPPLY KIT

MODEL XP-620K

ElencoTM Electronics, Inc.

Assembly and Instruction Manual

PARTS LIST

If any parts are missing or damaged, see instructor or bookstore. DO NOT contact your place of purchase as

they will not be able to help you. Contact ElencoTM Electronics (address/phone/e-mail is at the back of this

manual) for additional assistance, if needed.

RESISTORS

Qty. Symbol Value Color Code Part #

1 R5 .18W5% 3W 101804

2 R3, R4 2.7W5% 1/2W red-violet-gold-gold 112701

2 R1, R2 150W5% 1/4W brown-green-brown-gold 131500

2 VR1, VR2 2kWPotentiometer 192422

CAPACITORS

Qty. Symbol Value Description Part #

5 C1 - C4, C8 10mF Electrolytic 271045

2 C5, C6 2200mF Electrolytic 292226

1 C7 4700mF Electrolytic 294744

SEMICONDUCTORS

Qty. Symbol Value Description Part #

4 D1 - D4 1N4001 Diode 314001

4 D5 - D8 1N5400 Diode 315400

1 Q1 A70 Transistor PNP 320070

1 Q2 2N6124 Transistor PNP 326124

1 IC1 LM-317 Integrated Circuit 330317

1 IC2 LM-337 Integrated Circuit 330337

1 IC3 LM-7805 Integrated Circuit 337805

MISCELLANEOUS

-1-

Qty. Description Part#

1 Transformer 440720

1 PC Board 512013

1 Fuse 1.25A 530125

1 Rocker Switch 541204

1 Cover 611120

1 Chassis 612020

1 Heat Sink 615010

2 Knob 622009

1 Strain Relief 624003

5 Insulating Washer 624007

4 PC Board Stand-off 625001

2 Black Binding Post 625031

5 Lockwasher, Binding Post 625031LW

5 Nut, Binding Post 625031HN

2 Red Binding Post 625032

1 Yellow Binding Post 625034

5 Screw 6-32 x 3/8” Phillips 641640

2 Screw 8-32 x 3/8” Phillips 641840

4 Screw #6 x 3/8” Black Truss Head 642652

2 Screw #6 x 3/8” black AB Phillips 642660

2 Nut 7mm 644101

Qty. Description Part#

1 Nut 6-32 Large 644600

4 Nut 6-32 Small 644601

2 Nut 8-32 644800

2 Flat Washer 8mm x 14mm 645101

2 Lockwasher 5/16” 646101

2 Lockwasher #8 646828

4 Rubber Feet 662003

1 Fuse Holder Body 663005LB

1 Fuse Holder Nut 663005N

1 Fuse Holder Cap 663005UB

1 Fuse Holder Washer 663005W

3 Mica Insulator 780002

1 Silicon Grease 790005

6” 20 Ga. Red Wire 813210

48” 22 Ga. Red Wire 814201

48” 22 Ga. Orange Wire 814310

48” 22 Ga. Blue Wire 814610

1 Line Cord 862105

2” Shrink Tubing 1/2” Dia. 891101

1.5” Shrink Tubing 3/4” Dia. 899110

1 Solder Tube 9ST4

-2-

PARTS IDENTIFICATION

Resistor 2kW

WPotentiometer Capacitor Diode Transistor

Integrated Circuit Transformer PC Board Fuse

Heatsink

Switch Knob Strain Relief

PC Board Stand-off

Binding Post Assembly Fuse Assembly

Flat Washer Lockwashers

MicaNuts

7mm 6-32 / 8-32

#8 5/16”

Binding Post

Lockwasher

Nut

.18W3W Resistor

-3-

IDENTIFYING RESISTOR VALUES

Use the following information as a guide in properly identifying the value of resistors.

BAND 1

1st Digit

Color Digit

Black 0

Brown 1

Red 2

Orange 3

Yellow 4

Green 5

Blue 6

Violet 7

Gray 8

White 9

BAND 2

2nd Digit

Color Digit

Black 0

Brown 1

Red 2

Orange 3

Yellow 4

Green 5

Blue 6

Violet 7

Gray 8

White 9

Multiplier

Color Multiplier

Black 1

Brown 10

Red 100

Orange 1,000

Yellow 10,000

Green 100,000

Blue 1,000,000

Silver 0.01

Gold 0.1

Resistance

Tolerance

Color Tolerance

Silver +10%

Gold +5%

Brown +1%

Red +2%

Orange +3%

Green +0.5%

Blue +0.25%

Violet +0.1%

BANDS

12 Multiplier Tolerance

IDENTIFYING CAPACITOR VALUES

Capacitors will be identified by their capacitance value in pF (picofarads), nF (nanofarads), or mF (microfarads). Most

capacitors will have their actual value printed on them. Some capacitors may have their value printed in the following

manner. The maximum operating voltage may also be printed on the capacitor.

Second Digit

First Digit

Multiplier

Tolerance The letter M indicates a tolerance of +20%

The letter K indicates a tolerance of +10%

The letter J indicates a tolerance of +5%

FortheNo.01234589

Multiply By 1 10 100 1k 10k 100k 0.01 0.1

Multiplier

Note: The letter “R” may be used at times

to signify a decimal point; as in 3R3 = 3.3

103K

100V

Maximum Working Voltage

The value is 10 x 1,000 = 10,000pF or .01mF 100V

10mF 16V

METRIC UNITS AND CONVERSIONS

Abbreviation Means Multiply Unit By Or

p Pico .000000000001 10-12

n nano .000000001 10-9

mmicro .000001 10-6

m milli .001 10-3

– unit 1 100

k kilo 1,000 103

M mega 1,000,000 106

1. 1,000 pico units = 1 nano unit

2. 1,000 nano units = 1 micro unit

3. 1,000 micro units= 1 milli unit

4. 1,000 milli units = 1 unit

5. 1,000 units = 1 kilo unit

6. 1,000 kilo units = 1 mega unit

-4-

Introduction

The most important factor in assembling your XP-620K Power Supply Kit is good soldering techniques. Using

the proper soldering iron is of prime importance. A small pencil type soldering iron of 25 - 40 watts is

recommended. The tip of the iron must be kept clean at all times and well tinned.

Safety Procedures

• Wear eye protection when soldering.

•

Locate soldering iron in an area where you do not have to go around it or reach over it.

•Do not hold solder in your mouth. Solder contains lead and is a toxic substance. Wash your hands

thoroughly after handling solder.

• Be sure that there is adequate ventilation present.

Assemble Components

In all of the following assembly steps, the components must be installed on the top side of the PC board unless

otherwise indicated. The top legend shows where each component goes. The leads pass through the

corresponding holes in the board and are soldered on the foil side.

Use only rosin core solder of 63/37 alloy.

DO NOT USE ACID CORE SOLDER!

CONSTRUCTION

Solder Soldering Iron

Foil

Solder

Soldering Iron

Foil

Component Lead

Soldering Iron

Circuit Board

Foil

Rosin

Soldering iron positioned

incorrectly.

Solder

Gap

Component Lead

Solder

Soldering Iron

Drag

Foil

1. Solder all components from

the copper foil side only.

Push the soldering iron tip

against both the lead and

the circuit board foil.

2. Apply a small amount of

solder to the iron tip. This

allows the heat to leave the

iron and onto the foil.

Immediately apply solder to

the opposite side of the

connection, away from the

iron. Allow the heated

component and the circuit

foil to melt the solder.

1. Insufficient heat - the

solder will not flow onto the

lead as shown.

3. Allow the solder to flow

around the connection.

Then, remove the solder

and the iron and let the

connection cool. The

solder should have flowed

smoothly and not lump

around the wire lead.

Here is what a good solder

connection looks like.

2. Insufficient solder - let the

solder flow over the

connection until it is

covered. Use just enough

solder to cover the

connection.

3. Excessive solder - could

make connections that you

did not intend to between

adjacent foil areas or

terminals.

4. Solder bridges - occur

when solder runs between

circuit paths and creates a

short circuit. This is usually

caused by using too much

solder. To correct this,

simply drag your soldering

iron across the solder

bridge as shown.

What Good Soldering Looks Like

A good solder connection should be bright, shiny,

smooth, and uniformly flowed over all surfaces.

Types of Poor Soldering Connections

-5-

ASSEMBLE COMPONENTS TO PC BOARD

Figure A

Diodes have polarity. Be sure

that the band is in the correct

direction.

Figure B

Electrolytics have a polarity

marking indicating the (–)

lead. The PC board is marked

to show the lead position.

Figure C

Mount the transistor with the

flat side as shown on the top

legend. Leave 1/4” between

the part and PC board.

Band

D5 - 1N5400 Diode

D6 - 1N5400 Diode

D7 - 1N5400 Diode

D8 - 1N5400 Diode

(see Figure A)

C1 - 10mF Electrolytic

C2 - 10mF Electrolytic

C3 - 10mF Electrolytic

C4 - 10mF Electrolytic

C8 - 10mF Electrolytic

(see Figure B)

C7 - 4700mF Electrolytic

(see Figure B)

Q1 - A70 Transistor

(see Figure C)

D4 - 1N4001 Diode

D3 - 1N4001 Diode

D2 - 1N4001 Diode

D1 - 1N4001 Diode

(see Figure A)

R2 - 150WResistor

R1 - 150WResistor

(brn-green-brn-gold)

C6 - 2200mF Electrolytic

C5 - 2200mF

Electrolytic

(see Figure B)

R3 - 2.7WResistor

R4 - 2.7WResistor

(red-violet-gold-gold)

R5 - .18WResistor

Flat

1/4”

(–) (+)

Polarity

Mark

-6-

PC BOARD WIRING

Cut the wires to the required length. Strip 1/4” of insulation off of both ends. Insert the lead into the hole and

solder it to the foil side.

0123

Use this ruler to measure the wires when cutting them to their required lengths.

4567

4” Red

Hole K

4” Orange

Hole J

3” Red

Hole I

3” Orange

Hole H

3” Blue

Hole G

4” Blue

Hole F

4” Red

Hole E

6” Blue

Hole D

6” Red

Hole C

3 1/2” Red

Hole W

3” Orange

Hole V

3 1/2” Blue

Hole U

3” Blue

Hole T

3 1/2” Orange

Hole S

3” Red

Hole R

4 1/2” Blue

Hole Q

5” Orange

Hole P

4 1/2” Red

Hole O

5” Blue

Hole N

4 1/2” Orange

Hole M

5” Red

Hole L

-7-

Install the binding posts with the colors in order, as shown in Figure D. Remove the large nut and splitwasher.

Insert the post into the hole and fasten it with the nut and splitwasher. Tighten down the nut with pliers.

Cut off the tabs on the two potentiometers and install them with the lugs up, as shown in Figure D. Secure

in place with a 5/16” lockwasher, 8mm flat washer and 7mm nut.

Turn both potentiometer shafts all the way counter-clockwise. Line up the line on the

knobs with the first line on the voltage scale. Press knobs onto the shaft of the

potentiometers.

Note the lug configuration on the rocker switch. Push the switch into the hole in the

chassis with lug 1 on top as shown in Figure D.

PANEL ASSEMBLY

Figure D

Lug 1

Lockwasher

Nut

Red

Black

Yellow

Rocker Switch

Rear View of Rocker Switch

7mm Nuts

8mm Washers

5/16” Lockwashers

Potentiometers * Cut off tabs

Red

Black

Carefully bend the leads of IC1, IC2,

IC3 and Q2 at right angles with pliers.

Install IC1, IC2 and Q2 in the

positions shown in Figure E. Fasten

in place using the parts shown in

Figure F. Spread the silicon grease

on the back of the transistor and ICs.

IC1 - LM-317 IC

IC2 - LM-337 IC

Q2 - 2N6124 Transistor

Install IC3 as shown in Figure Fa.

IC3 - LM-7805 IC

Mount the fuse holder to the top hole in the back of the chassis,

with the side lug up, as shown in Figure G. Fasten in place with

the fuse holder nut. After the holder is secure, insert the fuse and

screw the cap on.

Separate the wires of the line cord 3” from the end. Strip the

insulation off the end of all three wires to expose 1/4” of bare wire.

Insert 6” of the line cord into the bottom hole on the back

of the chassis, as shown in Figure G. Place the line cord

into the slot of the strain relief and squeeze the two

sections together with pliers. Then, insert the strain relief

into the hole.

One side of the transformer has only 2 black wires. Cut

these wires so that they are 4 1/2” in length (see Figure H).

Strip the insulation off the end of the wires to expose 1/4”

of bare wire.

Cut the red, blue and black wires on the other side of the transformer so that they are 3” in length. Strip the

insulation off the end of the wires to expose 1/4” of bare wire.

Cut the yellow wires flush with the transformer.

Install the transformer with the black wires side as shown in Figure J. Use an 8-32 x 3/8” screw, #8

lockwasher and an 8-32 nut on each side to fasten in place, as shown in Figure I.

-8-

Figure E

LM7805

LM-337

LM-317

2N6124

Mica

Figure F

Small 6-32 Nut

IC1, IC2,

Heat Sink

Insulator Washer

6-32 x 3/8”

Screw Silicon GreaseMica

Figure Fa

Small 6-32 Nut

IC3

LM7805

Heat Sink

Insulator Washer

6-32 x 3/8” Screw Insulator Washer

Figure G

Ribbed

Smooth

1/4”

Figure I

8-32 Nut

#8 Lockwasher

8-32 x 3/8” Screw

Figure H

4” Red

4” Blue

4 1/2” Black

Side Lug

Pliers

Fuse Holder

Fuse

Cap

Washer

Nut

4” Blue

4” Black

-9-

Solder the black transformer wire (B), as shown in Figure J to lug 2 on the rocker switch.

Twist the black transformer wire (A) and the ribbed or flat line cord wire together. Solder the two wires to

lug 1 on the rocker switch, as shown in Figure J.

Slide the 3/4” diameter shrink tubing over the switch and shrink into place.

Solder the two red transformer wires to the holes marked T2 on the PC board.

Solder the black transformer wire to the hole marked CT1 on the PC board.

Solder the two blue transformer wires to the holes marked T1 on the PC board.

Slowly push the PC board stand-offs into the four holes on the bottom of the chassis. Push the PC board

down into place.

WIRING LINE CORD, FUSE, TRANSFORMER AND SWITCH

Figure J

PC Board

Chassis

Side Lug

End Lug

Smooth Line Cord

Flat or Ribbed Line Cord

(A) Black Red

Red

2” Tubing

Yellow

Ribbed

Line Cord

Install the line cord ground lug to the chassis

using a 6-32 x 3/8” screw and a 6-32 large

nut in the location shown in Figure J.

Strip the insulation off of both ends of the

6” red 20 ga. wire to expose 1/4” of bare

wire. Solder one end of the wire to lug 3 on

the rocker switch, as shown in Figure J.

Slip the 2” section of shrink tubing over the

other end of the 6” 20 ga. red wire and the

smooth or round line cord wire. Solder the

line cord wire to the end lug on the fuse

holder, as shown in Figure J. Solder the 6”

20 ga. red wire to the side lug on the fuse

holder. Slide the shrink tubing over the fuse

holder, covering the two lugs. You may use

a hair dryer, heat gun (at lowest setting or

you will melt the tubing) or the heat

emitting from your soldering iron.

CAUTION: DO NOT touch any wires or

tubing with the iron.

Slip the 6” strip of red wire (leading from the

side lug of the fuse holder), the (A) and (B)

black transformer wire, and the ribbed line

cord wire through the 3/4” diameter piece of

shrink tubing (as shown in Figure J).

Blue

Black

Blue

(B) Black

6” 20 Ga.

Red

T2 T2 T1

CT1

3/4” Shrink

Tubing

6-32 x 3/8” Screw

6-32 Large Nut

Indice

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