XP-620K REV-O 6-25-03.qxd
Contents
1. Qty Description Part Qty Description Part 1 Transformer 440720 1 Nut 6 32 Large 644600 1 PC Board 512013 A Nut 6 32 Small 644601 1 Fuse 1 25A 530125 2 Nut 8 32 644800 1 Rocker Switch 541204 2 Flat Washer 8mm x 14mm 645101 1 Cover 611120 2 Lockwasher 5 16 646101 1 Chassis 612020 2 Lockwasher 8 646828 1 Heat Sink 615010 4 Rubber Feet 662003 2 Knob 622009 1 Fuse Holder Body 663005LB 1 Strain Relief 624003 1 Fuse Holder Nut 663005N 5 Insulating Washer 624007 1 Fuse Holder Cap 663005UB 04 PC Board Stand off 625001 1 Fuse Holder Washer 663005W 2 Black Binding Post 625031 3 Mica Insulator 780002 5 Lockwasher Binding Post 625031LW 1 Silicon Grease 790005 5 Nut Binding Post 625031HN 6 20 Ga Red Wire 813210 2 Red Binding Post 625032 48 22 Ga Red Wire 814201 1 Yellow Binding Post 625034 48 22 Ga Orange Wire 814310 5 Screw 6 32 x 3 8 Phillips 641640 48 22 Ga Blue Wire 814610 O2 Screw 8 32 x 3 8 Phillips 641840 1 Line Cord 862105 4 Screw 6 x 3 8 Black Truss Head 642652 2 Shrink Tubing 1 2 Dia 891101 O2 Screw 6 x 3 8 black AB Phillips 642660 1 5 Shrink Tubing 3 4 Dia 899110 2 Nut 7mm 644101 1 Solder Tube 9ST4 PARTS IDENTIFICATION Resistor 2kQ Potentiometer Capacitor Transistor PC Board Heatsink Strain Relief PC Board Stand off Fuse Assemb2. Peel off the protective paper from the bottom of the rubber feet and apply one to each corner on the bottom of the chassis as shown in Figure M lt x 6 x 3 8 Screws Truss Head Bottom View Figure M TESTING THE XP 620 POWER SUPPLY Testing the XP 620 Power Supply is very simple Before applying power to the unit be sure that all wiring and soldering is firm If so obtain a digital voltmeter Apply power to the XP 620 and measure the output voltages The variable voltage supplies should read between 2 and 16 volts The 5V supply should read between 4 50 and 5 50 volts Next short the output of each supply They should turn off and recover when the short is removed If you have a 10 ohm 10 watt resistor place it across the output terminal a 2 watt will work but use it only a few seconds The output of the supply should not change more than 2 volts Do the same on the 5V supply using a 2 5 ohm 12 watt resistor Again the output should not change more than 2 volts In making this test the voltmeter leads should be clipped to the terminal directly and not to the load leads This is to prevent errors in voltage drop due to contact resistance of the load Should any of these tests fail please refer to the troubleshooting guide 12 TROUBLESHOOTING GUIDE No 2 15V Output Voltage 1 Check the AC voltage at anode of D1 It should read about 17VAC If not check the fuse transformer ON OFF switch or line cord
3. 2 Measure voltage at output of D1 It should read about 24VDC If not check D1 D3 and C5 3 If 20V is OK check IC1 No Negative Voltage Output 1 Check the voltage at the output of D4 It should be 24VDC Check D2 D4 and C6 and make sure that they are not in backwards 2 If DC is OK then check IC2 No 5V Output 1 Check the voltage across the transformer winding It should read about 12 volts If not check the diode bridge or C7 2 Measure the DC voltage at the output of the diode bridge It should read about 12 volts If not check the diode bridge or C7 3 If DC is OK check IC3 Q1 and Q2 Poor Regulation on any Supply 1 Check DC voltage at the input of the regulator It should be greater than 18 for 2 15V output and 8V for 5V output 2 Check AC ripple at the input of the regulator It should be less than 5V for the variable supply and the 5V supply 3 If the ripple is greater then check the diodes and its filter capacitor Fails to Shut Down on 5V Overload 1 Check transistor Q1 and resistors R3 R4 and R5 Unable to Draw 3 Amps at 5 Volts 1 Check transistor Q2 and resistors R3 and R4 13 CIRCUIT DESCRIPTION Introduction The Model XP 620 Power Supply features three solid state DC power supplies The first supply gives a negative 1 5 to 15 volts at 1 ampere The third has a fixed 5V at 3 amperes All DC supplies are fully regulated A special IC circuit keeps the output voltage within 2V when goin
4. Electrolytics have a polarity marking indicating the lead The PC board is marked to show the lead position D5 1N5400 Diode D6 1N5400 Diode D7 1N5400 Diode D8 1N5400 Diode see Figure A C1 10uF Electrolytic C2 10uF Electrolytic C3 10uF Electrolytic C4 10uF Electrolytic C8 10uF Electrolytic see Figure B C7 4700uF Electrolytic see Figure B Q1 A70 Transistor see Figure C Figure C Mount the transistor with the flat side as shown on the top legend Leave 1 4 between the part and PC board D4 1N4001 Diode D3 1N4001 Diode D2 1N4001 Diode D1 1N4001 Diode see Figure A R2 150Q Resistor R1 1500 Resistor brn green brn gold C6 2200uF Electrolytic C5 2200uF Electrolytic see Figure B R3 2 7Q Resistor R4 2 7Q Resistor red violet gold gold R5 18Q Resistor 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 4 Red Hole K 4 Orange Hole J 3 Red Hole 3 Orange Hole H 3 Blue Hole G 4 Blue Hole F O 4 Red Hole E 6 Blue Hole D O 6 Red Hole C 2 3 4 5 Use this ru
5. This circuit is known as a half wave rectifier Here SE the diode conducts only half of the time when the AC wave S is positive as shown in Figure 2C Use of this circuit is SN N 20V simple but inefficient The big gap between cycles require F Output of capacitor C1 much more filtering to obtain a smooth DC voltage Ripple depends on load current expanded transformer voltage is positive will current flow through the NN D Output of Full Wave Rectifier Figure 2 Figure 4 By addition of a second diode and transformer winding we can fill in the gap between cycles as shown in Figure 4 This circuit is called full wave rectification Each diode conducts when the voltage is positive By adding the two outputs the voltage presented to capacitor C5 is more complete thus easier to filter as shown in Figure 2E When used in 60 cycles AC input power the output of a full wave rectifier will be 120 cycles Capacitor C5 is used to store the current charges thus smoothing the DC voltage The larger the capacitor the more current is stored In this design 2200uF capacitors are used which allows about 3 volts AC ripple when one amp is drawn 14 In practice the current through the diodes is not as shown in Figure 2C Because capacitor C5 has a charge after the first cycle the diode will not conduct until the positive AC voltage exceeds the positive charge in the capacitor Figure 5 shows a better picture of what the current flow lo
6. the the copper foil side only Push the soldering iron tip against both the lead and the circuit board foil LILI WLLL solder will not flow onto the Component Lead P lead as shown Soldering iron positioned incorrectly Circuit Board 2 Insufficient solder let the Soldering Iron solder flow over the connection until it is covered Use just enough solder to cover the connection 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 3 Excessive solder could make connections that you Solder did not intend to between adjacent foil areas or 3 Allow the solder to flow terminals 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 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 4 Here is what a good solder connection looks like LL Wii ASSEMBLE COMPONENTS TO PC BOARD Figure A Figure B AT Band IT Polarity Mark Diodes have polarity Be sure that the band is in the correct direction
7. 4 1 2 in length see Figure H Strip the insulation off the end of the wires to expose 1 4 Ribbed of bare wire Figure G 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 O Cut the yellow wires flush with the transformer C 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 4 Red 4 Red 4 Blue 8 32 Nut lt 8 Lockwasher 4 1 2 Black 4 Black 4 Blue Figure H I 8 32 x 3 8 Screw Figure WIRING LINE CORD FUSE TRANSFORMER AND SWITCH 2 Tubing aS Side Lug SE End Lug des Oo Oo Oo 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 tub
8. angles with pliers 6 32 x 3 8 We GE Install IC1 IC2 and Q2 in the Par ory TT Screw y in Figure F Spread the silicon grease on the back of the transistor and ICs N O O positions shown in Figure E Fasten Ae and Transistor This Side 7 h Install IC3 as shown in Figure Fa Oo O Q2 2N6124 Transistor o Si Small 6 32 Nut N y ma u place using the parts shown in Insulator Washer lt ICT ICH Heat Sink Q2 N Figure Fa J 6 32 x 3 8 Screw Insulator Washer S Small 6 32 Nut N Figure E mM D P VW Insulator Washer lt IC Heat Sink LM7805 IC1 LM 317 IC IC2 LM 337 IC 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 Side Lug A Fuse Holder go Pliers 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 S gt 1 4 lt 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 Smooth these wires so that they are
9. trigger O D Full wave 5 The DC voltage is smoothed by usinga half wave rectification circuit small value capacitor with a high voltage value Large value capacitor 90 out of phase rectification circuit O O O O nl A B C D 6 An in efficient rectification circuit usually contains O A large gaps between cycles O B twice the AC voltage needed O C more diodes o h D all of the above 7 The maximum current that a diode can handle is determined Dy O A the transformer s current rating O B the amount of AC ripple O C three times the diode rating oO D peak current rating 8 The LM317 will shut down when O A the output voltage is too high O B no current is being drawn O C the junction overheats O D the output voltage drops to 1 25V 9 The LM317 regulator contains O A a pass transistor O B a constant current source O C a differential amplifier O0 D all of the above 10 The LM317 is basically O A a 1 25V regulator O B a 6 25V regulator O C a 2 5V regulator O D a negative voltage regulator VOL V6 08 02 0 9 0 S C v 0 a2 a siemsuy 17 SPECIFICATIONS ON XP 620 POWER SUPPLY Input Voltage 110 130VAC Output Voltage 1 5 15VDC 1A at 120V input 1 5 15VDC 1A 3 5VDC 3A Output Regulation 200mV each supply Line Regulation 100mV each supply Ripple Max 5mV rms Current Protection 1A limi
10. 05 IC will only draw the 2A it was designed to handle and never heat up to turn itself off Another transistor Q1 is added to limit maximum current Resistor R5 is added to sense the current in transistor Q2 When approximately 3A is drawn in transistor Q2 the voltage drop in resistor R5 will turn on transistor Q1 This will force more current in the LM 7805 IC Eventually the LM 7805 IC will overheat turning itself off and thus limiting the circuit at about 3 2A The first 2A of current is drawn by the LM 7805 IC The next 3A are drawn by transistor Q2 Thereafter the current is drawn by the LM 7805 IC until it overheats and turns itself off This is a very effective circuit capable of regulating the output voltage at a constant 5 volts and yet delivering over 3A of current 16 QUIZ 1 AC voltage is supplied to the rectifier stages by the O A step up transformer O B step down transformer OC 1 to 1 transformer O D AC to DC transformer 2 The secondary windings of the transformer are O A 90 out of phase CB 180 out of phase CC 270 out of phase O D 320 out of phase 3 Diodes allow current to flow O A when the anode is more negative than the cathode O B when the cathode is more positive than the anode O C in one direction O0 D when a negative or positive voltage is on the anode 4 What circuit is more efficient for rectifying AC to DC CA Hartley oscillator OB Half wave O C Schmitt
11. POWER SUPPLY KIT MODEL XP 620K 7 0004917 ELENCO BR PRECISION Etat NEOGULATE y r CO PWEN fihp KR Model Fann PLT GA d RK ah CN NEGATIVE POSITIVE OUTPUT LA ny m Assembly and Instruction Manual Elenco Electronics Inc Copyright 2003 1989 Elenco Electronics Inc Revised 2003 REV O 75320K 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 Elenco Electronics address phone e mail is at the back of this manual for additional assistance if needed RESISTORS Qty Symbol Value Color Code Part 01 R5 180 5 3W 101804 02 R3 R4 2 70 5 1 2W red violet gold gold 112701 2 Ri R2 1509 5 1 4W brown green brown gold 131500 2 VR1 VR2 2KQ Potentiometer 192422 CAPACITORS Qty Symbol Value Description Part O5 C1 C4 C8 10uF Electrolytic 271045 o2 C5 G 2200uF Electrolytic 292226 1 Gs 4700uF 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 ICH LM 317 Integrated Circuit 330317 1 IC2 LM 337 Integrated Circuit 330337 1 IC3 LM 7805 Integrated Circuit 337805 MISCELLANEOUS
12. esistor VR1 will vary the voltage from 2V to 15V The Negative Voltage Regulator Figure 6A The theory of the negative voltage regulator is the same as the previously discussed positive regulator The basic differences is that diodes D2 and D4 are reversed producing a negative voltage across capacitor C6 The LM 337 IC is designed to operate from a negative supply The 5 Volt Power Supply In the previous discussion of the variable voltage regulators the ICs can handle about 1A of current In the design of the 5V supply we need 3A of current To meet this current requirement we must add an external pass transistor capable of delivering 3A Figure 7 shows a simplified 5V regulator with an external PNP pass transistor In this circuit transistor Q1 is a power transistor capable of 8 10VDC delivering over 3A Transistor Q2 is biased off until the LM 7805 IC draws about 2A When 2A is drawn by the LM 7805 IC the voltage drop across the 3 ohm resistor is 6V enough to turn on transistor Q2 Transistor Q2 takes over and delivers the current to the output Note that if the output voltage goes down the LM 7805 regulator will draw more current forcing the output voltage back to 5V Thus the LM 7805 Figure 7 regulator controls the output voltage and keeps it at 5V Unfortunately this circuit has no control of the output maximum current If the output is shorted to ground transistor Q2 will be overloaded and eventually be damaged The LM 78
13. g from no load to 1 ampere The output is fully protected from short circuits This supply is ideal for use in school labs service shops or anywhere a precise DC voltage is required The Positive 2 15V Power Supply Figure 1 shows a simplified circuit diagram of the positive supply It consists of a power transformer a DC rectifier stage and the regulator stage 120VAC input Transformer _17VAC Mano JS Voltage SEN 120V to 17V Converter Regulator Regulated Simplified diagram of positive power supply Output Figure 1 Transformer The transformer T1 serves two purposes First it reduces the 120VAC input to 17VAC to 8VAC to allow the proper voltage to enter the rectifier stages Second it isolates the power supply output from the 120VAC line This prevents the user from dangerous voltage shock should the user be standing in a grounded area AC to DC Converter Voltage Waveform for Suppl The AC to DC converter consists of diodes D1 and D3 and EE epg capacitor C5 Transformer T1 has two secondary windings A Mee which are 180 degrees out of phase The AC output at each ipalng Half Wave Rectifier winding is shown in Figure 2A and 2B B Transformer Diodes are semiconductor devices that allow current to flow Winding BC in one direction The arrow in Figure 3 points to the C Output of Figure 3 direction that the current will flow Only when the diode D1 fk diodes Figure 3 shows the simplest possible rectifier ee circuit
14. ing 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 6 20 Ga Tubing aN Smooth Line Cord a Ribbed 4H p Line Cord Oz O gt O gt 6 32 x 3 8 Screw 6 32 Large Nut e uo er Flat or Ribbed Line Cord Figure J 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 O 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 PC Board Chassis WIRE BINDING POSTS AND 317 337 Solder the wires from the board to the binding posts as
15. is to the 2N6124 and LM 7805 solder into place as shown in Figure L 5 Red wire L from the PC board To middle lead Of 2N6124 5 Orange wire P from the PC board to left lead of 2N6124 5 Blue wire N from the PC board to right lead of 2N6124 O 4 1 2 Red wire O from PC board to middle lead of LM 7805 O 4 1 2 Blue wire Q from PC board to left lead of LM 7805 4 1 2 Orange Wire M from PC board to right lead of LM 7805 After wiring be sure that the leads do not touch each other and cause a short Solder the wires from the PC board to the potentiometers as shown in Figure L 4 Red wire E from PC board to middle lug of the positive voltage pot 4 Blue wire F from PC board to right lug on the positive voltage pot 4 Orange wire J from PC board to middle lug on the negative voltage pot 4 Red wire K from PC board to right lug on negative voltage pot 11 2N6124 Potentiometers e6uelo S D 21 v njg S anid At v Positive Voltage Figure L Negative Voltage ELENCO ELECTRONICS INC FINAL ASSEMBLY Fasten the heat sink to the chassis with two 6 x 3 8 black screws as shown in Figure M Fit the cover onto the chassis Fasten in place with two 6 x 3 8 truss head black screws on each side as shown in Figure M
16. ler to measure the wires when cutting them to their required lengths 3 1 2 Red Hole W O0 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 PANEL ASSEMBLY O 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 1 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 O 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 CEA potentiometers e amp QO 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 A La Cut off tabs A G L 5 16 Lockwashers NS af lt 8mm Washers SCH D Lockwasher Black NS Red zl Figure D Rocker Switch Rear View of Rocker Switch Carefully bend the leads of IC1 IC2 j Figure F IC3 and Q2 at right
17. ly Flat Washer Lockwashers IDENTIFYING RESISTOR VALUES Use the following information as a guide in properly identifying the value of resistors BAND 1 BAND 2 1st Digit 2nd Digit D Color Multiplier Black 1 1 Resistance Tolerance Tolerance 10 5 Color igi Color Black Black ees Brown Brown Brown Orange Yellow Green Blue Brown 1 Brown Red 2 3 0 5 0 25 Orange Orange Yellow Yellow Green Green Blue Blue Violet Violet Silver 0 1 Gray Gray Gold White White BANDS 1 2 Multiplier Tolerance IDENTIFYING CAPACITOR VALUES Capacitors will be identified by their capacitance value in pF picofarads nF nanofarads or uF 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 ame Fomor T 5 4 8 8 9 First Digit Note The letter R may be used at times to signify a decimal point as in 3R3 3 3 Second Digit Multiplier ses The letter M indicates a tolerance of 20 The letter K indicates a tolerance of 10 The letter J indicates a tolerance of 5 L Maximum Working Voltage The value is 10 x 1 000 10 000pF or 01uF 100V METRIC UNITS AND CONVERSIONS Abbreviation Means Multiply Unit By 1 000 pico units 1 nano unit Pico 000000000001 nano 000000001 d e micro 000001 1 000 micro units 1 milli uni
18. nsistor Q2 is extremely high Transistor Q5 is called the pass transistor It controls the current reaching the 2V output Transistors Q3 and Q4 are emitter followers Their function is to raise guet one the impedance of the pass transistor Note that transistors Q2 Q3 Q4 and Q5 fice and resistor R1 form a close loop Also note that the feedback to the base of Q2 is negative that is when the base of Q2 goes positive the output at emitter Q5 goes negative Now if the 2V output voltage goes down because of current drain at the output the base of Q2 will drop forcing the collector voltage of Q2 to go higher This will bring the output voltage back to 2V This is the basis of all negative feedback regulators R1 Figure 6 Another feature of the LM 317 regulator is to protect the IC against overload and output shorts If the IC is overloaded the junction of an overload transistor will overheat A transistor will sense this overheating and shut down transistor Q5 15 The LM 317 IC is basically a 2V regulator To be able to vary the output 2 15V we stack the IC on a DC voltage as shown in Figure 6A When VR1 equals 0 the output voltage is 2V as determined by the LM 317 IC Note that the voltage across R1 is always 2 volts When R1 equals VR1 the voltage across VR1 will equal the two volts across R1 therefore the output voltage will be four volts When VR1 is 5 times R1 the output voltage is 12 volts As you can see varying r
19. oks like assuming no loss in the diode It takes a few cycles for the voltage to build up on the capacitor This depends on 4 Tor ai inding the resistance of the winding and diode After the initial start up there will be a charge and discharge on the capacitor depending on the current drawn by the Voltage C1 output load Remember current only flows through the diode when the anode is C Current more positive than the cathode Thus current will flow in short bursts as shown through diodes in Figure 5C Figure 5 The DC load current may be one ampere but the peak diode current may be three times that Therefore the diode rating must be sufficient to handle the peak current The 1N4001 has peak current rating of 10 amps Regulator Circuit The regulator circuit in the Model XP 620 Power Supply consists of a LM 317 integrated circuit This IC is specially designed to perform the regulation function Figure 6 shows a simplified circuit of how the LM 317 IC works Transistors Q1 and Q2 form a circuit known as a differential amplifier Transistor Q1 base is connected to a stable 1 5V reference voltage The base of Q2 is connected to the regulator output circuit through a voltage divider network The collector of transistor Q2 is connected to a current source This basically is a PNP transistor biased to draw about 1mA of current Transistor Q2 sees the current source as a very high resistor of about 1 meg ohms Thus the gain of tra
20. shown in Figure K 3 Blue wire from G on the PC board To the Yellow post 1 5 15V 3 Orange wire from H on the PC board To the Black post common 6 Blue wire from D on the PC board To the Black post common 6 Red wire from C on the PC board To the Red post 5V 3A 3 Red wire from I on the PC board To the Red post 1 5 15V Place the heat sink with ICs and transistor in the position as shown in Figure K Insert the wires from the PC board through the rectangular hole in the chassis to the ICs and solder into place Tin the leads Form the end of the wires into a tight loop for easy tight connection to leads before you apply solder 3 1 2 Red wire W from PC board To middle lead of LM 317 3 1 2 Orange wire S from PC board To left lead of LM 317 3 1 2 Blue wire U from PC board To right lead of LM 317 3 Red wire R from PC board To middle lead of LM 337 3 Blue wire T from PC board To left lead of LM 337 ELENCO ELECTRONICS INC 3 Orange wire V from PC board To right lead of LM 337 After wiring the ICs be sure that none of the leads touch each other and cause a short Figure K 10 WIRE 2N6124 7805 amp POTENTIOMETERS Insert the wires from the PC board through the rectangular hole in the chass
21. t milli 001 1 000 milli units 1 unit 1 000 nano units 1 micro unit unit 1 i ail t 1 kil t kilo 1 000 000 un s ilo uni mega 1 000 000 1 000 kilo units 1 mega unit CONSTRUCTION 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 e Wear eye protection when soldering e Locate soldering iron in an area where you do not have to go around it or reach over it e Do not hold solder in your mouth Solder contains lead and is a toxic substance Wash your hands thoroughly after handling solder e 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 What Good Soldering Looks Like Types of Poor Soldering Connections A good solder connection should be bright shiny smooth and uniformly flowed over all surfaces 1 Solder all components from Soldering Iron 1 Insufficient heat
22. t 2 15VDC 3A limit 5VDC Short Protection 1A limit 2 15VDC 3A limit 5VDC Output Impedance 025Q each supply SCHEMATIC DIAGRAM orl 257 TO 15 isv COM OSV ele ZEN To po XP620 REV B kg a kel SE on H N I SE S RA le EN EN D a Si o m o 4 D Di NM dh aE Ch Ih A a m S a E al og S S x t x OT a Qa a t Jr D o he f T E E th m EI E a ad RED RED FE DC MALE Shi 1 25A PLUG 18 Elenco Electronics Inc 150 W Carpenter Avenue Wheeling IL 60090 847 541 3800 http www elenco com e mail elenco elenco com
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