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Modular PSU & Soldering station

Universal enclosure that can be used as a lab power supply, soldering station or combination of two.

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The goal of this project is to create a universal enclosure that can be used as a lab power supply, soldering station or combination of two.

Enclosure consists out of main body and front panel.

Main body is designed to be easily 3D printed in one piece without any supports.

Front panel is designed to be cut from 3mm thick tinted plexiglass sheet or 3D printed. On the front panel there are mounting holes for Ruideng DPS3003/5 power supply modules and/or Ksger T12 soldering iron controller. In general, a front panel for any combination or type of modules can be made, since outline dimensions are provided.

To power everything there is space for two Meanwell LRS-100-24 power supplies in the main body part. They each can provide 24 volts @ 4.5A. 100 watts of power per channel is enough for any soldering iron or lab power supply hobbyist may use. They each have a small voltage adjusting potentiometer that can be used to increase output voltage by few volts.

Use of quick connect terminals is not a must. Soldering will do just fine. Just make sure to insulate solder joints.


IMPORTANT:

This project uses main voltages that are deadly. Please use proper safety and follow wiring schematics and instructions outlined in video.

Before powering double check your wiring and before first use test output voltages(polarity and values).

100_Modular_PSU&Soldering_Station.zip

3D models, Wiring schematics, Bill of materials, DXF drawings.

x-zip-compressed - 5.45 MB - 01/18/2021 at 07:21

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  • 1
    Things you will need

    Bill of materials(quantity depends on your configuration):

    This is everything(almost) laid out on the table:

  • 2
    Printing enclosure

    Enclosure was printed on Prusa I3MK3S using default settings for 0.3mm layer height preset in PLA material and also it was printed on Ender 3 Pro using 0.6mm nozzle and default settings for 0.28mm layer height in PLA material. Everything printed without no problems and without using supports.

    Here are some thermal cam images that show thermal performance of enclosure. Since I'm limited to 150W DC load I loaded each channel with 75W and let it run over night. As it can be seen the top of the enclosure reaches around 40 °C and sides around 30°C. This is expected since hot air is expanding upwards. There are also 50°C hotspots that correspond to internal placement of components(power transistors, switching diodes). I did test one channel with 100W load and temperatures were around 5°C higher. All tests were conducted at room temperature of 25°C.

    During the test enclosure was mildly warm(sides barely noticeable) to touch and it felt that construction kept its rigidity.

    This is the third revision of enclosure and first two versions are in everyday use for more than a year. They were used in lab environment for low power applications like powering electronic modules and high power ones like battery bank charging and they performed without issues. 

  • 3
    Wiring instructions

    For wiring schematics refer to images below(pdfs also available). First image shows wiring diagram for unit with two DPS3005 modules, while second one shows unit with one DPS3005 and KSGER T12 module. For more information about assembly refer to video above. 

    Your wiring should look something like this:

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Discussions

Marcin wrote 3 days ago point

Amazing project! It looks sooo goood. Already started to order parts. :) 

I'm considering using LRS-150-36 or LRS-200-36 power supply (would be nice to have access to full range of voltage/current that DPS3005 offers), so would it be possible for you to share F3D files? Just enlengthened enclosure would work for 150W, but 200W model is also 18mm thicker.

Is there some way to tip you?

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Tony wrote 5 days ago point

Love the added print specs and heat data! You went above and beyond! Thank you!

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james.vansickle wrote 5 days ago point

This is a great project!  I'm duplicating this using the LRS-350-24 supplies and adding USB for lab automation.  Challenge will be finding a suitable enclosure.

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Matt Zeglen wrote 5 days ago point

This is a really cool project. I've worked on projects and found myself with stacks of power supplies destined for the garbage. This is a great way to turn them into a useable benchtop supply. It's also an excellent project for the local college IEEE chapter and engineering fraternity.

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Tobias wrote 6 days ago point

I am seriously envious.. :-) Even a fanless PSU..

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Yopo wrote 01/19/2021 at 18:39 point

Is it possible to get a PSU + soldering cover with hole for the T12 module? I have no way to make one out of acrylic. Would appreciate an answer. :)

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Tony wrote 01/19/2021 at 19:14 point

I realized this as well and once my T12 arrives, I plan on just altering the .STL the maker provided (unless they provide one with the cutout for the screen) - if I end up doing that, I'll let you know.

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Yopo wrote 01/20/2021 at 08:19 point

Thank you. :)

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Mile wrote 6 days ago point

I can do it, but I am busy right now with another project so don't hold your breath :D 

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Yopo wrote 6 days ago point

No problem, it will take a while until the parts arrive anyway. If I don't have a front panel by then, I'll try it myself or Tony has already made one. But thanks :)

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ハイエナ お母さん wrote 01/18/2021 at 10:36 point

Really good project. Do you have any plans to add a hot air solder reflow handset to make it a triple whammy? Solder/Solder Reflow station and Dual bench PSU would be perfect

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Mile wrote 6 days ago point

Not for now. I am planning for some time now to buy hot air controller to try it out but I am really busy.

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tinkerzone wrote 01/18/2021 at 01:01 point

Hi, Can you confirm that the wiring diagram is correct? I'm finding it very confusing with the Red wires going to the Negatives, and black to positives

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Mile wrote 01/18/2021 at 09:16 point

There were some labeling mistakes. They are corrected now.

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tinkerzone wrote 01/19/2021 at 04:19 point

No worries, thanks for fixing!

Are you able to confirm that if you set to modules to the same voltage (say 15v) and then connected the positive of one to the negative of the other (to set a 0 volt ground) you would be able to use it as a +/-15v supply?

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Mile wrote 6 days ago point

Yes, you can use it as regulated split power supply source.

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Tony wrote 01/15/2021 at 20:57 point

I took a quick look at the files - do you publish the slicer settings you used for the enclosure? I'm most interested in the filament you used and resolution. Do you think this requires PETG or ABS, or would PLA work? (I wonder if the heat generated by the power supplies could potentially deform PLA?)

I plan on making a PSU/soldering station version once I'm comfortable enough with my printer to entrust a 2-day print to it.

Thank you for sharing such beautiful and functional work!

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Yopo wrote 01/17/2021 at 14:44 point

I printed it on my Anycubic i3 Mega with PLA, 0.3mm thickness and no support structure. There were no problems printing and with 0.3mm it already looks very good.

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Tony wrote 01/17/2021 at 15:43 point

Good info, thank you - have you used the enclosure yet? My concern is about PLA's tendency to soften in things like hot cars; I wonder if it might be a bad choice if the PSUs put out enough heat.

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Yopo wrote 01/18/2021 at 06:20 point

No, I have not tested it yet. I ordered the parts last Saturday and unfortunately they will take a while to arrive. I don't think the power supplies are particularly hot/warm, there are also more than enough ventilation holes.

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Tony wrote 01/18/2021 at 15:20 point

Right on. I will order my parts and print with the same general settings. The case is very ventilated at the very least, and it looks like the likely hottest parts are air-adjacent, not directly against the plastic anyway. I've been having a hell of a time trying to print PETG properly; I'd rather just do PLA because I know it'll print beautifully. Thanks!

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Mile wrote 6 days ago point

Enclosure was printed in PLA @ default settings and 0.3mm layer height on Prusa i3 and ender 3. Model itself is very easy to print. If you are concern about thermal performance I added "Step No. 2". Previous versions of enclosure are in use for more than a year now and there are no problems. Now, obviously if you use it space with no air circulation(and heat build up) you will have problems.

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Tony wrote 6 days ago point

Yep, makes sense! Just wanted to make sure -thank you for sharing your knowledge!

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Eric Bidault wrote 01/14/2021 at 17:14 point

Nice project! This enclosure is beautiful, would love to get the fusion project.

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Benjamin Prescher wrote 01/12/2021 at 13:01 point

Well done! I really like the design. Is there a link to Thingiverse for this? If the housing could be parameterized, it would certainly be a great fit for many projects. Best Ben

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Mile wrote 01/14/2021 at 11:23 point

Thank you. There are 3d models attached in the “FILES” section. I posted previous versions on Thingiverse, but I gave up on it since the site is broken. They have bugs that go back a few years and are still not fixed to this day. Step file is included so everyone can make small changes to it. If someone needs, I can send a fusion360 project.

In future revisions I may provide a parametric defined model, but I can't make any promises.

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