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Finished, without phase switching

A project log for High Voltage DC Power Supply

Not isolated not regulated DC power supply Rectifying mains voltage for various builds

SUFSUF 11/27/2017 at 15:460 Comments

So, I continued to work on the issues from the previous post.

"Mill a hole for the mains socket and the circuit breaker to the backpanel"

done

"Mill the holes for the banana jacks to the front panel"

Actually it was much simpler than I meant originally. My step drills eventually arrived. Sooner than expected. Never used such tool previously. On the first try I was able to drill the holes in no time.

"Finish the wiring"

done

"Set the correct decimal dots"

It wasn't easy to remove those solder blobs, but done

"build a dummy load to be able to test the current measurement"

Actually a professional DC electronic load what is able to work above 300V isn't cheap. So I decided to pick a 100W 1K resistor and screwed onto an old s478 heathsink. The question is if the fan have to be used. Finally it worked without it.

"Calibrate"

done

"Paint the front panel"

done

Actually I had serious problem with assembling the panel meters into the front panel. Most of the fixing clamps are broken of (because of the material aging or bad construction, who knows)

<missing pic>

I hate that hot snore glue, but I had no other option here, to keep the panel meters in its place:

"Build the phase switching electronics (not mandatory, maybe after finish)"

Actually I've quite a progress with it, but it will be the subject of an other post. Not finished yet, so it is not assembled into the unit yet.

"Create the console for the caps"

This was funny. I don't know why I completely forgot that the outside (and therefore of the mounting screw also) of those large cans are the negative pole of the capacitor. building two caps with different potential on the same conductive (aluminum) mount is not a best idea of the world:

Luckily I realized this before switching on, and exchanged the mounting plate to a plastic one (unused etched FR4):

As I'm at the end of the todo points. The project is almost finished (just the phase switching electronics missing):

What's next:

I'll finish the phase switching electronics and install it.

The PSU itself has some room for improvement. Like cold start current limiting and proper capacitor draining. I'm not quite sure, that those improvements will be done in the near future. The usability of the equipment will tell.

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