Will
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Post by Will on May 16, 2009 16:41:33 GMT
For free use by Rock Grotto members, my dual regulator board. I will update this original post as things get changed It's not spectacular, but if you need to etch a basic PSU, hopefully this'll help. It's basically the jaycar PSU board, but with trimpots to make the output variable, and a space before the rectifiers for a 'transformer tuning capacitor'. It also has space to use those nice big chunky Aavid-Thermalloy heatsinks, like these www.rapidonline.com/Electronic-Components/Semiconductor-Hardware/Heatsink/Compact-vertical-TO220-TO218-TO247-heatsink/60146/kw/HeatsinkFuture improvements would be to introduce some filtering after the rectifiers, but I need to learn some more first. Feel free to post suggestion/theory! Schematic. Item Value Note: C1 varies See note ****. C2, C5 2200uf, 25V 5mm pitch, 13mm diameter C3, C8 10uF, 25V 3.5mm pitch, 8mm diameter C4, C9 220uF, 25V 3.5mm pitch, 8mm diameter D1-D4 1N4002 substitute UF4002 for better performance D5-D8 1N4002 R1, R4 240R R2, R3 5k Variable resistor IC1 LM317 IC2 LM337 Layout. And a link to a 600dpi image so that you can etch it. www.mediafire.com/?5zvmwwmwwn1 (sorry about the pop-ups] The board is 2.8" high by 3" long for sizing purposes. Not yet tested, but feel free to to try it and give feedback. 17/05/09 added values, link to traffo tuning
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Post by Deleted on May 16, 2009 21:51:39 GMT
Will Looks interesting. I look forward to seeing a built up version. Alex
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robertkd
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Post by robertkd on May 17, 2009 0:20:02 GMT
Will, could I be so bold as to suggest relocating the regulators so there is more separation between the heatsinks and the filter capacitors. The reasoning is, why bake the electrolytic capacitors, they'll dry out soon enough Robert
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Will
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Post by Will on May 17, 2009 0:30:24 GMT
A good reason!
Could you suggest a distance, perhaps. I would stretch the board to accommodate.
Mind you, you could always use high temp versions.
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robertkd
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Post by robertkd on May 17, 2009 0:41:15 GMT
Will, sure high temp units but that only put off the inevitable just a thought perhaps rotate the regulators so the tab(s) face towards the out side of the PCB if possible push the regs toward the output side of the PCB as well. I'd be cheeky and say in your climate 5mm spacing would be enough, but for me as much as possible of course there are always constraints but 10mm to 20mm of free air space. Robert
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Will
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Post by Will on May 17, 2009 0:42:06 GMT
Aaargh! I'm trying to insert the link to transformer tuning rockgrotto.proboards.com/index.cgi?board=m&action=display&thread=3240but the damn forum software tells me I've not entered a message, which a clearly just bloody did! Anyway, the link is above. Robert, I did try and put the regs as you suggested, but I was'nt happy with the resulting layout. 10-20mm extra on the board length will be fine. This'll happen tomorrow, er later today!
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robertkd
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Post by robertkd on May 17, 2009 0:46:06 GMT
Yep I've been getting that as well on occasion recently
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Post by Deleted on May 17, 2009 2:00:05 GMT
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Will
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Post by Will on May 17, 2009 6:29:00 GMT
Alex that's brilliant, thanks!
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Will
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Post by Will on May 17, 2009 8:56:07 GMT
Revision OneSeeing as the forum fails to let me modify my original post, here is a revised board layout, based on Roberts suggestions from last night/earlier this morning The schematic remains the same, as does the parts list. The regulators have been moved to improve long term reliability of the PSU. New layout. New download file for etching, @600dpi, board size still 3"wide, 2.8" tall www.mediafire.com/?ymi4jvzfunzSome people have already downloaded the original etch, I think it would be better to use this one.
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Will
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Post by Will on May 17, 2009 9:08:35 GMT
You will also now need to link pads 1&2, 3&4 with wire links.
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Post by Deleted on May 17, 2009 9:11:12 GMT
Will The original version would have been fine,using the smaller heatsinks, except some people like to drop 10V across their LM317/LM337 regulators when 3 or 4 volts would suffice ? ;D Alex
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robertkd
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Post by robertkd on May 17, 2009 10:30:12 GMT
Will The original version would have been fine,using the smaller heatsinks, except some people like to drop 10V across their LM317/LM337 regulators when 3 or 4 volts would suffice ? ;D Alex Will, pay no attention, Alex just wants you to make a piss poor copy of the already crippled SC version, limited to sweet bugger all, when instead you can make something really versatile gee Alex when your running the Will Dual Rail PSU with adequate heat sinking on your SC Class A HA next 45 c summer you'll be saying "wow it's the only thing that didn't loose it's cool all summer" Can we add more ground plane if only to a) reduce the amount of copper to deslove b) provide a convenient point to solder the heat sink mounting pins I know this also incurs thermal insulators and PCB drilling but
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Post by Deleted on May 17, 2009 10:39:44 GMT
Robert Looks like you don't have to worry about the "bean counters" in your organisation ? ;D Next, you will be wanting 2oz. copper too ! Alex P.S. A couple of other minor niggles with the layout/suggestions so far, are that 25T trimpots such as the commonly available Spectrol series, have 3 in a line leads, also you would need to standardise on a particular type of pin mounting heatsink that is generally available world wide, otherwise it becomes an expensive exercise for many. Also, I do not see any provision for a front panel LED.
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robertkd
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Post by robertkd on May 17, 2009 10:51:33 GMT
Robert Looks like you don't have to worry about the "bean counters" in your organisation ? ;D Next, you will be wanting 2oz. copper too ! Alex Alex, Well tbh once the design is fully featured you have so many options of loading it up with no heat sinking, minimal heat sinking, serious heat sinking and as the regulators are in a convenient location straight off the PCB onto some aluminium blocks all with minimal heating of the rest of the circuit components. Oh and yeah I thought 2oz laminate was a given Robert
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Post by Deleted on May 17, 2009 10:55:45 GMT
Robert See edited post. Alex
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robertkd
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Post by robertkd on May 17, 2009 11:02:15 GMT
Alex,
gee easy fixed,
a) add an additional hole to accommodate both types
b) move the pads slightly in towards the the middle, don't specifically dill/mark for any specific type which allows end user to adapt to what ever is available/needed
Robert ;D
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Post by Deleted on May 17, 2009 11:05:49 GMT
a} Agreed (Trimpots)
b}Many end users will not have PCB drills. (Heatsinks)
c} Provision for supplying a Front Panel LED ?
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robertkd
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Post by robertkd on May 17, 2009 11:20:11 GMT
a} Agreed (Trimpots) b}Many end users will not have PCB drills. (Heatsinks) yes and no, typically the solder pins are about 2mm most users have access to even a hand drill and 2mm bit (5/64 ??) or for me pop the pins drill and thread the heat sink and 3mm (1/8 ??) in the PCB ;D of course but lets get the versatility first after all an R can be easily in-lined and can be heat shrinkable. Oh and keep the mounting holes symmetrical Robert
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Post by Deleted on May 17, 2009 11:36:54 GMT
Yes, and looks like an afterthought ! What's wrong with a heatsink like this one from Jaycar, or it's little brother which is only 25mm high ? Same mounting. CAT. NO. HH8522 RRP $2.65 PC Mount TO-3P Heatsink - 40mm High Will accept up to TO- 3P size flat pack transistors. (This includes TO-220). Includes 2 PC pins, which help stabilise the heatsink and allow you to solder to PCB pads. - 2 sizes. 40MM HIGH (6099 TYPE) - Thermal resistance 11°C/W - Size 34(W)x12(D)x40(H)mm. - See above drawing for dimensions. QTY 1+ $2.65 4+ $2.30 10+ $1.95 www.jaycar.com.au/productView.asp?ID=HH8522&keywords=heatsink&form=KEYWORD
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robertkd
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Post by robertkd on May 17, 2009 12:05:25 GMT
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robertkd
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Post by robertkd on May 17, 2009 12:07:26 GMT
er ah sorry Will after this banter you'd probably wish you were shopping for blinds or something Robert
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Post by Deleted on May 17, 2009 12:24:51 GMT
Robert This one from Rapid,at the link provided appears to be very similar to the Jaycar 40mm H one that I suggested, and should be eminently suitable for the majority of typical RG applications. 10 DEG C /W TO220 HEATSINK WITH LUGS RC 36-0442 If you want much bigger heatsinks, expect to use something bigger than Will's present design PCB. Alex Like a 49 year old Queenslander wearing shorts ? O.K. enough banter, Sydney is much colder than "Beautiful one day and perfect the next" so a warm bed beckons !
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robertkd
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Post by robertkd on May 17, 2009 12:48:30 GMT
Robert This one from Rapid,at the link provided appears to be very similar to the Jaycar 40mm H one that I suggested, and should be eminently suitable for the majority of typical RG applications. 10 DEG C /W TO220 HEATSINK WITH LUGS RC 36-0442 If you want much bigger heatsinks, expect to use something bigger than Will's present design PCB. Alex Like a 49 year old Queenslander wearing shorts ? O.K. enough banter, Sydney is much colder than "Beautiful one day and perfect the next" so a warm bed beckons ! yeah your right it's getting cold, down to 17 c and the outlook for tomorrow ah perfect look at that Robert
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jonclancy
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Post by jonclancy on May 17, 2009 14:13:39 GMT
EAGLE has a Bourns 3296W device, so no probs amending that...
Cheers
Jon
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