K5RWK March 2013 Program. Homebrew Project Anderson Powerpole Connectors. Kit A Crowbar Protector to Anderson Powerpole Assembly instructions

Transcription

1 K5RWK March 2013 Program Homebrew Project Anderson Powerpole Connectors Kit A Crowbar Protector to Anderson Powerpole Assembly instructions Doug Knabe KN5DK

2 A. 12V Crowbar Voltage Protector Anderson Power Pole Finished Assembly Active protection against: Overvoltage Line spikes Polarity reversal

3 Crowbar Schematic

4 A. Step 1 Verify Kit Contents 2x Anderson Powerpole 30A kits Crowbar pwb kit Fuse holders Pre-drilled Box 25A Fuses Red/black shells Crimp Terminals 14 AWG Cu wire Cu pad Pre-drilled Perf bd 27kΩ 15V Zener 10uF 15V SCR 10Ω TVS lugs 4-40 hw 3 Lengths of 14 awg zip wire pair

5 Step 1 Install Anderson PP Connectors Install Anderson PP connectors on one end of both 6 zip wires

6 Step 2. Assemble Connector Shells RACES/ARES Standard genderless connector Specific connector assembly orientation required RED on the LEFT Hood up Tongue down Tab here (not slot) Viewing from the contact side (opposite the wire side) Slide shells together before inserting contacts

7 Step 3 - Strip zip wire 1. Square off the wire ends 2. Split zip conductors back about 1 inch 3. Strip insulation back approximately 5/16 inch

8 Step 4 - Insert conductors in correct orientation 1. Insert conductor into crimp terminals. Should be flush and wire should barely be seen on front of terminal. 2. Verify that there isn't an excess amount of conductor exposed at end of crimp terminals. It should be almost if not flush with insulation

9 Step 5 - Insert terminals into crimper 1. Insert crimp terminal curve down into crimper. 2. Give one or two clicks to hold contactor WRONG Correct Crimper orientation

10 Step 6 - Crimp contacts to zip wire 1. Re-insert wire if necessary 2. FIRMLY SQUEEZE handle all the way thru the cycle and release. 3. Conductor done!

11 Step 7 - Terminal Orientation Align terminals Correct terminal orientation for shell insertion

12 Step 8 Insert contacts until click Orient contacts as show prior to crimping/soldering Contact curve down Tongue down Push in and listen for a click on each contact for locked insertion Contact Tongue down Spring

13 Step 9 Pair the two fuse holders 1. Open Fuse Holder lid 2. Slide smaller tab into larger slot 3. Close lids (to protect) Caution: Lids and latches break too easily

14 Step 10 Insert Fuse Holders into Box 1. Align all four stakes with holes in lid 2. Press fuse holder into lid It's a tight fit, so push hard, but be sure stakes are lined up with holes

15 Step 11 Strip 3 zip wire 1. Strip 1/2 insulation from one end of the 3 zip wire 2. Strip 5/16 insulation from other end of 3 zip wire 3 zip wire

16 Step 12 Solder 6 Zip wire to fuseholder 1. Solder 6 zip wire to fuseholder as shown 2. Solder 3 zip wire to radio side using the 1/2 stripped end Note: Shorten red lead 5/8 for power side Shorten black lead 5/8 on radio side Radio side Power side

17 Step 13 Attach ring terminals to 3 zip wire Either solder or crimp or both will work

18 Resistor Color Codes Black Brown Red Orange Yellow Green Blue Violet Gray White

19 Component Orientation Electrolytic Caps - Polarity vital for survival Diodes, Zeners, TVS Cathode end=bar end Short Lead =Neg Long Lead =Pos

20 Step 14 - Initial board assembly 1. Insert SCR into slots in board 2. Secure SCR with 4-40 screw / nut finger tight 3. Insert TVS Cathode near SCR Anode (between A&K) G A K A K Note: Cathode is marked with a bar

21 Step 15. Insert Cu tab 1. Flip board over and install Cu tab over TVS lead. In some cases, the TVS hole might be too small, so drill it larger. 2. Secure tab with 4-40 screw / nut finger tight

22 Step 16 Install ground bus Route the 14AWG ground wire as shown. Leave at least 2-3 holes between the SCR gate and the gnd wire. K A G

23 Step 17. Install discretes 1. Install the discretes as shown with correct polarity 2. Double check polarity of cap short lead should connect to gnd Cap short lead (-) wire Ground bus on back side 27k 27kΩ TVS Zener 10Ω 10μ F G A K Zener Cathode connected to SCR anode 3. Solder all connections once you are sure they are correct

24 Step 18 - Attach fuse holder leads to perf board Red lead to SCR Anode Black lead to CU gnd lug Tighten securely

25 Step 19 - Assemble box Attach labels to correct end of the box Power label is on side no extra wires attached to fuse holder

26 Step 20 Verify operation 16.5v Protector Output Voltage 1. Connect Crowbar Protector as shown. 2. Set power supply current limit to reasonable level (~1A) 3. Raise PS voltage while monitoring Protector output voltage 4. Protector output voltage should fall to a few volts when input voltage exceeds 16.5V indicating that SCR crowbar has triggered 5. Reverse supply leads 6. Protector output voltage should never go more than -1.5V

27 Finished! Enjoy your new adapter

28 Step 17 Verify Continuity and no Shorts TVS Zener 27kΩ 10Ω 10μF --