Elenco Variable Voltage Power Supply Kit User Manual

POWER SUPPLY KIT

MODEL XP-15K

Instruction & Assembly Manual

Copyright © 2012, 1991 by ELENCO®All rights reserved. Revised 2012 REV-P 753015

No part of this book shall be reproduced by any means; electronic, photocopying, or otherwise without written permission from the publisher.

ELENCO

®

INTRODUCTION

Assembly of your XP-15K Regulated Variable Power Supply Kit will prove to be an exciting project and give much
satisfaction and personal achievement. If you have experience in soldering and wiring technique, you should have no
problem in the assembly of this kit. Care must be given to identifying the proper components and in good soldering habits.
Above all, take your time and follow the easy step-by-step instructions. Remember, “An ounce of prevention is worth a
pound of cure”. Avoid making mistakes and no problems will occur.

USE SAFETY GOGGLES WHEN ASSEMBLING THIS KIT!!

SPECIFICATIONS FOR XP-15K POWER SUPPLY

Output Voltage 0 - 15VDC

Output Current

0.3A @ 12V, 0.2A @ 15V

Load Regulation 0.1V

Line Regulation 0.1V

Ripple Max. 0.01V rms

Short Protection IC THERMO

Output Impedance 0.3Ω

-1-

PARTS LIST

If you are a student, and any parts are missing or damaged, please see instructor or bookstore. If you purchased
this kit from a distributor, catalog, etc., please contact ELENCO

®

(address/phone/e-mail is at the back of this manual)

for additional assistance, if needed. DO NOT contact your place of purchase as they will not be able to help you.

RESISTORS

Qty. Symbol Description Color Code Part #

r 1 R2 150Ω 5% 1/4W brown-green-brown-gold 131500
r 2 R1, R4 2.2kΩ 5% 1/4W red-red-red-gold 142200
r 1R3 2kΩ Potentiometer 192421

CAPACITORS

Qty. Symbol Description Part #

r 1C2 4.7μF 50V Electrolytic 264747
r 1 C4 220μF 16V Electrolytic 282244
r 1 C3 470μF 35V Electrolytic 284746
r 1 C1 2,200μF 35V Electrolytic 292226

SEMICONDUCTORS

Qty. Symbol Description Part #

r 8 D1-8 1N4001 Diode 314001
r 1 U1 LM317 Regulator 330317
r 1 D9 LED Red 350002

MISCELLANEOUS

Qty. Description Part #

r 1 Transformer YD-1485 440111
r 1 PC board 510002
r 1 Heat sink 615009
r 1 Knob 622009
r 1 Case top 623061
r 1 Case bottom 623062
r 1 Strain relief 2-wire 624002
r 1 Binding post black 625031
r 2 Nut binding post 625031HN
r 2 Lockwasher binding post 625031LW
r 1 Binding post red 625032
r 4 Screw 2.8 x 8mm 641102
r 1 Screw 4-40 x 1/4” 641430

Qty. Description Part #

r 2 Screw 6-32 x 3/8” Blk 641652
r 1 Nut 7mm 644101
r 1 Nut 4-40 644400
r 2 Nut 6-32 644600
r 1 Washer flat 8 x 14mm 645101
r 4 Washer fiber #6 645602
r 2 Lockwasher #6 646600
r 4 Rubber foot 662015
r 1 Label top 723071
r 1 Line cord 2 wire 862100
r 2” Shrink tubing 890120
r 1 Solder lead-free 9LF99

-2-

PARTS VERIFICATION

Before beginning the assembly process, familiarize yourself with the components and this instruction book.
Verify that all of the parts are present. This is best done by checking off the parts in the parts list.

RESISTORS CAPACITOR SEMICONDUCTORS

Electrolytic (radial)

Diode

2kΩ Potentiometer

LM317 Regulator LED

Knob

Transformer YD-1485

MISCELLANEOUS

Strain relief 2-wire

Heat sink

Carbon film

PC Board

Case top

Case bottom

Binding posts

Black Red

Binding post nut

Binding post

lockwasher

Screws

2.8 x 8mm

4-40 x 1/4”

6-32 x 3/8”

black

4-40

7mm

Nuts

6-32

Washers

Flat

8 x 14mm

Fiber #6

Lockwasher #6

Rubber foot

Shrink tubing

Label

Lead-free solder

-3-

CONSTRUCTION

Solder

Soldering Iron

Foil

Solder

Soldering Iron

Foil

Component Lead

Soldering Iron

Circuit Board

Foil

Rosin

Soldering iron positioned
incorrectly.

Solder

Gap

Component Lead

Solder

Soldering Iron

Drag

Foil

1. Solder all components from the
copper foil side only. Push the
soldering iron tip against both the
lead and the circuit board foil.

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.

1. Insufficient heat - the solder will
not flow onto the lead as shown.

3. Allow the solder to flow 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.

Here is what a good solder
connection looks like.

2. Insufficient solder - let the
solder flow over the connection
until it is covered.
Use just enough solder to cover
the connection.

3. Excessive solder - could make
connections that you did not
intend to between adjacent foil
areas or terminals.

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.

What Good Soldering Looks Like

A good solder connection should be bright, shiny, smooth, and uniformly
flowed over all surfaces.

Types of Poor Soldering Connections

Introduction

The most important factor in assembling your XP-15K Regulated
Variable 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.

Solder

For many years leaded solder was the most common type of solder
used by the electronics industry, but it is now being replaced by lead­free solder for health reasons. This kit contains lead-free solder, which
contains 99.3% tin, 0.7% copper, and has a rosin-flux core.

Lead-free solder is different from lead solder: It has a higher melting
point than lead solder, so you need higher temperature for the solder to
flow properly. Recommended tip temperature is approximately 700

O

F;
higher temperatures improve solder flow but accelerate tip decay. An
increase in soldering time may be required to achieve good results.
Soldering iron tips wear out faster since lead-free solders are more
corrosive and the higher soldering temperatures accelerate corrosion,
so proper tip care is important. The solder joint finish will look slightly
duller with lead-free solders.

Use these procedures to increase the life of your soldering iron tip when
using lead-free solder:

• Keep the iron tinned at all times.

• Use the correct tip size for best heat transfer. The conical tip is the
most commonly used.

• Turn off iron when not in use or reduce temperature setting when
using a soldering station.

•

Tips should be cleaned frequently to remove oxidation before it becomes
impossible to remove. Use Dry Tip Cleaner (Elenco

®

#SH-1025) or Tip
Cleaner (Elenco®#TTC1). If you use a sponge to clean your tip, then use
distilled water (tap water has impurities that accelerate corrosion).

Safety Procedures

• Always wear safety glasses or safety goggles to
protect your eyes when working with tools or
soldering iron, and during all phases of testing.

• Be sure there is adequate ventilation when soldering.

•

Locate soldering iron in an area where you do not have to go around
it or reach over it. Keep it in a safe area away from the reach of
children.

• Do not hold solder in your mouth. Solder is a toxic substance.
Wash hands thoroughly after handling solder.

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.

DO NOT USE ACID CORE SOLDER!

'