Elenco Electronics XP-620K Assembly And Instruction Manual
POWER SUPPLY KIT
MODEL XP-620K
Assembly and Instruction Manual
ElencoTMElectronics, Inc.
Copyright © 2003, 1989 ElencoTMElectronics, Inc. Revised 2003 REV-O 75320K
PARTS LIST
If any parts are missing or damaged, see instructor or bookstore. DO NOT contact your place of purchase as
they will not be able to help you. Contact ElencoTMElectronics (address/phone/e-mail is at the back of this
manual) for additional assistance, if needed.
RESISTORS
Qty. Symbol Value Color Code Part #
1 R5 .18W 5% 3W 101804
2 R3, R4 2.7W 5% 1/2W red-violet-gold-gold 112701
2 R1, R2 150W 5% 1/4W brown-green-brown-gold 131500
2 VR1, VR2 2kW Potentiometer 192422
CAPACITORS
Qty. Symbol Value Description Part #
5 C1 - C4, C8 10mF Electrolytic 271045
2 C5, C6 2200mF Electrolytic 292226
1 C7 4700mF Electrolytic 294744
SEMICONDUCTORS
Qty. Symbol Value Description Part #
4 D1 - D4 1N4001 Diode 314001
4 D5 - D8 1N5400 Diode 315400
1 Q1 A70 Transistor PNP 320070
1 Q2 2N6124 Transistor PNP 326124
1 IC1 LM-317 Integrated Circuit 330317
1 IC2 LM-337 Integrated Circuit 330337
1 IC3 LM-7805 Integrated Circuit 337805
MISCELLANEOUS
Qty. Description Part#
1 Transformer 440720
1 PC Board 512013
1 Fuse 1.25A 530125
1 Rocker Switch 541204
1 Cover 611120
1 Chassis 612020
1 Heat Sink 615010
2 Knob 622009
1 Strain Relief 624003
5 Insulating Washer 624007
4 PC Board Stand-off 625001
2 Black Binding Post 625031
5 Lockwasher, Binding Post 625031LW
5 Nut, Binding Post 625031HN
2 Red Binding Post 625032
1 Yellow Binding Post 625034
5 Screw 6-32 x 3/8” Phillips 641640
2 Screw 8-32 x 3/8” Phillips 641840
4 Screw #6 x 3/8” Black Truss Head 642652
2 Screw #6 x 3/8” black AB Phillips 642660
2 Nut 7mm 644101
Qty. Description Part#
1 Nut 6-32 Large 644600
4 Nut 6-32 Small 644601
2 Nut 8-32 644800
2 Flat Washer 8mm x 14mm 645101
2 Lockwasher 5/16” 646101
2 Lockwasher #8 646828
4 Rubber Feet 662003
1 Fuse Holder Body 663005LB
1 Fuse Holder Nut 663005N
1 Fuse Holder Cap 663005UB
1 Fuse Holder Washer 663005W
3 Mica Insulator 780002
1 Silicon Grease 790005
6” 20 Ga. Red Wire 813210
48” 22 Ga. Red Wire 814201
48” 22 Ga. Orange Wire 814310
48” 22 Ga. Blue Wire 814610
1 Line Cord 862105
2” Shrink Tubing 1/2” Dia. 891101
1.5” Shrink Tubing 3/4” Dia. 899110
1 Solder Tube 9ST4
-1-
PARTS IDENTIFICATION
Resistor 2k
W
Potentiometer Capacitor Diode Transistor
W
.18W 3W Resistor
Integrated Circuit Transformer PC Board Fuse
Switch
Heatsink
Knob
Strain Relief
PC Board Stand-off
Binding Post Assembly Fuse Assembly
Nut
Binding Post
7mm
Flat Washer Lockwashers
Lockwasher
6-32 / 8-32
#8 5/16”
MicaNuts
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IDENTIFYING RESISTOR VALUES
Use the following information as a guide in properly identifying the value of resistors.
BAND 1
1st Digit
Color Digit
Black 0
Brown 1
Red 2
Orange 3
Yellow 4
Green 5
Blue 6
Violet 7
Gray 8
White 9
BAND 2
2nd Digit
Color Digit
Black 0
Brown 1
Red 2
Orange 3
Yellow 4
Green 5
Blue 6
Violet 7
Gray 8
White 9
2 Multiplier Tolerance
1
Multiplier
Color Multiplier
Black 1
Brown 10
Red 100
Orange 1,000
Yellow 10,000
Green 100,000
Blue 1,000,000
Silver 0.01
Gold 0.1
BANDS
Resistance
Tolerance
Color Tolerance
Silver +10%
Gold +
Brown +1%
Red +2%
Orange +
Green +0.5%
Blue +0.25%
Violet +
5%
3%
0.1%
IDENTIFYING CAPACITOR VALUES
Capacitors will be identified by their capacitance value in pF (picofarads), nF (nanofarads), or mF (microfarads). Most
capacitors will have their actual value printed on them. Some capacitors may have their value printed in the following
manner. The maximum operating voltage may also be printed on the capacitor.
Multiplier
10mF 16V
For the No.01234589
Multiply By 1 10 100 1k 10k 100k 0.01 0.1
Note: The letter “R” may be used at times
to signify a decimal point; as in 3R3 = 3.3
The letter M indicates a tolerance of +
The letter K indicates a tolerance of +10%
The letter J indicates a tolerance of +5%
103K
100V
First Digit
Second Digit
Multiplier
Tolerance
Maximum Working Voltage
20%
The value is 10 x 1,000 = 10,000pF or .01mF 100V
METRIC UNITS AND CONVERSIONS
Abbreviation Means Multiply Unit By Or
p Pico .000000000001 10
n nano .000000001 10
m micro .000001 10
m milli .001 10
– unit 1 10
k kilo 1,000 10
M mega 1,000,000 10
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0
3
6
1. 1,000 pico units = 1 nano unit
2. 1,000 nano units = 1 micro unit
3. 1,000 micro units= 1 milli unit
4. 1,000 milli units = 1 unit
5. 1,000 units = 1 kilo unit
6. 1,000 kilo units= 1 mega unit
-3-
CONSTRUCTION
Introduction
The most important factor in assembling your XP-620K 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.
Safety Procedures
• Wear eye protection when soldering.
Locate soldering iron in an area where you do not have to go around it or reach over it.
•
• Do not hold solder in your mouth. Solder contains lead and is a toxic substance. Wash your hands
thoroughly after handling solder.
• Be sure that there is adequate ventilation present.
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 of 63/37 alloy.
DO NOT USE ACID CORE SOLDER!
What Good Soldering Looks Like
A good solder connection should be bright, shiny,
smooth, and uniformly flowed over all surfaces.
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.
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.
Component Lead
Foil
Solder
Foil
Solder
Foil
Soldering Iron
Circuit Board
Soldering Iron
Soldering Iron
Types of Poor Soldering Connections
1. Insufficient heat - the
solder will not flow onto the
lead as shown.
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.
Rosin
Soldering iron positioned
incorrectly.
Solder
Component Lead
Solder
Soldering Iron
Foil
Gap
Drag
-4-
ASSEMBLE COMPONENTS TO PC BOARD
Figure A
Band
Diodes have polarity. Be sure
that the band is in the correct
direction.
D5 - 1N5400 Diode
D6 - 1N5400 Diode
D7 - 1N5400 Diode
D8 - 1N5400 Diode
(see Figure A)
Figure B
Polarity
Mark
(–) (+)
Electrolytics have a polarity
marking indicating the (–)
lead. The PC board is marked
to show the lead position.
Figure C
Flat
1/4”
Mount the transistor with the
flat side as shown on the top
legend. Leave 1/4” between
the part and PC board.
D4 - 1N4001 Diode
D3 - 1N4001 Diode
D2 - 1N4001 Diode
D1 - 1N4001 Diode
(see Figure A)
C1 - 10mF Electrolytic
C2 - 10mF Electrolytic
C3 - 10mF Electrolytic
C4 - 10mF Electrolytic
C8 - 10mF Electrolytic
(see Figure B)
C7 - 4700mF Electrolytic
(see Figure B)
Q1 - A70 Transistor
(see Figure C)
R2 - 150W Resistor
R1 - 150W Resistor
(brn-green-brn-gold)
C6 - 2200mF Electrolytic
C5 - 2200mF
(see Figure B)
R3 - 2.7W Resistor
R4 - 2.7W Resistor
(red-violet-gold-gold)
R5 - .18W Resistor
Electrolytic
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