Powerpole Distribution: Difference between revisions

Revision as of 18:11, 17 August 2017

Powerpole Distribution Box Project

Status	Completed
Project Lead	User:TylerWard

Powerpole Distribution Box Project

A DC power distribution board using Anderson powerpole connectors

[PCB Design]

Status

Completed, designs are available at Github

Feature List

6 power-pole connectors
Individually fused connections with indicators
30A capacity (Limited by current rating of the fuse holders)

Costings

Costings below are for individual orders the main club order will be cheaper

Type	Item	Cost	Link
connector	12*45A pcb contacts	£9.90 for 15	[1]
connector	6* red 45A housings	£2.65 for 10	[2]
connector	6* black 45A housings	£2.65 for 10	[3]
Fuseholder	Keystone 3522	£6.56 for 100	[4]
Resistor	330ohm though hole 0.25w	£0.23 for 10	[5]
LED	3mm red/yellow	£0.24 for each	[6]
PCB	5*10cm 2oz blue	$40.95 for ~10 or (£3 each)	[7]

Build instructions

Tools Required

Soldering iron - high power (45W+) with a large tip as there is a large thermal mass.
Sidecutters
(Recommended) Helping hands or other PCB support tool.

Instructions

Solder resistors, capacitors and LEDs onto the PCB.
Push fuse holder contacts through the holes in the PCB.
Solder fuse holder contacts. These will suck up the heat, so may take a while to get up to temperature.
Assemble to top two case layers and attach the partly populated PCB
Assemble the powerpole contacts by joining them together and inserting the contacts.
Place the powerpole contacts ionto nto the PCB. To ensure correct placement, the top acrylic layers should be fitted first, otherwise the spring of the powerpoles will cause these layers to be offset.
Solder the powerpole contacts onto the PCB. The most straightforward way found to do this is to push the PCB and powerpole contacts down onto a hard heatproof surface, so that they sit in the correct place whilst they are soldered. They should be fairly quick to solder, as the powerpole housings can be melted if exposed to to much heat.
Check for any solder bridges across the fuses or powerpoles.
Assemble the remaining two acrylic layers of the case.
Enjoy your Distro!

Notes

@@ Line 47: / Line 47: @@
 '''Tools Required'''
-* Soldering Iorn (Should be a high power Iron (45W+) with a large tip do that it has a large thermal mass)
+* Soldering iron - high power (45W+) with a large tip as there is a large thermal mass.
 * Sidecutters
-* (Usefull) Helping hands or other PCB support tool.
+* (Recommended) Helping hands or other PCB support tool.
 '''Instructions'''
-# Solder resistors capacitors and LEDs onto the PCB.
+# Solder resistors, capacitors and LEDs onto the PCB.
-# Push Fuse holder contacts into pcb
+# Push fuse holder contacts through the holes in the PCB.
-# Solder Fuse holder contacts, these will suck up the heat so might take a bit to get up to temperature.
+# Solder fuse holder contacts. These will suck up the heat, so may take a while to get up to temperature.
 # Assemble to top two case layers and attach the partly populated PCB
 # Assemble the powerpole contacts by joining them together and inserting the contacts.
-# Place the powerpole contacts into the board (to ensure correct placement ensure the top acrylic layers are fitted first othwerwise the spring of the powerpoles will mean they go in off centre).
+# Place the powerpole contacts ionto nto the PCB. To ensure correct placement, the top acrylic layers should be fitted first, otherwise the spring of the powerpoles will cause these layers to be offset.
-# Solder the powerpole contacts on the board, I found the best way to do this is to push the board and contacts down onto a heatproof surface so that they sit in the correct place and then solder, these should be soldered fairly quickly as the powerpole housings can be melted if exposed to to much heat.
+# Solder the powerpole contacts onto the PCB.  The most straightforward way found to do this is to push the PCB and powerpole contacts down onto a hard heatproof surface, so that they sit in the correct place whilst they are soldered.  They should be fairly quick to solder, as the powerpole housings can be melted if exposed to to much heat.
 # Check for any solder bridges across the fuses or powerpoles.
-# Assemble the remaining two layers of the case.
+# Assemble the remaining two acrylic layers of the case.
-# Enjoy your Distro
+# Enjoy your Distro!
 === Notes ===