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B
efore commencing
assembly, you will need to
choose your USB-PD module to
connect via CON5. We recommend our
unit based on the AP33772S chip, as
long as you have a suitable power supply that provides a PPS output, since
the HUSB238-based module does not
support PPS. Our article in the previous issue discusses these two modules in detail.
You’ll also need a USB-C power supply that supports USB-PPS or USB-PD.
We found several units from Ikea’s
SJÖSS range that we thought were
good value (siliconchip.au/link/acct),
although some of them only support
USB-PPS up to 16V with a USB-PD
(fixed) profile for 20V. We used these
for much of our testing.
We even found a power bank that
supports USB-PPS up to 11V and
USB-PD up to 12V. With a suitable
power bank, the USB-C PSU does not
need to be tethered to a mains connection. Note that like other PSUs without a direct mains connection, the
USB-C PSU does not have an Earth
connection.
You can use a simple DC source if
you like. While it won’t be very efficient, it will no doubt be useful in
low-current scenarios.
If you are using a different enclosure than specified, we suggest you
use the bare PCBs to plan and mark
out the required holes. There are three
mounting holes on the main PCB that
can be used to attach M3 hardware.
The front panel has 2.5mm holes to
suit the fittings included with your
chosen enclosure. You could also copy
and use the overlay diagrams (Figs.5
& 6) as templates.
Construction
The main PCB will require the most
work since it contains most of the
components; it measures 73 × 77mm
and is coded 04107261. If you need
to program the microcontrollers (IC3
and IC4) in-circuit, keep in mind that
some of the programming pins are also
used at runtime and are connected to
components that may interfere with
programming.
In that case, we recommend having
a look at the next section on PIC programming before starting construction,
so you can avoid that problem. If you
have pre-programmed chips, no programming step is necessary.
There is also the option to program
siliconchip.com.au
Mighty
USB-C
Part 2 / 2
Bench PSU
We introduced our design for the Mighty USB-C Bench PSU last
month, which uses modern USB-C power delivery technology to
provide a variable power source and allow efficient operation at
different output voltages. Its is designed to reduce the needs for
obscure parts, while providing a comprehensive user interface.
By Tim Blythman
Delivers up to 20V at 2A (if the USB power source is capable)
Compact case measures 94 × 83 × 30mm
Detailed OLED display plus LED status
Rotary encoder for tactile voltage and current control
Highly configurable for efficiency or low-noise operation
Software features include fuse emulation
Detailed USB-PD source information
the chips out-of-circuit if you have suitable hardware. You’ll need something
like the PIC Programming Adaptor
from September 2023 (siliconchip.au/
Article/15943) combined with appropriate SMD-to-DIP adaptors. That article has information about obtaining
suitable adaptors.
The front panel PCB is fairly compact, so we recommend you keep
the enclosure on hand to check that
Australia's electronics magazine
everything fits as you go. Most of the
checks and calibrations should be performed before the unit is secured into
the case so that the test points can be
accessed. That will require all parts to
be fitted and the panel PCB to be connected to the main PCB.
Once everything has been checked
and calibrated, Q1 and the thermistor need to be affixed to the enclosure
using an insulated mounting kit. After
November 2026 75
the rear panel is fitted, the PCB is fastened to it using a machine screw. This
ensures that the main PCB does not
shift and flex Q1’s leads.
PIC programming
There are two main things to consider if you need to program the PICs
in-circuit (after soldering them).
Firstly, there are two different chips
that run different firmware, so ensure
that you don’t mix them up. Also,
some of the programming pins have
shared roles that might interfere with
programming if they are connected to
parts of the circuit that will load them.
The overlay diagram, Fig.5, shows
the components that are necessary for
programming marked in blue dashed
rectangles. The 10kW resistor and
100nF bypass capacitor for each IC are
the minimum parts needed for correct
operation, while the CON3 and CON7
headers are needed to connect the programmer.
So the simplest approach to programming IC3 and IC4 in-circuit is to
fit only these parts first, program the
chips, then fit the remaining parts.
You’ll also need a suitable programmer, such as a PICkit 4, PICkit
5, Snap or PICkit Basic, plus a power
supply if your programmer cannot
provide ‘target power’. 5V power can
be applied between the TP1 ground
test point and the TP3 5V test point.
Anything between around 3V and 5V
(eg, a 3V coin cell or a pair of 1.5V
alkaline cells) should be sufficient for
programming.
Start with IC4, which is programmed via CON7. Connect the
programmer, ensuring that the pin 1
chevron markers are aligned. IC4 is
an 8-pin PIC16F18115 and should be
programmed with the 0410726B.HEX
file; the other hex file should be too
large to work.
Open the MPLAB IPE, select the
part number, connect the programmer
(and power supply if needed). Press
Connect and ensure communication
is working and the chip is identified.
Load the HEX file, then perform the
Program and Verify steps.
Next, program the 20-pin IC3
(PIC16F18146) using a programmer
connected to CON3 and the 0410726A.
HEX file. It should be possible to program IC3 with all components fitted,
but we recommend doing it beforehand in case there are any problems later. Verify the programming,
76
Silicon Chip
Like the main PCB,
we used a header on
the front panel for ease of
disassembly. See how we soldered the
rotary encoder’s leads and used a short solid-core
wire to secure the free end of the OLED module.
then disconnect all programmers
and power supplies before resuming
assembly.
Main PCB construction
There are many SMD parts in this
project, so ensure you have the requisite SMD gear, such as flux paste,
solder-
wicking braid, tweezers and
fume extraction. Magnifiers and good
illumination are also very helpful.
Start with the finer-pitched parts,
such as IC1-IC4, REG1 and Q2-Q5.
Check each part’s polarity and be sure
not to mix up similar parts. All the
small transistors come in the same
package. Q2-Q4 are BC817 types,
while Q5 is a 2N7002 and REG1 is
an MCP1700 – all in the same SOT23 package.
IC1 is also in the same SOIC-8
package as IC4. Find their locations
and orientations on the Fig.5 overlay
diagram.
Apply flux to each component’s PCB
pads, rest each in place and adjust with
tweezers. Tack one lead and make sure
all the leads are aligned with their
pads and the part is flat against the
PCB before soldering the remaining
leads. Use solder-wicking braid (with
extra flux) to draw up any excess solder
that results in a bridge between adjacent pads.
Follow by fitting diodes D1, D2, D4,
D5 and regulator REG2, paying close
attention to their polarity and orientation. Note that D4 and D5 face in
opposite directions. If you have the surface-mounting version of RLY1, solder
it next. Note the bar at one end, which
should align with the pin 1 marker dot.
Now we can work through the passives according to the parts list and
Fig.5. Solitary inductor L1 is not polarised; nor are any of the capacitors.
There should be enough space to solder each set of components with the
same value without worrying about
other parts getting in the way.
We suggest starting with the capacitors, since they will not have markings on their bodies, then follow with
the resistors. Most of the passives are
M3216 (imperial 1206) size at 3.2 ×
1.6mm, except for the larger 50mW
current shunt resistor.
All the SMD parts should now be
affixed to the main PCB. It is then a
good time to clean off any excess flux
using an appropriate solvent. Inspect
for bridges and dry joints and rectify
as needed. When the main PCB has
dried, solder in the fuse clips. You can
Fig.5: the main PCB is
mostly a straightforward
SMD design. If you
need to program the
microcontrollers in-circuit,
you should initially only
populate the components in
the dashed blue rectangles.
You can add the others after
programming.
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siliconchip.com.au
Fig.6: using a PCB as a panel makes for an elegant result but sometimes requires some unusual assembly steps; the OLED
module is mounted upside-down using short stubs of wire. Check the clearances with the enclosure during the assembly
of this PCB, since the spaces around the OLED module and rotary encoder are quite tight.
insert the fuse to ensure the clips are
aligned correctly.
If RLY1 is a through-hole type,
solder it now. Fit Q1 next, with its
leads soldered at the very tips and
in the orientation shown by the silkscreen markings. Ensure it is mounted
squarely to the PCB. Leaving a good
amount of lead attached will allow the
body of the transistor to be positioned
in the enclosure.
Have a look at the photos to confirm the arrangement. Note how Q1
has been bent over to near its final
position. Once inside the case, the top
surface of Q1 is approximately 16mm
from the top surface of the PCB.
To secure the main PCB inside the
enclosure, we have provided a rectangular pad to which an M3 nut can
be soldered, adjacent to TP4. The nut
will need to be nickel- or zinc-plated,
or made of brass, to allow soldering.
Ensure that the nut is aligned parallel
to the edge of the PCB and take care
not to get any solder on the internal
threads.
If you don’t have a suitable PCB
holder, you could slide the PCB partway into the enclosure to support it
level and allow access to the underside of the pad. Solder the nut
in place and
try to get some solder up the sides to
form a solid fillet.
You can now solder the UBS-PD or
USB-PPS module to CON5. We fitted
the module under the main PCB to
allow room for the thermistor lead to
reach Q1. This also keeps the opening for the USB-C lead close to the
bottom of the unit. Use the male pin
headers, and leave a slight gap above
the USB-C socket’s shell so it doesn’t
touch the PCB to avoid damage to the
solder mask.
Trim the leads under the module so
that they are well clear of the enclosure. You could solder lead offcuts
or other solid-core wire to secure the
mounting holes near the USB-C socket.
You can now connect a USB supply
to the module and check some of the
voltages at the test points. Use TP1 as
the negative connection for your multimeter. TP4 should be close to 5V, while
TP3 will be sitting around 4.7V due to
REG2’s dropout voltage.
Both of these should be within 0.3V
of these values. If not, disconnect the
power and double-check everything.
TP2 should be between 9V and 11V,
probably just under 10V. If this is correct, then IC3 and IC4 are correctly
programmed.
If you are using a DC supply over
5.5V, there should be a nominal reading at TP4, with TP3 close
The location of Q1
and the thermistor is
close to that shown
here, although the lid
of the enclosure and the
insulating pad would
obscure everything below
the head of the screw. The
USB-C module mounts
under the main PCB to
assist with clearance for the
thermistor wiring. We fitted
headers to our prototype
for testing, but we expect
constructors will use
fixed wiring soldered
to the PCB.
siliconchip.com.au
Australia's electronics magazine
to 5V. TP2 should be about 5V higher
than TP4, since the default is for the
OA+ boost supply to run. Disconnect
the power for now and move onto the
front panel PCB.
Front panel PCB
The 0.8mm-thick black front panel
PCB is coded 04107264 and measures 29 × 89mm. Before commencing
assembly, check if you need to drill out
the holes for the output connections.
We used rubber grommets to protect
wires fed through these holes, but
you could drill them out to fit banana
sockets or binding posts if you prefer.
It will be easier to drill these before
the components are fitted.
Be sure that there is enough room to
fit the hardware, as the panel is quite
small. Also take care not to damage
the PCB finish or rip any traces off.
Drilling the fibreglass PCB should be
done with ventilation and respiratory
protection. We recommend working
outside with a face mask. Test-fit the
sockets and ensure that there is clearance to the remainder of the enclosure.
Fig.6 is the overlay diagram for the
front panel PCB. It has several components fitted in an unusual fashion,
so take a close look at the photos and
diagram to ensure that everything is
installed correctly. Keep the enclosure at hand to check your clearances.
Fit IC101, being sure to align the
pin 1 dot on the silkscreen to that on
the part. Follow with LED101, noting
that its dot is in the opposite direction.
This part is quite sensitive to heat, so
don’t dwell too long with the iron.
Follow with the 100nF capacitor and
1kW resistor. Clean off any excess flux.
Solder the tactile switches next,
with their stems protruding down
through the holes. Tack one lead and
take time to align each switch stem
centrally within the hole. Since the
stem and hole will be visible, any misalignment will be apparent. Solder the
remaining leads once the position is
correct.
November 2026 77
Placing the
USB-C module
underneath the
PCB helps with
clearance for the
thermistor wiring.
The nut near Q1
is soldered to the
PCB and helps to
hold it in place
relative to the
enclosure so that
Q1’s leads don’t
flex.
The final position of Q1 is very close to what is shown here. This requires
the very tips of Q1’s leads to be soldered to the PCB and a bend formed near
where the leads exit the body of the transistor.
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Silicon Chip
Australia's electronics magazine
To fit the rotary encoder, remove the
screw and washer, then carefully bend
the leads over so that they will reach
the PCB when the encoder is fitted.
Use the screw and washer to secure
the encoders to the panel. Check the
alignment and ensure that it is within
the silkscreen markings. When all is
well, solder each lead to its corresponding pad.
To fit the OLED module, form short
pieces of solid-core wire into an L
shape. The shorter part of the L
should fit within the MOD101
pads. Using tweezers, solder each
piece of wire to its pad, with the wire
pointing upwards from the centre of
the marked outline.
Remove the protective film and
any headers from the OLED module
and ensure the holes are clear, then
thread this over the L-shaped wires
on the panel PCB. Push the module
flat against the panel PCB and gently
adjust it as needed to align it with the
silkscreen outline. Solder each wire
to its corresponding pad and then
trim neatly.
The single pad between MOD101
and RE101 can be used to solder a
short length of wire to secure the other
end of the OLED module. Check our
photos to see how it should look.
The next step will be to connect the
two PCBs using hookup wire or similar. Each wire should be about 4-5cm
long. Prepare the six wires and solder each one to the back of the panel
PCB. Each wire can then be soldered
directly back to its matching counterpart on the main PCB. The silkscreen
markings can be checked if there is
any confusion.
The USB-C PSU is now functionally complete, but you will also need
to install the thermistor so that no
fault is detected. Temporarily screw
the thermistor to Q1 so that you can
work out the lead length before cutting; our prototype was cut to about
12cm in length. Then bare the leads
and solder them directly to the CON4
pads. The thermistor is not polarised.
You can leave the thermistor in
place for now so that it can detect any
thermal problems before final assembly is complete. The thermistor should
be insulated from the lug by the potting compound, but you can check this
with a multimeter.
Testing and calibration
Hold one of the panel switches
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down and apply a USB-C power supply to the CON5 module. The display
should light up and show a message
as the LED lights up red.
If the display shows a “Checking
panel” message for more than a second, the front panel PCB may not have
been recognised. In that case, check the
soldering around IC101 and the wiring back to CON1. The message should
show “Panel at: 0x20” for a PCF8574
or 0x38 if a PCF8574A is used.
The second line should show
that either a HUSB238 or AP33772S
was found and indicate the number
of USB-PD PDO profiles that were
detected. If this shows “DC source”
when a USB source is connected, the
USB-PD module may not be detected;
check the module. Release the switch
to allow the software to proceed past
this screen. The display should show
something similar to Screen 1. If nothing is seen on the display, check the
wiring to MOD101.
All the displayed values should be
sensible. The setpoints and actual values should start out at zero, the temperature shown should be around
ambient and the voltages on the bottom line should be about 5V and 4.7V
as per TP4 and TP3 earlier. The “L”
current-limiting indicator will probably be on, since the current setpoint
will be 0A.
Controls
On the main screen, the rotary
encoder controls the voltage or current
setpoint according to which is selected
by the angle brackets on the first line.
Toggle between the two by pressing
the rotary encoder to activate its internal switch. Pressing the UP or DOWN
buttons should activate or deactivate
the relay. When the relay is energised,
the LED shows green.
If a fault occurs, it is shown on the
first line of the display, the relay is
switched off and the voltage is forced
to a setpoint of 0V. Pressing DOWN
will reset the fault indication as long
as the fault itself has been cleared.
For example, if there is a temperature
diately saved to non-volatile memory.
There is a setting screen (Screen 7)
that can be used to save any changes
you’ve made or restore the settings to
their defaults. In Settings, the UP and
DOWN buttons usually have the same
effect as the rotary encoder, although
some screens use them for different
purposes.
#1 PDO listing (Screen 2)
Here you can view information
about the power data objects supported by your USB power source. Use
the rotary encoder to cycle between
them. Pressing UP or DOWN will
refresh the source PDO listing. If you
see NO PDO shown here, the source
is not PD-compatible or it couldn’t be
detected. A legacy 5V USB or fixed DC
source will also show this indication.
The specifications of the USB-C
we used for much of our testing.
Its USB-PPS profiles only allow
up to 16V, with a USB-PD profile
needed for higher voltages, up to
20V. Source: www.ikea.com
fault, the temperature must return to
the normal range before the PSU can
be reset. For a current trip, you may
need to adjust the current setpoint to
be above 0A. If multiple trips occur,
only one is cleared at a time. This
allows you to see if multiple faults
have occurred.
Pressing the rightmost NEXT button (>) will enter Settings, as long as
the output relay is off; you will see the
LED flashing if you attempt to enter
Settings with the relay on. Each Settings screen is numbered at upper left
for ease of navigation.
In Settings, the rotary encoder button will go BACK to the previous Settings screen, while the NEXT button
will move to the next and then loop
around to the main screen. See below
for the full range of settings and calibration factors.
As long as you have the thermistor
connected and mounted to Q1, you
can run your own tests on the USB-C
PSU assembly to check its operation.
The thermistor will detect if Q1 starts
overheating.
Settings Screens
Changes to settings are applied
immediately, but they are not imme-
#2-5 Operating options (Screen 3)
These screens show several operating options that can be toggled by
pressing UP or DOWN, or turning the
rotary encoder.
#2 V Tracking
This dictates whether the USB-PD
target voltage follows the setpoint or
the actual output voltage. The default is
to follow the setpoint, which will generally mean a fast response to changes,
but lower efficiency (more dissipation)
if current limiting is occurring, since
the setpoint will be higher than the
output voltage in that case.
#3 Current mode
This determines whether a current-
limiting event will also switch the
relay off. The default mode is simple
current limiting. Enabling a trip will
cause the relay to open if the current
limit is reached.
#4 Current set limiting
This forces the current limit setpoint
to ramp down if it exceeds the capabilities of the active PDO. It is on by
default; if switched off, it may result
in the power source shutting down if
too much current is drawn.
2
3
Screen 1 (left): the main control screen is full of information about the USB supply and transistor temperature, as well as
the voltage and current readings you might expect.
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Australia's electronics magazine
November 2026 79
#5 Load last setpoint
This causes the voltage and current
setpoints to be reloaded at startup.
During operation, these are saved to
EEPROM within ten seconds if they
have changed. The default is to reload
these values at startup, but this can be
disabled, in which case the setpoints
will be set to 0V and 0A at startup.
The relay state is not stored; it always
starts in the off state.
The Mighty
USB-C Bench
PSU is
compact,
versatile
and easy
to use.
#6 Temperature Alarm
This sets the thermistor temperature
at which the temperature display on
the main page will start flashing as a
warning. All temperatures are displayed in degrees Celsius (°C).
#7 Temperature Shutoff (Screen 4)
This sets the (higher) temperature at
which the output will be disconnected.
It’s also possible for an open-circuit
thermistor to cause it to trip; this is
indicated in the fault message.
#8 Voltage Headroom (Screen 5)
This sets the amount by which the
USB-PD source voltage must exceed
the target voltage (decided by #2 V
Tracking). A lower value will be more
efficient, but may result in a sluggish response to changes if the actual
voltage is chosen as the target. Values
down to 0.3V should work well as long
as the OA+ boost is active.
If OA+ boost is switched off, then
this may need to be increased (up to
5V) to ensure that the voltage setpoint
can be reached.
#10 Op amp supply boost (Screen 6)
This sets the duty cycle of the PWM
supplied to the OA+ supply boost circuit. A value of 0% shuts down the
boost circuit (for low-noise operation).
The default value of 6% was sufficient
to provide 5V of headroom in our testing, but this can be adjusted up to 15%
as needed.
#11 NV memory (Screen 7)
This is effectively an estimate of the
quiescent current used by the PSU. It
is deducted from the current available
from the USB-PD source to calculate
how much current is available for the
output. The default is 200mA, meaning that a 1.5A source will be limited
to a setpoint of 1.3A at the output.
This gives the option to save all
live settings and calibration values
to EEPROM, so they will be reloaded
at the next startup. This is done by
pressing DOWN. Pressing UP will
restore the live and EEPROM settings
from a backup in flash memory, so can
be used if the settings are corrupted.
A successful save or restore will be
shown as a message on this screen.
After the NV memory screen, the
4
5
#9 Current Headroom
10
remaining settings are mostly for calibration and should not need to be
changed after initial setup. Remember to go back and save the following
calibration values on the NV memory
screen to ensure that the updated values are loaded at boot.
#12 & #15 Calibration instructions
(Screen 8)
These give instructions for the use
of the voltage (#13-14) and current
(#16-17) calibration screens that follow. Continuing from this screen will
activate the relay and output according to preset parameters, so you should
only connect a multimeter set to either
volts or amps as appropriate.
#13-14 Voltage calibration
(Screen 9)
These pages switch on the relay and
6
12
11
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set the voltage and current limit to
suitable levels for trimming the offset
(#13) and scale (#14) of the voltage calibration. Ensure that the two displayed
voltage values match, then connect a
voltmeter to the output. Adjust the offset or scale displayed on the second
line until the voltage values match the
voltmeter.
#13 delivers a voltage near 0V to
best trim the offset, while #14 delivers
a higher value to allow the scale to be
adjusted. The two values interact to a
small degree, so it is best to check back
on each and make small adjustments
until both are satisfactory.
#16-17 Current calibration
(Screen 10)
These are similar to #13-14 except
they work with current and thus
expect an ammeter to be connected.
Ensure that the setpoint and actual values shown match. This means that the
PSU output will be current-limited.
Be aware that a high current draw
will likely cause Q1’s temperature to
rise, so if a thermal trip occurs, you
can return to #15 to reset the fault. Like
the voltage calibration, the two values
will interact to a degree, so you should
perform a few calibration iterations to
confirm the values are correct.
thermometer. Switch to the scale (#19)
page and apply a high temperature;
around 60°C will be sufficient. Adjust
the scale to match the reading on the
thermometer. Recheck the values to
confirm that they are accurate.
#20-22 Other voltage calibrations
(Screen 12)
These voltage measurements do not
require an offset, so they can be calibrated by a simple scale value. Use
a multimeter to measure the voltage
and adjust the calibration parameter
until the measured voltage matches
the display. Use TP2 (relative to TP1
ground) for #20 OA+, TP3 for #21 +5V
and TP4 for #22 IN+.
None of these are critical to the operation of the PSU, since they are simply
used for warning alerts and user feedback. They will be accurate to within a
few percent without calibration.
#23 DC Limit (Screen 13)
If a DC supply is used, this should
be set to the maximum working current of the DC supply. The value is
used by the USB-C PSU to calculate
the upper limit that the current can
be set to if the current setpoint limiting is enabled.
the absolute value of the configuration value.
#25-26 Calibration setup (Screen 15)
The values shown on these screens
set the voltages and currents used for
the #12-17 calibration steps. They are
the raw DAC values that are used to
set the voltage and current when the
relay is activated, so they should not
need to be changed at all.
The LO value on the left is set by the
rotary encoder, while the HI value on
the right is set by the UP and DOWN
buttons. In general, the LO values are
used for offset factors, to allow the
variable to be trimmed close to zero.
The HI voltage value is used for the
voltage scale factor, with the current
set to LO, since a voltmeter will present no load.
Similarly, the HI current value is
used for the current scale factor, with
the voltage set to the LO value, since
an ammeter will effectively present
a short circuit and require negligible
voltage at the output. As long as the
voltage and current values on #12-17
are able to be achieved, there is little
to no reason to change the values on
#25-26.
Enclosure
These calibrations will probably be
unnecessary unless you have a vastly
different thermistor, so we don’t recommend changing them otherwise.
Like the voltage and current calibration, the temperature is calculated
using scale and offset values. For this
calibration, you will need an accurate
thermometer and a way of changing
the temperature of the thermistor over
a wide range.
Apply a low temperature (around
ambient) and adjust the offset (#18)
so that the reading matches the
This is used to set the direction and
steps per detent of the rotary encoder.
The UP and DOWN buttons change the
configuration value, while rotating the
encoder will be reflected in the TEST
display. A movement of one detent
clockwise should cause the test value
to increase by one.
Make sure to rotate for several
detents to check that there are no
missed or extra steps due to rounding.
If the movement is backwards (a clockwise motion decreases the value), the
sign of the configuration value should
be flipped (eg, from -4 to 4). If the test
value changes too much, decrease
Once you have completed the calibration, disconnect the power supply
and unscrew the thermistor from Q1.
Bend Q1 over as shown in the photos
to allow the PCB to fit into the enclosure. Adjust it so that you can check
where the screw will need to be fitted.
You will need a hole in the top of the
enclosure to attach Q1 for heatsinking,
plus two on the back panel, one for the
USB-C socket of the USB-PD module
and another to thread the screw for
securing the PCB.
We have provided a drilling diagram (Fig.7) matching our prototype,
but you might like to use your assembled PCB to mark out where the holes
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(Screen 11)
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#24 Encoder setup (Screen 14)
Australia's electronics magazine
November 2026 81
need to be. In particular, it might be
better to drill the hole for Q1 to suit its
actual location. The panels and enclosure are quite thick but made of fairly
soft aluminium.
Make sure that the hole for Q1 has
no burrs that might short out to its tab,
since this will be live at the POWER+
voltage. The easiest way will be to rub
a small piece of sandpaper over the
inside of the hole and be sure to wipe
away any residue.
If you are using a DC source, you
might need to do something different
for the back panel. In that case, we suggest using a panel-mount DC socket
with flying leads back to the main PCB.
For the flying leads at CON2 or CON6,
consider soldering them to the underside of the PCB and feeding them up
through the strain relief holes.
We are now ready to close everything up. If you haven’t done so
already, terminate the leads for the
CON2 output and finalise your front
panel to suit. Slide the assembly into
the enclosure from the front and secure
the front panel PCB with the four
screws included with the enclosure.
The main PCB should be flush with
the back edge of the enclosure.
Fig.7: it’s best to
mark out your
panels for drilling
by lining them up
with the PCBs. The
hole for the USB-C
socket is shown as
rectangular, but
you could make
it by drilling out
a row of round
holes with a drill
and then leave the
corners rounded to
match the rounded
shape of the socket.
Rest the insulating pad on top of
Q1 and thread the 12mm-long M3
machine screw in from the outside.
Flip the enclosure over so that everything stays in place.
Add the thermistor, insulating
washer, flat washer and fasten the
nut to the screw to hold everything
together. The metal tab of Q1 is connected to its collector (and also the
POWER+ rail); this must be insulated
from the screw and enclosure. You
can check this with a multimeter set
to measure ohms.
Now attach the back panel using
the remaining case screws and use
the other 6mm-long machine screw to
secure the PCB to the back panel. This
will prevent the PCB from moving and
flexing Q1’s leads when the USB cable
is attached and detached. Finally, add
rubber feet to prevent the Power Supply from sliding around and scratching your workbench.
The PSU is now complete and ready
for use. We have set the temperature
setpoints to quite conservative values,
so you could increase them if you feel
comfortable doing so. The electronics
can handle somewhat higher temperatures, but the case may get too hot to
SC
touch at higher levels.
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