- Details
- Category: Hardware
Thanks to wide input voltage range, the CF-DIC can works with both AC mains voltage. Therefore, measurements for Vin = 230 Vac are presented in the first place. Its behavior with the lower input voltage is shown only if it is significantly different.
Table of contents
- QR Flyback
- CF-DIC power on with and without connected load
- Power on with shorted output
- Power off
- Synchronous Rectification controller
- Output voltage programming
- Output ripple and noise
The following measurements are for no external load connected to any of QR flyback outputs; i.e. it is powering only LED indicator and CF-DIC sections.
Fig. 1: Power up VIPer35 DRAIN voltage
Fig. 2: AUX secondary output (not rectified)
Fig. 3: VIPer35 ZCD input
CF-DIC power on with and without connected load
Observing the CF-DIC's power output voltage when power is applied is used to check if overshoot exists. A small overshoot is intentionally left since the main purpose of this converter is power pre-regulation and connected load cannot see such voltage disturbance. Having a small overshoot could improve output ripple and noise. Power on without load is shown on Fig. 4. With output voltage set to 25 V. Power on with max. current (5 A) and output voltage set to 48 V is shown in Fig. 5.
Fig. 4: Power on, Vout = 25 V, no load connected
Fig. 5: Power on, Vout = 48 V, resistive load connected, Iout = 5 A
The more demanding scenario is start up when traditional lamp is connected as a load. Its filament, when is cold, has a very low resistance and represents almost a short circuit. The converter has built-in protection against short-circuit (i.e. request to deliver huge current) and it is not tolerated for more then a few hundreds of milliseconds. If connected lamp cannot warm enough during that period, the LM5041B will be shut down and input power recycling is needed for initiate new start of operation.
Such scenario is shown on Fig. 6. for 230 Vac and Fig. 7. for 120 Vac. In both cases the protection acts before connected lamps (four 12 V halogen lamps connected in series) could warm up enough.
Once again, such behavior is intentionally provided, and is not an issue when converter is used as a power pre-regulator.
Fig. 6: Power on, Vout = 48 V with halogen lamps connected
Fig. 7: Power on, Vin=120 Vac, Vout = 48 V with halogen lamps connected
On Fig. 8. is shown HV buck output on start up with shorted output until the protection is tripped. We can see that shut down comes a little bit earlier then with lamps connected since their initial resistance is slightly higher.
Fig. 8: HV buck output on start up with shorted output
The power off should happen smoothly, without surprisingly high disturbance of the output voltage regardless if the load is connected or not. The Fig. 9. shows output voltage drop with connected bleeder resistor (R70) of 4.7 kΩ and Fig. 10. with resistive 10 Ω load connected.
Fig. 9: Power off, Vout = 25 V with bleeder resistor connected (R70)
Fig. 10: Power off, Vout = 25 V, Iout = 2.5 A with 10 Ω load connected
Synchronous Rectification Controller
The IR11688 controller incorporates gate voltage regulation function and the gate output shape will vary with connected load. The measurements that follows shown how it looks like for Iout = 1, 2 and 3 A.
Fig. 11: IR11688 GATE output for Iout = 1 A
Fig. 12: IR11688 GATE output for Iout = 2 A
Fig. 13: IR11688 GATE output for Iout = 3 A
An example of voltage across SR MOSFET under load is shown on Fig. 14., and one of IR11688's controller VR input on Fig. 15.
Fig. 14: SR MOSFET Vds for Vout = 48 V, Iout = 5 A
Fig. 15: SR VD input (filtered with 1 kΩ + 47 pF), Vout = 40 V
The CF-DIC's output voltage, when is working as power pre-regulator, is externally programmed with control voltage applied on its U_Ctrl input (pin 4 and 5 on X2 connector). The following two measurements shows how it is responding on 8 Hz square waveform that produce 4 V (Fig. 16.) and 16 V (Fig. 17.) step on the output. In both case 10 Ω load was connected, causing 0.4 A and 1.6 A change in delivered current. The second case is especially demanding with Vin = 230 Vac: because the feedback loop speed is limited, with such sharp change in output voltage and considerable load, it could easily drive CF-DIC into very dangerous zone (HV buck duty will rise considerably in short time) and damage some of the parts. But, thanks to the implemented Active Duty limiter, it can accept safely such programming sequence for prolonged period of time.
Fig. 16: Output programming (4 V step) with 10 Ω connected load
Fig. 17: Output programming (16 V step) with 10 Ω connected load
It is mentioned in the Introduction section that CF-DIC project is initiated by need to replace “off-the-shelf” AC/DC off-line converter. Therefore it is interesting to find out how its output ripple and noise looks in comparison with e.g. Mean Well LRS-150-48 that was used in the EEZ H24005 power supply. The used methodology for testing ripple and noise is rather simple and limited, but if both converters are tested under equal conditions, measured results can be used at least for relative comparison, i.e. to judge which one is “louder” then the other.
The ordinary Rigol x10 probe with spring ground tip is used to measure voltage output across 15 uF (elco) + 100 nF (MFCC) capacitors connected in parallel as shown on Fig. 18. Input bandwidth is limited to 20 MHz.
Output voltage is set to 48 V and output current to 3 A (Mean Well) and 5 A (CF-DIC). The measured level of output ripple and noise in case of CF-DIC is significantly lower for both Vin = 230 Vac (Fig. 19.) and 120 Vac (Fig. 20.).
Fig. 18: Output ripple and noise test points
Fig. 19: Output ripple and noise for Vin = 230 Vac
Fig. 20: Output ripple and noise for Vin = 120 Vac
- Details
- Category: Hardware
Hardcopy of this text is part of the EEZ H24005 complete kit.
IMPORTANT NOTICE
EEZ H24005 is a completely open source project covered by GPL v3 (http://gplv3.fsf.org) and TAPR v1.0 (http://www.tapr.org/OHL) licenses. Its parts are subject to continuous development and improvements.
EEZ H24005 kit is not an end user product. As such it has not undergone any conformance testing and it may not comply with some or all technical or legal requirements that are applicable to finished products including, but without limitation, directives regarding electromagnetic compatibility, recycling (WEEE), FCC, CE, or UL.
By using the kit, the user acknowledges and agrees that any use of assembled EEZ H24005 is solely at the user’s own risk, and that user is solely responsible for compliance with all legal and regulatory requirements in connection with such use.
Envox d.o.o. supplies EEZ H24005 kit AS IS, without any warranties, with all faults, at the buyer’s and further users’ sole risk. The user assumes all responsibility and liability for proper and safe handling of the goods. Further, the user indemnifies Envox d.o.o. from all claims arising from handling or using any part of the EEZ H24005 neither assembled nor in kit form.
All documents, manuals, and information on the EEZ H24005 power supply project official website (please start with document: http://bit.ly/2ua4p7J) and GitHub repository (www.github.com/eez-open) are intended only to assist the reader in the assembly and use of the product. Envox d.o.o. shall not be liable for any loss or damage arising from the use of any information or any error or omission in such information or any incorrect use of the product.
Please note that while EEZ H24005 power outputs are of low voltages (below 50 Vdc), they may still pose a threat of personal injury. Further, AC mains power voltages may be involved when assembling and using the EEZ H24005. High voltages can be lethal and in the worst case may lead to electrocution and death. Assembling and using the EEZ H24005 requires an understanding of electronic circuits and basic computer programming skills.
If you need assistance, please contact us using Contact us (http://bit.ly/2ptLouB) or post your problem on the EEVblog forum (http://bit.ly/2oG4YFD).
Feel free to open a New issue in GitHub (hardware related: http://bit.ly/2oFRc5P or firmware: http://bit.ly/2sNHwty). Please check first to see if a similar issue already reported.
See also CrowdSupply’s Proclamation of users rights: http://bit.ly/2oPaWV4
- Details
- Category: Hardware
- Ethernet cable
- Cooling fan cable
- AUX temperature sensor cable
- AC switch patch cables
- Cable set #1
- Cable set #2
- Pre-assembled cables
- BOM
1. Ethernet cable
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Total length |
250 (± 5) mm |
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Type |
4 pairs Ethernet, stranded wire |
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TME |
HELUKAT100-FTP-FP or e.g. cut CA00600.00C01 to size |
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Farnell |
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Connectors |
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Side A |
X8 |
Side B |
X18 |
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Housing type |
Receptacle, 0.1” |
Housing type |
See side A |
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TME |
TME |
See side A |
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Farnell |
Farnell |
See side A |
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Pin: |
Female |
Pin |
See side A |
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Pin quantity |
8 |
Pin quantity |
7 |
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TME |
TME |
See side A |
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Farnell |
Farnell |
See side A |
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Polarising key |
Position #3 |
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TME |
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Farnell |
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Wiring
|
Name |
Position |
Color / description |
Position |
Color / description |
|
LED link |
1 |
Brown-white |
1 |
Brown-white |
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LED act |
2 |
Brown |
2 |
Brown |
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Shield |
3 |
Blue-white |
3 |
Polarising key |
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RX+ |
4 |
Orange-white |
4 |
Orange-white |
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RX- |
5 |
Orange |
5 |
Orange |
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TX+ |
6 |
Green-white |
6 |
Green-white |
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TX- |
7 |
Green |
7 |
Green |
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+3.3V |
8 |
Blue |
8 |
Blue |
Picture
|
Total length |
100 (± 5) mm |
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Type |
3 wire, already mounted on the cooling fan |
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Fan: |
TME: MB60251V1-G99 |
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Connectors |
|||
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Side A |
X6 |
Side B |
N/A |
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Housing type |
Receptacle, 0.1” |
Housing type |
N/A |
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TME |
TME |
N/A |
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Farnell |
Farnell |
N/A |
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Pin |
Female |
Pin |
N/A |
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Pin quantity |
3 |
Pin quantity |
0 |
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TME |
TME |
N/A |
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Farnell |
Farnell |
N/A |
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Additional info |
|||
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Fan is already equipped with cable that has to be cut to size and terminated with connector |
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Wiring
|
Name |
Position |
Color / description |
|
12 Vdc |
1 |
Red |
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GND |
2 |
Black |
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Sense |
3 |
Yellow |
Picture
3. AUX temperature sensor cable
|
Total length |
145 (± 5) mm |
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Type |
Max. 0.35 mm2 singe wire, stranded |
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TME |
E.g. brown: LGY0.35/25-BR (or any other color) |
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Farnell |
E.g. brown: 2425402 (0.22 mm2) |
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NTC |
TME: NTCLE100E3103JB0, Farnell: 1187031 |
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Wire |
TME: LGY0.35/25-BR, Farnell: 2425402 |
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Connectors |
|||
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Side A |
X17 |
Side B |
N/A |
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Housing type |
Receptacle 0.1” |
Housing type |
N/A |
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TME |
TME |
N/A |
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Farnell |
Farnell |
N/A |
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Pin |
Female |
Pin |
N/A |
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Pin quantity |
2 |
Pin quantity |
0 |
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TME |
TME |
N/A |
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Farnell |
Farnell |
N/A |
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Additional info |
|||
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The temperature sensor is already equipped with cable that has to be terminated with connector
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Wiring
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Name |
Position |
Color / description |
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MCU_VCC |
1 |
Any color |
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NTC |
2 |
Any color |
Picture
|
Total length |
45 (± 5) mm |
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Type |
0.75 mm2 singe wire, stranded, min. 250 VAC |
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TME |
Brown: LGY0.75/25-BR, Blue: LGY0.75/25-BL |
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Farnell |
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Connectors |
|||
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Side A |
AC output |
Side B |
AC Switch input |
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Pin |
Female quick disconnect |
Pin |
See side A |
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Pin quantity |
2 |
Pin quantity |
See side A |
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TME |
TME |
See side A |
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Farnell |
Farnell |
See side A |
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Additional info |
|||
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Required for Schurter 4304.6090 IEC inlet (C14, 6765, 10A)
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Wiring1
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Name |
Position |
Color / description |
Position |
Color / description |
|
Line |
1 |
Brown |
1 |
Brown |
Wiring2
|
Name |
Position |
Color / description |
Position |
Color / description |
|
Neutral |
1 |
Blue |
1 |
Blue |
Picture
5.1. Section A: Power board (CH2) X1 cable
|
Length |
420 (± 5) mm |
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Type |
0.75 mm2 singe wire, stranded, min. 250 VAC |
||
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TME |
Red: LGY0.75/25-RD, Black: LGY0.75/25-BK Green-Yellow: LGY0.75/25-YL/GR |
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Farnell |
|||
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Connectors |
|||
|
Side A |
Power board X1 (Ch2) |
Side B |
AC/DC module power output |
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Housing type |
Male, Mini-Fit Jr. |
Housing type |
Ferrule, single wire |
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TME |
TME |
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Farnell |
Farnell |
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Pin |
Female |
Quantity |
2 |
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Pin quantity |
3 |
Housing type |
Ferrule, twin entry |
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TME |
TME |
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Farnell |
Farnell |
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Quantity |
1 |
Wiring
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Name |
Position |
Color / description |
Position |
Color / description |
|
Earth |
1 |
Green-Yellow |
N/A |
Ferrule, twin entry |
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Vin- |
2 |
Black |
N/A |
Ferrule |
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Vin+ |
3 |
Red |
N/A |
Ferrule |
5.2. Section B: AC/DC module Earth
|
Length |
70 (± 1) mm |
|
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Type |
0.75 mm2 singe wire, stranded, min. 250 VAC |
||
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TME |
|||
|
Farnell |
|||
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Connectors |
|||
|
Side A |
AC/DC module Earth output |
Side B |
AC/DC module Earth (in) |
|
Housing type |
Use twin entry ferrule, See B side, Section A |
Housing type |
Ferrule, twin entry |
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TME |
|
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|
Farnell |
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|
Quantity |
1 |
5.3. Section C: Chassis Earth
|
Length: |
170 (± 5) mm |
|
|
|
Type: |
0.75 mm2 singe wire, stranded, min. 250 VAC |
||
|
TME |
|||
|
Farnell |
|||
|
Connectors |
|||
|
Side A |
AC/DC module Earth (in) |
Side B |
Chassis Earth (bottom plate) |
|
Housing type |
Use twin entry ferrule, See B side, Section B |
Housing type |
Non-insulated, Ring terminal, 3 mm |
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TME |
|
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Farnell |
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Quantity |
1 |
5.4. Section D: Arduino Shield Earth
|
Length: |
350 (± 5) mm |
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Type: |
0.75 mm2 singe wire, stranded, min. 250 VAC |
||
|
TME |
|||
|
Farnell |
|||
|
Connectors |
|||
|
Side A |
Chassis Earth (bottom plate) |
Side B |
Arduino Shield Earth input (J3) |
|
Housing type |
Use ring terminal, See B side, Section C |
Housing type |
Female quick disconnect |
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TME |
|
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|
|
Farnell |
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|
Quantity |
1 |
6.1. Section A: Power board X1 cable
|
Length |
330 (± 5) mm |
|
|
|
Type |
0.75 mm2 singe wire, stranded, min. 250 VAC |
||
|
TME |
Red: LGY0.75/25-RD, Black: LGY0.75/25-BK Green-Yellow: LGY0.75/25-YL/GR |
||
|
Farnell |
|||
|
Connectors |
|||
|
Side A |
Power board X1 (Ch1) |
Side B |
AC/DC module power output |
|
Housing type |
Male, Mini-Fit Jr. |
Housing type |
Ferrule, single wire |
|
TME |
TME |
||
|
Farnell |
Farnell |
||
|
|
|
|
|
|
Pin |
Female |
Quantity |
2 |
|
Pin quantity |
3 |
Housing type |
Ferrule, twin entry |
|
TME |
TME |
||
|
Farnell |
Farnell |
||
|
|
|
|
|
|
|
|
Quantity |
1 |
Wiring:
|
Name |
Position |
Color / description |
Position |
Color / description |
|
Earth |
1 |
Green-Yellow |
N/A |
Ferrule, twin entry |
|
Vin- |
2 |
Black |
N/A |
Ferrule |
|
Vin+ |
3 |
Red |
N/A |
Ferrule |
6.2. Section B: AC/DC module Earth
|
Length |
165 (± 5) mm |
|
|
|
Type |
0.75 mm2 singe wire, stranded, min. 250 VAC |
||
|
TME |
|||
|
Farnell |
|||
|
Connectors |
|||
|
Side A |
AC/DC power module Earth (in) |
Side B |
AC inlet Earth |
|
Housing type |
Use twin entry ferrule, See B side from Section A |
Housing type |
Female quick disconnect |
|
|
|
Quantity |
1 |
|
|
|
TME |
|
|
|
|
Farnell |
|
|
|
|
|
|
6.3. Section C: AUX PS module Earth
|
Length |
115 (± 5) mm |
|
|
|
Type |
0.75 mm2 singe wire, stranded, min. 250 VAC |
||
|
TME |
|||
|
Farnell |
|||
|
Connectors |
|||
|
Side A |
AC inlet Earth |
Side B |
AUX PS module (X3) |
|
Housing type |
Use Female quick disconnect terminal, See B side, Section B |
Housing type |
Male, Mini-Fit Jr. |
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|
TME |
|
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|
Farnell |
|
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|
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|
Pin |
Female |
|
|
|
Pin quantity |
5 |
|
|
|
TME |
|
|
|
|
Farnell |
|
|
|
|
|
|
Wiring:
|
Name |
Position |
Color / description |
Position |
Color / description |
|
– |
– |
Female quick disconnect |
1 |
Earth |
6.4. Section D: Lower AC/DC module power input
|
Length |
200 (± 5) mm |
|
|
|
Type |
0.75 mm2 singe wire, stranded, min. 250 VAC |
||
|
TME |
Brown: LGY0.75/25-BR, Blue: LGY0.75/25-BL |
||
|
Farnell |
|||
|
Connectors |
|||
|
Side A |
AUX PS module (X3) |
Side B |
Lower AC/DC module power input |
|
Housing type |
See Side B, Section C |
Housing type |
Ferrule, twin entry |
|
TME |
- |
TME |
|
|
Farnell |
- |
Farnell |
|
|
|
|
|
|
|
Pin |
Female |
Quantity |
2 |
|
Pin quantity |
2 |
|
|
|
TME |
|
|
|
|
Farnell |
|
|
|
|
|
|
|
|
Wiring:
|
Name |
Position |
Color / description |
Position |
Color / description |
|
Neutral |
2 |
Blue |
N/A |
Ferrule, twin entry |
|
Line |
3 |
Brown |
N/A |
Ferrule, twin entry |
6.5. Section E: Upper AC/DC module power input
|
Length |
75 (± 1) mm |
|
|
|
Type |
0.75 mm2 singe wire, stranded, min. 250 VAC |
||
|
TME |
Brown: LGY0.75/25-BR, Blue: LGY0.75/25-BL |
||
|
Farnell |
|||
|
Connectors |
|||
|
Side A |
Lower AC/DC module power input |
Side B |
Upper AC/DC module power input |
|
Housing type |
Use twin entry ferrule, See B side, Section D |
Housing type |
Ferrule, single wire |
|
|
|
TME |
|
|
|
|
Farnell |
|
|
|
|
|
|
|
|
|
Quantity |
2 |
6.6. Section F: AUX PS module power input
|
Length |
110 (± 5) mm |
|
|
|
Type |
0.75 mm2 singe wire, stranded, min. 250 VAC |
||
|
TME |
Brown: LGY0.75/25-BR, Blue: LGY0.75/25-BL |
||
|
Farnell |
|||
|
Connectors |
|||
|
Side A |
AUX PS module (X3) |
Side B |
Lower AC/DC module power input |
|
Housing type |
See Side B, Section C |
Housing type |
Female quick disconnect |
|
TME |
- |
TME |
|
|
Farnell |
- |
Farnell |
|
|
|
|
|
|
|
Pin |
Female |
Quantity |
2 |
|
Pin quantity |
2 |
|
|
|
TME |
|
|
|
|
Farnell |
|
|
|
|
|
|
|
|
Wiring:
|
Name |
Position |
Color / description |
Position |
Color / description |
|
Neutral |
4 |
Blue |
N/A |
Female quick disconnect |
|
Line |
5 |
Brown |
N/A |
Female quick disconnect |
7.1. Arduino shield power cable
|
Length |
300 mm |
|
|
|
Type |
Ribbon cable with IDC connectors; 10x28AWG |
||
|
TME |
|||
|
Farnell |
N/A |
||
Picture
Pinout:
|
Name |
Position |
Description |
|
Gnd |
1 |
Ground |
|
Gnd |
2 |
Ground |
|
PWR_DIRECT |
3 |
Triac control (continuous power) |
|
PWR_SSTART |
4 |
Triac control (soft-start) |
|
FAN_SENSE |
5 |
Tachometer output |
|
FAN_PWM |
6 |
Fan PWM speed control |
|
DOUT2 |
7 |
Power relay control |
|
+5V |
8 |
+5 V for Arduino Shield |
|
Gnd |
9 |
Ground |
|
+5V |
10 |
+5 V for Arduino Shield |
7.2. Arduino USB cable
|
Length |
300 or 500 mm |
|
|
|
Type |
USB Micro to 5-pin receptacle cable |
||
|
TME |
N/A |
||
|
Farnell |
N/A |
||
|
AliExpress |
e.g. High Quality 50CM micro usb 5pin male to 1x 5Pin Female 0.1" USB header PCB motherboard cable |
||
Pinout:
|
Name |
Position |
Color |
Description |
|
VCC |
1 |
Red |
+5 Vdc |
|
D- |
2 |
White |
Data - |
|
D+ |
3 |
Green |
Data + |
|
GND |
4 |
Black |
Ground |
|
Shield |
5 |
Black |
Shield |
|
Type |
Part (Farnell) |
Part (TME) |
Total |
|
|
Receptacle |
2 |
|
||
|
Receptacle |
1 |
|
||
|
Receptacle |
1 |
|
||
|
Receptacle Mini-Fit Jr. |
2 |
|
||
|
Receptacle Mini-Fit Jr. |
1 |
|
||
|
Pin |
15 |
|
||
|
Polarising key |
1 |
|
||
|
Pin |
5 |
|
||
|
Pin |
11 |
|
||
|
Female quick disconnect |
6 |
|
||
|
Ferrule |
6 |
|
||
|
Ferrule, twin entry |
5 |
|
||
|
Ring terminal |
1 |
|
||
|
Cat5e cable |
0.25 m |
|
||
|
0.75 cm2 cable (Brown) |
0.43 m |
|
||
|
0.75 cm2 cable (Blue) |
0.43 m |
|
||
|
0.75 cm2 cable (Red) |
0.75 m |
|
||
|
0.75 cm2 cable (Black) |
0.75 m |
|
||
|
0.75 cm2 cable (Yellow-Green) |
1.61 m |
|
||
|
0.35 cm2 cable |
0.29 m |
|
||
|
12 Vdc cooling fan |
– |
1 |
|
|
|
NTC |
1 |
|
||
|
IDC ribbon cable |
– |
0.3 m |
|
|
|
USB Micro cable |
Shenzhen Wonderwing Electronics Ltd. or search e.g. Aliexpress |
0.5 m |
|
|
 Wire harness
r5B12
|
|
Wire harness for EEZ H24005 programmable power supply. |
|
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