Assembly procedure for SHVPS v4b2

1 Pre-assembly Procedure

  • Take a PCB and clean it with isopropyl alcohol. Wear gloves during assembly.

2 Soldering of Low Voltage Components

  1. Solder dual MOSFETs Q1 and Q2. Make sure that the notch on the chip is aligned with the notch on the PCB overlay.
    Order code: Farnell 1498963
    Part number: FDS8858CZ
    Description: Dual MOSFET, N and P Channel, 8.6 A, 30 V, 17 mohm, 10 V, 1.6 V
    step_1
  2. Solder capacitors C1 and C2. Polarity is not important.
    Order code: Farnell 2426964
    Part number: GRM319R61C106KE15D
    Description: SMD Multilayer Ceramic Capacitor, 1206 [3216 Metric], 10 µF, 16 V, ± 10%
    step_2
  3. Solder capacitor C4. Polarity is not important.
    Order code: Farnell 1833891
    Part number: 12063C334KAT2A
    Description: SMD Multilayer Ceramic Capacitor, 1206 [3216 Metric], 0.33 µF, 25 V, ± 10%
    step_3
  4. Solder the resistors R1 and R4. Polarity is not important.
    Order code: Farnell 2332118
    Part number: CRGH1206F27R
    Description: SMD Chip Resistor, Thick Film, 27 ohm, 200 V, 1206 [3216 Metric], 500 mW, ± 1%
    step_4
  5. Solder resistors R2 and R8. Polarity is not important. Note that R8 is vertical; do not solder it on the pad D3.
    Order code: Farnell 1795172
    Part number: CR1206-FX-1500ELF
    Description: SMD Chip Resistor, Thick Film, 150R, 1%, 0.25W, 1206
    step_5
  6. Solder resistors R3, R5, R7, and R10.
    Order code: Farnell 2307294
    Part number: ERJ8ENF1001V
    Description: SMD Chip Resistor, Thick Film, 1 kohm, 200 V, 1206 [3216 Metric], 250 mW, ± 1%
    step_6
  7. Solder resistor R11.
    Order code: Farnell 1632523
    Part number: MC1206S4F1002T5E
    Description: SMD Chip Resistor, Thick Film, 10K, 1%, 0.25W, 1206
  8. Solder resistor R9.
    The value of R9 depends on the output voltage of the HVPS. Please select the appropriate value below.
    For the 5kV model:
    Order code: Farnell 2327394
    Part number: ERJP08F9532V
    Description: SMD Chip Resistor, Thick Film, 95.3 kohm, 500 V, 1206 [3216 Metric], 660 mW, ± 1%, ERJP08 Series
    For the 3kV model:
    Order code: Digikey P80.6KFCT-ND
    Part number: ERJ-8ENF8062V
    Description: RES SMD 80.6K OHM 1% 1/4W 1206
    For the 2kV model:
    Order code: Digikey P120KFCT-ND
    Part number: ERJ-8ENF1203V
    Description: RES SMD 120K OHM 1% 1/4W 1206
    For the 1.2kV model:
    Order code: Farnell 2327378
    Part number: ERJP08F8872V
    Description: PANASONIC ELECTRONIC COMPONENTS  ERJP08F8872V  SMD Chip Resistor, Thick Film, 88.7 kohm, 500 V, 1206 [3216 Metric], 660 mW, ± 1%, ERJP08 Series
    For the 500V model:
    Order code: Farnell 2327103
    Part number: ERJP08F2153V
    Description: PANASONIC ELECTRONIC COMPONENTS  ERJP08F2153V  SMD Chip Resistor, Thick Film, 215 kohm, 500 V, 1206 [3216 Metric], 660 mW, ± 1%, ERJP08 Series
    More details on the design of the voltage divider and the resistance values.
    step_8
  9. Solder D1 (Green). Note the polarity! The green markings on top of the LED should face the thick line on the PCB overlay.
    Order code: Farnell 2062262
    Part number: SML-LX1206GW-TR
    Description: LED, QuasarBrite, Green, SMD, 3.2mm x 1.6mm, 20 mA, 2.2 V, 565 nm
    step_9
  10. Solder D3 (Red). Note the polarity! The green markings on top of the LED should face the thick line on the PCB overlay.
    Order code: Farnell 2062231
    Part number: SML-LX1206IW-TR
    Description: LED, QuasarBrite, Red, SMD, 3.2mm x 1.6mm, 20 mA, 2 V, 635 nm
    step_10
  11. Solder Reg1.
    Order code: Farnell 1825292
    Part number: AP1117E50G-13
    Description: Fixed LDO Voltage Regulator, 6.4V to 18V, 1.2V Dropout, 5Vout, 1Aout, SOT-223-3
    step_11
  12. Solder D2. Note the polarity! The line on the diode should match the line on the PCB overlay.
    Order code: Distrelec 170-15-894 (old order code: 60 57 24)
    Part number: STPS2L40U
    Description: Schottky diode, 2 A, 40 V, DO-214AA=SMB
    step_12
  13. Solder S1. Polarity is not important
    Order code: Farnell 3121185
    Part number: B3FS-1050
    Description: Tactile Switch, Non Illuminated, 24 V, 50 mA, 0.98 N, Solder, B3FS Series
    step_13
  14. Solder C3. Note the polarity! The line on the diode should match the marking on the PCB overlay.
    Order code: Farnell 2473573 (old order code 1793889)
    Part number: T491D227K016AT
    Description: Surface Mount Tantalum Capacitor, 220 µF, 16 V, T491 Series, ± 10%, 2917 [7343 Metric]
    step_14
  15. Solder S2.
    Order code: Farnell 674357
    Part number: 09-10290-01
    Description: Slide Switch, SPDT, Through Hole, 500 mA
    step_15
  16. Solder edge connector K56GVFTRDC. The edge connector is supplied in long strips. Using a pair of pliers break off a row of 10 pins.
    Order code: Farnell 9729100
    Part number: SL 3.25.36G
    Description: Wire-To-Board Connector, Right Angle, SL Series, 36 Contacts, Plug, 2.54 mm, Through Hole, 1 Rows
    step_16
  17. Solder h5V. Polarity is not important.
    Order code: Distrelec 300-24-522 (old order code: Farnell 1022245)
    Part number: 61300311121
    Description: Pin header 3P Single row / straight / without shroud
    step_17
  18. Solder hD1, hD3, hS1, hS2 if you intend to have components D1, D3, S1, S2 panel mounted. Polarity for these headers is not important.
    Order code: Farnell 1668221
    Part number: SSA-102-S-G
    Description: SAMTEC  SSA-102-S-G  Board-To-Board Connector, SSA Series, 2 Contacts, Receptacle, 2.54 mm, Through Hole, 1 Rows
    If you intend to place the board in the minimalistic enclosure, soldering these headers is not necessary. If you intend to place the board in the full enclosure, only headers hS1 and hS2 are necessary.
    step_18
  19. Solder H2. Polarity is not important.
    Order code: Farnell 1022230
    Part number: M20-9980345
    Description: Board-To-Board Connector, Vertical, M20 Series, 6 Contacts, Header, 2.54 mm, Through Hole, 2 Rows
    step_19
  20. Solder J1. 
    Order code: Farnell 1200151
    Part number: NEB/J 25 R
    Description: DC Power Connector, Jack, 1 A, 2.35 mm, Through Hole Mount
    step_20
  21. Solder header sockets for microcontroller. The header sockets are supplied in long strips. Score the plastic with a craft knife and break off 17 contacts with a pair of pliers. Clean up the rough edge with the craft knife or sandpaper.
    Order code:  Farnell 2396216
    Part number: 929974-01-36
    Description: Board-To-Board Connector, 929 Series, 36 Contacts, Receptacle, 2.54 mm, Through Hole, 1 Rows
    step_21
  22. Solder L1. Polarity is not important.
    Order code: Distrelec 158-00-420 (old order code: 335529)
    Part number: ELC16B821L
    Description: Inductor, radial 820 uH 0.88 A ±10%, Panasonic Automotive & Industrial Systems
    step_22
  23. Prepare optocouplers OC1 and OC2. Please follow the instructions below:
    Bending of the leads:
    Bend the leads as shown in the series of images below.
    bending_oc
    Mark pin 1 (before painting):
    Bend the tip of pin 1 so that it can be identified after painting the optocoupler.
    Painting of the optocoupler:
    The optocoupler is painted to prevent inteference from neighbouring optocouplers and IR light which is present in the environment. Tipp-Ex is used because it creates a relatively good barrier to IR light and is easy to apply. Simply paint the plastic body of the optocoupler with a single layer of Tipp-Ex and let it dry. It is best to do it rapidly and in single strokes. Making multiple passes results in a sticky mess which is very unsightly.
    Mark pin 1 (after painting):
    Use a permanent pen to mark pin 1 with a dot next to the pin.
    METADATA-START
    Order code: MPI Distribution AG OC100G
    Part number: OC100G
    Description: HV Opto-Coupler 10 kV
  24. Solder optocouplers OC1 and OC2. Make sure that the polarity is correct.
    step_24
    (unlike what is shown on the picture above, the EMCO DC/DC converter and resistor R6 are not yet soldered)
  25. Place the jumper on h5V in the ON position, and the jumper h2 in the Button position.
    Order code: Farnell 9728961
    Part number: CAB 4 GR
    Description: Jumper (Busbar), Jumper, 0.6 to 0.64mm Wire Wrap Pins and 0.6 to 0.7mm Dia, 2 Ways, 2.54 mm
    step_24
  26. You are ready to test the low voltage part of your HVPS

3 Testing procedure of the Low-voltage part of the HVPS

Before assembling the High-voltage components, go through the low-voltage testing procedure and ensure that the circuit is working properly. Only proceed with the assembly of the HV components if all the low voltage tests have passed.

4 Soldering of High Voltage Components

  1. Solder R6. Do not fully insert this resistor. Insert it so that 2mm of the leads can be seen above the top surface of the PCB.
    The value of R6 depends on the output voltage of the HVPS. Please select the appropriate value below.
    For the 5kV model:
    Order code: Farnell 1550763
    Part number: SM102031006FE
    Description: OHMITE  SM102031006FE  Through Hole Resistor, Slim-Mox, 100 Mohm, 5 kV, Radial Leaded, 1 W, ± 1%, Slim-Mox Series
    For the 3kV model:
    Order code: Digikey SM102035005FE-ND
    Part number: SM102035005FE
    Description: RES 50M OHM 1W 1% RADIAL
    For the 2kV model:
    Order code: Digikey SM102035005FE-ND
    Part number: SM102035005FE
    Description: RES 50M OHM 1W 1% RADIAL
    For the 1.2kV model:
    Order code:  Digikey 22MGBCT-ND
    Part number: HHV-50FR-52-22M
    Description: RES 22M OHM 1/2W 1% AXIAL
    For the 500V model:
    Order code:  Digikey 22MGBCT-ND
    Part number: HHV-50FR-52-22M 
    Description: RES 22M OHM 1/2W 1% AXIAL
    More details on the design of the voltage divider and the resistance values.
    hv_step_1
  2. Solder EMCO1
    EMCO1 is the DC/DC converter of the HVPS, and its voltage rating defines the maximal output voltage of the HVPS. Use the following values:
    For the 5kV model:
    Order code: EMCO/Condatas A50P-5
    Part number: A50P-5
    Description: 5 kV A Series Isolated, Proportional DC To HV DC Converter 5V input
    For the 3kV model:
    Order code: EMCO/Condatas A30P-5
    Part number: A30P-5
    Description: 3 kV A Series Isolated, Proportional DC To HV DC Converter 5V input
    For the 2kV model:
    Order code: EMCO/Condatas A20P-5
    Part number: A20P-5
    Description: 2 kV A Series Isolated, Proportional DC To HV DC Converter 5V input
    For the 1.2kV model:
    Order code: EMCO/Condatas A12P-5
    Part number: A12P-5
    Description: 1.2 kV A Series Isolated, Proportional DC To HV DC Converter 5V input
    For the 500V model:
    Order code: EMCO/Condatas A05P-5
    Part number: A05P-5
    Description: 500 V A Series Isolated, Proportional DC To HV DC Converter 5V input
    hv_step_2
  3. Solder the red HV socket H3
    Order code: Distrelec 140-21-352
    Part number: 0040.1102
    Description: Socket ø 2 mm red, 0040.1102, Schurter
    hv_step_3
  4. Solder the black HV socket H3
    Order code: Distrelec 140-21-351
    Part number: 0040.1101
    Description: Socket ø 2 mm black, 0040.1101, Schurter
    hv_step_4

5 Testing procedure of the High-voltage part of the HVPS

Once you have finished the assembly of the high-voltage components, you are ready to test the high-voltage portion of the circuit. Follow these instructions.

6 HV cables

  1. Cut the appropriate length of HV electrical cable.
    Red wire:
    Order code: Digikey W2722R-100-ND
    Part number: 2722/22 R/C
    Description: TEST LEAD 22AWG 5000V RED 100′
    Black wire:
    Order code: Digikey W2722B-100-ND
    Part number: 2722/22 B/C
    Description: TEST LEAD 22AWG 5000V BLACK 100′
  2. Manually enlarge the opening of the 2mm banana plug cover with a 3mm drill bit so it can fit over the HV cable.
    Red banana plug:
    Order code: Farnell 1699020
    Part number: 25.205.1
    Description: MULTICOMP  25.205.1  BANANA PLUG, 10A, 2MM, CABLE, RED
    Black banana plug:
    Order code: Farnell 1699021
    Part number: 25.205.2
    Description: MULTICOMP  25.205.2  BANANA PLUG, 10A, 2MM, FREE, BLACK
  3. Solder the banana plugs to the wires and install the protective covers
  4. At the other extremity of the cable, install the connector you need for your application. We use Alligator clips as versatile connectors.
    Red Clip:
    Order code: Digikey 36-5034-ND
    Part number: 5034
    Description: ALLIGATOR CLIP INSULATED RED
    Black Clip:
    Order code: Digikey 36-5035-ND
    Part number: 5035
    Description: ALLIGATOR CLIP INSULATED BLACK

7 Next steps

Once you have finished assembling and testing (Low voltage testing, High voltage testing) your HVPS, you should place in in a safe enclosure and proceed with configuration/calibration.