Assembly procedure for SHVPS v6bx

What is new?

Version 6 of the board has the exact same functionality and schematics than Version 4 (and version 5, described in the HardwareX article). The main difference is that we have modified the components so that they can all be sourced from a single manufacturer (Digikey). Ordering the components should therefore be much easier. The only components that need to be purchased seprarately are the two OC100G High voltage opotcouplers, which can be obtained from VMI, or one of their worldwide distributors.

Previous version

Instructions to assemble board v4bx

1 Pre-assembly Procedure

  • Take a PCB and clean it with isopropyl alcohol. Wear gloves during assembly.
  • Refer to the bill of material available in the download section to order the required components.
  • The Gerber files to manufacture the board are available in the download section. The board can be made for a few dollars from manufacturer such as JLCPCB

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: Digikey FDS8858CZCT-ND
    Part number: FDS8858CZ
    Description: Dual MOSFET, N and P Channel, 8.6 A, 30 V, 17 mohm, 10 V, 1.6 V
  2. Solder capacitors C1, C2, and C5. Polarity is not important.
    Order code: Digikey 1276-3038-6-ND
    Part number: CL31A106KAHNFNE
    Description: 10µF ±10% 25V Ceramic Capacitor X5R 1206 (3216 Metric)
  3. Solder capacitor C4. Polarity is not important.
    Order code: Digikey ‎399-1285-1-ND
    Part number: C1206C334K3RACTU
    Description: 0.33µF ±10% 25V Ceramic Capacitor X7R 1206 (3216 Metric)
  4. Solder the resistors R1 and R4. Polarity is not important.
    Order code: Digikey ‎408-1908-1-ND‎
    Part number: ‎HRG3216Q-27R0-D-T1
    Description: 27 Ohms ±0.5% 1W Chip Resistor 1206 (3216 Metric) Anti-Sulfur, Automotive AEC-Q200, Moisture Resistant Thin Film
  5. Solder resistors R2 and R8. Polarity is not important.
    Order code: Digikey ‎CR1206-FX-1500ELFCT-ND‎
    Part number: CR1206-FX-1500ELF
    Description: SMD Chip Resistor, Thick Film, 150R, 1%, 0.25W, 1206
  6. Solder resistors R3, R5, R7, and R10.
    Order code: Digikey ‎541-2245-1-ND‎
    Part number: ‎RCA12061K00FKEA‎
    Description: 1 kOhms ±1% 0.25W, 1/4W Chip Resistor 1206 (3216 Metric) Anti-Sulfur, Automotive AEC-Q200 Thick Film
  7. Solder resistor R11.
    Order code: Digikey 311-10KERCT-ND
    Part number: RC1206JR-0710KL
    Description: RES SMD 10K OHM 5% 1/4W 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: Digikey 311-95.3KFRCT-ND‎
    Part number: ‎RC1206FR-0795K3L‎
    Description: 95.3 kOhms ±1% 0.25W, 1/4W Chip Resistor 1206 (3216 Metric) Moisture Resistant Thick Film
    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: Digikey 311-88.7KFRCT-ND
    Part number: RC1206FR-0788K7L
    Description: RES SMD 88.7K OHM 1% 1/4W 1206
    For the 500V model:
    Order code: Digikey 311-215KFRCT-ND
    Part number: RC1206FR-07215KL
    Description: RES SMD 215K OHM 1% 1/4W 1206
    More details on the design of the voltage divider and the resistance values.


  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: Digikey ‎67-1002-1-ND‎
    Part number: SML-LX1206GW-TR
    Description: LED, QuasarBrite, Green, SMD, 3.2mm x 1.6mm, 20 mA, 2.2 V, 565 nm
  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: Digikey ‎67-1003-1-ND‎
    Part number: SML-LX1206IW-TR
    Description: LED, QuasarBrite, Red, SMD, 3.2mm x 1.6mm, 20 mA, 2 V, 635 nm
  11. Solder Reg1.
    Order code: Digikey NCP1117ST50T3GOSCT-ND
    Part number: ‎NCP1117ST50T3G‎
    Description: Linear Voltage Regulator IC Positive Fixed 1 Output 5V 1A SOT-223
  12. Solder D2. Note the polarity! The line on the diode should match the line on the PCB overlay.
    Order code: Digikey 497-5574-1-ND‎
    Part number: STPS2L40U
    Description: Schottky diode, 2 A, 40 V, DO-214AA=SMB
  13. Solder S1. Polarity is not important
    Order code: Digikey SW791-ND‎
    Part number: ‎B3FS-1050‎
    Description: Tactile Switch SPST-NO Top Actuated Surface Mount
  14. Solder C3. Note the polarity! The line on the diode should match the marking on the PCB overlay.
    Order code: Digikey ‎399-8415-1-ND‎
    Part number: T491D227K016AT
    Description: Surface Mount Tantalum Capacitor, 220 µF, 16 V, T491 Series, ± 10%, 2917 [7343 Metric]
  15. Solder L1. Polarity is not important.
    Order code: Digikey ‎732-1701-1-ND‎
    Part number: ‎7447709821‎
    Description: 820µH Shielded Wirewound Inductor 950mA 1 Ohm Max Nonstandard
  16. Solder S2.
    Order code: Digikey ‎563-1571-ND‎
    Part number: MHS122-1‎
    Description: Slide Switch SPDT Through Hole, Right Angle
  17. 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: Digikey 2057-PH1RB-17-UA-ND
    Part number: ‎PH1RB-17-UA‎
    Description: CONN HEADER R/A 17POS 2.54MM
  18. Solder h5V. Polarity is not important.
    Order code: Digikey ‎732-5316-ND
    Part number: 61300311121
    Description: Pin header 3P Single row / straight / without shroud
  19. 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: Digikey SAM1121-02-ND‎
    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.
  20. Solder H2. Polarity is not important.
    Order code: ‎Digikey 952-2120-ND‎
    Part number: M20-9980345
    Description: Board-To-Board Connector, Vertical, M20 Series, 6 Contacts, Header, 2.54 mm, Through Hole, 2 Rows
  21. Solder J1. 
    Order code: Digikey ‎CP-102BH-ND‎
    Part number: PJ-102BH‎
    Description: Power Barrel Connector Jack 2.50mm ID (0.098″), 5.50mm OD (0.217″) Through Hole, Right Angle
  22. 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:  Digikey ‎SAM1093-17-ND‎
    Part number: SLW-117-01-T-S‎
    Description: CONN RCPT 17POS 0.1 TIN PCB
  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 interference 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
  25. Place the jumper on h5V in the ON position, and the jumper h2 in the Button position.
    Order code:Digikey ‎S9001-ND‎
    Part number: SPC02SYAN‎
    Description: 2 (1 x 2) Position Shunt Connector Black Closed Top 0.100″ (2.54mm) Gold
  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: Digikey SM102031006FE-ND‎
    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.
  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: Digikey ‎1470-3201-ND
    Part number: A50P-5
    Description: 5 kV AG Series Isolated, Proportional DC To HV DC Converter 5V input
    For the 3kV model:
    Order code: Digikey 1470-3200-ND
    Part number: A30P-5
    Description: 3 kV AG Series Isolated, Proportional DC To HV DC Converter 5V input
    For the 2kV model:
    Order code: Digikey 1470-3198-ND
    Part number: A20P-5
    Description: 2 kV AG Series Isolated, Proportional DC To HV DC Converter 5V input
    For the 1.2kV model:
    Order code: Digikey 1470-3192-ND
    Part number: A12P-5
    Description: 1.2 kV AG Series Isolated, Proportional DC To HV DC Converter 5V input
    For the 500V model:
    Order code: Digikey 1470-3184-ND
    Part number: A05P-5
    Description: 500 V AG Series Isolated, Proportional DC To HV DC Converter 5V input
    sk
  3. Solder the red HV socket H3
    Order code: Digikey ‎486-3655-ND‎
    Part number: 0040.1102
    Description: Socket ø 2 mm red, 0040.1102, Schurter
  4. Solder the black HV socket H4
    Order code: Digikey 486-3654-ND
    Part number: 0040.1101
    Description: Socket ø 2 mm black, 0040.1101, Schurter

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: ‎Digikey 501-1318-ND‎
    Part number: ‎‎5936-2‎
    Description: Banana Plug Connector Miniature Solder Red
    Black banana plug:
    Order code: Digikey ‎501-1345-ND
    Part number: ‎5936-0
    Description: Banana Plug Connector Miniature Solder 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.