Author Topic: FirstWatt F5 (fdlsys)  (Read 1750 times)

fdlsys

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FirstWatt F5 (fdlsys)
« on: June 21, 2011, 11:56:57 pm »
I thought it would be a good idea to start individual build topics?

And so it begins...



Not difficult at all - easier than paint-by-numbers (very limited colour palette ;))

NB:
- Thermistors are in just for show since the leads are too short for permanent placement. I'll make a plan when I have a better idea about the FET placement and distance.
- Missing 150ohm resistors... Ruuuuudiii!!!  >:( ;D
- 3w/2w resistors draw the heat from the soldering iron like mad - push the temperature up a bit when doing these, and let the solder flow well to the other side of the hole until it "grows" on the lead. My no-name soldering station is max 48w, I soldered everything easily with about 3/5 setting on the dial; power resistors took 3/4.
- Brown(ish) bits on the side of the PCB are humble "furniture sliding" felt pads, +- 3mm thick, cut to a rectangle where short side fits small (blue) resistor hole spacing and longer side fits the power resistors (grey) hole spacing. I place it under the resistor, bend the leads on the other side and solder. After it cools down just pull the pad out - voilà, equal spacing and nice distance from the PCB, so that you can read the values underneath and so that there is some air between the resistors and the PCB (just in case...).
- There are many (bad) resistor colour-code calculators on the Net. This one is GOOD. http://www.hobby-hour.com/electronics/resistorcalculator.php

...to be continued...

PS: All kudos to Rudi - you should see what his dining table looks like! :o
Kids are mixing resistors and transistors with cereal (mmmh, crunchy!), better half wears a thermistor necklace (dangerous temperatures control! :D)... poor puppy chews on the toroids.
« Last Edit: June 22, 2011, 12:17:54 am by fdlsys »
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Tachyon

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Re: FirstWatt F5 (fdlsys)
« Reply #1 on: June 22, 2011, 12:30:21 am »
And so it begins  :D
After silence, that which comes nearest to expressing the inexpressible is music - Aldous Huxley

ghostinthemachine

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Re: FirstWatt F5 (fdlsys)
« Reply #2 on: June 22, 2011, 08:21:31 am »
Hey!! Who said you can start without me?

Good going there...  ;)
Over 3000 posts and counting...

Crankshaft

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Re: FirstWatt F5 (fdlsys)
« Reply #3 on: June 22, 2011, 08:30:16 am »
I didn't realise that the solder would automatically draw though to the other side of the PCB.  Are there any tricks to ensure this process work consistantly?  Do you reckon one should stand the large resistors off the board (hot)?

I am going to get one of those resistor leg bending jigs. 

Looking good fdlsys.

Crank

Rudi

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Re: FirstWatt F5 (fdlsys)
« Reply #4 on: June 22, 2011, 09:31:34 am »


NB:
- Thermistors are in just for show since the leads are too short for permanent placement. I'll make a plan when I have a better idea about the FET placement and distance.
- Missing 150ohm resistors... Ruuuuudiii!!!  >:( ;D
- 3w/2w resistors draw the heat from the soldering iron like mad - push the temperature up a bit when doing these, and let the solder flow well to the other side of the hole until it "grows" on the lead. My no-name soldering station is max 48w, I soldered everything easily with about 3/5 setting on the dial; power resistors took 3/4.
- Brown(ish) bits on the side of the PCB are humble "furniture sliding" felt pads, +- 3mm thick, cut to a rectangle where short side fits small (blue) resistor hole spacing and longer side fits the power resistors (grey) hole spacing. I place it under the resistor, bend the leads on the other side and solder. After it cools down just pull the pad out - voilà, equal spacing and nice distance from the PCB, so that you can read the values underneath and so that there is some air between the resistors and the PCB (just in case...).
- There are many (bad) resistor colour-code calculators on the Net. This one is GOOD. http://www.hobby-hour.com/electronics/resistorcalculator.php

...to be continued...

PS: All kudos to Rudi - you should see what his dining table looks like! :o
Kids are mixing resistors and transistors with cereal (mmmh, crunchy!), better half wears a thermistor necklace (dangerous temperatures control! :D)... poor puppy chews on the toroids.


mistakes happen. will check the other kits. you lucky. I will replace them for you
so don't you have a digital volt meter? is that why you were so grumpy when you realised I didn't mark everything for you so that you can colour by numbers.
Never argue with an idiot. The people watching might not know the difference.

fdlsys

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Re: FirstWatt F5 (fdlsys)
« Reply #5 on: June 22, 2011, 09:34:33 am »
I didn't realise that the solder would automatically draw ...
The best characteristic of solder is that works on a capillary principle. The tighter the spot, the easier the draw.
That's why the power resistors are a bit more work - PCB holes are bigger, resistors themselves are designed to dissipate the heat...
RANDBURG, the cradle, Earth Mk2

fdlsys

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Re: FirstWatt F5 (fdlsys)
« Reply #6 on: June 22, 2011, 09:37:08 am »
mistakes happen. will check the other kits. you lucky. I will replace them for you
so don't you have a digital volt meter? is that why you were so grumpy when you realised I didn't mark everything for you so that you can colour by numbers.
Look who's calling me grumpy!!
Of course I do and of course I did check. I have a work-flow, y'know ;)
RANDBURG, the cradle, Earth Mk2

Rudi

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Re: FirstWatt F5 (fdlsys)
« Reply #7 on: June 22, 2011, 09:44:52 am »
Look who's calling me grumpy!!
Of course I do and of course I did check. I have a work-flow, y'know ;)

 ;D  ;D.............yeah yeah, I'm the grumpy and rud-e one, I know

what resistors were left over once you were finished.?
Never argue with an idiot. The people watching might not know the difference.

fdlsys

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Re: FirstWatt F5 (fdlsys)
« Reply #8 on: June 22, 2011, 10:22:53 am »
what resistors were left over once you were finished.?
Only the .47/3w PSU ones (8, if I remember correctly). Didn't have the time last night to check the other kit.
BUT: Don't worry about it, I'll pop over - easy enough ;)

I'm just recording the progress, having fun, making jokes, doing my bit to help/guide (being the 1st on the bleeding edge)... of course that mistakes happen. No big deal!
RANDBURG, the cradle, Earth Mk2

undefined.za

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Re: FirstWatt F5 (fdlsys)
« Reply #9 on: June 22, 2011, 11:12:18 am »
Exciting!!!! Looking good so far man!

dotVIBE

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Re: FirstWatt F5 (fdlsys)
« Reply #10 on: June 22, 2011, 11:16:34 am »
awesome. Keep 'em coming, us uber noobs (me!) are going to use these as build guides.  ;D :o ;D
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Rudi

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Re: FirstWatt F5 (fdlsys)
« Reply #11 on: June 22, 2011, 12:49:10 pm »
FOUND ALL OF THE 150R resistors. thanks to fdlsys he saved you a trip to the shops.
Never argue with an idiot. The people watching might not know the difference.

scottl1976

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Re: FirstWatt F5 (fdlsys)
« Reply #12 on: June 22, 2011, 01:42:37 pm »
Hey fdlsys, that's looking great. I cant wait to get going on this. Keep the photos coming for the noobs! :) :) :)

fdlsys

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Re: FirstWatt F5 (fdlsys)
« Reply #13 on: June 22, 2011, 02:08:19 pm »
Thanks gents, will do, most definitely, with pleasure, etc. :)

Now comes the difficult part:
- Completing the build (PSU an'all an'all) and
- powering it all up from the "MDF base plate" if you know what I mean;
- with heatsinks attached so that the bias can be adjusted and temperature measured for stability/reliability

With Class-A designs, you cannot just lay the heatsinks on their backs and provisionally attach the FETs and expect that anything is going to work - let alone be stable.
You MUST bias, measure and test (60-120 minutes) with heatsinks in the position that they will assume in the "production model" (fins on the outside and going vertically, for example).
FETs must be attached like it's the last time you'll ever fit them, otherwise they will overheat faster than you can unplug.

Only after this all passes the QA, I will be able to do a functional + aesthetic design of the case that will make me feel proud  ;D

...to be continued...
RANDBURG, the cradle, Earth Mk2

d0dja

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Re: FirstWatt F5 (fdlsys)
« Reply #14 on: June 22, 2011, 03:44:56 pm »
This is REALLY going to be a learning experience for me  :o