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Engagement
  • Author Author: three-phase
  • Date Created: 9 Jun 2019 9:23 PM Date Created
  • Views 471 views
  • Likes 10 likes
  • Comments 6 comments
  • test rig
  • 4mm jacks
  • wago terminal block
  • sma connectors
  • current amplifier
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Amplifier test board

three-phase
three-phase
9 Jun 2019

This is the test board I made up for the experimenting with polymer capacitors challenge based around my current amplifier project. I had meant to include this in the first challenge blog, but published the blog without including it, so I will put it in my own blog with a few things that went well and improvements that could be made.

 

Blog 1 - Using polymer capacitors in the current amplifier

 

Blog 2 - Test results for polymer capacitors in the current amplifier

 

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The video shows how easy it is for me to remove the amplifier board to changeout the capacitors.

 

The one thing that has impressed me are the Wago terminal blocks I used for the AC power supply and DC fan supply connections. I have come across spring style terminals in lamp fitting many years ago, but have never really used them for anything else. The apparatus I work on will generally have DIN style screw terminals with a cage clamp, but as I have started to wire up my new garage, I have utilised them some more and their ease of use made me look at alternatives available for my test board.

 

As can be seen below, these spring style terminals do not cause any damage to the ferrules inserted into them, unlike the standard electrical screw connector block commonly available.

 

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A close up picture shows the screw indentations on the ferrule that has been in the screw terminal block. Multiple tightening and releasing will eventually lead to the ferrule needing to be replaced.

 

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The close up shows the screw indentations and the undamaged red ferrule ,that has been utilised I the Wago terminal block.

 

The other good think about the Wago blocks is that they have much less exposed metal - giving a safer working environment for testing.

 

The other thing that has impressed me is Gorilla glue, that I used to hold together the metal bracket for the SMA connectors. I know that there is not much pressure on the plate as I am only unscrewing a couple of SMA connectors, but the joint between the two right angle sections is just on its edges and it has held without any problems. I did rough up the galvanised finish before applying the glue.

 

image

 

A couple of things that have not worked so well.

 

image

 

The red identified SMA lead is a little too close to the metal bracket glued on and makes the SMA connector awkward to disconnect. I have also positioned the complete bracket with all of the connections too close to the amplifier board supports. This doesn't leave much room when unscrewing the red and blue SMA connectors.

 

I also planned to utilise wing nuts on the 4mm jacks for the amplifier output leads. However, I positioned all of the holes centrally in the bracket and the wing nuts fouled and could not be screwed on, so I resorted to normal hexagon nuts. The use of these though has eventually damaged the 4mm jacks and the metal insert has started to pull out of the plastic holder.

 

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You can see this on the yellow 4mm jack, where the metal section has now pulled through more in comparison to the black jack. Some more Gorilla glue may be in order soon to fix this.

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Top Comments

  • jw0752
    jw0752 over 3 years ago +4
    Hi Donald, A really nice looking setup. I also run into the problem of centering things for aesthetic reasons only to realize later that the hole would have been better offset. John
  • genebren
    genebren over 3 years ago +3
    Very clean fabrication on your amplifier test setup. This is a pretty cool way to do some side by side and/or incremental testing of your design. Well done! Gene
  • three-phase
    three-phase over 3 years ago in reply to genebren +2
    Many thanks Gene.
  • three-phase
    three-phase over 3 years ago in reply to shabaz

    The 222 I have used quite a bit now, I tend to prefer the harder operation, it gives me a feeling that the connection is more sturdy. I also find them a bit easier to access the test hole for carrying out the R1+R2 readings, than the other series connectors. The 221 series are great for conduit boxes due to their smaller size.

     

    They also make the 773 series that are straight push-in connectors, really only suitable for solid wires and not stranded, they are also not as easy to take the wires back out.

     

    image

     

    Kind regards

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  • three-phase
    three-phase over 3 years ago in reply to jw0752

    Thanks John. I think I need to pay more attention to taking a look behind every now and again. I am also guilty of just making things up as I go along instead of laying them out first.

     

    Kind regards.

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  • shabaz
    shabaz over 3 years ago

    Hi Donald,

     

    Nice work. It looks fantastic. Those connectors you're using look great for bolting down into internal chassis/industrial and test rig projects.

    Wago stuff is really nice.

    I used the 'electrician' versions recently during a flat renovation. The typical 'electrician-style' Wago connector was the 222 series,

    image

    but it was new to me that there is a 221 series, it is a lot thinner compared to 222, and is easier on the fingers, and greater flexibility on wire sizes that fit too.

    (Plus easier to visually inspect due to transparency, etc).

    image

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  • jw0752
    jw0752 over 3 years ago

    Hi Donald,

     

    A really nice looking setup. I also run into the problem of centering things for aesthetic reasons only to realize later that the hole would have been better offset.

     

    John

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  • three-phase
    three-phase over 3 years ago in reply to genebren

    Many thanks Gene.

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