Graymark 803, Manual

Page 1: ...POWERSUPPLY 0esigned and pmted in U S A Dr I Subsidiary of Buck Engineering Co lnc tNTEFINATIclNAL INC 7I L ...

Page 2: ...to PHASE ll PHASE ll is industrially speaking the assembly operation This phase is con cerned with arranging the components and fittings onto the chassis This phase will provide you with experiences such as component identif ication component mounting solder techniques lead dress and final assembly into the plastic cabinet PHASE lll provides you with Operation tnstructions Product Specif ications ...

Page 3: ...earning experience The Final Evaluation is provided so that your instructor can indicate your degree of achieve ment on the entire project rur Narne PARTS IDENTIFICATION AND INVENTORY EXPERIENCE SOLDERING EXPERIENCE TRANSFORMER EXPERI ENCE Construction Instrumentation And Measurement FULL WAVE RECTIFIER EXPERIENCE Construction lnstrumentation And Measurement FILTER CIRCUIT EXPERIENCE Construction ...

Page 4: ...0V at 135 mA Terminal Strip 4P l Line Cord AC 2 conductor with molded plug Knob plastic Line cord stopper plastic Terminal post with mounting hardware red Terminal post with mounting hardware black Plastic tubing Black 5 length Plastic tubing clear 1 wire 1 red 1 blue and 1 yellow Solder rosin core 60l40 Self tapping screw Washer shoulder insulating Washer f lat insulating Panel steel Cabinet plas...

Page 5: ...econd figure in the resistor value o Third color represents the multiplier of the first two figures Fourth color represents the resistor tolerance 4ih coloR TOLERANCE BLOCK DIAGRAM NO COLOR SILVER 10 GOLD BLACK BROWN RED 100 1 000 ORANGE YELLOW 10 000 GREEN 100 000 BLUE 1 000 000 VIOLET 10 000 000 GRAY 100 000 000 WHITE 1 000 000 000 Red Violet Orange 27000 Creen Blue Red 5600 Silver 1O o 27000 or...

Page 6: ... by forming tight mechanical connections before you apply solder 6 Wear safety glasses while unsoldering and solder ing to avoid eye injury caused by a hot solder splash or flying bits of wrre leads 7 Position the flat side of the soldering iron firmly against thc wjre lead and terminal to preheat the metal parts to be soldered See Fig 6 B While the connection is being heated apply the solder Do n...

Page 7: ...s illustrated in Fig B It shows that the changing magnetic field created by the varying current in the primary winding induces a voltage in the secondary winding as the magnetic field cuts across the turns of wire in this coil The relationship between the input voltage primary and the output voltage secondary is determined by the number of turns of wire in the primary and the number of turns of wi...

Page 8: ...ubing in half Slip one piece over each line cord lead Con nect one lead to lug A of the transf ormer and solder solder 1 Connect the other iead to Iug B of the transformer and solder solder 1 Slip the tubing down over the 2 lugs to insulate them Refer to Fig E3 d Obtain four 5 inch lengths of hookup n ire Strip l a inch of insulation from both ends of each wire and tin e Connect and solder one of ...

Page 9: ...condary winding and the center tap PIug in the Iine cord Read and record this voltage Ect 1 in the space provided in Fig C lt should be ap proximately 25 volts AC g UNPLUC THE LINE CORD h 4ove the VON 1 test probe from tack 1 to tack 3 so you can measure the voltage be tween the other side of the secondary wind ing and the center tap Plug in the line cord Read and record this voltage Ect 2 in the ...

Page 10: ... hich is a ratio of the ripple voltage rms and i average DC voltage This is expressed mathematicall 25 of ripple _ Ermsof Ripple Voltage 100 E average CONSTRUCTION 1 Solder the ANODE lead of rectifier diode CR1 i tack 1 as shown in Fig K Refer to Fig L for dioc lead identification 2 Solder the ANODE lead of rectifier diode CR2 tack 3 3 Solder the CATHODE leads leads nearest the colc bands of both ...

Page 11: ... ve tlts DC This is the E3ys12gs voltage c UNPLUC THE LINE CORD Then change the meter to a range that will measure 15 volts AC and substitute the AC test probe for the DC probe connected to bus wire A d Plug in the line cord Read and record this voltage measurement lt should be about l 0 volts AC This is the E1mq of Ripple Voltage e UNPLUC THE LINE CORD Remove the test probes from the breadboard f...

Page 12: ...ge tank lt stores an elecirical voltage r vhen the rectilier output voltage is high and discharges when the rectifier voltage drops This has the eficct oi li tttening out lhe peaks of the pulses and filling in the valleys betr veen them This results in a relatively smooth DC voltage Refer to Fig ll CONSTRUCTION 1 Solder the POSITIVE lead of filter capacitor 100 7 F 35VDC electrolytic to bus wire A...

Page 13: ...ng the proper voltages into the equation Refer to previous steps b and d for the voltage readings 1 Ripple Ey ps of ripple voltage OPTIONAL EXPERIENCE For this test you wili need an oscilloscope The purpose of this test is to visually show the rectification process and the effect the filter capacitor has on smoothing the DC voltage l Solder the lK ohm resistor betlveen bus wires A anrl C 2 Unsolde...

Page 14: ...m both ends then tin Connect and solder be tween tack 11 and bus wire C 5 Solder potentiometer R l to tacks 9 10 1 1 a shown in Fig R 6 Solder anti oscillation capacito r C2 02y F betrr ee bus wire A and bus wire B Refer to Fig R 7 Solder bleeder resistor R3 1K ohms brorvn blaci red betw een bus wire B and bus wire C as sho This resistor is used to bleed off any charge tl may remain on capacitor C...

Page 15: ... space provided in Table I f Next add together V and V and place the sum in the space provided in Table I 9 Complete Table I by adjusting the poten tiometer for each of the output voltages V listed in the table Then record a V measurement for each of these output voltage settings Next total each combina tion of V and V Is the total for each com bination approximately the same They should e You can...

Page 16: ... lug B center Iug of the potentiometer and solder solder 1 Refer to Fig 5 u d A ryASHER LOCK WASHER BLACK TERMINAL FIG 2 5 Cut a 2lh inch length of RED l rookup wire and strip r inch of insulation from both ends Connect one end to the E V1 ITTER lead of the transistorand solder solder 1 Refer to Figs 4 and 5 Con nect the other end to lug D of the terminal strip as in Fig 5 6 Cut a 1 inch length of...

Page 17: ...d to lLrg D of the tc r nrin tl slrip 1 r CLrt both leads of capacitor C3 470 uF to inch length Connect the POSII IVE lead to lug D of the terminal strip and solder solcler 5 Connect the other lead to the solder lug on the BLACK terminal po5t as shorvn inFig 7 and solder solder 2 l7 CLrt both leads of capacitor C1 100 uF to inch Iength Connect the POSITIVE iead to lug A of the terrnrnal strrp and ...

Page 18: ...osition The voltmeter should now read between 15 and 1B volts DC lf this voltage is not obtained UNPLUC THE LtNE CORD recheck all wiring component placement solder connections and then refer to the Service Flow Chart on page 22 6 This completes the testing of your Model 803 Power Supply UNPLUC THE LINE CORD Have instr uctor initial your Progress Cuide Ql o u1 o CABINET ASSEMBLY 1 Position the fron...

Page 19: ...he voltage con tr ol to the MIN position and then unplugging the line cord from the wall receptacle TRAN POWER SUPPLY OPERATING SUGGESTIONS o Should you desire to monitor the output voltage from your Power Supply connect a voltmeter to the circuit as shown in Fig 13 No voltage indications are shown on the control dial be cause the output voltage at any particular setting will vary according to the...

Page 20: ... CR3 resistor R2 pote ntiorneter R l capacitor C2 and transistor Q1 The transistor acts as a i ariable resistor to control the outpirt i oltage and js in turn controlled by the potentiorneter 20 LEARNING EXPERIENCE AND SKILL DEVELOPMENT REVIEW This project has afforded you the opportunity of expanding your knowledge of electronics and electrical devices through experiments and related techni cal i...

Page 21: ...s is red gray black T F 6 The transformer used in this project has a center tap in the prinrary winding T F 7 Trvo zener diodes are used in the full wave rectifier T F B The two leads of a diode are the emitter and the collector MATCHINC ln ihe space provided place the correct LETTER that matches the schematic symbol from the column on the right lf A r 1 DIODE RECTIFIER 2 TRANSFORMER 3 WIRE CONNEC...

Page 22: ...or fittings that have been damaged through careless ness or incorrect assembly Maii you r req uest for replacement part to G raymark Parts Department P O Box 5020 Santa Ana CA 92704 Enclose the following 1 Your name and mailing address 2 Date project was purchased 3 Part number and description as listed in the PARTS LIST of the part to be replaced 4 lf replacement part is not covered by the war ra...

Page 23: ...rchase Be sure that all parts and fittings are attached to the kit Pack the kit in a strong carton and place at least 3 inches of packing material such as shredded paper or excelsior between all sides of the kit and the carton Seal the carton with gummed tape and tie with a heavy string Write FRACILE HANDLE WITH CARE on sev eral sides of the carton Print clearly your name and return address in the...

Page 24: ...I l l 7 s PROJECTS GRAYMARK SELF TECH GnaytTraFk Graymark lnternational lnc Box 5O2O Santa Ana California92TO4 Printed in U S A ...