And some more build progress. I'm not using the standard EMW enclosure so my assembly is slightly different than the instructions. I'm building the enclosure around the heatsink, using the heatsink itself as part of the enclosure. I'm quite impressed by the physical layout of the high power pieces along with the driver board. It would be nice if the main control board was a bit more integrated or lined up nicer with the driver board since they have the most board to board wires. The overall layout of everything that mounts to the heatsink is very well done though and is a very efficient use of 3D space without limiting access to the mounting bolts for the IGBT's or rectifiers.
(Reminder, this is the air cooled PFC version of the charger)
The only "issue" I have with the kit is many of the parts don't fit the footprint on the PCB, I believe mine was one of the first kits so lets just hope I got leftovers from the previous design. Val, make sure you update to the proper components to fit the PCB and make assembly simpler and nicer.
I used my CNC router to drill markers holes for the main layout, the holes were then tapped as M4, M5 as required along with the shallow temp sensor hole.
I made a small change to the diode block "wiring" I used a pair of 0.1875" x 0.5" x 0.9" copper blocks drilled with the appropriate holes to both mount to the diode block putting the two diodes in parallel as well as having a hole sized to the 8 Awg wire. This is where a good soldering iron comes in handy, a low power iron would not solder 8awg to a copper block. The legs on the Hall sensor are also too big for the PCB holes and must be trimmed down slightly to fit, don't take off too much material though!!
Instead of mounting the Inductors with the leads facing up I decided that one connection from each inductor could be soldered directly to the PCB. This simplifies assembly and will reduce the wiring a bit but it will slightly complicate servicing the power PCB if it's every required to replace an IGBT or something else.
Instead of the bent steel straps as per the instructions I decided to build a "beam" to clamp both inductors to the heatsink. This beam will also become the mounting point for the "top" of the enclosure as it's shown in the photo.
I made it the same length as the heatsink so the sides of the enclosure will bolt up to both the heatsink as well as the ends of the beam.
As you can see there is nothing fancy about the "beam" it is made up from some aluminium I had laying around. 1.25" x 0.125" C channel (1" internal) gives the perfect spacing to straddle the inductors without interfering with the wires. A piece of 1" x 0.5" and 1" x 0.375" bar stock fill in most of the channel so that it both sits on the inductors where I want it to and doesn't sit on the plastic part. I'll add some screws to the middle and ends to make it one piece so there should be minimal flex when it's tightened down to hold the inductors with the single center bolt.
IMAGE REMOVED BECAUSE IT SHOWED THE DRIVER BOARD INSTALLED BACKWARDS WHICH WILL BLOW UP YOUR PFC IGBT AND MANY OTHER SMALL PARTS!
And finally a general view from the other side with the driver board etc. Right now everything is dry fit for testing and assembly. Once I'm happy with the whole layout I'll be mounting everything permanently and using heatsink compound and loctite.
The final charger should be fairly compact at 10.25" x 7" x around 9.5 -10.5"
This is the initial rendering of the top panel, all of the "divots" would be through holes for airflow, the display and buttons would be front and center(ish), this would mount to the heatsink in the same orientation as the driver board with the heatsink fins open at the bottom. You will notice the drilled/tapped holes in the sides of the heatsink where all of these panels will attach.
This is the initial idea for the bottom panel, it would cover the full size of the heatsink with mounting for the fans with some through holes for wiring since the power brick would be mounted just above the fans in the open area. Since I have limited space two of the screws that mount the panel to the heatsink would be attached through the fans themselves.
One warning, when assembling the main power board be careful of the polarity of C11, there are two + signs within the circle the larger one is correct, the smaller one could throw you off. I had actually installed it backwards initially but caught it with a quick double check of the PCB file before soldering. This would be a big boom at some point!!
The one question I do have though is about PWM fan control, is this implemented already via the Fan out on the main control board or is that simply to control a relay to turn the fans on/off, if so what decides when to turn the fans on/off???