Bench top power supply - TFX, not ATX based by maco2229

Last crawled date: 3 years, 5 months ago

CHANGE LOG
2021-01-09
added photo of used TFX power supply: the exact model is Fortron FSP250-60SBV
updated info about brass inserts in BOM (it is designed for M3 X D4.6 X L5.7)
2021-01-09
STEP file added to allow you modify the project easily
Assembly guide added (please find attached pdf in files list)
added stl files for top and bottom lid - for those who don't want to cut them out from plywood
added pdf template for cutting the top and bottom lids
added melt-in brass inerts to the BOM
Disclaimer
I did my best to make this design safe but overall I am an amateur and hobbyist. I can't guarantee you won't hurt yourself during making this thing, so if you feel uncomfortable to work with electricity, please don't start playing with it.
As well, this is not laboratory power supply. I don't know the level of noise or any other parameters which is required for lab PSUs, so don't even think about this thing that way.
Introduction
Bench top power supply built on top of an old TFX 250W power supply (you can probably by one on your local market for about $10-15)
The design is inspired by the "Back Horn Speaker V2.0 BL2 - Bluetooth, Active, Passive" by guppyk (https://www.thingiverse.com/thing:4668173)
Bill of materials
Product
Amount
Link
Rocker switch
5
https://aliexpress.com/item/1000005699023.html
Dual USB charger
1
https://s.click.aliexpress.com/e/_AmzlmT
12V LED rocker switch
1
https://s.click.aliexpress.com/e/_ANc8qP
Step up buck converter
1
https://s.click.aliexpress.com/e/_9vhU95
Buck Converter CC CV 1.8-32V 5A Power Module
1
https://s.click.aliexpress.com/e/_Ac5D8P
0.56'' 0-100V 10A LED Digital Voltmeter Ammeter
3
https://s.click.aliexpress.com/e/_9vbHCJ
Fuses (5x20, 10A)
4
https://s.click.aliexpress.com/e/_AaPtEL
Fuse holders
4
https://s.click.aliexpress.com/e/_9jOzf9
Banana socket (red)
4
https://s.click.aliexpress.com/e/_AU55QT
Banana socket (black)
4
https://s.click.aliexpress.com/e/_AU55QT
2x 22 Ohm 10W resistors or 1x 8 Ohm 50W resistor with heatsink
2(1)
https://s.click.aliexpress.com/e/_AVklGr https://s.click.aliexpress.com/e/_9gjnQx
IEC socket
1
https://s.click.aliexpress.com/e/_9xd9PH
LM2596 step down converter (optional, for fan speed voltage control)
1
https://aliexpress.com/item/4000064597454.html
Sunon 6010 12V fan
1
https://s.click.aliexpress.com/e/_A7tuKR
Insulated connectors
1 set
https://s.click.aliexpress.com/e/_AnuYWR
Brass Hot Insert Nuts M3 X D4.6 X L5.7
12
https://s.click.aliexpress.com/e/_A1hMur
Some of the above links are affiliate. If you feel uncomfortable with this try to search products on your own.
Assembly
Please look at the Thing Files list for full guide

Wiring
Wiring scheme is included in files list (PDF) and on the preview images list.
Printing
Prepare yourself for a long print. I am printing quite fast (about 100-120mm/s) and I was printing outer walls for about 14h on 0.28 layer height (0.4 nozzle).