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Graymark 803 User Manual

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POWERSUPPLY
0esigned and
pmted
in
U.S.A.
Dr
I
Subsidiary
of
Buck
Engineering Co.,
lnc.
tNTEFINATIclNAL,INC.
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Graymark 803 Specifications

General IconGeneral
Input Voltage105-125 VAC
Output Voltage0-20 VDC
Output Current0-3 Amps
Load Regulation±0.1% + 5mV
Ripple and Noise1 mV RMS
Display TypeAnalog Meter

Summary

INTRODUCTION

TOOL REQUIREMENT

Lists the necessary tools for assembling the project, plus optional tools.

PROGRESS GUIDE

Parts Identification and Inventory

Experience in identifying and inventorying project components.

Soldering Practice

Guidance and practice in proper soldering techniques.

Phase I: Breadboard Construction

Constructing the unit in a breadboard format for experimental work.

Phase II: Chassis Assembly

Assembling components and fittings onto the project chassis.

Phase III: Evaluation

Reviewing and evaluating the project's completion and learned skills.

PARTS LIST

Component Identification Visuals

Visual identification of electronic components used in the project.

SCHEMATIC AND BLOCK DIAGRAMS

Schematic Diagram Overview

The circuit diagram of the Model 803 Power Supply.

Block Diagram Overview

Overview of the power supply's circuit stages.

Resistor Color Code Reference

Chart for interpreting resistor color bands and values.

SOLDERING EXPERIENCE DETAILS

Soldering Iron and Solder Selection

Recommendations for soldering iron wattage and solder core type.

Tip Preparation and Connection Readiness

Ensuring the iron tip is tinned and connections are clean.

Soldering Technique and Best Practices

Proper methods for heating, applying solder, and cooling connections.

Solder Flow and Connection Quality

Visual examples of correct and incorrect solder connections.

PHASE I: BREADBOARD CONSTRUCTION

Breadboard Introduction and Circuit Stages

Introduction to breadboarding and the project's circuit stages.

Transformer Experience and Theory

Understanding transformer function and the turns-ratio law.

Breadboard Preparation and Materials

Instructions for preparing the breadboard base and gathering materials.

BREADBOARD WIRING DIAGRAMS

Breadboard Schematic Layout

Diagram showing bus wire connections to tacks on the breadboard.

Transformer Wiring Procedure

Illustration of wiring the power transformer (T1) to the breadboard.

Line Cord Preparation and Installation

Steps for preparing and securing the AC line cord.

INSTRUMENTATION AND MEASUREMENT

Electrical Safety Precautions

Essential safety rules for working with electricity and circuits.

Transformer Voltage Test

Demonstrates transformer step-down action by measuring voltages.

FULL-WAVE RECTIFIER EXPERIENCE

Rectification and Voltage Ripple Explained

Explains rectification and the concept of voltage ripple.

Rectifier Circuit Construction

Steps for soldering diodes and the load resistor.

Diode Resistance Testing

Tests diode functionality by measuring resistance in both directions.

RECTIFIER CIRCUIT MEASUREMENT

Diode Lead Identification

Diagram showing diode lead identification (anode/cathode).

Percent-of-Ripple Test (No Filter)

Measures ripple voltage without a filter circuit.

FILTER CIRCUIT EXPERIENCE

Capacitor Filter Functionality

Explains how a capacitor filter smooths DC voltage pulsations.

Filter Circuit Construction

Steps for soldering the filter capacitor (C1).

FILTERED DC MEASUREMENT

Percent-of-Ripple Test (With Filter)

Measures ripple voltage of the filtered DC output.

Optional Oscilloscope Experience

Using an oscilloscope to visualize rectification and filtering.

VOLTAGE CONTROL EXPERIENCE

Voltage Control Circuit Explanation

Explains how transistor Q1 and potentiometer R1 control output voltage.

Voltage Control Circuit Construction

Steps for connecting transistor Q1, bias resistor R2, and other components.

OUTPUT VOLTAGE TESTING

Variable Output Voltage Test

Tests the variable output voltage control of the power supply.

Output Voltage Measurement Table

Table for recording output voltage (Vo) and transistor voltage (Vce).

PHASE II: CIRCUIT ASSEMBLY

Front Panel Component Mounting

Steps for mounting potentiometer, terminal posts, and transistor Q1.

Wiring Connections to Terminal Strip

Illustration of connecting wires to terminal strip lugs.

TESTING PROCEDURE

Potentiometer and Voltmeter Setup

Steps for setting potentiometer to MIN and connecting voltmeter.

Output Voltage Verification

Steps for rotating potentiometer and checking voltage range.

Testing Completion

Confirms the completion of the power supply testing procedure.

CABINET ASSEMBLY PROCEDURE

Front Panel and Knob Installation

Steps for attaching the front panel and control knob to the cabinet.

Cabinet Assembly Completion

Confirms the completion of the cabinet assembly.

PHASE III: EVALUATION AND OPERATION

Operating Instructions and Suggestions

Steps for using the power supply with electronic devices and monitoring output.

Safety Warning: Short Circuits

Warning about short circuits and incorrect connections.

HOW YOUR PROJECT WORKS

Transformer Circuit Function

Explains the function of transformer T1 in stepping down voltage.

Rectifier Circuit Function

Describes how diodes CR1 and CR2 change AC to pulsating DC.

Filter Circuit Function

Explains the role of capacitors and resistor in smoothing DC.

Control Circuit Function

Details the function of the zener diode, resistor, capacitor, and transistor.

LEARNING EXPERIENCE AND SKILL REVIEW

REVIEW EVALUATION

True/False Statements

Statements to be marked as true or false regarding project principles.

Schematic Symbol Matching

Matching schematic symbols to their component names.

Completion Questions

Fill-in-the-blank questions about transistor leads and voltage measurements.

SERVICE AND PARTS INFORMATION

Service Flow Chart for Troubleshooting

A chart to aid in locating and diagnosing problems with the unit.

Ordering Replacement Parts

Instructions for requesting and ordering replacement parts.

Factory Servicing Assistance

Guidance for obtaining technical assistance and factory repair.

SHIPPING AND BREADBOARD INSTRUCTIONS

Important Service Eligibility Note

Note on eligibility for service regarding solder and modifications.

Breadboard Schematic Preparation

Instruction to cut out the breadboard schematic for Phase I.

Breadboard Schematic Diagram

The breadboard schematic diagram to be cut out for Phase I.

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