Powerpole Distribution

Powerpole Distribution Box Project
Status	Completed
Project Lead	User:TylerWard

Powerpole Distribution Box Project

[PCB Design]

Status

• Completed, designs are available at Github

Feature List

• 6 power-pole connectors
• Individually fused connections with indicators
• 30A+ capacity (Limited by current rating of the fuse holders)

Costings

Costings below are for individual orders the main club order will be cheaper

Type	Item	Cost	Link
connector	12*45A pcb contacts	£9.90 for 15	[1]
connector	6* red 45A housings	£2.65 for 10	[2]
connector	6* black 45A housings	£2.65 for 10	[3]
Fuseholder	Keystone 3522	£6.56 for 100	[4]
Resistor	330ohm though hole 0.25w	£0.23 for 10	[5]
LED	3mm red/yellow	£0.24 for each	[6]
PCB	5*10cm 2oz blue	$40.95 for ~10 or (£3 each)	[7]

Build instructions

Tools Required

• Soldering Iorn (Should be a high power Iron (45W+) with a large tip do that it has a large thermal mass)
• Sidecutters
• (Usefull) Helping hands or other PCB support tool.

Instructions

1. Solder resistors capacitors and LEDs onto the PCB.
2. Push Fuse holder contacts into pcb
3. Solder Fuse holder contacts, these will suck up the heat so might take a bit to get up to temperature.
4. Assemble to top two case layers and attach the partly populated PCB
5. Assemble the powerpole contacts by joining them together and inserting the contacts.
6. Place the powerpole contacts into the board (to ensure correct placement ensure the top acrylic layers are fitted first othwerwise the spring of the powerpoles will mean they go in off centre).
7. Solder the powerpole contacts on the board, I found the best way to do this is to push the board and contacts down onto a heatproof surface so that they sit in the correct place and then solder, these should be soldered fairly quickly as the powerpole housings can be melted if exposed to to much heat.
8. Check for any solder bridges across the fuses or powerpoles.
9. Assemble the remaining two layers of the case.
10. Enjoy your Distro