Case For Ali Express 5V 2A PSU JCPOWER JC-10-5

This is a wall mountable case for the 110/220V to 5V 2A PSU, model number JCPOWER JC-10-5 that can be found cheaply on Ali Express. It is the first public model produced using the model I have created for this power supply that you can find here.

Electricity can kill, injure and cause damage to property and persons. Hence, please read the disclaimer at the bottom and move on if you are not confident in your knowledge and skill to assemble this device.

Required Parts

• Panel mount switch, part number H8550VBACA, available globally at component outlets
• JCPOWER JC-10-5 PSU (if following link, be sure to select the 2A version)
• 2x M4S Ruthex inserts, for the part that connects to the power cable retainer
• 6x M4 Ruthex inserts, for all the rest
• 8x M4 x 8mm screws
• Some appropriate electrical cable with an earth wire
• A method of connecting the cables to the switch (read assembly guide)

Printing

All parts are made to be printed directly on the print bed with no supports in a sensible orientation, however this assumes your setup will work with the small amount of bridging needed for the holes in the enclosure.

I have operated this at its full rating and in my relatively cool workshop it was not warm enough to need a more heat tolerant plastic. However, if you are operating it in a warmer environment please consider this.

If you do not want to wall mount this, you should be able to remove the tabs for this in the slicer as they should be listed as separate objects in certain slicers.

Assembly

Throughout this guide, please ensure the power cable you have is not connected until you have fully assembled it. This guide probably should not be needed by a knowledgeable person, who will be able to assemble it without instruction. But maybe read it anyway.

First we will install the PSU. A little regret is not making these particular Ruthex M3 to make this less fiddly. Maybe in a future update.

1. Complete the Ruthex insert installation.
2. Screw one of the M4x8 screws most of the way into the Ruthex in the bottom of the case closest to the DC terminals.
3. Hang a screw in the mount point at the AC end of the PSU, meaning on the metal case not the PCB. Slide the other end of the PSU on to the screw from the former step, lowering the other end carefully into the screw hole.
4. Tighten these screws up.

Now the Switch:

1. Thread the cable through the hole into the PSU, then out through the switch hole.
2. The switch is DPST, for this:
   1. Work out which terminals to connect both live and neutral cables to and connect them. If this is confusing or you do not know how, please consider stopping here and buying a PSU with an enclosure or getting someone knowledgeable to finish the build. 
   2. Some will tell you solder is fine (if soldering, ensure no stress/tension on cables). Some will tell you soldering is not and to crimp connectors on the cables to plug on to the switch. We're not getting into this, but the latter is more recommended these days.
3. Cut some more cable, connect the other switch terminals to the live and neutral terminals on the PSU.
4. CONNECT THE EARTH CABLE TO THE PSU. This is an important safety thing.
5. The switch is push-fit into the panel. Push push!
6. ATTACH THE POWER CABLE RETAINER. This is an important safety device.
7. Screw the top panel on.
8. Attach a plug to the other end of the power cable. Make sure the earth is connected.

Turn on and test. Note that it is probably best to ensure the PSU is off when connecting things to the DC terminals, as it involves sticking a screwdriver, presumably made of metal, into the hole in the top of the PSU. Be safe and also please read the disclaimer below.

Disclaimer

While we do our best to supply you with quality creations, our creations and any instructions or guidance are supplied as-is with no warranty of guarantee of any kind. By downloading and using these models you assume sole responsibility for any damages that may be incurred as a by-product of you or any third party building, owning or operating the models, including damage to third party property or persons.