I’ve designed a new power supply mount for the Wilson II which incorporates the power switch previously used along with a IEC power inlet so that a common power cord can be used without modification. It also keeps the AC line wires a little shorter and tucked away to make it harder to touch something you don’t want to. If you’ve built the Wilson II previously, this new mount basically combines the lower PSU mount along with the power switch mount.
The power inlet that I’m using is a standard IEC 60320 C14 receptacle or just “IEC 320-C14”, which includes a line fuse.
Here’s how to assemble it:
1. Parts List
Besides the power supply itself, you will need:
A. Printed power supply mount bracket (psu-mount-bottom.stl)
B. IEC 60320 type C14 receptacle with line fuse (27x32mm panel mount size). (For example, Digikey P/N Q202-ND)
C. Panel mount power switch (12x18mm, rocker, 3-prong style shown).
D. 2x M3x14mm screws and M3 hex nuts (or SAE 4-40 1/2")
E. 2x M4x10mm screws
F. 18AWG wires prepared as shown: 1 for Earth ground, one for AC line from receptacle to switch, one for AC line from switch to PSU, and one for Neutral to PSU+Switch. In the photos below, I’m using Green for earth ground, Orange for AC Line, and Blue for Neutral. The longer wires are approximately 5-6" long.
2. Attach AC Line, Neutral, and Earth ground wires to the power supply
There should be etchings or labels on your PSU to indicate which screw terminal is which, but mine has Earth ground, Neutral, and AC Line as the last three on the right, respectively.
3. Snap the power switch into place in the mounting bracket and install the IEC receptacle
Be sure to orient the power switch with the “off” position down. The plastic bracket prints with some support material in the receptacle opening, so you’ll have to remove that first, and then push the receptacle into place (the fuse should go “down”). Use two M3x14mm screws and hex nuts to secure the receptacle. Slide the power supply into the top side of the mount and secure with two M4x10mm screws.
4. Attach the push-fit connectors to the spades on the receptacle and the power switch
On my power switch, the Neutral wire goes to the top most post (near the “1” side of the switch) which is slightly brass colored. The other two silver colored posts are for AC line in and out. On the IEC receptacle, earth ground is located at the top, followed by Neutral, with Line being the post at the bottom (the fuse is in series with Line).
Use a zip tie to secure the wires to each other when they are all connected. This will hep prevent any loose wires or snags.
5. Attach the 12V and Ground output wires to the power supply
Use the slots on the side of the mount to access the screw terminals with a Phillips screwdriver. Use another zip tie to secure the 12V wire harness to the mount. This will provide some strain relief and keep things tidy.
6. Mount the power supply to the Wilson II frame##
Mount the power supply to the Wilson II frame exactly as you would normally - using two M5x10mm screws to secure the slotted tabs to the frame. For the top side of the power supply, use the original power supply mounting bracket (psu-mount.stl) which is fastened to the PSU using two M4x10mm screws.