65V 9A 480W Power Supply

This 65V 9A 480W Bench Power Supply is built around a XY6509X power management module obtained from Ali-Express for AU$28.79.

XY6509X

The specifications and user manual is attached below.

Power supply module

The 72V 600W power supply module was also sourced from Ali-Express for AU$41.59. See full specification in PDF attached.

Binding Terminals

I went for high quality binding terminals. They are a bit more expensive at AU$2.17 each also from Ali-Express.

Mains switch, socket and fuse

The power socket unit includes a fuse and switch. It costs AU$5.03 at Ali-Express.

Case

The case is 255*190*80mm and was purchased from Ali-Express for AU$15.49 + $2.64 postage. This is quite cheap for a case of this size. Quality wise, it isn't as good as a ABS case of similar size but it does come with feet that can tilt the case at a angle. This is really a nice feature. Overall it was good value for the cost.

Assembly

I designed two spacers to sit under the power supply to lift it off studs that are part of the case. The STL files are attached to 3D print these spacers. Use a 0.2mm layer height.

The power supply has 4 screw holes on the base for mounting it into the case. These holes are 152mm apart along one axis and 50mm apart on the other axis. Drill four 4mm holes such that the power supply mounts as close to the back and side as it can. Countersink the 4 screw holes and screw on the power supply using 15mm M4 countersunk (flat head) screws.

There is a STL file that can be used as a template to drill out the hole for the XY6509X power management module and the binding posts. I also added a DC power socket as I have a number of pre-made cables that use a DC power plug. These are fine for low current projects where-as the binding posts are more suited to high current projects.

Mount the power socket assembly on the side of the case. You need to position it so the holes to fix the unit is only on the bottom half of the case.

Wiring can be challenging as space around the power supply and power socket is tight. I used spade terminals on the power socket module, fork connectors on the power supply, ferrules for the connections to the XY6509X power management module and eye connectors on the binding posts.

When connecting to the barrier terminal connectors on the XY6509X with high voltages or high currents, I strongly recommend using Ferrules when screwing in the cables. (See TO FERRULE OR NOT TO FERRULE).

One of the options for the XY6509X power management module is to add a temperature sensor. It uses a 10K NTC 3950B temperature sensor which you can get from Ali-Express for under AU$2. I stuck mine using double sided tape to the inside of the front panel.

Conclusion

The XY6509X power management module provides excellent features at a low cost. The final cost of this project was just under AU$100.