Model Info

• This is a Gridfinity compatible case for a 60W electronic load (Aliexpress, not an affiliate link). It is not compatible with the 110W version.
• This is intended as an ‘auxiliary’ or ‘secondary’ electronic load for low-power testing, or to give your existing 60W load an enclosure if you already have one. It is better to simply buy a proper electronic load if you can afford it.
• No liability is assumed for this model. This has been tested for several hours operating at the top end of 60W, but it is also dependent on user skill of manual assembly. Failure to assemble correctly or use appropriate wire gauge may cause overheating or short circuits.

Required Hardware (Non Affiliate Links)

• 1x 60W electronic load 
• 6x ISB-M3 heat-set inserts.
• 1x DC-021M panel mount jack. (2.1x5.5mm) or the DC-025M (for 2.5x5.5mm)
• 2x Panel Mount Banana Plug Binding Post Pairs
• 1x 21x15mm Rocker Switch
• 6x M3x6 machine screws of any type.
• 10x Dupont male-to-female wires.
• (Recommended) 4x 1x5 Dupont wire housings
• Red/black wire, 18AWG or better recommended.
• WAGO or other wire connectors for the input power.

Printing

• It is recommended to print in your preferred heat resistant filament - if you print in PLA and run the electronic load for prolonged periods of time, it may warp or distort if you are in a hot environment. I have tested this in a climate controlled office environment with PLA and it seems fine.
• Support reinforcers and blockers are already configured in the print profile.

Assembly

• Install 6x heat-set inserts in the bottom of the case.
• Remove the display/control PCB by removing the 4 sets of M3 screws and standoffs from both sides. The PCB will unplug by pulling it directly upwards.
• Re-install the standoffs onto the display/control PCB, but reverse the direction so that the standoffs are on the same side as the 7-segment displays.
• Pre-wire the rocker switch with a pair of wires. Pre-wire the DC input jack to the input power jack (left side), while leaving leads to connect to the rocker switch for power. Do not connect it to the rocker switch yet.
• Pre-wire the ‘load’ side terminals with a short length of wire pair.
• Pre-wire the ‘sense’ connection with another short length of wire pair.
• Pre-wire the display/control dupont extension wires by plugging them into the load board (do not connect to the display/control PCB yet as things will get crowded). It is recommended to swap out the 1x1 header enclosures for 1x5 header enclosures if you have them to make installation easier, but it is not essential.
• Mount the electronic load board into the case using M3 machine screws.
• Mount the DC input socket on the back panel. Install the rocker switch. Connect the input power wires to the power switch.
• Mount the lower ‘sense’ binding posts, using one of the washers for the binding posts. Connect the sense leads to the rear of the binding posts.
• Mount the upper ‘load’ binding posts, using the second washer. Connect the load leads to the rear of the binding posts.
• Mount the display/control PCB using the other 4 M3 screws obtained from the earlier disassembly. The 7-segment displays, LEDs, and encoder should align with the holes.
• Test your electronic load. Once satisfied, you can friction-fit (or glue) the lid into place.