Atorch DL24 Electronic DC Load Case V2

Overview

This project takes an Atorch DL24 Electronic Load module and makes some minor modifications to it and encloses it into a custom 3D printed enclosure to provide improved handling and board protection.  The project also converts the DL24 to use a USB-C power source.

There’s a lot to like about the DL24.  It’s core function as an electronic load is well done.  Areas that need significant improvement includes the documentation and supports apps on Windows, iOS and Android.  Whilst the remote apps are not essential, I would use them more if they were better implemented.

The DL24 draws less than 1W of power, so can be powered from most USB power adapters.  The 5V USB output voltage is brought up to the needed 6-12V by a MT3608 buck booster module.

Specifications

• 4 wires voltage measurements
• Up to 150W power dissipation
• Discharge modes: Constant current, constant power, constant resistance, and constant voltage
• User selectable thresholds and time limits 
• Bluetooth and USB monitoring capability
• External wired NTC temperature probe
• 2.4in LCD colour display
• Real time monitoring
• Temperature-controlled fan

Parts List

• Atorch DL24 Electronic Load module
• DC-DC Step-up Inverter power module (MT3608)
• USB-C panel mounted socket
• Electronics enclosure and button extensions x 4 – 3D printed
• 3 x 3mm x 7mm self-tapping screws
• 2 x 3mm x 12mm countersunk screws
• 1 x M3 x 10mm screw
• 1 x M3 x4mm brass insert
• Double sided tape (~15mm in length)

Wiring

Wiring is low voltage and low current, so multistrand 24awg hook-up wire is used to interconnect components.  All wire connections are soldered.

ASSEMBLY

Carefully adjust the MT3608 output voltage to 10V BEFORE wiring it to the DL24 module.  Adjusting the output voltage for the first time with the DL24 module connected is likely to destroy it!

The DL24 PCB is held in place by three 3mm x 6mm countersunk screws.  The front cover is held in-place by two 3mm x 12mm countersunk screws.  I used a M3 x 10mm screw and a M3 x 4mm brass insert to keep the USB-C connector in place.  Insert the brass insert carefully with a heat source, like a soldering iron. The MT3608 is held in-place with double sided tape.

The main undocumented USB and Bluetooth LED’s are made visible on the front panel.  Short sections of clear 1.75mm 3D filament are placed in front of the LED’s, transferring the indicator lights.

Fitting the USB-C panel mount …

Note the three locations marker with red arrows for the DL24 module 3mm x 7mm self-tapping screws mounting screws.

THANK YOU

I hope that you can find this print useful, too.  If so, you can support my work by buying me a coffee …

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Remember to leave a comment, perhaps a like to keep me enthused to make more.  I have a 100+ published designs.  Do check them out.

PRINTING INFORMATION

The print STL files can be printed as one print profile, but the display cover extra detail means all parts printed with it will print at the same detail and take longer to print.

My prints are made in 1.75mm eSUN PLA+ Silver filament, with 0.2mm layer height on a Bambu Lab H2D printer with a 0.4mm hotend, except for the display cover.

The display cover has embedded text.  To be readable, the text size needs a 0.2mm nozzle.  By default, the layer height gets adjusted to 0.1mm.  The cover is printed in eSUN PLA+ Silver and White.

The buttons are printed in eSUN PLA+ Black.

Both the print profiles and the individual STL files are included for download.

The DC Load Module is also sold with the beeper part in another location.  (22mm in, 50mm up, referenced from the bottom right corner).  If your DC Load Module has this alternate beeper position, you are catered for, too.  See alternate screen cover 3D printed part 3MF profile that fits this beeper location.

Appendix:  Parts

Atorch DL24 Electronic Load Module

Used to simulate a connected load to for example, a battery, a power supply.  The power capacity is logged and tracked.  When a user defined threshold is met, the load test ends. Results are summarised on a screen display.

Specifications:

• 4 wires voltage measurements
• Up to 150W power dissipation
• Discharge modes: Constant current, constant power, constant resistance, and constant voltage
• User selectable thresholds and time limits
• Bluetooth and USB monitoring capability
• External wired NTC temperature probe
• 2.4in LCD colour display
• Real time monitoring
• Temperature-controlled fan
• https://vi.aliexpress.com/item/1005005690292845.html?spm=a2g0o.productlist.main.7.7a70Ixx0Ixx0wC&algo_pvid=6e266fba-5a24-41fa-b49e-6bf450810cc7&algo_exp_id=6e266fba-5a24-41fa-b49e-6bf450810cc7-6&pdp_ext_f=%7B%22order%22%3A%221744%22%2C%22eval%22%3A%221%22%7D&pdp_npi=4%40dis%21AUD%2143.11%2131.90%21%21%21199.10%21147.33%21%402103205117527081397624234ecc9a%2112000034019505988%21sea%21AU%21179731625%21X&curPageLogUid=fuxu534SOClX&utparam-url=scene%3Asearch%7Cquery_from%3A

MT3608 DC-DC Adjustable Voltage Step Up Module

Specifications:

• Input voltage: 2 ~ 24V (No REVERSE VOLTAGE PROTECTION!)
• Maximum output voltage: 28V
• Maximum output current: 2A (recommended for use within 1A)
• Efficiency: ≤93%

USB-C Panel Mount Socket

Example unaffiliated purchase link …

https://vi.aliexpress.com/item/1005003658327018.html

Appendix:  Images