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Building a Heater Circuit for a Near-Space Payload

Building a Heater Circuit for a Near-Space Payload. AEM 1905: Spaceflight with Ballooning University of Minnesota. Heater circuit parts. Perfboard (AKA solderable breadboard). 5 Watt ceramic resistors. Rocker switch. 9-volt battery snaps. Wire: two ~ 6 in and two ~ 12 in.

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Building a Heater Circuit for a Near-Space Payload

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  1. Building a Heater Circuitfor a Near-Space Payload AEM 1905: Spaceflight with Ballooning University of Minnesota

  2. Heater circuit parts

  3. Perfboard (AKA solderable breadboard)

  4. 5 Watt ceramic resistors

  5. Rocker switch

  6. 9-volt battery snaps

  7. Wire: two ~ 6 in and two ~ 12 in

  8. Shrink-wrap (AKA heat-shrink tubing)

  9. Wire mesh (AKA hardware cloth)

  10. Strip the ends of all 4 segments of wire

  11. Line up one short wire end with the 3 red ends from the 3 battery snaps

  12. Twist the exposed metal wires together

  13. Solder the twisted wires together to make the electrical connection permanent

  14. Cover the connection with shrink-wrap

  15. Use heat gun to shrink the wrap

  16. Repeat with black wires – finished product

  17. Wrap one end of each long wire to the 2 tabs on the back of the rocker switch

  18. Solder wires in place – may require turning up the soldering iron temperature a bit

  19. Cover solder joints with shrink-wrap

  20. Completed rocker switch with wires

  21. Place 3 resistors onto perfboard

  22. Bend leads so that 3 resistors are in series

  23. Solder leads together then clip excess

  24. Connect switch, batteries, and resistors in series; put on the shrink-wrap first.

  25. Bend wires when making connections so any strain is carried by wire, not by solder.

  26. Slide down and shrink the wrap – here is the completed heater circuitry

  27. Cut and bend wire mesh into a cage

  28. Cover resistors with wire cage to prevent accidental contact with heating elements

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