Power Supply Rebuild: Installing a new 230V Power Filter, Varistor and Fuse

So I did this part of the power supply rebuild a while ago, but never really documented “how” I did it, so thought adding this would be informative to complete the loop on what you need to do.

Here’s the existing power filter and varistor as it arrived from the US:

Power Filter = grey box at the top of the picture with white/red and block/yellow wires coming out of the “back” of it

Varistor = Red circular disk with yellow insulation covers around it’s legs connecting to the “front” of the power filter

So we need a new 230/240V Power Filter, and a new 230/240V Varistor like these

Power Filter

Varistor

So in order to connect them to the existing wires, I used crimp clips on each of the wires, and ‘piggy back’ crimp sockets to connect the “front” wires and the varistor together

Basically add the yellow shielding from the original varistor to each of the new varistor legs and crimp female single ‘lucar’ crimp terminals to the end of each leg.

De-solder the existing wires from the “back” of the Power Filter and crimp female single ‘lucar’ crimp terminals to the end of each and connect to the “back” of the Power Filter.

De-solder the existing wires from the “front” of the Power Filter and crimp ‘piggy back’ crimp terminals to the end of each.

Plug the “front” wires with the piggy-back connectors into the front of the Power Filter, and plug the Varistor into the extra piggy back terminal male connector on each (see photo below)

Put the unit in place in the existing transfomer rig, make sure all of the wires are connected properly (mains AC Live and Neutral to the “front” of the Power Filter) and then you should be good to go

The existing 110V fuse (connected to the brown wire / Live of the wiring in the photo above) also needs to be upgraded to a 230/240V version, so I used a 3A, 250V rated glass blow fuse as follows

So the wiring is

Live (brown) -> Fuse -> Black wire -> Power Filter Live [Black covered pin]
Neutral (blue) -> Power Filter Neutral [Black covered pin]
Earth (green/yellow -> Power Filter Ground [Silver non-covered pin nearer the top of the Power Filter]