tonitu said:Hi Dennis, I also had the same problem , Even if it does not burn the diode , 22 VAC in the heater line is too high when you dont load the PSU, and the diode can burn. In Spain the line can vary from 205 Volts to 235, this cause a lots of problems in this kind of regulation. Dan told me : Please no more than 20 vac in the heater!!, and it works perfectly. When the line is near 220vac, No problem without load, whem rise a little the temperature in the zener is critical. Hope this help.
I repaired Dennis' PSU in the meantime, he had a short circuit between the B+ and the heater.
Make sure that you don't connect the 22ohm and the 6.8k resistor legs!
I think it is always better to test the PSU with loading resistors - approx 33ohm/2W for the heater and 230kohm/0,6W for the B+,make sure the voltages are not drifting too much, I'd test every PSU for 1hour at least.