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Power Supply Assembling
Power Supply Assembling
INDUSTRIAL ARTS:
ELECTRONICS
(ASSEMBLE AND DISASSEMBLE
CONSUMER ELECTRONIC
PRODUCT AND SYSTEM)
Learner’s Material
Department of Education
Republic of the Philippines
Technology & Livelihood Education – Grade 9
Industrial Arts: Electronics - (Assemble and Disassemble
Consumer Electronic Product and System)
Learner’s Material
First Edition, 2014
Republic Act 8293, section 176 states that: No copyright shall subsist in any work
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Every effort has been exerted to locate and seek permission to use these materials from
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ownership over them.
Introduction .......................................................................................................................1
Pre/Diagnostic Assessment ..........................................................................................1
Information Sheet 1.1 .....................................................................................................2
Self-Check 1.1 ...................................................................................................................4
Information Sheet 1.2 .....................................................................................................5
Self-Check 1.2...................................................................................................................9
Information Sheet 1.3 ...................................................................................................10
Self-Check 1.3.................................................................................................................12
Activity Sheet 1.1 ...........................................................................................................13
Self-Check 1.1 .................................................................................................................15
Activity Sheet 1.2 ...........................................................................................................16
Self-Check 1.2.................................................................................................................18
Activity Sheet 1.3 ...........................................................................................................19
Self-Check 1.3.................................................................................................................20
Pre/Diagnostic Assessment .......................................................................................21
Information Sheet 2.1...................................................................................................22
Self-Check 2.1.................................................................................................................23
Activity Sheet 2.1 ...........................................................................................................24
Self-Check 2.1.................................................................................................................26
Summative Assessment ................................................................................................27
ASSEMBLE AND DISASSEMBLE CONSUMER
ELECTRONIC PRODUCT AND SYSTEM
INTRODUCTION:
PRE/DIAGNOSTIC ASSESSMENT
Directions: Read each statement carefully and select the letter of the correct
answer. Write your answer on a separate sheet of paper.
1. It refers to a hand tool that is used in holding, gripping, and cutting of soft
and fine wires in assembling electronic circuit?
A. Pliers B. Scissor C. Tweezers D. Vise grip
2. In a bridge-type rectifier circuit, there are four terminal joints. Select the one
that could give a DC+ output.
A. Anode-Cathode B. Infinite
C. Two Anode D. Two Cathode
3. In a bridge-type rectifier circuit, there are four terminal joints. Select the
one that could give a DC - output.
A. Anode-Cathode B. Infinite
C. Two Anode D. Two Cathode
4. In a bridge-type rectifier circuit, there are four terminal joints. Select the one
that is connected to one of the AC output of transformer.
A. Anode-Cathode B. None
C. Two Anode D. Two Cathode
1
5. It is the positive electrode of a device and the “P” material of a diode.
A. Anode B. Bridge-type Rectifier
C. Cathode D. Full wave rectifier circuit
7. It is the copper clad designed, etched and bored to which components are
inserted into the hole and soldered to form its circuit connection.
A. Breadboard B. Printed Circuit Board
C. Strip board D. Terminal
10. What is the stage of the power supply that reduces the amount of ripple
voltage and smoothen the pulsating DC output voltage of rectifier circuit?
A. Bleeder B. Filter circuit
C. Rectifier circuit D. Step-down transformer
Soldering tools:
Soldering iron
Soldering lead
Desoldering tool
Soldering stand
2
Screwdriver
1. Flat head
2. Philip
1. 2.
1.
Pliers 2.
1. Diagonal
cutting pliers
2. Long nose
pliers
1. 2.
1. Wire stripper
2. Utility knife
Boring tools
Mini drill with
power supply
Drill bit (in
proportion
with terminals of
component)
Multitester/ Volt-
Ohm-Milliammeter
(VOM)
Analog
Copper clad
Sand paper
Pencil and paper
Ruler
Masking tape
Cleaning brush
Cleaning agent
Permanent marker
3
(IN4001)
1 pc Capacitor
(1,000uF/16v)
1 pc Resistor (
1KΩ 1/4w))
Wires
(1 m #22 solid/
1 m #18 stranded)
1 pc Rotary switch
(2 poles 5
positions)
2 pcs Alligator clip
(1 red & 1 black)
AC cord w/plug
Rubber grommet
Fuse with holder
(.5 A)
Chassis/
compartment
Personal Protective
Equipment
EDS wrist strap
Mask
Apron
Schematic Diagram
of AC/DC multi-
secondary
unregulated power
supply
SELF-CHECK 1.1
Tools and Materials in Assembling Power Supply
1 2 3 4 5
4
6 7 8 9 10
11 12 13 14 15
A basic power supply consists of three basic stages: the power transformer
stage, rectifier stage, and filter stage. If there is a need to regulate the output
voltage, a regulator circuit is added.
Transformer stage
In order to reduce the 220 volts/60 Hz power supply at our home, there is a
need for a step-down transformer. Most electronic circuits require a low-voltage
power supply in Direct Current (DC) form. The primary and secondary voltage,
current and power rating of a transformer is important thing to consider.
5
Note that secondary voltage indicates the rated voltage. When the secondary
winding of a transformer has no load, the measured voltage must be 10% higher
than its rated voltage. This is the allowance for the voltage drop when loaded.
Types of Rectifier Circuit
There are two types of rectifier, Half-wave Rectifier and the Full-wave
Rectifier. Under a Full-wave rectifier, there are two types, the Center-tapped and
the Bridge Rectifier.
1. Half-wave Rectifier Circuit
One rectifier diode D1 and one load resistor RL are needed to
conduct one alteration in every cycle of small AC input.
Note: Compare the difference of the three circuits in your lecture:
a. Half-wave
b. Full-wave
b.1 Center-tapped
b.2 Bridge
6
3. Full-Wave Bridge Type Rectifier Circuit
The full-wave bridge type rectifier circuit uses four rectifier diodes D1, D2,
D3, D4 and a load resistor (RL). A center-tapped transformer is not necessary in
this circuit. This circuit can deliver a higher current range to the load because all
of the cycles are consumed by the four diodes.
The operation of this rectifier circuit is different from the Half-wave and Full-
wave center-tapped. The conduction of AC voltage starts from Line-A going to
Line-B.
First Conduction
The negative half-cycle will be conducted to the cathode of diode D1, and
then thru the RL it will conduct to the cathode of diode D4 goes to Line-B. In this
case D1 and D4 are conducting.
7
Characteristics of a Full-Wave Bridge Type Power Supply
a. Expensive
b. Needs a lower value of capacitance
c. Needs four rectifier diodes
Filter Stage
This stage of the power supply smoothen the pulsating DC output voltage of
rectifier circuit by reducing the amount of ripple voltage. It also provides the charge
voltage for the load while the rectifier diode is not conducting.
(+) +
Rectifier Filter
Stage Stage
(-) -
Placing additional
capacitor in the output.
Filter Circuit
This circuit is actually a resistor in series with the positive line together with
two bypass capacitors C1 and C2. It is good in lowering the DC voltage output.
Placing a resistor
in series with the
positive line can
cause voltage
drop.
This circuit has a good filtering effect to the pulsating DC output of the
rectifier. It uses minimal value of capacitance and it is good in low current
8
and high current applications. The only disadvantage is that the inductor in
series with the positive line takes up big space in mounting it in the PCB.
SELF-CHECK 1.2
AC-DC POWER SUPPLY
II. Directions: Draw the schematic diagram of bridge type rectifier circuit:
(for five points)
Criteria Points
Complete components/ correct connection/ with label/ correct symbols 5
9
INFORMATION SHEET 1.3
PRINTED CIRCUIT BOARD OF AC-DC POWER SUPPLY
The copper clad has conductors that are thin strips of copper, usually bonded to
a baseboard called substrate. The two very common substrate materials used in
printed circuit are the phenolic and epoxy plastic.
Copper
Substrate
Copper Clad
Many different chemical solutions can be used to etch circuit boards ranging
from slow controlled speed etches used for surface preparation to the faster etches
used for etching the tracks. Some are best used in horizontal spray process
equipment while others are best used in tanks. Enchants for PTH work have to be
selective and be non-aggressive to tin / tin lead plating, which is used as the etch
resists. Copper etching, normally exothermic, requires high speed etching to carry
out solution cooling. This is normally done by placing titanium water cooling coils
into enchant.
10
Manufacturing Printed Circuit Board
1. PCB size and shape. The PCB must be big enough for the entire
component to be mounted on a specific area.
3. High Temperature Dissipation. Too much heat is the number one problem
of all components. Bigger space is needed so that heat sink (absorb heat
from the active component) can be provided to the component. This will
protect the component from burning up.
5. Space for Bolt and Nut. The designer should place a good space for
mounting the PCB with bolt and nut in securing the entire board to the
chassis.
Cover Surface
Copper Conductor
Substrate
Copper/Conductor
Substrate
11
Tools and Materials Needed In PCB Etching
SELF-CHECK 1.3
PRINTED CIRCUIT BOARD OF AC-DC POWER SUPPLY
Directions: Read each statement and write the term being described in each
number on your answer sheet.
Note: If you got all the answers right, that is an excellent mark. If you missed one or
more item/s, go back to information sheet 1.3, review the questions, and study them
more closely. Before you proceed to the next lesson you must get all the answers
right.
12
ACTIVITY SHEET 1.1
DESIGNING AND PREPARING PCB OF AC-DC POWER SUPPLY
Directions: Given the resources needed, the students will design and prepare a
PCB of AC-DC Power Supply individually by following the procedures given. After
the activity, the students output will be graded through the given Performance
Check.
Resources:
High grade magnifying glass with AC-DC power supply kit (1.5 – 12
lamp volts variable power supply)
Drawing instrument Pencil and paper
Analog multi tester (voltmeter/VOM) Permanent marker and ruler
13
2. Prepare a first draft for the arrangement of components considering the
given size of copper clad( 1”x2”).
Note: Actual size of the component should be adapted for component arrangement
and mounting. (Illustrations below are just a sample; you can make your own
layout of components.)
14
7. Using masking tape, cover the entire copper
side and transfer the design on it. Cut the
design and leave the transferred design.
Directions: Read the criteria in the box and check the box if you performed the
item. A check is equivalent to one point.
Criteria Performed
15
ACTIVITY SHEET 1.2
PRINTED CIRCUIT BOARD ETCHING
Directions: Given the resources needed, perform the procedure in PCB Etching to
produce a PCB of AC-DC power supply (rectifier circuit). The students will
perform individually. They will be guided by the procedure/steps given in PCB
etching. Observe safety at all times. Students will be rated through
Assessment Checklist 1.1.2. Each student will be given 20 minutes. Etching
could be done simultaneously.
Resources:
Before proceeding, the students should prepare the following:
Ferric Chloride
Chloride
Plastic
Basin
4. Etch the PCB by immersing it in a basin filled with ferric chloride until
the uncovered part of the copper clad is totally etched.
PCB
5. After 10 - 15 minutes, check the PCB if all the parts needed to be removed
are totally etched (using the two popsicle sticks in hauling). If there are still
unnecessary copper, return it into the plastic basin filled with ferric chloride
16
and check it again after 3 – 5 minutes.
6. Haul the PCB from the plastic basin and wash with running water to remove
the remaining etching solution and other residues.
7. Dry PCB with a clean piece of cloth.
8. Pour a little amount of lacquer thinner on a clean dry piece of cloth and wipe
the markings of the permanent marker in the copper clad.
(Note: In doing this, you should still wear surgical gloves.)
9. Aided by bright light, inspect the PCB for possible hairline break or short. If
there is a hairline path between the copper conductors, cut it by a knife or
cutter. If there is a break between the copper conductors, solder it.
10. Apply plastic varnish to the newly etched PCB to prevent corrosion or rust,
and let it dry for a couple of minutes.
B. Hairline Short in the PCB Conductor arises if the Printed Circuit Board
designing or etching is done improperly. To eliminate the hairline short, cut it
with a knife.
17
SELF-CHECK 1.2
PCB ETCHING
Directions: Rate yourself on how competently you have applied the skill in PCB
Etching using the criteria below by checking on the appropriate box (points 1
to 5, 5 being the highest). Compute for the rating by dividing each item by 5,
multiply by 100. Average the rating of the six criteria to get the final rating.
Points
Criteria Rating
5 4 3 2 1
Workmanship
Use of Tools
Use of Personal Protective Equipment
SPEED
House Keeping
Finished Design
Total
Criteria Description
Followed the steps accordingly/ Less 1 point for every
Workmanship missed procedure.
Used tools/ materials in right task/ Less 1 point for
Use of Tools every misused.
Use of Personal Used PPE during the whole activity/ Less 1 point for
Protective Equipment every forgotten instances
18
ACTIVITY SHEET 1.3
BORING ETCHED PCB OF AC/DC POWER SUPPLY
Resources:
1.2 Insert the drill bit 1mm diameter in size and attach it to the chuck
of the unit.
1.3 Turn the precision screwdriver clockwise to tighten the jaw of the
unit. Be sure that the drill bit is well secured on the chuck.
1.4 Before inserting the 12 volts adaptor, you should turn off the unit.
1.5 Test the rotation of the unit if it is well aligned. If not, align it
following steps no. 1 and 2.
To control the unit, hold the mini drill at the lower part and firmly
position your arm. Then with the mini drill held perpendicularly to your
work surface, lightly press downward to the holes to be drilled in the PCB
19
but be sure that the PCB has a piece of wood under it to avoid damaging the
table. With practice, you will be able to get the procedure correctly.
3. Boring Procedure
2. Using mini drill bore hole perpendicularly to the surface of the PCB
with arrow marking.
3. Clean the surface of the PCB and look for open line or short circuit.
4. Apply varnish on the clad surface to prevent it from corrosion.
SELF-CHECK 1.3
BORING ETCHED PCB OF AC/DC POWER SUPPLY
Directions: Rate yourself on how competent you have applied the skill in Boring
etched PCB using the criteria below by checking on the appropriate box
(points 1 to 5, 5 being the highest). Compute for the rating by dividing each
item by 5, multiply by 100. Average the rating of the six criteria to get the final
rating.
Points
Criteria Rating
5 4 3 2 1
Workmanship
Use of Tools
Use of Personal Protective Equipment
SPEED
20
House Keeping
Finished Design
Total
Criteria Description
Followed the steps accordingly/ Less 1 point for every
Workmanship
missed procedure.
Used tools/ materials in right task/ Less 1 point for every
Use of Tools
misused.
Use of Personal Used PPE during the whole activity/ Less 1 point for every
Protective Equipment forgotten instances
Finished within the time/ Less 1 point for every five
SPEED
minutes delay
The workplace is clean before, during and after the activity/
House Keeping
Less 1 point for every dirt observed
Neat and presentable output and / Less 1 point for every
Finished Design
unusual marks at the output
PRE/DIAGNOSTIC ASSESSMENT
21
INFORMATION SHEET 2.1
AUXILIARY AND ELECTRONIC COMPONENTS OF POWER SUPPLY
The internal parts of the power supply are shown in the figure below.
22
7. LED Power Indicator is used to indicate that the power supply in “ON”
position.
8. Alligator Clips are used to connect the two-line output to the load.
SELF-CHECK 2.1
AUXILIARY AND ELECTRONIC COMPONENTS OF
POWER SUPPLY
I. Directions: Identify the parts of AC-DC Power Supply as numbered (1-10). Write
the answer on your answer sheet.
23
ACTIVITY SHEET 2.1
MOUNTING AND SOLDERING COMPONENTS OF AC-DC POWER
SUPPLY
Directions: Using the given tools, supplies and materials, mount the
electronic components to the finished PCB and perform soldering
techniques to assemble rectifier circuit of an AC-DC power supply.
Read some information and follow the instruction/ procedures given.
Assessment checklist will be used to rate the performance.
Resources:
o Supplies and Materials
- Designed PCB
- Soldering Lead, 60/40
- 4 pcs. Rectifier diode- 1N4001
- Electrolytic capacitor – 3,300 uF/25V
- Jumbo LED with holder
- Resistor- 1KΩ, 5 watts
- Schematic diagram of AC/DC Bridge-type power supply
- Design of AC/DC Bridge-type power supply (copper side
and component placement guide)
Procedures:
24
3. Mount/ insert the terminals of the components in the PCB. Observe proper
connection and polarity in mounting and double check with the design
made.
4. With the proper mounting of components, solder the components
accordingly.
Note: Active components must be mounted last. Utmost care must also be
observed.
5. Cut the excess terminals of the components.
6. Check the solder and spaces between solder joints and lines for possible
short circuit.
7. Test the circuit using the multi-tester.
8. Observe proper mounting of components according to standard.
Working area set with tools, instrument and materials needed in mounting and
soldering components of ac-dc power supply.
Mounting of components
25
SELF-CHECK 2.1
Mounting and Soldering Components of AC-DC Power Supply Project
Directions: Rate yourself on how competently you have applied the skill in PCB
Etching using the criteria below by checking on the appropriate box (points 1
to 5, 5 being the highest). Compute for the rating by dividing each item by 5,
multiply by 100. Average the rating of the six criteria to get the final rating.
Points
Criteria Rating
5 4 3 2 1
Workmanship
Use of Tools
Use of Personal Protective Equipment
SPEED
House Keeping
Finished Design
Total
Criteria Description
Followed the steps accordingly/ Less 1 point for every
Workmanship
missed procedure.
Used tools/ materials in right task/ Less 1 point for
Use of Tools
every misused.
Use of Personal Used PPE during the whole activity/ Less 1 point for
Protective Equipment every forgotten instances
Finished within the time/ Less 1 point for every five
SPEED
minutes delay
The workplace is clean before, during and after the
House Keeping
activity/ Less 1 point for every dirt observed
Neat and presentable output and / Less 1 point for
Finished Design
every unusual marks at the output
26
SUMMATIVE ASSESSMENT
Directions: Read each statement carefully and write only the letter of the best
answer.
4. In PCB designing bigger space is required so that heat sink can be installed,
what design factor is being considered?
A. PCB size and shape.
B. Position of the terminal.
C. High Temperature Dissipation
D. Accessibility of Components.
E. Space for Bolt and Nut.
CRITERIA SCORE
Complete blocks and symbol with labels. 5
With only one block or symbol or label missing 4
With two blocks or two symbols or two labels or any two 3
combinations missing.
With three blocks or three symbols or three labels or any three 2
combinations missing.
With four blocks or four symbols or four labels or any four 1
combinations missing.
No drawing. 0
27
11-20. Explain the procedures in soldering and desoldering.
Suggested Scoring Rubrics
CRITERIA 5 3 2 1
Sequence and Some ideas Some signs
No idea or
transition of and sequence of and/or
ORGANIZATION unclear flow
ideas was may be change of
of ideas.
effective. improved. ideas.
Contained
some
Convincingly Inappropriate
DETAILS appropriate Too general.
interpreted. /off topic
details or
examples.
CRITERIA 5 3 1
All solders are One to three solders For or more solders
smooth, shiny are not are not
Quality
and no sharp smooth/shiny and smooth/shiny and
edges. have sharp edges. have sharp edges.
Finished the task Finished the task
Unable to finish the
Speed on or before the beyond the given
task.
given time time.
28