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Power Supply Project

Aviskar Panday Chitram


COMP 1107
December 3rd 2014

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

Table of Contents
Introduction: Theory of Operation and Intended Use.3
Power supply circuit diagram..4
Part list.4
Construction procedure..5
Multisim circuit stage drawings.6
Testing..13
Conclusion..15
Appendices..16

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

Introduction
Theory of operation
The Power Supply Project completed is a C6724 0-12V Variable Power Supply. It was
installed into a metal, custom designed casing for protection, appearance, and functionality. The
purpose of the Power Supply is to convert 120V AC into a DC current which can be adjusted
from 0V to 12V DC. The transformer steps down the 120V AC to 17.1V AC. When the voltage
is lowered by the second coil, it then travels through the 4 diodes which converts the AC current
into a DC current (AC meaning alternating current, DC meaning direct current). The DC voltage
then travels to the first capacitor (C1) where it is filtered. From here the voltage is distributed to
the NPN power transistor, or heat sink, which is powered by the potentiometer and helps prevent
the circuit from overheating. The transistor base is negative when the potentiometer wiper is at
the bottom or lower position. When the transistor base is negative, it is not conductive and the
output voltage of the power source is 0V DC. When the wiper of the potentiometer is turned to
the positive side, the base of the transistor becomes positive. When the transistor base is positive,
it increases the output voltage of the system. The other resistors and capacitor further filter the
voltage. The Power Supply can be powered on and off with the simple movement of a slide
switch which is connected to the AC power cable. When the switch is set to provide power to the
circuit, red light emitting diode (LED) connected to the circuit will light up indicating the Power
Supply is on. The C6724 0-12V Variable Power Supply is one the most efficient power supplies
on the market today.

Intended usages
When powering the C6724 0-12V Variable Power Supply, set the potentiometer so the
there is no voltage flowing through the circuit (0V). Dosing this makes it safer to apply leads to
the output ports and plugging in the device you are attaching to the Power Supply. To see where
the potentiometer is set, test the output ports with the digital multimeter set to measure volts.
Once this tested, you can apply power to the circuit and adjust the potentiometer to get the DC
current that is desired. Once the potentiometer is set, you are then ale to turn the circuit on and
off when desired and when turned on it will give you the same voltage reading. You should turn
the supply off when not in use. This is a good safety habit to start that will be able to carry over
into the working world.

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

Power supply circuit diagram


The circuit is figure 1 was designed in Multisim to show the current flow through the
power supply. It also shows all the components of the circuit and the corresponding values.

Q1
2N2222A
V1
120Vrms
60Hz
0
S1
Key = Space
F1

PRI

LED1

D1

T1

R2
160

SEC
10:1

1B4B42

C1
220F
R1
6.2k

1_AMP

R3

500
Key=A

C2
220F
R4
4.7k

0%

Figure 1

Power supply parts list

C1, C2
D1-D4
F1
L1
P1
Q1
R1
R2
R3
S1
T1
Misc.

220F 25V Electrolytic Capacitor


1N4004 Diode
Pigtail Fuse
Red LED
500 Potentiometer
NPN Power Transistor
6.2K Resistor (Blue, Red, Red)
160 Resistor (Brown, Blue, Brown)
4.7K Resistor(Yellow, Violet, Red)
Slide Switch
Transformer
PC Board, Heatsink, (3) Nuts, (3) Bolts, Line Cord, Insulated Wire, and
Double Stick Tape

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

Construction procedure
1. Before soldering, ensure that your mounting holes are successfully punched.
2. The first step taken after the mounting holes is to solder the 4 diodes in to position. They
are very small and do not hinder when soldering on the other components. The diodes are
to be facing in the correct position to ensure the current was converted to DC property.
3. The second step is to solder the 3 resistors into positions since they are also very small
components. The 3 resistors values are 6.2k, 160, and 4.7k.
4. Next, solder on capacitors 1 and 2 so that their negative terminals are facing the left side
of the circuit board.
5. The next component to be soldered in place is the pigtail fuse.
6. Next, solder the transformer into place. It is important to ensure that terminals 1-4 on the
transformer are facing the fuse and terminals 5-8 are facing the other components.
Terminals 1-4 represent the primary coil of the transformer while terminals 5-8 represent
the secondary coil of the transformer.
7. Next solder the NPN power transistor into position to ensure overheating does not occur
with extended use.
8. Next solder leads onto the board to connect the potentiometer, LED, banana jacks, and
power cord.
9. After soldering these components into place, the next step is to build the power supply
case. Make AutoCAD templates (attached) with specific dimensions designed to secured
the power supply circuit board and construct the design using sheet metal in the machine
shop.
10. When the supply case is completed, finish soldering the potentiometer, LED, power switch,
and banana jacks in place with respect to the grommet holes made on the AutoCAD
template.
11. Once all the components are soldered successfully and mounted into their designated
grommet holes, the PCB can now be mounted onto the case with the mounting holes made
in step 1.

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

Multisim Circuit stage 1


The following Multisim diagram (Figure 2) represent the first stage of the power supply
circuit with the voltage source of 120 Vrms and 60 Hz, a transformer with a turn ratio of 10:1 with
two digital multimeters (Figure 3 & 4) reading Vpri and Vsec, a SPST switch to control the current
flow and a fuse.
XMM1
V1
120Vrms
60Hz
0
S1
Key = Space

XMM2

T1
PRI

SEC
10:1

F1
1_AMP

Figure 2

Figure 3

Figure 4

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

The following Multisim diagram (Figure 5) represent the same circuit as Figure 2 with
an oscilloscope attached to the circuit instead of the digital multimeters, to measure the
constantly changing voltage coming from the transistor (Figure 6).

XSC1

Ext Trig
+
_

V1
120Vrms
60Hz
0

A
+

T1

S1
Key = Space

PRI

SEC
10:1

F1
1_AMP

Figure 5

Figure 6

Vpri rms

120

Volts

Vsec rms

12

Volts

Turns Ratio

10:1

Vsec peak

16.7

Volts

Figure 7

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

Multisim Circuit stage 2


The following Multisim diagram (Figure 8) represents the second step in creating the
full power supply circuit. In this step, a 4-diode bridge is added to convert at the output of the
diodes (Figure 9) and an oscilloscope is added to see the pulsating DC voltage and secondary
peak voltage (Figure 10).
XSC1
V1
120Vrms
60Hz
0

XMM1

Ext Trig
+
_

D1

T1

S1
Key = Space

PRI

A
+

SEC
10:1

1B4B42

F1
1_AMP

Figure 8

Figure 9

Figure 10

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

Multisim Circuit stage 3


The following Multisim diagram (Figure 11) represents the third step in creating the
complete power supply circuit. In this step a 220F electrolytic capacitor is added to the output
of the diode circuit. A multimeter is added to measure the DC voltage at the capacitor (Figure
12) and an oscilloscope is added to the measure the Vpeak of the capacitor (Figure 13).
XSC1
XMM1
Ext Trig
+
_
B

A
+

V1
120Vrms
60Hz
0
S1
Key = Space
F1

D1

T1
PRI

SEC
10:1

1B4B42

C1
220F

1_AMP

Figure 11

Figure 12

Figure 13

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

Multisim Circuit stage 4


The following Multisim diagram (Figure 14) represents the fourth step in creating the
complete power supply circuit. In this step a Light Emitting Diode (LED) and 6.2 k resistor is
added to the output of the capacitor circuit. A multimeter is added to measure the DC voltage at
the LED (Figure 15).
XMM1

V1
120Vrms
60Hz
0
S1
Key = Space

PRI

LED1

D1

T1
SEC
10:1

1B4B42

F1

C1
220F
R1
6.2k

1_AMP

Figure 14

Figure 15

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

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Multisim Circuit stage 5


The following Multisim diagram (figure 16) represents the fifth step in creating the
complete power supply circuit. In this step a 160 resistor is added in series with a 500
potentiometer is added across the LED circuit. A multimeter is added to measure the DC voltage
at the potentiometer wiper (Figure 17).

V1
120Vrms
60Hz
0
S1
Key = Space

PRI

F1

LED1

D1

T1

R2
160

XMM1

SEC
10:1

1B4B42

C1
220F
R1
6.2k

1_AMP

R3

500
Key=A
50 %

Figure 16

Figure 17
VDC output @ 25%
VDC output @ 50%
VDC output @ 75%
VDC output @ 100%

1.156V
3.287V
6.643V
11.371V

Volts
Volts
Volts
Volts

Figure 18

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

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Multisim Circuit stage 6


The follow Multisim diagram (Figure 19) represents the sixth and last step in creating
the complete power supply circuit. In this step a NPN transistor (2N2222A) is added to the
potentiometer circuit. Also, a 220F electrolytic capacitor and a 4.7 k resistor are added to the
transistor circuit. A multimeter is added to measure the DC Voltage across the 4.7 k resistor at
different percentages (Figure 20).
XMM1
Q1
2N2222A
V1
120Vrms
60Hz
0
S1
Key = Space

PRI

LED1

D1

T1

R2
160

SEC
10:1

F1

1B4B42

C1
220F
R1
6.2k

1_AMP

R3

C2
220F
R4
4.7k

500
Key=A
100 %

Figure 19

VDC output @ 25%


VDC output @ 50%
VDC output @ 75%
VDC output @ 100%

Figure 20
1.0786V
3.165V
6.598V
10.943V

Volts
Volts
Volts
Volts

Figure 21

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

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Testing
Milestone 1 The Printed Circuit Board Assembly
In Milestone 1, we will examine the quality of the components layout on the printed circuit board,
see Fig. 1, (minus the switch S1, the AC line cord, and the potentiometer P1).
We will also examine the quality of the soldering.
Next, we will measure the voltage at the transformer secondary, and also the voltage across
the 220 uF capacitor C1.

V primary rms = ______________120V AC______ __

V secondary rms = ____________17.1V AV________

V dc at capacitor C1 = __________21.9 DC_________

Fig. 1. Top View of the Power Supply Circuit Board

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

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Milestone 2 The Complete Circuit


In Milestone 2, we will examine the layout and routing of the wiring, the assembly of the
potentiometer, the assembly of the switch, quality of the soldering, the layout of the components in
the box.
1. Use electrical tape to cover up the transformer primary solder points, which has 120VAC present.
Completed with success.
2. Switch S1: Use only two terminals of the switch, end and middle. Connect one switch terminal
to the circuit board, and the other switch terminal to the power cable, as shown in Fig. 2. Use
electrical tape and heat shrink tubing as necessary.
Completed with success.
3. If you are using a metal box to mount the circuit board, connect the green wire of the power
cable in the metal box, with one of the mounting screws.
Completed with success.

Fig. 2. The power circuit board with wiring details

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

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Conclusion
The process of creating the power supply as a project was more like fun rather than
work. It was interesting to see several of my classes work together to complete a common goal,
and creating and understanding how a power supply works. At the beginning of the semester, I
was excited to hear that we would be building a power supply. As the project was spilt up into
different tasks between the classes, I found it easy to get them done in the timeline given. Overall,
this project develop my knowledge and skill set so that not only I was able to complete the task of
creating a power supply but I was able to successfully apply what I have learned throughout the
semester in real life with home projects. After completing this task, I am looking forward towards
what more my program has in stored for us. I cant wait to build something bigger in next semester!

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

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Appendices
1. Chaney Electronics Work Book
Electronics project kit. U.S.A: Chaney electronics, 2007. 1-3. Print

2. Computer 1107 Workbooks


Multisim: The power supply circuit: converting AC to DC voltage. Oshawa: Durham College, n.d.
1-8. Print.

Aviskar Panday Chitram, 100557251, COMP 1107, Power Supply Project

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