COLLEGE OF ENGINEERING COLLEGE OF COMPUTER STUDIES

Department of Electrical and Electronics Engineering

DC POWER SUPPLY
PROJECT

Submitted by:
COMO, Nigel Brett D.
SAJISE, Sharmaine M.

Submitted to:
Engr. Sarcos

Submitted on:
October 8, 2014

I. INTRODUCTION

In order to make a DC Power Supply, the first thing we have done to come up
with some ideas on how we want our power supply to work based on the requirements
given to us which is to produce a Vout which ranges from 0 Volts -12 Volts. After coming
up with the desired concepts we drew a schematic circuit diagram with the help of
National Instruments Multisim and Ultiboard. The DC Power Supply should produce a
Vout which ranges from 0v to 12v so we ran simulations with the Multisim app and found
out that it exceeds our minimum requirement of 12 Volts. After finishing the desired
layout shown on Figure 1 below, we transferred it to the Ultiboard app, arranged and
traced the necessary connections as shown on Figure 2 at which we viewed its
supposed actual output using 3d view. After the Ultiboard, we constructed it on the
breadboard to test if the design is working in actual scenarios shown n Figure 3. Once it
is tested, the layout was printed using an inkjet printer and a transparency film shown in
Figure 4. Then we prepared the materials to be used for the construction of the power
supply.

Figure 1: Multisim Schematic Diagram

Figure 2: Ultiboard 3d View

Figure 3: Bread boarding of the Schematic

Diagram

Figure 4: Printed Layout

We prepared the materials to be used for the pre-sensitized circuit board. The
materials used are pre-sensitized circuit board, photoresist developer, ferric chloride,
and acetone.
The pre-sensitized circuit board is cut with the desired size and then we peeled
off the white film. After that we attached the transparency film to the pre-sensitized
circuit board using a small picture frame and scotch tape to hold it. Before exposing it to
the UV light (in our case we used a regular 14W lamp shade), the surrounding should
be be dimmed of light. The exposure should be around 30minutes or more to ensure
that the design will be intact with the circuit board.

Prepare the photoresist developer solution, the measurement should be 1 liter of

water per pack of the chemical. Before performing it, we have to wear gloves because
the solution is dangerous. Mix the solution with the water thoroughly before placing the
circuit board. Shake the PCB with the mixed solution to wash away the undesired part
and leaving the photoresist that was exposed to the light. Once the design showed up
remove the PCB on the solution and wash it through running water to stop the reaction.
Etch the copper using the ferric chloride. Place the PCB in the basin with the
ferric chloride and shake it. As soon as all the copper is etched away, remove the PCB
and wash it again thoroughly with running water. Dry the PCB using a clean cloth and
then using the acetone remove the photoresist. After that the PCB is now ready to be
drilled and to be attach with the components. The whole process is shown in the
Figures below.

Figure 5: Etching Process

After placing all of the components, solder the parts to hold it tightly. Check if
there are connections. If theres error re-do the soldering. Once it is finished, place the
constructed circuit board in its casing.

Figure 6: Soldering and Packaging

II. PRINTED CIRCUIT BOARD DESIGN

(b)

(a)
Figure 7: PCB Copper Tracings

Explanation:
The flow of the circuit is from right to left in the Figure 7 (a) shown above. The
first box labeled in Figure 7 (b) represents the input of the circuit which contains the
bridge circuit that consists of 4 1N4007 diodes. The second box represents the filter
component of the power supply that contains a 2200uF 35V capacitor. Following the
flow of the circuit, the third box contains the indicator whether the circuit is already
turned on or not. The indicator component that we placed is a 5mm LED. The fourth box
is the resistor for overcurrent protection of the LED. The fifth box is resistor for the zener
diode. The sixth box represents the regulator component which is the 1N4753A zener
diode. Placed after the regulator is the variable component which changes the voltage
output. This component is the 5k potentiometer contained in the seventh box. Lastly
the eighth box which contains the smoothing capacitor of 1uF.

Materials Used:

Figure 8: Materials

1 Pre-sensitized (+) acting PCB w/ developer

1 Ferric Chloride
1 220V to 12-0-12V transformer
1 Fuse

1 SPST
1 2200uF Capacitor
1 1uF Capacitor
4 1N4007 Diode
1 - 1N4753A Diode
2 1.2k resistor
1 5mm LED
1 5K Potentiometer

Errors:
There were few errors which we have performed during the etching and
assembly. During the Photoresist process, we forgot to measure the volume of water to
be mixed with the developer solution and mixed water with the ferric chloride solution
resulting into improper etching of some copper parts. We repeated the whole process
and completed it as we want it to be. During the assembly in the soldering part of the
process, we overexposed the components to the heat of the soldering tip thereby
damaging it and is unusable. This resulted into the shiny parts that could be seen in the
PCB as we de-solder the components. We have also used improper wattage of the
resistors resulting into the burning out of the resistors. We have also used excessive
soldering lead which resulted into its overflowing and followed the copper tracings.

III. COMPONENTS LAYOUT

To solder the part and the wirings, the soldering iron should be heated first.
Using the lead and the soldering iron put it on the part where you would want to connect
the wires or to hold the parts. Do not use too much soldering lead because it can
overflow and would not stick to the right part.

Figure 9: Finished output of the

Soldering process

Figure 10: Components and Wiring Layout

The Figure above shows the Components layout and the Wiring layout of the
PCB. This was done using the ultiboard.

IV. PACKAGE OF THE POWER SUPPLY

V. TESTING

Explanation:
We tested the Circuit if it could produce our desired output after soldering. The
output shows 0.1 V 26V. After the testing of the PCB alone, we placed it inside the
packaging and tested it again if it still produces the same output. After finding out that
everything is fine. We finally placed labels on the packaging.

VI. LEARNING OUTCOMES

Nigel Brett D. Como

During the construction of this project, we have learned and explored things
which are new to us and refined our mastery of some things which we already know of.
We consulted different sources of information in the internet, books, upperclassmen and
professors.

To start with our project, we came up with some raw concepts on how we want
our power supply to work and what items we would use. During our planning process,
my partner and I have decided to go with a Zener diode regulated power supply to
lessen the complexity of our project since its still new to us. For us to have an idea on
how our power supply would work, we used a computer application from National
Instruments named Multisim. We learned how to use Multisim and simulated different
situations for our power supply circuit. After our circuit worked fine with the Multisim
app, we went through our design and listed the needed components. We learned how to
determine which components fits best with our power supply and learned how to look
into their limitation and capabilities with the help of their respective data sheets. The
Data sheets helped us make adjustments with our power supply.

After finalizing our circuit design, my partner and I used another application from
National Instruments named Ultiboard and converted our circuit design into a PCB
design. We learned how to use the ultiboard app and trace the components connection
for the actual PCB output. We learned that the schematic diagram we came up with
needed footprints which represent its actual appearance on the board. After tracing the
copper connections on the board, it is ready to be printed. We then went to RAON and
looked for the necessary parts. We learned that each component that we know virtually

have some additional specs that we didnt expect it to have. So we bought some
components of same values but with different specs. After buying the components we
are now ready to move with the PCB making.

To convert our PCB design into an actual PCB we used a pre-sensitized (+)
acting PCB. We learned how to transfer our design as we follow the instructions of the
label. After 30 minutes of exposure to light, we removed the PCB and soaked it into the
developer solution while agitating it regularly. Once the figure showed, we rinsed the
board with running water. We learned that the longer we let the board exposed to the
light, the better the results are and if the board is soaked too long, some part of the
design would be dissolved. Once developed, we soaked it to the etching solution. We
learned how to etch the PCB with the use of Ferric Chloride solution which dissolves the
unwanted copper parts.

Our PCB design is now ready for drilling. We learned how to drill holes into the
PCB and learned how delicate the drill bits for PCB are. Before finally plugging in the
components in the holes, we used the breadboard to test the circuit in actual scenarios.
We learned that the ideal situations that we had in Multisim were a little different from
the actual. We learned that resistors could burn out if its wattage isnt observed
carefully. We learned how to de-rate components to avoid malfunctions and added a
safety device which is the fuse. When our design worked fine we now moved to the
PCB soldering.

During the soldering process, we learned how to solder components to the board
but we made few errors resulting into the shiny marking in the PCB itself. We learned
that exposing components to the heat of the soldering tip for too long could damage
components which in our case happened and prompted us to change the components.
After soldering, we learned how to choose the right size for our packaging for us to have
enough space to place all components. Finally, we tested our power supply for any
malfunctions which could have risen. Now our Zener Regulated Power Supply is done.

Sharmaine M. Sajise
We have learned a lot of things during the construction of the DC Power Supply
project. There are many new things that we have encountered. There are also mistakes
that helped us to investigate, study and analyze whats wrong and that increased our
knowledge about that topic.

By our own efforts we learned how to design a schematic circuit that have certain
requirements. We have learned how to use the Multisim and the Ultiboard which helped
us in simulation. After accomplishing the design and having it tested via Multisim we
came up with materials to be used. Since the concept is new to us, we decided to use a
Zener diode to regulate the power supply. We have printed the schematic diagram with
a transparency film and then we attach it to the pre-sensitized circuit board to mix with
the solutions. We have learned what are the dos and donts. We have experienced
several errors too. We have learned what is the proper way to expose the PCB on the
UV lighting and also the proper measurement and time to place the PCB with the
photoresist developer and ferric chloride.

Once the PCB is ready we head to drilling it and putting up the parts. This is our
first time to drill and it is somewhat difficult because the drill bits are too small and frail.
Despite the fact that the design worked perfectly fine with the Multisim still we have
constructed the parts in the breadboard. After a successful testing we have soldered the
parts. Soldering the parts will hold the components in place. This is also a new thing
that we have learned. It is quite hard to solder the parts. There are also a lot of
scratches or markings found in our PCB, indicating that we were amateurs. After the
completion of soldering the parts we put the PCB in its casing. Lastly, we have to check
and test wheter our power supply is working. And at last, there are no further errors and
we came up with a Zener diode regulated power supply which produces a Vout of 0.1V
to 26.1V.

VII. PICTURES OF THE FINAL DC POWER SUPPLY

DC POWER SUPPLY

Explanation:
After some few tweaks and adjustments our DC Power Supply is ready and is
producing an output of 0.1 Volts to 26 Volts. We used a prefabricated casing and made
few adjustments like placing more holes and erasing the labels. We placed proper
labels on the packaging for easy identification and now its done.