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Program/Course: Electronic Product Assembly & Servicing NC II

Unit of Competency: ASSEMBLE ELECTRONIC PRODUCTS

Module Title: ASSEMBLING AC-DC POWER SUPPLY

This module contains information and suggested learning activities on Assembling

AC-DC Power Supply. It covers the knowledge, skills and desirable attitudes required in
Assembling Electronic Products. After reading this you are able to assemble electronic
products and demonstrate an understanding of concepts and underlying principles in
assembling electronic products based on task requirement and acceptable procedures and
standards.
This module consists of three (3) learning outcomes. Each learning outcome (LO)
contains learning activities supported by instructional sheets. Before you perform the
instructions, read the information sheets and answer the self-check and activities provided
to ascertain to yourself and your teacher that you have acquired the knowledge necessary
to perform the skill portion of the particular learning outcome.
Upon completing this module, report to your teacher for an assessment to check your
achievement of knowledge and skills required in this module. If you pass the assessment,
you will be given a certificate of completion

SUMMARY OF LEARNING OUTCOMES

LO. 1. – Identify the parts an AC-DC power supply.
LO. 2. – Designing and Etching PCB of AC-DC Power Supply
LO. 3. – Mount and solder the electronic components at the appropriate location in the PCB
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TECHNICAL TERM

• AC – (Alternating Current) a type of current which move in multiple direction.

• DC – (Direct Current) a type of current which move in only one direction.
• Rectifier – A device which is used to convert Alternating Current (AC) to Direct
Current (DC).
• Diode – is the perfect device used as rectifier because of its capability to conduct
current in only one direction.
• OHS – Occupational Health and Safety a safety standard which requires industry work
to comply to make things in order and keeping safety as priority.
• Full Wave Rectifier – The rectifier that makes use of full AC wave in both positive
and negative half cycles.
• Output – A terminal at which a component, circuit or piece of equipment delivers
current, voltage, or power.
• Primary winding – The first winding of a transformer. Winding that is connected to
the source as opposed to secondary which is a winding connected to the load.
• Printed Circuit Board – (PCB) An insulating board containing conductive parts for
Circuit connections.
• Regulated Power Supply – A power supply where the output voltage is not affected
by its loading factor.
• Schematic Diagram – An illustration of an electrical or electronic circuit with the
components represented by symbols.
• Secondary Winding – output winding of a transformer that is connected to the load.
• Short Circuit – A very low resistance between two points in a circuit causing
excessive current.
• Block Diagram – is a diagram of a system which the principal functions are
represented by block connected by lines that show relationship/process of the blocks.
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LO 1. Identify the parts of an AC-DC power supply

Objectives:
a. Enumerated the types of AC-DC power supply.
b. Identified the parts of an AC-DC power supply
c. Listed and acquired the electronic components needed in assembling AC-DC power
supply

3 Basic Stages & the

220v AC – is a common AC supply in our convenient outlets.

Step down transformer – this is used to reduce the 220v AC in to smaller voltage.
Rectifier – a component or device used to convert AC to DC voltage.
Filter – this circuit reduce ripple voltage to become smooth DC voltage
Regulator – used to maintain the DC voltage output to keep up with the varying need of
power.
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Load – it is a device that consumes the voltage output of the power supply such as light bulb,
electric motors and etc.

RECTIFIER STAGE

Question: What are the types of Rectifier Circuits or AC-DC Power Supply?
- There are three types of AC-DC Power Supply. Namely (1) Half-Wave Rectifier
Circuit, (2-a) Full-Wave Center-Tapped Rectifier Circuit and (2-b) Full-Wave Bridge
Type Rectifier Circuit

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.

This circuit allows current flow through the load for only one-half of each cycle. Only
the positive half cycle of the input voltage will be conducted by the D1 (Forward Bias) and
the negative half cycle of the input voltage will be zero volts because the D1 will not conduct
(Reverse Bias).

Characteristics:
a. Uses single primary winding and single secondary winding Transformer.
b. Needs only one diode.
c. Cheapest rectifier circuit.
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2. Full Wave Rectifier – is the most common used in DC power supplies. The difference
between a half-wave and the full wave rectification is that the half-wave rectifier allows
unidirectional (one way) current while a full-wave rectifier allows bidirectional current
to the load during each cycle.
2-a. Full-Wave Center-Taped Rectifier Circuit – Using this type of circuit, you’ll need
a center-tapped transformer, two rectifier diodes and a load resistor (RL). Each
of the diode supplies one-half the DC load current.

A positive input half cycle forward-biases the upper diode D1 and reverse-biases the
lower diode D2. The two diode conduct positive half-cycle of the input voltage then if their
output will equal to full-wave rectification.

Characteristics:
a. Uses center-tapped Transformer
b. Needs two diodes

2-b. Full-Wave Bridge Type Rectifier Circuit

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This is the most commonly used rectifier circuit in DC power supply. It uses four
diodes, when the input is positive diodes D2 and D3 are forward bias and conduct current
and voltage is developed across RL. Then when the input voltage is negative the diode D1
and D4 are forward biased and conduct current in the same direction through RL as during
the positive half-cycle, the same time during this cycle the D2 and D3 are reverse-biased.

First Conduction

The negative half-cycle will be going to conduct to the cathode of diode D1, thru the
RL and going to conduct to the cathode of diode D4 then Line-B. In this case D1 and D4 are
conducting.
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Second Conduction

The positive half-cycle will be going to conduct to the anode of diode D2, thru the RL
and going to conduct to the anode of diode D3 then Line-B. In this case D2 and D3 are
conducting.

Characteristics:
a. Expensive
b. Needs a lower value of capacitance
c. Needs four rectifier diodes

FILTER STAGE

Rectifier do not give pure DC output but only generate pulsating DC. Batteries produce
pure DC current but usually limited to low power application. Pulsating DC is not pure
because it contains AC components called Ripple.
The filtering stage is one of the stages of the power supply which filters the pulsating
DC. Output of rectifier stage and make it a pure DC voltage. The main function of the filter
circuit is to increase the DC output and to smoothen the pulsating DC.

Filter Ripple
Ripple
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Basic Methods of Filtering

1. Simple Capacitor in Parallel

You can parallel as many electrolytic capacitors as you want. This will increase the
amount of capacitance causing good filtering effects to DC output. This is used for high
current applications. The only disadvantage is that it will occupy a bigger space.

2. Filter with RC Circuit

This circuit is actually a resistor in series with the positive line together with 2 bypass
capacitor C1 & C2. It is good in lowering the DC voltage output.
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3. Filter with Inductor

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 and high current application. The
only disadvantage is that the inductor in series with the positive line takes up big space in
mounting it in the PCB.

REGULATOR STAGE

The regulator is a circuit that maintains a constant DC voltage for variation in the input
linear voltage on in load. The two most common voltage regulator using IC are the Fixed
positive linear voltage regulator (78xx) & Fixed negative linear voltage regulator (79xx).
1- Output 1- Input
2- Ground 2- Ground
(A) 3- Input 1- Input
3- Output
2- Output
3- Ground

(B)

The 78xx series three-terminal fixed positive voltage regulator

(A) Typical Packages (B) Standard Configuration
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A full-wave bridge type regulated power supply using 78xx series positive voltage regulator

79xx series three-terminal fixed negative voltage regulator

Note:
Remember, in choosing voltage regulator IC, the input voltage must be greater than
the rated output voltage of the regulator IC, but not much greater than the output rated
voltage. Usually not more than 100% of input to the output.

Fixed Positive Voltage Regulator IC Fixed Negative Voltage Regulator IC

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7809

7909
Schematic diagram of 9 volts, dual polarity Power Supply

Parts of AC-DC Power Supply

(Variable Power Supply)

External and internal Parts:

The parts of an AC-DC power supply are as follows:

1. Front Pane – It contains the power

switch, voltage selector switch, and
the power indicator.

2. Rear Panel – It contains the fuse

and the AC line cord

3. Alligator Clip - A special type of connector used to connect the power supply to the
electronic gadget.
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4. Capacitor – A capacitor acts as the filter. The one that removes ripples from the output
of the rectifier circuit. The type of capacitor used in this purpose is the electrolytic
capacitor.
5. Case and Cover – It serves as the housing of an AC-DC power supply.
6. Diode – A device which only allows current to flow in only one direction.
7. Fuse – A protective device used to prevent the circuit from short circuit or damage.
8. LED – A transducer which converts electrical energy to light, serve as light indicator
that the rectifier stage is working.
9. Line cord/AC cord – A type of cord used to connect the unit to the voltage source.
10. On-Off switch – a single pole – single through switch, used to switch on and off the
circuit.
11. Printed Circuit Board – PCB – a conductive pattern formed on one or both sides of
an insulating base by etching, plating or stamping.
12. Resistor – A resistor restricts the flow of current (in this circuit it acts as shunt resistor,
used to restrict current flow in to the LED.
13. Rotary Switch – A switch that is operated by a rotating shaft. It is used to select the
desirable voltage output.
14. Transformer – A component that consist of two or more coils which are coupled
together by magnetic induction (in this circuit it is used to step down the voltage from
to 12v, 9v, 6v,4.5v and 3v. this is a multi-tapped transformer).
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SELF-CHECK 1.1
AC-DC Power Supply

GENERAL DIRECTION: Write all your answers in separate sheets of paper. Do

not write anything in this module.

Direction: Answer the following questions below.

1. How many stages do basic power supplies have?

2. What component do we need to use in a simple basic filtering stage?

3. Why is a bridge type rectifier the most expensive type rectifier stage?

4. What stage of the power supply step-down the high AC voltage to lower AC

voltage?

5. What stage of the power supply converts small AC voltage to pulsating DC

voltage?

6. How many basic methods of filtering do the filtering stages have?

7. How many types of rectifier circuits do basic power supplies have?

8. What stage of the power supply smoothens the pulsating DC into pure DC output

voltages?

9. How many diodes full-wave center tapped power supplies have?

10. Why is a half-wave rectifier the cheapest type rectifier stage?

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SELF-CHECK 1.1 KEY

AC-DC Power Supply

1. Three
2. Filter Capacitor / Electrolytic Capacitor
3. It uses four rectifier diodes
4. Transformer stage
5. Rectifier stage
6. Three
7. Three
8. Filter Stage
9. Two
10. It uses one diode
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SELF-CHECK 1.2

Assembling AC-DC Power Supply

I. Direction: Fill in the blank with the names of the parts indicated in the
diagram. (1-9). Write the answer in your test notebook.

________ 10. Based on the given circuit, what type of power is this?

II. Direction: Draw the schematic diagram of the following circuit:

a. Half-wave power supply
b. Full-wave center tapped
c. Full-wave bridge type
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SELF-CHECK 1.2 KEY

I.
1. Transformer
2. AC plug
3. LED
4. Rotary Switch knob
5. Alligator Clip
6. Rubber Grommet
7. Rotary Switch
8. Printed Circuit Board
9. Fuse Holder
10. Full-wave Bridge Type Power Supply
II.

a. Half-wave power supply

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b. Full-wave center tapped

c. Full-wave bridge type

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LO. 2. – Designing and Etching PCB of AC-DC Power Supply

Objectives:
a. Identify procedure in making PCB design and etching process,
b. Prepare Printed Circuit Board (PCB) design and perform etching process for AC – DC
power supply and

A printed circuit board (PCB) has components inserted into the hole and soldered to
form its circuit connection. Its main purpose is to reduce the space and to troubleshoot easily
when problem arises.
The printed circuit board (PCB) has conductors that are thin strip of copper, usually
bonded to a baseboard called substrate. There are two very common substrate materials
used in printed circuit, the phenolic and epoxy plastic.

PCB is one of the 19th century greatest electrical products made. It introduced smaller,
faster (etching process), and cheapest models. This of course refer to the time it takes to
produce products out of wires and other electrical components. A PCB is a baseboard upon
which electronic components are mounted and soldered.

Copper – a conductor where the components terminal leads are soldered. Also called the
solder side or copper side.
Substrate – consists of thin copper layer which firmly bounded to an insulating base material.
This is the side where the electronic components are placed. Substrate side and also called
the components side.
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PCB Designing

1. Prepare Schematic Diagram

The first to consider before designing a PCB is, you must prepare or construct
a foil pattern or design according to the Schematic Diagram (this diagram is used to
show the interconnection of components through symbols).
2. Prepare the Tools and Materials Needed for Designing
a. PCB – material used to mount electronic components in able to form a circuit.
b. Masking Tape – used as etching resist. It is the material used to cover the copper
so that it will never be removed by the etching solution.
c. Cutter Blade – used to cut the excess making tape to form the intended foil
pattern.
d. Pencil or ball pen – use to make a sketch as guide for cutting the making tape.
e. Ruler – used a measuring device for an organize placement of components

a. b.

c. d.

e.

i.
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3. Making of Printed Circuits Board

Note: In PCB designing, we should not focus only on the size of the pathways linking to the
other component, but also on the types, kinds, and characteristics of component. Here are
the other design factors needed.

a. PCB size and shape – The PCB must be big enough for the entire component to be
mounted where it is anticipated.
b. Position of the Terminal – Input, output and supply voltage if possible should be
placed near the border for easier way during troubleshooting or minor repair.
c. High Temperature Dissipation – Too much heat is the number one problem of all
components. Bigger space is needed so that heat sink can be provided to the
component. This will protect the component from burning up.
d. Accessibility of Components – This component that is adjustable or variable
(example: potentiometer, trimmer resistor or capacitor) should be placed near the
border to make the troubleshooting or minor repair easier.
e. Space for Bolt and Nut – The designer should place an allowance for mounting the
PCB with bolt and nut in securing the entire board to the chassis.

Procedure in Preparing the Layout Diagram in the PCB

1. Prepare the schematic diagram of the circuit. The dash line shows the part of the
circuit which will be mounted in the PCB.
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2. Arrange the component circuit in a graphing paper to show/illustrate the same design
factor in PCB lay outing. Note: Actual size of the component should be adapted for
component arrangement and mounting.

3. Interconnect each component by copying the connection in the schematic diagram.

Foil Pattern based on the Schematic Diagram of Variable Power Supply

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4. Double-check the connection.

5. Trace the designed PCB by using a carbon paper and mark it on the copper side of
the clad board with a masking tape attached to the copper side.
6. And use a high point permanent marker for marking. Do the marking three times and
be careful not to shorten each line marking.
7. Then use the cutter blade to cut and remove the unnecessary masking tape.

Characteristics of Good PCB Design – 4C’s

1. Clean. It should be clean so that the representation of the schematic diagram is easy
to mark and troubleshoot the PCB.
2. Compressed. Reducing the size for space saving in chassis.
3. Creative in Design. There is a pattern or image when it is created.
4. Consistency in Component. The components should be well arranged in group.

PERFORMANCE CHECK

Designing and Preparing PCB of AC-DC Power Supply

Direction: Answer the following by putting a check mark in the appropriate box.
Did you: YES NO

1. Prepare the schematic diagram of the circuit?

2. Arrange the components in the circuit in graphic paper to

follow the design factor in PCB layout?

3. Interconnect each component?

4. Trace the design?

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5. Produce a good characteristics PCB design (clean,

compressed, creative and consistent with the component
size?

5 Yes Remarks 4 Yes Remarks

Excellent Very Satisfactory

3 Yes Remarks 2-1 Yes Remarks

Satisfactory Needs Improvement

Student’s Signature______________________ Date ______________

Teacher’s Signature______________________ Date _________________

Printed Circuit Board Etching

It is the removal of unwanted portion or layer of conductive materials (that is copper)

bonded to an insulating base called substrate. By using a chemical reaction to the copper
called ferric chloride, it liquefies the uncovered surfaces of the designed copper clad board
that creates a PCB.
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• Before etching

• After etching

Tools and Materials Needed in PCB Etching

1. Designed PCB – Ready for etching process

2. A bottle of the Ferric Chloride. (The quantity of bottle will depend upon the area
of the PCB) – used to remove excess copper.
3. Plastic Basin – It is the medium of ferric chloride
4. Popsicle sticks (2 pieces) – It is used for hauling the designed PCB.
5. Old newspaper – It is placed under the plastic basin for the prevention of accidental
spill of chemical over the table.
6. Apron – Prevent our clothes from dirt or stains.
7. Piece of Cloth – used for drying off water or etching solution.
8. Plastic Varnish 1 bottle – used as coating of our PCB after etching.
9. Lacquer Thinner – used to clean the PCB.
10. Surgical Gloves – PPE for our hands to avoid contact of hazardous substances.
11. Knife or Cutter – used to cut unwanted connections.
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PRACTICUM
Printed Circuit Board Etching

Direction: Given the resources needed, perform the procedure in PCB Etching to produce
a ready for mounting and soldering components.

Steps in PCB Etching

1. Prepare the necessary tools and materials needed in PCB etching.

2. Wear your apron and surgical gloves in order to prevent accidental splash of the
solution on your clothes or on your skin.
3. Pour the ferric chloride in the 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 not yet, return it into the plastic
basin filled with ferric chloride. After 3 – 5 minutes check it again.
6. Haul the PCB from the plastic basin and wash it in a free flowing water to remove
the remaining residue in the PCB.
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basin
PCB

7. With a clean and dry piece of cloth, wipe the wet PCB.
8. Pour a little amount of lacquer thinner on a clean dry piece of cloth and wipe the
markings of the permanent marker pen in the copper clad. (Note: In doing this, you
should wear your 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. And if there
is a break between the copper conductors, solder it.

Techniques to correct PCB Hairline Break or Short

A. Hairline Break. It is an open copper foil in the Printed Circuit Board. Most of the
time this is due to improper PCB designing or etching. To eliminate the hairline
break, just place a hook up wire and solder it.
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B. Hairline Short in the PCB Conductor. It arises if the printed circuit board
designing or etching is done improperly. To eliminate the hairline short, you should
cut it with a knife.

Hairline Short in the PCB Conductor

PCB Etching
Assessment Criteria

Direction: Encircle the number which will show how competent you have applied the skill
using the criteria below. Compute for the total result.
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Criteria Points Final

Workmanship 3 4 6 8 10
Use of Tools & PPE 3 4 6 8 10
SPEED 3 4 6 8 10
House Keeping 3 4 6 8 10
Finished Design 3 4 6 8 10
Total

Assessment Criteria

Score Descriptive Grade

96-100 Excellent
86-95 Very good
81-85 Good
75-80 Fair
74 – BELOW Poor

Student’s Signature______________________ Date ______________

Teacher’s Signature______________________ Date _________________

Boring

Direction: Given the resources needed, perform the procedure in

designing and preparing a PCB of AC-DC power supply.
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Conditions

• Tools and Materials

- Mini Drill
- PCB
- Piece of wood
- Drill bit
- Varnish

• Mini Drill Setup

1. Loosen the chuck by using a long metal tool and change the drill bit. This is
done in a counter clockwise movement.

Drill Bit

Mini-drill

2. Insert the drill bit 1mm diameter in size and attach it to the chuck of the unit.
3. Turn the long metal tool clockwise to tighten the jaw of the unit. Be sure that
the drill bit is well secured on the chuck.
4. Before inserting the 12 volts adaptor, you should turn off the unit.
5. Test the rotation of the unit if it is well aligned. If not, align it following the
steps no. 1 and 2.

• How to Use a Mini Drill?

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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 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.

• Boring Procedure

1. Prepare all the materials needed.

a. Mini drill
b. Designed PCB
2. Mark where the holes are to be drilled.

Hole Marks
3. Using the mini drill, bore hole perpendicularly to the surface of the PCB.

4. Clean the surface of the PCB and look for open line or short circuit.
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5. Apply plastic varnish to the newly etched PCB to prevent corrosion or rust, and let it
dry before touching it.

SCORING RUBRICS FOR

Boring

Note: You should read the following before and after performing the process.
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Workmanship 55%
1. Tools were properly used according to its function. 25
2. PPE was observed completely while working. 25
3. Proper tools were used and PPE were observed while working. 5
Speed 5%
Finished task before time frame 5
Finished task within the time frame 4
Finished task 15 minutes after the time frame 3
Finished task 30 minutes after the time frame 2
Finished task 31 minutes and more 1
Housekeeping 5%
1. The whole area was cleaned after the assembly 5
2. The whole area was dirty after the assembly 1
Finished Design 35%
• Finished design based from the given
schematic diagram 35
• Finished design was correct but with access copper
clad on the finished design 30
• Finished design was correct but with cut on the line 25
• Finished design was with shorted line that will cause
a short circuit 10
• Finished design was incorrect 2

Total 100%

Rating System
Score in Percent Descriptive Grade
95% - 100% Outstanding
80% - 94% Very Satisfactory
75% - 79% Satisfactory
74% and below Needs Improvement
Note: If you got 74 and below, you need to go over the procedures and ask
assistance from your classmates who passed this activity or from your
teacher.
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Self-check
Etching and Boring Process

Direction: Identify what is being ask in every test item. Write tour answer in a
separate sheet, do not write anything in this sheet.

1. What do you call the process of removing the excess copper in the PCB?

2. What is the process of making tiny holes in the PCB for the insertion of the

components terminals?

3. What is the solution will you used to etch or remove the excess copper of the PCB?

4. What is the material will you used in able to protect the designed PCB from rust and

corrosion?

5. After etching process, you notice that the foil pattern has broken lines, how will you

solve the problem?

6. What tool will you use in making holes so that the components terminal will pass

through into the PCB?

7. What will you do if you notice unnecessary connection in your designed PCB?

8. What is PCB?

9. How will you remove ink makings into the PCB?

10. What part of the PCB sometimes call the components side?
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Self-check Key
Etching and Boring Process

1. Etching Process

2. Boring Process

3. Ferric Chloride

4. Plastic Varnish

5. Put some Hock-up wires and solder

6. Mini Drill (12 volts)

7. Cut unwanted connection with Cutter Blade

8. Printed Circuit Board

9. Lacquer Thinner

10. Substrate Side

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LO. 3. Mount and solder the electronic components at the appropriate

location in the PCB

Objective:
a. Identify the tools and materials needed for mounting and soldering electronic
components in the PCB,
b. Perform mounting and soldering procedure and
c. Testing the functionality of the assemble electronic product.

Mounting and Soldering AC-DC Power Supply Project

Direction: Using the given tools, supplies and materials, mount the electronic
components to the PCB and perform soldering procedure to
assemble an AC-DC power supply project.

• Supplies and Materials

1. PCB (with finish copper foil pattern)
2. Soldering Lead, 60/40 – used to mount/connect components’ terminals in to the
copper side
3. AC cord with plug – used to connect circuit in to the source.
4. Toggle Switch (on/off) – used to control the circuit’s operation.
5. Fuse and fuse holder (1A) – used to prevent the circuit from excessive current
or short circuit.
6. Selector switch – 2 poles 6 positions – used to select the desirable voltage
output in the variable power supply.
7. 4 pcs. Rectifier diode – used to convert AC-DC (Bridge type Rectifier)
8. Electrolytic capacitor – 3,300 uF/25V, serve as filter capacitor.
9. Jumbo LED with holder – used as auxiliary wire for voltage output of the circuit.
10. Transformer, Primary voltage 0-220 volts; (Multi-tapped transformer)
(Secondary voltage output 0V, 3V, 4.5V, 6V, 9V, 12V; current rating 750mA)

• Tools and Equipment

- Long nose pliers – use to bend the components’ terminals
- Soldering iron - 20-40 watts, used to melt solder and make joints.
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Simple Power Supply Project

In all the basic electronic theories, power supply assembling is the most common
application needed by the students. In this project, they will be able to apply all the
knowledge they have learned since the very start of their lessons. This project will enable
them to practice the five characteristics of a good assembler. These are the planning,
assembling, testing, troubleshooting and appreciating the work.\

Schematic Diagram of a Multi-Volts Unregulated Power Supply

• Auxiliary Components of Power Supply

There are some minor components needed to be familiarized with and their
uses. These are the AC plug with cord, power switch, fuse holder and fuse, selector
switch, selector knob, indicator lamp and alligator clips.

- AC Plug with Cord is used for connecting the 220V input voltage of the power
supply.
- Power Switch is used to control the flow of 220VAC to the power supply by turning
off or on.
- Fuse Holder & Fuse is used to protect the unit from any sudden short from the
load or too much rising of power from the line source.
- Selector Switch is used to select the output voltage of the power supply from 3V
to 12V DC
- Selector Knob is a plastic holder of the selector switch.
- Indicator Lamp is used to show if there is a presence of power in the circuit.
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- Neon Lamp is for 220V AC monitoring lamp.

- Led is for output monitoring lamp
- Alligator Clips are used to connect the two-line output to the load.
Red clip for positive.
Black clip for negative

Note: When performing soldering activity make sure that you familiarize the schematic
diagram and what are the components to be mounted and soldered.
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Procedure: Mounting and Soldering

1. Prepare all the materials needed – gather all the material and arrange things
orderly
2. Clean the terminals of the components to be soldered and the PCB copper
side.
- It is important to clean the terminals of the components to avoid cold solder or
bad solder.

3. Mount the components in the PCB – in mounting or placing components always

take note, always test the component before mounting and observe proper
placement and polarity of component so that unnecessary event will be prevented.
4. Solder components – for soldering use the 25 – 40 watts soldering iron to avoid
cold solder of joints and overheating of components. Heat and vibration are some of
the possible cause which can cause malfunction of the circuit.

Appearance of solder
- In soldering components spend 3-5 second time for soldering each joint.
- Good solder is volcano shape formed by the solder into the components terminal
- Heat generating components most be equipped with heatsink to avoid overheating.
- Component must be placed in the PCB correctly (observe proper placement of
different component).
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The difference of good and bad solder joints

- There are some components which are sensitive into heat such as transistors
and IC, to protect them when soldering use longnose pliers to serve as heatsink
into the terminal which is being solder.
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5. Cut the excess terminals of the component – after soldering the components
terminals cut the excess terminal to avoid short circuit.

6. Test the circuit using the multi-tester – after soldering all the components of the
circuit testing with the used of the multi-meter is important. Perform continuity testing
and resistance check, make sure that the circuit is not shorted before plugging into
the source. When the circuit is plugged into the source perform voltage checking to
test the functionality of the assemble electronic product.
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Self-Check
Mounting and Soldering

Direction: Identify what are being ask in every test item then write it into a
separate sheet of paper, do not write anything in this sheet.

1. What component will you use to protect circuit from excessive current?

2. What is the best component will you used for the convenient and safe selection of

the output voltage of your variable AC-DC Power Supply?

3. In what part of the PCB does the components terminals are solder?

4. What is the best component will you use to determine that the rectifier stage is

working?

5. What particular tool will you use to bend or manage the insertion of the electronic

components into the tiny holes of the PCB?

6. What material will you use to connect the assembled circuit into the convenient

outlet/220vAC source?

7. What is the standard power rating of the soldering tool which is good for soldering

electronic work to avoid cold or bad solder and overheating?

8. What is the indicator of a good solder joint?

9. Why it is important to cut the excess terminals of the components?

10. What are the factors need to considered in mounting electronic components into the

PCB?
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ASSESSMENT CHECKLIST FOR JOB SHEET

Mounting and Soldering AC-DC Power Supply Project

Direction: Encircle the number which will show how competent you have applied the skill
using the criteria given below. Compute for the total result.

Criteria Points Final

Workmanship 2 4 6 8 10
Use of Tools & Use PPE 2 4 6 8 10
SPEED 2 4 6 8 10
House Keeping 2 4 6 8 10
Finished Design 2 4 6 8 10
Total

Assessment Criteria
Score Descriptive Grade
96-100 Excellent
86-95 Very good
81-85 Good
75-80 Fair
70-74 Poor
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Self-Check Key
Mounting and Soldering

1. Fuse

2. Rotary Switch

3. Copper Side

4. LED/Light Indicator

5. Long Nose Pliers

6. AC Cord

7. 20 – 40 Watts

8. Volcano Shape Joint

9. To avoid short circuit

10. Polarity and proper placement

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REFERENCES

1. Gantalao, Fred T., Lasala, Rommel M., Enriquez Michael Q. Basic Electronic

2. Diola, Victoriono p. et al; Competency-based Learning Material;

Department of Education 2009