How to build a 24-volt DC power supply

Written by david r. wetzel
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How to build a 24-volt DC power supply
24 VDC Power Supply (germes-online.com, isplc2006.org, bikudo.com, cablesdirect.com)

Building a 24 VDC power supply is fun and challenging at the same time. These power supplies have a multitude of uses including pool pumps, garage down openers, and other applications. This power supply uses 110 VAC as the input, with 12 VDC at four amps output. These directions work well for any size DC power supply, with the only requirement being to change the electronic components to provide the desired power output.

Skill level:
Challenging

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Things you need

  • 1 -- Bread or Strip Board 6 inch by 6 inch
  • 1 -- 6 foot 14 AWG extension cord with the receptacle end removed
  • 1 -- 110 VAC to 24 VDC Step-Down Transformer 4 Amp Ring Type
  • 1 -- 24 VDC Bridge Rectifier
  • 1 -- 24 VDC Smoothing Capacitor
  • 1 -- 24 VDC Voltage Regulator Circuit with Heat Sink
  • 2 -- Terminal Blocks 2 Way with Screws for Printed Circuit Boards
  • 1 -- 4 Amp Fuse Holder for Printed Circuit Board
  • 1 -- 4 A Quick Blow Fuse
  • 2 -- Feet #14 AWG Insulated Copper Wire
  • 1 -- Wire Stripper/Cutter
  • 1 -- Solder Gun
  • 1 Roll -- Tin Solder/Resin Core
  • 1 Tube -- Glue

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Instructions

  1. 1

    Glue the two 2-way terminal blocks to one end of the bread board (see tips). Ensure the screw attachments are pointed upwards and the wire connection point's project cleanly through the bread board holes. Label one 2-way terminal block AC Input and the other DC Output.

    How to build a 24-volt DC power supply
    2-Way Terminal Block
  2. 2

    Glue the voltage regulator on the opposite side of the bread board from the 2-way terminal blocks. Ensure the wire connection point's project cleanly through the bread board holes.

    How to build a 24-volt DC power supply
    Voltage Regulator with Heat Sink
  3. 3

    Glue the step-down transformer on the bread board near the AC 2-way terminal block with the output side opposite the terminal block. Ensure the wire connection point's project cleanly through the bread board holes.

    How to build a 24-volt DC power supply
    Ring Type Step-Down Transformer
  4. 4

    Glue the fuse holder on the bread board near the output side of the step-down transformer. Ensure the wire connection point's project cleanly through the bread board holes.

    How to build a 24-volt DC power supply
    Fuse Holder
  5. 5

    Glue the bridge rectifier on the bread board between the fuse holder and voltage regulator. Ensure the wire connection point's project cleanly through the bread board holes.

    How to build a 24-volt DC power supply
    Bridge Rectifier
  6. 6

    Glue the smoothing capacitor on the bread board in a clear area between the voltage regulator and DC output terminal block. Ensure the wire connection point's project cleanly through the bread board holes.

    How to build a 24-volt DC power supply
    Smoothing Capacitor
  7. 7

    Cut and strip about one quarter inch off both ends of two 14 AWG insulated wire two inches long. Solder each wire to the both inputs of the step-down transformer and solder the other ends to AC input terminal block.

  8. 8

    Cut and strip about one quarter inch off both ends of two 14 AWG insulated wire two inches long. Solder the one wire to the output side of the step-down transformer and the other end of the wire to one of the inputs for the bridge rectifier. Solder one end of the other wire to the output side of the step-down transformer and the other end to the fuse holder.

  9. 9

    Cut and strip about one quarter inch off both ends of one 14 AWG insulated wire 2 inches long. Solder the one wire to the output side of the fuse holder and the end to the other input of the bridge rectifier.

  10. 10

    Cut and strip about one quarter inch off both ends of two 14 AWG insulated wire two inches long. Solder both wires, one to each output side of the bridge rectifier. Solder the other end of both wires to both sides of the smoothing capacitor.

  11. 11

    Cut and strip about one quarter inch off both ends of two 14 AWG insulated wire two inches long. Solder one wire to each side of the smoothing capacitor. Solder the other ends of both wires to the inputs of the voltage regulator.

  12. 12

    Cut and strip about one quarter inch off both ends of two 14 AWG insulated wire seven inches long. Solder one wire to both outputs of the voltage regulator and solder the other ends to the DC output terminal block.

  13. 13

    Strip about one half inch off each wire of the extension cord (end with receptacle removed). Attach each wire to the terminal with screws on the AC input 2-way terminal.

  14. 14

    Install 4 Amp fuse in fuse holder. Now the power supply is ready.

Tips and warnings

  • Only use one small drop of glue to hold all the terminals, transformer, fuse holder, smoothing capacitor, and bridge rectifier in place.
  • All components must be evenly spaced across the bread board, allowing enough room between each component to avoid heat build-up.
  • All wire connections are on the bottom side of the bread board.
  • Install a 24 VDC fan if heating becomes a problem. The fan can be connected between the 24 VDC output terminal and voltage regulator.
  • Anytime someone is working around 110 VAC there is a extreme danger of electrocution.
  • Do not use excessive heat when soldering wire to electronic parts, because too much heat will destroy the part.
  • Any 24 VDC power supply must be installed in metal or wood case to avoid shock hazard from the 110 VAC.

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