This is a portion of my CNC motion control board assembly documentation.

CNC Controller Motion Board Power Supply Wiring (Rev. D)

The power supply is wired in the following steps:
The 120VAC portion of the circuit is wired together using 14AWG white solid copper wire. I would have preferred a somwhat narrower gage, but my local hardware store did not stock the 18AWG wire that I wanted. One end of the switch is connected to the fuse holder and the other end is connected to the line cord plug. The other end of the line cord plug is attached to the transform. The other end of the transform is connected to the fuse holder. The ground pin of the line cord plug is connected to chasis using a piece of bare 14AWG wire. Heat shrink tubing is threaded onto each wire (except the ground wire.)
After the soldering is done, the heat shrink tubing is positioned over the solder joint. If you are lucky enough to have a heat gun, use it to shrink the tubing over each solder joint. I am not so lucky, so I use a matches. The goal here is to make it difficult for some idiot (like me) to accidentally reach into the 120VAC section and get an electrical shock.
The output of the transformer is fed into the the bridge rectifier using 14AWG white wire. Again, pieces of heat shrink tubing are threaded onto the wires.
The heat shrink tubing is shrunk over each of the connections. Also, I put heat shrink tubing over the 12 volt center tap. I am a lot less concerned about electrical shock on the 24VDC section of the circuit, but avoiding accidental shorts is work taking precautions for.
The 24VDC output from the bridge rectifier is routed to the printed circuit board using 14AWG wire. The 24VDC line is red and the ground return is black. Again, the heat shrink tubing is pre threaded over the wires.
Again, the heat shrink tubing is shrunk to seal the connection.
The capacitors are connected together using 14AWG wire. Again, red is 24VDC and black is ground return. I could not figure out how to easily do the heat shrink tubing thing, so I just put gaps in the insulation.
Each wire is carefully soldered. As you can see, the red and black wires do not even touch.
For the smoke test, the on/off switch is turned off, the power cord is plugged in, and the power plug is plugged into an outlet strip (not shown) with a built in circuit breaker.
The DVM (Digital Volt Meter) is set up to measure the voltage coming out of the transformer. The power switch is flipped, the voltage measures 22.5V and there is much cheering. Yeah!!! (By the way, the volt meter in the picture is reading 0.00 volts; this is because I have not flipped the switch on yet.)


Copyright (c) 2005 by Wayne C. Gramlich. All rights reserved.