Almaz boehm TVET collage

Module title; - designing and constructing simple circuit board

LEARNING MODULE 5
TVET PROGRAM TITLE: Basic Electrical/Electronic Equipment Servicing Level I
MODULE TITLE: Designing and constructing simple printed circuit board
MODULE CODE: EEL BEE1 M05 0811
NOMINAL DURATION: 50 Hours
MODULE DESCRIPTION: This module covers the knowledge, attitudes and skills required in
Designing and constructing simple printed circuit board in electrical/electronics industry. It
includes: Apply safety procedures, Design an electrical/electronic circuits, Construct an
electrical/electronic circuits on PCB
LEARNING OUTCOMES:
At the end of this module the trainer will be able to
LO1: Plan and prepare to construct/ electrical/electronic circuits
LO2: Construct electrical /electronic circuits on PCB
LO3: Test the construction of electrical/ electronic circuits
MODULE CONTENTS:
LO1: Plan and prepare to construct/ electrical/electronic circuits
1.1 planning and preparing to construct electrical/electronic circuits
1.1.1, checking materials
1.1.2, selecting appropriate tools and test instrument
1.1.3, planning task to insure occupational health and safety
1.1.4, Preparing circuits for connection and soldering
LO2: Construct electrical /electronic circuits on PCB
2.1, personal protective equipment
2.2, identifying important electrical/electronic components
2.3, soldering & de soldering methods
2.4, PCB construction process
2.5, using appropriate range of methods in constructing circuits
2.5.1, amplifiers 2.5.3, DC power supply
2.5.2, oscillators 2.5.4, digital circuits
2.5.5, air conditioner control circuits
LO3: Test the construction of electrical/ electronic circuits
3.1, conduct testing 3.2, checking the accurate operation of the circuit
LEARNING STRATEGIES:
 Lecture-discussion
 Demonstration
Practical exercises

Page 1
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board

Occupation: - Electrical Electronics equipment service Management level 4

UNIT OF COMPITANCY:- Design and construct simple printed circuit board
LO1:
Selecting Appropriate Tools And Test Instrument
 Consumable Materials
Below is the list of measuring instruments used in electrical and electronic work.
The following items are used for construct electrical/electronics circuit
 Soldering iron
 Long noise
 Side cutter de soldering pump

Types of test equipment

Basic equipment
The following items are used for basic measurement of voltages, currents, and components in the circuit under test.
 Voltmeter (Measures voltage)
 Ohmmeter (Measures
 Ammeter, e.g. Galvanometer or Milli Ammeter (Measures current)
Multimeter e.g., VOM (Volt-Ohm-Milliameter) or DMM (Digital Multimeter) (Measures all of the above

The following are used for stimulus of the circuit under test
 Power supplies
 Signal generator
 Digital pattern generator
 Pulse generator
The following analyze the response of the circuit under test:
 Oscilloscope (Displays voltage as it changes over time)
 Frequency counter (Measures frequency)And connecting it all togeth

Tools and Equipment

 Pliers, Cutters, Screw drivers, Steel rule, Soldering gun, Hand drill , Multi-tester,

Page 2
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
Pliers Goggles, Gloves and overall.
 planning task to insure occupational health and safety
 Electrical test instruments that are used in hazardous areas (e.g. in or near explosive
dusts and atmospheres)
 to be in good working order, clean and have no cracked or broken insulation
 where appropriate, test leads and testing devices should be provided with over current
protection
 Occupational health and safety (OHS) or workplace health and safety (WHS) is
an area concerned with protecting the safety, health and welfare of people engaged in
work or employment
 the maintenance and promotion of workers’ health and working capacity;
 the improvement of working environment and work to become conducive to safety
and health

Personal Protective Equipment

 Employers are responsible for providing, replacing and paying for personal protective
equipment
 PPE should be used when all other measures are inadequate to control exposure. It
protects only the wearer, while being worn
 Protective clothing therefore remains a necessary part of working area. The items
required would depend on the harmful effects of the Work area and the way in which it
is used In practice,

LO2 construct electrical /electronic circuit on board

In order to construct electrical electronics circuit on board
Identifying Important Electrical/Electronic Components
Page 3
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
 Diode:- The term diode and rectifier will be used interchangeably, however, the term
diode usually implies a small signal device with current typically in milliamp range, and
a rectifier. The most important function of a diode is to act as one way valve for passage
of current

 Capacitor:- a device used to restore or store electrical energy when charged . It is an

electronic device made up of two conducting plates separated from each other by a
dielectric (insulating material), paper, oil, plastic

 Resistor:- Is a circuit element used to resist, oppose or limit the amount of current flow
of current whether it is in a series or in a parallel connection. and thereby develops a
voltage drop across on it

 Fuse:- is a protective device having a short length of wire that melts when the current
passes through it exceed a predetermined (rated) value
 Its critical component is a thin metal wire that will melt when heated by a prescribed electric current,
opening the circuit of which it is a part, and so protecting the circuit from an over current condition

Page 4
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
 Fuses are rated with current and voltage ratings that indicate the maximum circuit current and voltage in
which the fuse can be used

 Transformer:- is an electronic/electrical device consisting of two or more coils coupled by

magnetism induction. It also a device that increases or decreases the voltage of alternating current.
 It is a device that is used to transfer electrical energy from one circuit to another by means of an
electromagnetic field

 Switch: - it connects and disconnects different wiring connections in a circuit to serve

the purpose.

Soldering & De Soldering Methods

 Soldering & De Soldering Methods
What is solder?
 Is an alloy (mixture )of tin and lead ,typically 60% tin and 40% lead .it malt the temperature of about
190 c0 coating a surface with solder is called tinning because of the tin content of solder. Lead is
poisonous and you should always wash your hands after using solder.
 Solder for electronic use contains tin cores of f flux ,like the wire inside a mains flux .the flux is
corrective , like an acid, and it clean the metal surface as the solder melt .
Page 5
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
 Using soldering iron
 The most fundamental skill needed to assemble any electronic project is that of soldering.
 Soldering is defined as the joining if metal by a fusion of alloy which have relatively low malting point
 A soldering iron (sometimes called a soldering pencil) is like a wand that gets very, very hot so that
when you touch it to the solder, it melts it. You can find a variety of soldering iron models

Soldering iron Sold ring iron stand soldering

lead
 Fig Basic Equipment Used In Soldering
 The Soldering Iron Tip
 Transfer thermal energy from the heater to the solder connection it most soldering iron tip, the base
metal is copper or same alloy because of its excellent thermal conductivity determines how fast thermal
energy can be sent from the heater to the connection .
 Preparing the soldering iron (Clean first all dirty and corroded part to be soldered).
 place the soldering iron it is stand and plug in .the iron will take a few minutes to reach its operating
temperature of about 400” c
 Dampen the sponge in the sand .the best way to do this is to lift it out of the stand and hold it under a
cold tap for a moment, then the squeeze to remove excess water .it should be damp, not dripping wet.
 Wait a few minute for the soldering iron to warm up. You can check if it is ready by trying to melt a little
solder on the tip.
 Wipe the tip of the iron on the damp sponge .this will clean the tip.
 melt a little solder on the tip of the iron .this is called “tinning “ and it will help the heat to flow the iron
s tip to the joint , it only needs to be done when you plug in the iron Soldering iron with stand You are
now ready to start soldering :

 Hold the soldering iron like a pen, near the base of the handily (as illustrate below) ,imagine you are
going to write your name ,remember to remove to never touch the hot element or tip.

Page 6
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
 Hold the soldering iron on to the joint to be made ,make sure it touches both the component lead and the
track .hold the tip there for a few second (2or 3second )
 Feed a little solder on to the joint .it should flow smoothly on to the lead and track to form a volcano
shape as illustrated .apply the solder to the joint, not the iron .
 Remove the solder then the iron, while keeping the joint still allow the joint a few second to cool before
you move the circuit board.
 Inspect the joint closely ,it should look shiny and have a volcano shape .if not you will need to reheat it
and feed in a little more solder .this time ensure that both the lead and track are heated fully before
applying solder .

Proper Handling Of Soldering Iron

 How To Make The Perfect Solder Joint
 All parts must be clean and free from dirty and grease
 Try to secure the work firmly.
 ”tin” the air on tip with a small amount of solder .do this immediately, with new tips being used for the
first time.
 Clean the tip of the hot soldering iron on a damp sponge.
 many people then add a tiny amount of fresh solder to the cleansed tip
 Heat all part of the joint with the iron from under a second or so.
 Continue heating, then apply sufficient solder only, to form an adequate joint.
 remove and return the iron safety to its stand
 It only task two or three seconds at most .to solder the average PCB joint.
 Do not move parts unit the solder has cooled.
 Use De Soldering Pump
 When electronic component need to be remove from a circuit .there will be undoubtedly come a time
when you need to remove the solder from a joint possible to replace a faulty component or fix a dry
joint .the usually way is to use a disordering pump which work like a small spring loaded bicycle pump
only in reverse .a proper soldering technique can soon be acquired with practice .

Page 7
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board

Desoldring Pump
 Steps Using Desoldring Pump( Soldring Sucker)
 Set the pump by pushing the spring –loaded plunger down until it Locke
 Apply both the pump nozzle and the tip of you soldering iron to the joint
 Wait a second or two for the solder to melt.
 Then the process the bottom on the release the plunger and suck the molten solder in to the tool.
 repeat if necessary to remove as much solder as possible .the pump will need emptying occasionally by
un screwing the nozzle

 Using desoldring pump (soldring sucker )

 Step in using solder remover wick (copper braid )
 Apply both the end of the wick and the tip of you soldring iron to the joint
 As the solder melts of it will flow on to the wick ,away from the joint
 Remove the wick first then the soldering iron
 Cut off and discard the end of the wick coated with solder
 Remember, skill is very important to make it this better and safe, so practice, practice and more practice.

Parts of list of power supply

 Power transformer primary 0-229v,secondary 24-0-24 to 30-0-30v current out put 3to 8 ampere
 Power switch
 Fuse 3A
 Diodes 1n5401
Page 8
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
 Capacitors 4700uf/50v
 Resistors 3k,5w
 Printed Circuit Board (PCB)
 The circuit board is one of the 19 century greatest product to come out .it introduced smaller faster
(etching process )and cheaper model this of course refer to the time it takes to produce a product out of
wire and other electrical component

PCB where electronic component mounting

 Copper
 Substrate
 PCB Cross Section
Substrate -consists of thin copper layer which is firmly bonded to an insulating based material .this is the
side where the electronic component are placed .substrate side is also component side.

Copper – a conducted where the component terminal leads are soldering .also called solder side.

 Tools &material s use in PCB design &etching process

 Printed circuit board (PCB):- is baseboard upon which electronic component are mounted and
soldered.
 Ferric chloride (granules or liquid):- a dark –red iron containing salt which is used to melt the
copper in the PCB.
 Masking tape or adhesive tape: - easy –to –remove adhesive tape used to cover parts of surface
that are not meant to be painted.
 cutter blade:- a sharp blade used to cut masking tapes not needed to the design of the PCB
 Pencil:- writing instrument, a thin cylindrical instrument used for drawing or writing ,it consists of a
road of graphite or some other erasable marking material inside a wooden or metal sheet.
 Ruler:- straight tool for measuring and drawing a strip of plastic ,wood ,or metal with at least one
straight egg and unit of length marked on it .it is used for measuring and for drawing straight lines.
 Sand paper:- strong paper coated with a basic material :strong paper coated on one side with sand or
another abrasive use smooth surface .
Page 9
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
 plastic tray:- a rectangular shape , which is used to etch the PCB with the ferric chloride
 Mini drill with bit (0.8mmtypicaly) with adaptor (+12vdc supply) boring tool with drill; a tool or
machine that hold drive and horse with a drill.

PCB Designing
PCB Design:

PCB design is usually done by converting your circuit’s schematic diagram into a PCB layout
using PCB layout software. There are many cool open source software packages for PCB layout
creation and design. The first thing to consider before designing a PCB is you must prepare or
construct a schematic diagram according to your design ,let as the schematic diagram below.

 For example :-
 half wave rectifier
 full wave centre tap rectifier
 full wave bridge rectifier

Materials required for making Circuit Board

 FeCl3 powder/solution (same as etching solution),
 photo/glossy paper, permanent black marker,
 blade cutter,
 sandpaper,
 kitchen paper and
Page 10
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
Step1 Take printout of circuit board layout
Take a print out of your PCB layout using the laser printer and the A4 photo paper/glossy paper.

STEP 2: Cutting the copper plate for the circuit board

Cut the copper board according to the size of layout using a hacksaw or a cutter
STEP 3: Transferring the PCB print onto the copper plate
Method 1 Iron on glossy paper method (for complex circuits): Transfer the printed image (taken from a laser
printer) from the photo paper to the board. Make sure to flip top layer horizontally

STEP 4: Ironing the circuit from the paper onto the PCB plate

Remove the paper off by peeling it from a low angle.

STEP 5: Etching the plate

 Dip the PCB into the etching solution (Ferric chloride solution, FeCl3) for approximately 30 mins.
 The FeCl3 reacts with the unmasked copper and removes the unwanted copper from the PCB.
 This process is called as Etching. Use pliers to take out the PCB and check if the entire unmasked area
has been etched or not. In case it is not etched leave it for some more time in the solution.

Page 11
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board

 Gently move the plastic box to and fro so that etching solution reacts with the exposed copper. The
reaction is given as:
Cu + FeCl3 = CuCl3 + Fe
After every two minutes check if all the copper has been removed. If it hasn’t then place it back in the
solution and wait.
 CAUTION: Always use gloves while touching the plate having the solution.

Page 12
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board

STEP 6: Cleaning, disposing and final touches for the circuit board

Now, drill holes using a PCB driller like this: PCB driller and solder all your cool components. If you want that
traditional green PCB look, apply solder resist paint on top: PCB lacquer. And finally! Your super cool circuit
board would be ready

For more practice to preparation of PCB by using software, we should follow below steps.
Making a printed circuit board
Step– 1 Make a design using PRETOUS soft ware on PCs

Page 13
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
 Print out the circuit from PC
 Warm up the laminator
 print the Image
 Clean the PCB

Cut the board to the correct size for your image

 Transfer the Image
 Removing the Paper
 Inspect and Correct
 Etch, Drill, Clean, and Stuff
 etch the board

 drilling the Etched board

 attach the component

 Solder the Component
LO2. Construct Electrical /Electronic Circuits on PCB

 Purpose: - the liner should able to know how to make printed circuit board (PCB) design and etching process.
Page 14
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
 Equipment ,tool ,materials:- printed circuit board (PCB), ferric chloride (granules or liquid ), masking tape,
cutter blade, pencil, Ruler, sand paper plastic tray, minil drill with bit (0.8mmtypicaly ) with adaptor (+12vdc
supply )&electronic component used in the project.
 Condition or situation of the operation :- give the time from of 4 hours the Lerner require to design the
(PCB)layout perform etch process ,boring the PCB according to the require component &assemble the electronic component
base on the schematics diagram &pictorial diagram .check the require material ,select the appropriate tool &
equipment ,ensure the occupational health & safety ,and proper the consumer electronic product &system in the practical
area .
 Procedures:- in the practical work area prepare and place the require material ,tool &equipment ,and ensure the safety
requirement and select the require consumer electronic products &system according to the task requirement .
 Step 1 prepare tool, materials &equipment needed

Ferric chloride granules Ferric chloride liquid

Masking tape cutter blade

 Amplifier
 What is amplifier?
 Amplifier is a device which magnifies signals. The heart of an amplifier is a source
controlled by an input signal

Page 15
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
Why is Amplifier needed?
 Sound is transmitted in electronic devices by representing sound as a varying electric
current.
 A microphone diaphragm is moved back and forth using the sound signals and the
microphone translates this movement into an electrical signal.
 The electrical signal fluctuates to represent the compressions and rarefactions of the
sound wave.
 A recorder encodes this electrical signal as a pattern in some sort of medium. A player re-
interprets this pattern as an electrical signal and uses this electricity to move
a speaker cone back and forth. This re-creates the air-pressure fluctuations originally
recorded by the microphone

Oscillator
is a mechanical or electronic device that works on the principles of oscillation: a periodic fluctuation between
two things based on changes in energy
DC power supply
A DC Power Supply Unit (commonly called a PSU)deriving power from the AC mains (line) supply performs a
number of tasks:
 It changes (in most cases reduces) the level of supply to a value suitable for driving
the load circuit.
 It produces a DC supply from a pure AC wave.
 It prevents any AC from appearing at the supply output.
 It will ensure that the output voltage is kept at a constant level, independent of
changes in:
 The AC supply voltage at the supply input.
 The Load current drawn from the supply output

Page 16
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
The Transformer

Fig7. Typical Input Transformer

In a basic power supply the input power transformer has its primary winding connected to the mains(line)
supply.
A secondary winding, electro-magnetically coupled but electrically isolated from the primary is used to obtain an
AC voltage of suitable amplitude, and after further processing by the PSU, to drive the electronics circuit it is to
supply.
The Rectifier Stage
Three types of silicon diode rectifier circuit may be used, each having a different action in the waythat the AC
input is converted to DC.
Half Wave Rectification
A single silicon diode may be used to obtain a DC voltage from the AC input.
The half wave rectifier conducts on only half of each cycle of the AC input wave, effectively blocking the other
half cycle, leaving the output wave.

Full Wave Rectification

If a transformer with a centre tapped secondary winding is used, more efficient full wave rectification can be
used. The centre-tapped secondary produces two anti-phase outputs.
The output frequency of the full wave rectifier is therefore twice the input frequency.
The higher output frequency also makes the smoothing of any remaining AC ripple easier.

Page 17
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board

The Bridge Rectifier

The full wave bridge rectifier uses four diodes arranged in a bridge circuit as shown in Fig10.to give full wave
rectification without the need for a centre-tapped transformer. An additional advantage is that, as two diodes
(effectively in series) are conducting at any one time, the diodes need only half the reverse breakdown voltage
capability of diodes used for half and conventional full wave rectification

The current paths on positive and negative half cycles of the input wave are shown in below fig

Fig11. Current Flow on the Positive Half Cycle

Page 18
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board

Fig12. Current Flow on the Negative Half Cycle

Filter Components
A typical power supply filter circuit can be best understood by dividing the circuit into two parts, the reservoir
capacitor and the low pass filter. Each of these parts contributes to removing the remaining AC pulses, but
indifferent ways.

Voltage Regulators
There are two types of voltage regulators:
1. Linear regulators
2. Switching regulators

Digital circuit

Page 19
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
Circuits that handle only 0 and 1 signal are called digital circuit called digital circuit.
Application of logic gate
 Used for in calculator and computer
 In digital measuring technique
 In digital process of communication
 In musical instruments, games and domestic appliances

Half Adder and Full Adder Circuit

Half Adder and Full Adder circuits are explained with their truth tables in this article. Design of Full Adder using
Half Adder circuit is also shown
With the help of half adder, we can design circuits that are capable of performing simple addition with the help of
logic gates.
Let us first take a look at the addition of single bits.
0+0 = 0
0+1 = 1
1+0 = 1
1+1 = 10
These are the least possible single-bit combinations. But the result for 1+1 is 10. Though this problem can be
solved with the help of an EXOR Gate, if you do care about the output, the sum result must be re-written as a 2-
bit output.
Thus the above equations can be written as
0+0 = 00
0+1 = 01
1+0 = 01
1+1 = 10
Here the output ‘1’of ‘10’ becomes the carry-out. The result is shown in a truth-table below. ‘SUM’ is the normal
output and ‘CARRY’ is the carry-out.

INPUTS OUTPUTS
Page 20
A B SUM CARRY
Electrical/Electronic Technology Department
0 0 0 0
P.by Habtemariam molla
0 1 1 0
1 0 1 0
1 1 0 1
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board

From the equation it is clear that this 1-bit adder can be easily implemented with the help of EXOR Gate for the
output ‘SUM’ and an AND Gate for the carry. Take a look at the implementation below

Full Adder
This type of adder is a little more difficult to implement than a half-adder. The main difference between a half-
adder and a full-adder is that the full-adder has three inputs and two outputs. The first two inputs are A and B
and the third input is an input carry designated as CIN. When full adder logic is designed we will be able to string
eight of them together to create a byte-wide adder and cascade the carry bit from one adder to the next.

The output carry is designated as COUT and the normal output is designated as S. Take a look at the truth-table

Page 21
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board
INPUTS OUTPUTS
A B CIN COUT S
0 0 0 0 0
0 0 1 0 1
0 1 0 0 1
 0 1 1 1 0
Air Conditioner Control Circuits
Air 1 0 0 0 1 conditioner control circuits: Control the
1 0 1 1 0 various components to start and stop them
in the 1 1 0 1 0 correct sequence to maintain space
temperature for comfort. The three main
1 1 1 1 1
components controlled are the indoor fan,
the compressor, and the outdoor fan. These components are used in air cooled air
conditioning equipment. The control circuit uses low voltage for safety
LO3. Test the construction of electrical/ electronic circuits
 Conduct Testing
 Checking The Accurate Operation Of The Circuit
 Conduct Testing

When testing any form of electronics equipment there several precautions you must take
 Make sure the equipment is disconnecting from any form of power supply .because
electrical current can damage your testing instrument and equipment when used in
properly.
 After the bad has populated it may be tested in variety ways..
 Checking The Accurate Operation Of The Circuit
 While the power is ON – in circuit test where physical measurement, i.e. voltage
current and frequency
 While the power is off, visual inspection of guide line for PCB component placement.
 Inspection are a common used to maintain quality control in the state of PCB
manufacture

Page 22
Electrical/Electronic Technology Department
P.by Habtemariam molla
 Almaz boehm TVET collage
Module title; - designing and constructing simple circuit board

Page 23
Electrical/Electronic Technology Department
P.by Habtemariam molla