Module-1 Electronics Mechanic

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Module-1 Electronics Mechanic

Modular Course in Skill Development

BASIC TRAINING MODULE

FOR
HHP & AV

Credit- 3
Basic Electronics

DEVELOPMENT COMMISSIONER
MICRO, SMALL & MEDIUM ENTERPRISES
GOVT. OF INDIA
NIRMAN BHAWAN, NEW DELHI – 110108

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Module-1 Electronics Mechanic

Credit-3 BASIC ELECTRONICS [30 Hours]

This credit consists of 5 units. Unit 1 explains inductors. Unit 2 explains about conductor,
insulator, wire. Unit 3 explains about different types of power supplies. Unit 4 explains about
soldering, desoldering equipments and Basic symbols used in electronics. Unit 5 contains
assignments and practical exercises.

TOPICS:-

Unit-1 Inductors

Unit-2 conductor, insulator, wire

Unit-3 Power Supplies

Unit-4 soldering, desoldering equipments

Unit-5 Assignments and practical exercises

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Unit-1: Inductor
OBJECTIVE:

Skill:

At the end of the training you should have learnt about inductors and its application

Knowledge:

At the end of this unit trainee should have a

 Basic ideas on inductors
 Knowledge about types of inductors
 Knowledge about practical uses

Structure:

1.1 Inductor and inductance

1.2 Types of inductors
1.3 Practical use of inductor
1.4 Assignments

1.1 Inductor And Inductance

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 An inductor is also called a coil.

 It is a two terminal electrical component which resists changes in electric current
passing through it.
 It consists of a conductor such as a wire, usually wound into a coil.
 When a current flows through it, energy is stored temporarily in a magnetic field in the
coil.
 An inductor is characterized by its inductance just like resistor is characterized by its
resistance.

 Inductance the ratio of the voltage to the rate of change of current, which has units
of henries (H).
 Inductors have values that typically range from 1 µH (10−6H) to 1 H.

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 Inductors are widely used in alternating current (AC) electronic equipment, particularly
in radio equipment.
 They are used to block the flow of AC current while allowing DC to pass; inductors
designed for this purpose are called chokes.
1.2 Types of Inductor
1.2.1 Air Core Inductor
 The term air core coil describes an inductor that does not use a magnetic core made of a
ferromagnetic material.
 The term refers to coils wound on plastic, ceramic, or other nonmagnetic forms, as well
as those that have only air inside the windings.
 Air core coils have lower inductance than ferromagnetic core coils.
 But are often used at high frequencies because they are free from energy losses
called core losses that occur in ferromagnetic cores, which increase with frequency.
1.2.2 Radio Frequency Inductor

 At high frequencies, particularly radio

frequencies (RF) (3 KHz to 300 GHz),
inductors have higher resistance and
other losses.
 In RF inductors, which are mostly air
core types, specialized construction
techniques are used to minimize these
losses.

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1.2.3 Ferromagnetic Core Inductor

 Ferromagnetic-core or iron-core inductors use a magnetic core made up of
ferromagnetic material or ferromagnetic material such as iron or ferrite to increase the
inductance.
1.2.4 Laminated Core Inductor
 Low-frequency inductors are often made
with laminated cores to prevent eddy currents,
using construction similar to transformers.
 The core is made of stacks of thin steel sheets
or laminations oriented parallel to the field, with an
insulating coating on the surface.

1.2.5 Ferrite-Core Inductor

 For higher frequencies, inductors are made with cores of ferrite.
 Ferrite is ceramic ferromagnetic material that is non conductive, so eddy currents
cannot flow within it. 
1.2.6 Toroidal Core Inductor
 In an inductor wound on a straight rod-shaped core, the magnetic field lines emerging
from one end of the core must pass through the air to reenter the core at the other end.
 The shape often used is a toroidal or doughnut-shaped ferrite core.

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1.2.7 Choke
 A choke is designed specifically for blocking higher-frequency alternating current (AC) in
an electrical circuit, while allowing lower frequency or DC current to pass.
 It usually consists of a coil of insulated wire often wound on a magnetic core, although
some consist of a donut-shaped "bead" of ferrite material strung on a wire.

 Like other inductors, chokes opposes changes to the current passing through them.
 Its low electrical resistance allows both AC and DC to pass with little power loss, but it
can limit the amount of AC passing through it due to its reactance.

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1.2.7 Variable Inductor

 Probably the most common type of variable inductor today is one with a moveable
ferrite magnetic core, which can be slid or screwed in or out of the coil.
 Moving the core farther into the coil increases the permeability, increasing the magnetic
field and the inductance.
 Many inductors used in radio applications (usually less than 100 MHz) use adjustable
cores in order to tune such inductors to their desired value, since manufacturing
processes have certain tolerances (inaccuracy).

 A type of continuously variable air core inductor is the variometer.

1.3 Practical Use Of Inductor

 As useful as inductors are, the biggest problem with using them is their physical size.
 Inductors often dwarf all other electronic components used in a circuit and add a lot of
weight as well.

1.3.1 Filters

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 Inductors are used extensively with capacitors

and resistors to create filters for analog circuits
and in signal processing.
 Alone, an inductor functions as a low-pass
filter, since the impedance of an inductor
increases as the frequency of a signal
increases.
 When combined with a capacitor, whose
impedance decreases as the frequency of a
signal increase, a notched filter can be made
that only allows a certain frequency range to pass through.

1.4 Assignments
1. For ____________ frequencies, inductors are made with cores of ferrite.
(higher/lower)
2. What is a choke ?
3. What is variable inductor?
4. What are the types of inductor?
5. Write one practical use of inductor.

Unit-2: Conductor, Insulator and Wires

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OBJECTIVE:

Skill:

At the end of the training you should have learnt about conductors, insulators and
wires especially those present in Electronics Laboratories.

Knowledge:

At the end of this unit trainee should have a

 Basic ideas on conductors
 Basic ideas on insulators
 Importance and role of conductors and insulators in wires

Structure:

2.1 Insulators
2.2 Properties of insulators
2.3 Types of insulators
2.4 conductors
2.5 Properties of conductors
2.6 Types of conductors
2.7 wire
2.8 Types of wires.
2.9 Assignments

2.1 Insulators

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 The materials that don’t conduct heat and electricity through them are called
insulators.
2.2 Properties Of Insulators
 Different insulators have different breakdown voltages, and are used for
different purposes.
 For example, plastic may be used as an insulator in households where the
current is not very high, but it cannot be used for industrial purposes.
 Ceramic or porcelain may be the best insulator in such applications, as it has a
very high breakdown voltage.
 example, non-metals such as glass, wood and plastic -- excellent insulators.
 Air permeability, the ability of a material to allow air to flow through its pores,
is a necessary property for heat or thermal insulators.
2.3 Types Of Insulators
2.3.1 Porcelain:

2.3.2 Paper

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2.3.3 Glass

2.3.4 Plastic

2.3.5 Rubber

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2.3.6 Insulation Paste

2.4 Conductors
 The materials that can conduct heat and current through them are called conductors.

2.5 Properties Of Conductors

 Conductivity of metal should be high.
 It can be able to conduct high current.
 It should with stand high temperature

2.6 Types Of Conductors

The example of conductors materials are:

2.6.1 Silver

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2.6.2 Copper

2.6.3 Gold

2.6.4 Aluminum

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2.6.5 Iron

 Silver and gold are the best conductors followed by copper and aluminum.
 Copper and aluminum are available in abundance in nature; therefore the cost of these
metals is cheaper than the other conductors. So copper and aluminum are the most
commonly used for electrical work.
2.7 Wire
 Definition-A metallic conductor made in the form of a thin solid cylindrical string, is
called an electrical wire.
 Wires are used as a medium for carrying current from one point to another point in an
electrical/electronic circuit.

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 All wires have at least one metal strand which is able to conduct electricity.
 This is known as the conductor. This conductor is generally surrounded by a material
which does not conduct electricity called insulator or insulation sheath.
 Different types of wires-

2.8 Types of wires

 Single Strand Wires
 Multistrand wires
2.8.1 Single Strand Wires
 If the conductor of a wire is a single strand of metal, then the wire is known as a single
strand wire, commonly called hook-up wire.

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 These wires are commonly used for jumpering, experimental circuit wiring of electronic
circuits.
2.8.2 Multistrand wires

 If the wire consists of several strands of metal then the wire is known as Multi-strand
wire.
Some of the advantages of multi strand wires over single strand wire are listed below:

1. Multi strand wires are more flexible and hence can be routed in any direction more
easily.
2. Multi strand wires are more rugged and hence are less likely to cut when bend.

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3. Multi strand wires can carry more current when compared to a single strand conductor
of same dimension.
4. Multi strand wires are more suitable for high frequency application due to reduce skin
effect (discussed later)
5. Multi strand wires are better cooling due to air gap between strands.
6. Multi strand wires cause cancellation of the effect of magnetic field.

 Because of the above advantages, multi strand wires are used extensively in electronic
circuit connections.

2.9 Assignments

1. What are Conductors?

2. What are Insulators?
3. What is a wire?
4. Name the Types of wires.
5. Write two lines for properties of conductor and insulator.

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Unit-3: Power Supply

OBJECTIVE:

Skill:

At the end of the training you should learnt about different types of power supplies.

Knowledge:

At the end of this unit trainee should be able to

 Define different batteries and cells and power supplies.
 Define the testing and trouble shooting methods.

Structure:

3.1 Power Supply Sources

3.2 Batteries
3.3 Classification of Batteries.
3.4 Cell
3.5 Measuring cell voltage
3.6 Switching power supplies
3.7 Unregulated power supply
3.8 Regulated power supply
3.9 SMPS
3.10 UPS
3.11 Converters
3.12 Testing and troubleshooting

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3.13 Assignments

3.1 Power Supply Sources

 Devices that produce electricity are generally called as Power supply sources.
 These power sources produce electricity by converting some form of energy into
electrical energy.
 A system that converts AC current from the wall outlet into the DC currents required by
electronic circuits.
 A computer power supply converts AC into multiple DC voltages.
 For example, 12 volts is commonly used for drives, while 3.3v and 5v are used by the
chips and other motherboard components.
 Power supply comes in different sizes and shapes according to their fields of application.
 The following figure shows some of them.

 Laptops use an external power supply, called a "power adapter" or "power brick."
 It converts AC to a single DC voltage that goes to the laptop's internal power supply,
which generates all other required voltages.

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 External adapters are used to reduce the size and Weight of the laptop.

3.2 Batteries

 Batteries are the power supply sources in which energy is contained in it.
 So, no external energy is needed for the battery to produce electricity.
 Therefore, batteries are one of the most important power sources.
 In a battery, electrical energy is produced by the chemicals contained within the battery.
 Cells are the basic units of a battery.
 Several cells are used to make a battery.
3.3 Classification of Batteries

 Batteries are classified mainly under two categories

1. Primary Batteries 2. Secondary batteries

3.3.1 Primary Batteries –

 Converts chemical energy into electrical energy.
 This uses the chemicals within it to start the action of energy conversion.

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 The most common types of primary batteries and cells.

 The below picture shows primary batteries or cells.

PICTURE: DIFFERENT PRIMARY BATTERIES

3.3.2 Secondary Batteries –

 These batteries must be first charged with electrical energy.

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 Once the battery is fully charged, it will then convert chemical energy to electrical
energy.
 Secondary batteries first stores electrical energy supplied to it and then they supply
electrical energy as and when required.
 Hence secondary batteries are commonly called storage batteries.

3.4 Cell
 A cell consists of a pair of metal strips called electrodes and dipped in a chemical
solution called electrolyte.

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 A battery may consist of two or more number of cells.

Dry and Wet cells

 The electrolyte can be in liquid form or a paste form.
 Cells with paste form electrolyte are known as DRY cells.
 Cells with liquid form of electrolyte are called WET cells.
3.4.1 Primary Cells
 Primary cells are those which once fully used have to be thrown-out or destroyed.
 This is because the electrodes and electrolyte used in this type of cells cannot be reused.
 So, primary cells are non-rechargeable cells. Generally, the electrolyte used in primary
cells is of paste form.
3.4.2 Secondary Cells
 Secondary cells are those which once used can be reused by charging them.
 Hence, secondary cells are rechargeable cells.
 Generally, the electrolyte used in secondary cells is in liquid form.

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 However, there are rechargeable cells with paste form electrolyte also.
3.4.3 Dry Cells And Batteries
 As the electrolyte used in dry cells is in paste form, it does not spill or leak.
 Hence, dry cells are used extensively in portable electrical and electronic gadgets.
 The two electrodes of dry cells are brought out and are available as +ve and -ve
terminals of the cell.
 Usually the metallic cell container serves as the -ve of the cell as shown in below picture.
 The voltage that appears across the terminals depends upon the electrodes and the

chemicals used in the cell.

 The voltage of a cell is so made as to suit the commercial requirement.
 Generally the voltage across the terminals of a dry cell range between 1.2 to 1.5 volts.
 A dry cell with zinc as the -ve electrode, carbon as the +ve electrode with zinc chloride
as the electrolyte is referred to as zinc-carbon cell or zinc chloride cell.
3.4.4 Weak, Dead Cell
 Dry cells are used in various gadgets like flash lights, tape recorders etc, the cells convert
the chemical energy built into them into electrical energy.
 In doing so, the dry cell slowly gets consumed.

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 This means, the voltage across the cell terminals decreases and the current it can
supply to the connected load becomes less and less.
 A stage will reach when the dry cell is no more capable of supplying sufficient
voltage/current through the connected load.
 Then the cell is said to have become weak or dead.
 As a thumb rule, dry cell can be declared unfit for use if, the voltage across its terminals
is less than 75% of its rated output voltage.
3.5 Measuring Cell Voltage
 To measure the voltage of a dry cell, a voltmeter having a full scale deflection value
greater than, but close to the rated output of the dry cell, should be used.
 Also the meter's minimum measurable voltage (value of one small scale div) should be
as small as possible (at least 0.2 volts).

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 As most of the cells have voltages less than 2 volts, the meters used to measure cell
voltage should be free from errors volts.
 Before using a meter for measurements, it is necessary to check if the meter needle is
moving freely over the graduated scale.
 Voltmeters used for measuring DC voltages will have their input terminals marks +ve
and -ve. For making voltage measurement, the +ve terminal of the meter must be
connected to the +ve terminal of the battery and the - ve terminal of the meter to the -
ve terminal of battery.
 If the terminals are reversed, the meter deflects below zero. This may cause temporary
or sometimes permanent damage to the meter movement.
 The following precautions should always be taken while making voltage measurement
of cells or other voltage sources;
 Check if the right type and range of meter is being used for measurement.

3.6 Switching Power Supplies

 Power supplies known as "switching" power supplies are commonly used.

 Their names are derived from the type of circuit used to change the voltage.
 Table below shows different types power supply generated by the PC power supply.

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Fig:-Shows Different Power Supply Generated By The PC Power Supply

3.7 Unregulated Power Suppply:-

 "Unregulated" or Brute Force Power Supplies will provide an approximate output

dependant on the load and input voltage.

 Any variation in the input voltage has a direct affect on the output.

 The unregulated power supply is a simple supply as it only contains a step down (or Up)
transformer, couple of rectifier diodes and a possibly a filter capacitor.

 The output does not remain constant with loading or line changes.

 Unloaded output can be almost double the rated output under rated load, for example
—

 If a battery voltage is 14.4 volts, the supply will produce ±28.8 volts (an extra 9.6 volts).

 This is why amplifiers with unregulated power supplies have significantly different
power ratings, with different battery voltages.

 A change in battery voltage directly affects the rail voltage.

3.8 Regulated Power Supplies

 With regulated supplies there are 2 basic types based upon how the regulation is
achieved, linear or switching.

3.8.1 Linear Regulator

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1. The linear regulated supply adds a regulator circuit to the basic unregulated
design.

2. A bulky transformer lowers (or raises) the voltage, rectifiers change current
to pulsing dc, the capacitor removes (filters) some of the pulse ripple and a
pass transistor & regulator circuit provide the constant output voltage under
varying load conditions.

3. Linear supplies have little or no rfi/emi.

3.8.2 Switching Regulator

1. A "switching" regulated power supply rectifies & filters the incoming ac line
voltage.

2. After that it switches the resultant high dc voltage at a high frequency

through a light weight transformer to reduce the size & weight of components
but will require extra filtering & shielding for RFI.

3. Switching power supplies can operate over the 90-265vac universal input

voltage range.

4. Switching regulated power supplies are quickly becoming the most used type

in order to reduce wasted energy costs and comply with international

standards.

3.9 SMPS

 SMPS or switch mode power supply is basically more complex than that of the linear
regulated power supplies.

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 The main advantage of using a SMPS that switch mode operation gives regulated DC
supplies that can deliver more power for a given cost, size ,and weight of power unit.

3.9.1 Block Diagram Of SMPS

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Figure shows a typical arrangement of SMPS

 The output rectification and filter are isolated from the high frequency switching section
by a high frequency oscillator and the voltage control feedback by an opto–isolator.
 The control circuit block is typical of specialist IC’s containing the high frequency
oscillator, which is generally used to drive an electronic power switching circuit through
high frequency square wave.
 In most of the SMPS regulation of both line and load is normally provided, this is
achieved by altering the mark to space ratio of the oscillator waveform before applying
it to switches.
 The mark to space ratio is controlled by comparing the voltage feedback from the
output of the supply with a reference voltage.

3.10 UPS

 An uninterruptible power supply (ups) is a device that has an alternate source of energy
that can provide power when the primary power source is temporarily disabled

 The switchover time is small enough to not cause a disruption in the operation of the
loads

3.10.1 Uses Of UPS

 Protects against multiple types of power disturbances.

 Only device that protects against an outage.

 Offers protection against:-

1. Equipment not operating properly.

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2. Computer and equipment damage.

3. Data loss.

4. Time and expense to recover back to where you were, if even possible.

Some of the most common design approaches used to implement ups systems are

 Standby.

 Linear interactive.

 Standby-Ferro.

 Double conversion online.

 TYPES OF UPS

 Delta conversion online.

3.10.2 Standby UPS

 This is the most commonly used ups

system.

 Figure aside shows the basic block

diagram of the ups system.

 Transfer switch is set to choose the ac

main supply as the primary source and
chooses the inverter supply only when
the power fails.

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 The inverter starts only when the power fails and thus the name standby.

3.10.3 Line Interactive UPS

 In this arrangement the battery to inverter is

always there and the battery charges during
the normal main supply.

 Figure aside shows the simple block diagram

of line interactive UPS system.

 When the power fails the switch gets

disconnected and the power flows to the inverter from battery.

 With the inverter always ON and connected to the output Provides better switching
transient and additional filtering.

3.10.4 Standby Ferro UPS

 This design depends upon on special saturating transformer which has three windings.

 The primary power path is from ac input through a transfer switch, through the
transformer and to the output.

 In the case of power failure, the transfer switch is opened and the inverter picks up
the output load.

 High reliability and excellent line filtering are the design strengths, however the design
has low efficiency when used with some generators.

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3.10.5 Double Conversion On-Line UPS

 These are the most commonly used ups for

above 15kva applications.

 It is quite similar to standby one except the

primary power is inverter rather than the ac
mains.

 During the ac power failure online

operation results in no transfer time, as the
input ac mains is charging the backup battery power which gives output to the
inverter.

3.10.6 Delta Conversion Online UPS

 Similar to the double conversion

online design the inverter always
supplying the load voltage.
 The exception form double online
design is that it also provides
power to the inverter output.

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3.10.7 Conclusion
Design type Practical Power Benefits Drawbacks Efficiency
range(kva)

Standby 0-0.5 Low cost, Use battery Very high

compact during
brownouts,
impractical
over2 kVA.
Line 0.5-5 High reliability, Impractical over Very high
Interactive good voltage
5kVA
condition

Standby Ferro 3-15 Excellent voltage Unstable in Low-

conditioning, combination medium
High reliability with other loads
and generators
Double 5-5000 Excellent voltage Expensive Low-
Conversion conditioning , under 5kVA medium
Online ease of
paralleling
Delta Conversion 5-5000 Excellent voltage Impractical High
online conditioning under 5kVA

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3.11 Converters

 These are the circuits that are usually been used to get our required or specified dc
voltage out of a range of dc supply.

 There may be basically three types of converters:-

1. Buck converters.

2. Boost converters.

3. Buck-Boost converters.

3.11.1 Buck Converter

 The buck converters are used in SMPS

where the output dc voltage required
being less than that of the input dc
voltage.

 The switching transistors present at the

output and input of the converter
switches on and off very quickly to
maintain the continuous output.

 The flywheel circuit drives transistors

during the off periods.

 The inductor present in the flywheel

circuit prevents the flow of current to increase to its peak value, thus preventing the
output to drive to its full.

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3.11.2 Boost Converter

 These are the converters which are used to boost the input dc voltage to a required
level to meet the requirements.

 At the beginning a high period square wave frequency is applied to the MOSFET which
turns it ON.

 As the MOSFET turns ON a current flows through the L1 (making it charged) but not in
the other parts of the circuit
because of the diode (d1) and
capacitor (c1) combination.

 During the fall time of the

switching square wave the
MOSFET gets turned OFF making
the a EMF to be produced in the
opposite polarity by the L 1
making two voltages to appear in
the load V(in) + V(L1).

 After the initial start signal to

MOSFET each time MOPSFET conducts the cathode of D1 is more positive than its anode
due to charge on C1.Even after the D1 is turned OFF the load continues to get (VIN+VL)
due the charge on C1.

3.11.3 Buck-Boost Converter

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 The buck-Boost converter is a type of switched mode power supply which combines the
principle of buck and boost converter.


 The buck converter

produces a voltage ranging from 0V to just less than the input and the boost converter
produce a voltage ranging from the same input to a much higher voltage compared to

 The control unit presents in the circuit senses the level of input voltage and then selects
the appropriate circuit operation .

 A simple block diagram of Buck-Boost converter is shown in the figure aside.

3.12 Testing And Trouble Shooting

3.12.1 Smps Structure

 Usually SMPS are divided into 2 parts.

 High voltage and low voltage part which is

generally notified under the circuit by a red
mark or by larger spacing on the tracks.

 Figure aside shows an example of that.

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 The primary section of the transformer is of the high voltage section and the secondary
section is the low voltage.

 Very often, if the ground of the output is not connected to the mains ground, a small high
voltage capacitor connects these two grounds at high frequency as shown in the figure
below by the blue capacitor.

3.12.2 Safety First

 As half of the circuit is directly connected to the mains and it is very important to work
on it during off condition only.

 Large value storage capacitors are present in the circuit and they remain highly
charged even though the supply is not there, so it is always better to look at the
capacitor whether they are fully discharged or not.

 If any capacitor is not discharged, then we have discharge it by connecting the two
leads of the capacitor through a resistor (few KΩ).

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3.12.3 Visual Inspection

 Check the capacitors, if there is any burned or dome shaped (bottom or top, shown in
the figure).

 If there is any replace it with a new one.

 A burned resistor can also be identified by its

black color and smell.

 Check the transformer, if it is burned and it

smells badly then it is better to replace the SMPS completely rather than replacing
transformer or repairing it as it is very hard find the parts and time consuming.

 Check the fuse present in the circuit as it

may give an idea about the origin of fault.

 If the fuse is slightly burned then the fault

is not catastrophic, but if it is badly burned
than we have to change a large no. of
components as the fuse burned out
because of very high current .

3.12.4 No Output Good Fuse

 In such condition we have to first look at the resistors present at the high voltage
section if there resistor ratings are correct or not if not just replace them.

 Secondly we have to check the diodes especially those connected to the power
transistor at the regulator section.

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3.12.5 No Output Blown Fuse

 If the fuse is blown it is very prominent that many other components got faulty.

 First check the power transistor if it is working or not If not then replace it with
appropriate ratings.

 Though there is very little chance of failure of controller IC, but it is better to check it.

3.12.6 SMPS Partialy Working

 It may happen that SMPS is runs for a fraction of seconds and shuts down, trying to
start after every few seconds and shuts down or it may produce a wrong output
voltage.

 In these cases usually semiconductors are correct; we have to check the capacitor.

 There may be something wrong with the feedback circuit, to check it we can connect a
dc voltage at the SMPS output and increasing the voltage we can check the feedback
circuits behavior.

3.12.7 Light Bulb Trick

 Even after replacing the faulty

components there is a chance of blowing
OFF the fuse again, to avoid this we may
do light bulb trick.

 Here we connect a bulb of 100W or so

and switch on the SMPS, the light bulb limits the power in the circuit if the short circuit
is not fixed yet.

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 After switching ON the SMPS if the light bulb gets ON for fraction of seconds and gets
OFF ,then the fault is fixed , but if it glows continuously ,it means there is still some
Fault and we have to start over again.

3.13 Assignments
1. What is a battery?
2. What are Secondary batteries?
3. What is the difference between Primary Batteries & Secondary batteries?
4. How many types of cells are there? Describe them?
5. How to measure a cell voltage?
6. What are the equipment present in dry cells?
7. What do you mean by weak or dead cell?

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Unit-4: Soldering and Desoldering Principles

OBJECTIVE:

Skill:

At the end of the training you should learnt about soldering and desoldering used in
different Electronics circuits.

Knowledge:

At the end of this unit trainee should be able to

 Explain the difference between soldering and desoldering.
 Explain the classification of solder.
 How to do soldering and desoldering

Structure:

4.1 Soldering
4.2 Equipments need to soldering
4.3 Desoldering
4.4 Equipments need for desoldering
4.5 Electronic symbols
4.6 Assignments

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4.1 Soldering
Definition:
 Soldering is a method of joining two metals together using a third metal, called solder.
 Soldering has many applications including assembling electronic components to circuit
boards, jewelry making, making some copper pipe plumbing connections, and building
or repairing radio controlled vehicles.
4.2 Equipments Need For Soldering
4.2.1 Soldering iron
 A soldering iron is a hand tool used in soldering.

 It supplies heat to melt the solder so that it can flow into the joint between two work
pieces.

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 It is used to solder small components like capacitor, resistor, diode, transistor, regulator,
speaker, microphone, display etc.
 When buying a soldering iron, select the one that is easy to hold and does not burn your
hand.
 It must also be ESD-Safe (Antistatic) because most electronic components are very
sensitive and can get damaged due to static charge or static electricity. 
 Hakko and Weller are two world renowned brands who manufacture, sell and export
world class soldering irons and other soldering tools and equipments.
 Soldering irons are most often used for installation, repairs, and limited production work
in electronics assembly.

4.2.2 Soldering Station

 A soldering station has 2 units – a station and iron.

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 It has option to control temperature depending on the heat requirement of the

soldering job being done.
 The soldering iron is attached with the soldering station.
 It is better and more convenient than traditional soldering iron.
 It makes soldering work much easier and faster.
 Hakko and Weller are two world renowned brands who manufacture, sell and
export world class soldering irons and other soldering tools and equipments

4.2.3 PCB Holder / PCB Stand:

 A PCB (Printed Circuit Board) holder or PCB stand is used to hold the PCB of a mobile
phone while soldering or repairing.

 It holds the PCB very strongly and doesn’t allow it to move thus helping in repairing.
 Again, it is important and wise to select a good quality PCB holder rather than a
cheaper and inexpensive one.

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4.2.4 Solder wire

 Solder is a fusible metal alloy used to join together metal work pieces and having a
melting point below that of the work piece(s).
 The melting range of Soft solder is typically 90 to 450 °C (190 to 840 °F). It is
commonly used in electronics, plumbing, and assembly of sheet metal parts.

 Composition of most solder wire is Tin / Lead in the ratio 60:40 or 63:37.
 Since the introduction of ROHS (Restriction of Hazardous Substances) from
electronics, more and more companies are using lead-free solder.
 Lead-free solder wire is available in many compositions but the most common
composition is Tin / Silver / Copper in the Ratio 96.5:3.0:0.5.
 Solder wire is available in different diameters such 2.0mm, 1.5mm, 1.0mm, 0.5mm,
0.2mm etc.
  Kester is a world renowned manufacturer and supplier of solder wire and other
soldering material.

4.2.5 Soldering Stand

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 A soldering iron stand keeps the iron away from flammable materials, and often
also comes with a cellulose sponge and flux pot for cleaning the tip.

4.2.6 Thinner or PCB Cleaner: 

 Thinner or PCB cleaner is used to clean the PCB of a mobile phone.
 The most common PCB cleaner used in mobile phone repairing is IPA or Isopropyl
Alcohol.

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 It is important to buy only good quality PCB cleaner as poor quality PCB cleaners can
damage the board.

4.2.7 Jumper Wire:

 This is a thin laminated or coated copper wire used to jumper from one point to another
on the track of a mobile phone while repairing.

 Most people doing the work of mobile repairing by using jumper to solve many
problems.

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4.2.8 Blade Cutter

 This is used to remove lamination from jumper wire.

 It can also be used for several other purposes.

4.2.9 Point Cutter

 It is used for cutting.

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4.2.10 Nose Cutter

 It is used for cutting.

4.2.11 Tweezers:

 These are needed to hold electronic components, ICs, jumper wire etc while
soldering and De-soldering.

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4.2.12 Multimeter:

 Used to find faults, check track and components.

 Always buy a good quality reliable ESD-Safe digital Multimeter.

4.2.13 Liquid Flux:

 It is used to clean PCB track.

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 Liquid flux improves quality of soldering.

 Kester flux is world renowned for good quality.

4.2.14 Paste Flux:

 This is also used while soldering.

4.3 Desoldering

 In electronics, de soldering is the removal of solder and components from a circuit

board for troubleshooting, repair, replacement, and salvage.

 De-soldering wire or De-solder wire is used to remove excess solder from track of PCB.
 Chemtronics is world renowned manufacturer and supplier of Desoldering wire.

4.4 Equipments Need To Disoldering

4.4.1 De-soldering pump

 A desoldering pump, colloquially known as a solder sucker, is a manually-operated

device which is used to remove solder from a printed circuit board.

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 The plunger type has a cylinder with a spring-loaded piston which is pushed down and
locks into place.
 When triggered by pressing a button, the piston springs up, creating suction that sucks
the solder off the soldered connection.
 The bulb type creates suction by squeezing and releasing a rubber bulb.
 The pump is applied to a heated solder connection, then operated to suck the solder
away.

4.4.2. Desoldering Braid

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A solder wick on a reel

Solder wick, before use

... and soaked with solder and residue

 Desoldering braid, also known as desoldering wick or solder wick, is finely braided 18 to
42 AWG copper wire coated with rosin flux, usually supplied on a roll.
 The end of a length of braid is placed over the soldered connections of a component
being removed.
 The connections are heated with a soldering iron until the solder melts and is wicked
into the braid by capillary action.
 The braid is removed while the solder is still molten, its used section cut off and
discarded when cool.
 Short lengths of cut braid will prevent heat being carried away by the braid instead of
heating the joint.

4.5 Electronic symbols

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4.6 Assignments
1. what is soldering?
2. how many types of solder wire is available?
3. What is the use of multimeter?
4. A soldering station has how many units and what are those?
5. What is the use of thinner?

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UNIT-6 Practical Exercise And Assignments

Assignments:

Give all the answer of the following questions:

1. Write an practical use of inductor.
2. What is the use of soldering iron?
3. what is an inductor?
4. what is Toroidal Core Inductor?
5. what is the use of filter?
6. write some examples of conductors.
7. What are the equipment present in dry cells?
8. What do you mean by weak or dead cell?
9. what is the use of soldering?
10. draw the symbol of resistor.
Answer all the objective type questions:
1. An inductor is also called as _________. (motor/coil)
2. In ferromagnetic core conductor, core is made up of ______________.
(ferrite/ferromagnetic)
3. Paper is a _____________. (insulator/conductor)

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Practical Exercise:

EXERCISE-1: How to de-solder.

OBJECTIVES:

At the end of this exercise you shall be able to:

1. De-solder different wrongly connected components .

Requirements:

Tools/Instruments Quantity
De-soldering pump 1 No.

De-soldering braid 2 pieces(20 to 30 feet)

Soldering rod

Procedure to de-solder:-

Step1: Take care about the safety.

Step2:Put the edge of the de-soldering braid over the soldered porion.

Step3: Molten the connection using soldering rod and remove the solder using de-
soldering pump till it is molten.

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