UNIVERSITI MALAYSIA PERLIS 2013/2014 (PLT 108) ENGINEERING SKILLS 2
MODULE PCB : PCB DESIGN
NAME : ID NUMBER : COURSE : DATE : CHECKED BY : C03: Ability to apply and construct the basic skills and standard practiced of PCB and electronic component fitting.
60 SUBJECT: ENGINEERING SKILLS 2
PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK
PLT 108
Prepared by MOHD SHIHABUDIN ISMAIL Page 1 of 9 LEARNING Students should be able to:- 1. Test or simulate the circuit on a Test PCB (with thru holes) before proceeding to actual PCB. 2. Convert the circuit schematic diagram to PCB layout manually by sketching the circuit layout on a sheet of paper as viewed from the component side. 3. Transform the circuit layout on the copper clad board. 4. Drill the mount points using hand-feed drilling machine. 5. Etch the board using acid etching method.
The list of the equipment required for this exercise. Board design: 1. Paper and pencil 2. Ruler 3. Permanent black marker with fine point 4. Tape 5. Scissors 6. Drill with tiny #65 twist bit (0.035" which is good for most electronic components) 7. Fine grade steel wool (0000 steel wool) or thinner or acetone 8. Dust mask for protection from copper dust when drilling 9. Copper clad PC board
Boards etching process: 1. Ferric Chloride (FeCl 3 ) chemicals CAUTION: FeCl 3 solution is toxic. It can cause skin burning or irritation. Please take all necessary precautions and use appropriate safety equipments. a) Rubber gloves b) Safety glasses c) Paper towels to clean up spillage d) A small resalable plastic container to put the FeCl 3 into for etching and storage afterwards e) A larger plastic container that the small one well go into for water and storage of materials afterwards. f) Warm water, goes in larger container to heat the FeCl 3 . g) A well ventilated work area as the vapor is also quite nasty and not good to breathe in. SUBJECT: ENGINEERING SKILLS 2
PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK
PLT 108
LAB SHEET PCB DESIGN: LAB 5 Page 2 of 9 TASK 1: TESTING THE CIRCUIT ON A TEST PCB (WITH HOLES) i. Test or simulate the given circuit on a test PCB (with holes). It is important to make sure the circuit works before proceeding to the PCB design because any mistakes on the PCB after it is sent in are not possible to fix.
Figure 1: Circuit diagram of Mobile Charger
List of components Quantity 1. Integrated Circuit LM317TIC 1 2. USB socket (female) 1 3. Resistor 16 1 4. Resistor 180 1 5. Resistor 1.2 k 1 6. Capacitor 1000 F 1 7. Transistor BC548 1 8. Diode (1N4007) 1 9. Zener Diode (6.8V) 1 SUBJECT: ENGINEERING SKILLS 2
PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK
PLT 108
LAB SHEET PCB DESIGN: LAB 5 Page 3 of 9 10. Variable Resistor (2.2 k) 1 11. Connector socket (male & female) 2 12. Transformer Unit (230v to 12V) 1 13. Test PCB (with thru holes) 1
ii. Solder the component onto the test PCB neatly without any soldering defects (such as solder horn, solder balls, cold solder etc).
Notes : Do not cut the component leg since you need to dismantle back the components to be installed on the actual PCB later.
iii. After complete soldering, show to the lecturer for checking. Then test the circuit by connecting it to the transformer unit available. Ensure the variable resistor knob is adjusted to maximum before connected to transformer unit.
iv. Measure the voltage output of the circuit by using Voltmeter and record the initial value. Adjust the variable resistor to adjust the voltage value to 5.0 V. TASK 2: SKETCH THE CIRCUIT LAYOUT ON A PAPER Convert the circuit schematic diagram to PCB layout manually by sketching the circuit layout on a sheet of paper as viewed from the component side first, so as to avoid any confusion. Please make sure to design the layout as compact as possible so that it well fit on the board.
Figure 2: Example of circuit layout design on a paper
Copy the confirmed final lay out onto the transparency plastic. SUBJECT: ENGINEERING SKILLS 2
PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK
PLT 108
LAB SHEET PCB DESIGN: LAB 5 Page 4 of 9 TASK 3: TRANSFORM THE CIRCUIT LAYOUT ON THE COPPER CLAD BOARD AND DRILL THE BOARD Make a copy of the layout design which is reverse of the original. i. Cut the copy of the layout out (on the transparency plastic) with scissors/ knife (anti cutter). ii. Tape the design (in reverse of the original) design onto the copper side of the PCB. CAUTION : Do not touch the copper side PCB by finger since it may affect the etching quality later. iii. Using the permanent marker pen, draw a solder pad and traces on the copper plate through the opening that you have cut. Please make sure the pen leaves a nice bold and thick line otherwise it will not resist the FeCl 3 as well. Confirm the traces and solder pad are completely drawn by marker pen. Then, remove the transparency plastic.
Figure 3: Drawing traces of layout on the PCB
iv. Drill a hole in the center of all the solder pads for the individual components using #65 drill bit. Use a small punch if necessary for drill guide. Other drill bit size might be used depends on the size of the components leg.
SUBJECT: ENGINEERING SKILLS 2
PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK
PLT 108
LAB SHEET PCB DESIGN: LAB 5 Page 5 of 9
Figure 4 : Drilling holes in PCB
v. After you have drilled all the holes, clean off all the dust.
i. The etching process need to be carried out by using Semi Auto Etching Machine (conveyor type). Refer to Figure 5. Caution : The operation of this machine need to be under supervision by technician. Temperature and timer need to be adjusted accordingly. Note : FeCl 3 solution is already in the machine. SUBJECT: ENGINEERING SKILLS 2
PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK
PLT 108
LAB SHEET PCB DESIGN: LAB 5 Page 7 of 9
Figure 6: PCB inlet slot for Etching machine
ii. Insert the PCB through the PCB inlet of the etching machine as shown in figure 6. iii. The etching process will be started automatically by the machine and take around 5 minutes to complete.
Figure 7: PCB outlet slot for Etching machine
i. After about 5 minutes the board should be completely etched and will come out through the outlet of the etching machine as shown in figure 7. Remove the PCB from the outlet tray and then dry it off on the paper towel. Ensure only required traces and copper pads remain on the PCB.
SUBJECT: ENGINEERING SKILLS 2
PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK
PLT 108
LAB SHEET PCB DESIGN: LAB 5 Page 8 of 9 TASK 5: CLEAN THE PCB i. Clean the marker off the traces using 0000 steel wool or thinner or acetone.