Assembling and testing electronic circuits QPEO2/036

Knowledge Learning outcomes -the learner will…Know how to assemble and test electronic circuit
s 

Assessment criteria ‐ the learner can…

(Knowledge to be assessed and evidenced)

1. Describe the specific safety practices and procedures that they need to observe when
assembling and testing electronics circuits (including any specific legislation, regulations or codes
of practice for the activities, equipment or materials).

When assembling and testing electronic circuits, the legislation of COSHH needs to be taken very
seriously. COSHH (Control of Substances Hazardous to Health) is the safe handling, storage and
disposal of potentially harmful substances.

Another legislation that needs to be taken very seriously is the Health & Safety at Work Act 1974
which is the main health and safety legislation in the UK and acts like an umbrella to cover all of the
subsequent regulations.

Also, when assembling and testing circuits, PPE is a very important factor to ensure everybody’s
safety. The PPE at Work Regulations 2002 are the responsibilities of employers to provide and
maintain appropriate PPE for the activities employees carry out. Other acts that need to be abided
by are the Electricity At Work Act, Management of Health And Safety and others.

2. Describe the hazards associated with assembling and testing electronic circuits (such as heat,
toxic fumes, spilled/splashed chemicals/solder, static electricity, using sharp instruments for
stripping cable insulation, connecting clips/probes into circuits), and how they can be maintained.

When assembling and testing electronic circuits, we should take care and be safe at all times. All
portable electronic equipment should be routinely PAT tested and carefully inspected before every
use.

Another factor that should be payed attention to is heat. A soldering iron can be very hot and can
cause a nasty burn. When not being used, the soldering iron should always be returned to the stand
and never simply laid to rest on a workbench. Always keep your workspace clear of potentially
flammable materials. The soldering iron should always be left to cool down before packing away.

Fumes are another potential hazard that needs controlling. Solder contains a corrosive additive
called flux that helps the soldering process. A fume extractor should always be used and placed near
to the circuit board to draw away fumes effectively and quickley.

Eye protection should always be worn when assembling electronic circuits. Stray wire clippings,
molten solder and chemicals used during circuit construction can all be very damaging if they get
into your eyes. The use of safety goggles are recommended at all times.

3. Describe the importance of wearing appropriate protective clothing and equipment (PPE), and
keeping the work area safe and tidy.

Personal Protective Equipment (PPE) includes things that we wear and/or use to help reduce the risk
of harm (either immediate or long term) to our personal well-being. The PPE required differs
depending on the activity being carried out and would be clearly defined in the risk assessment. It is
important to wear the correct PPE to protect you and others from any sort of harm. It is equally
important to keep your work area safe and tidy in order to prevent any accidents.

When handling dirt and chemicals, the use of gloves is recommended to prevent any damage to the
hands and skin. Eyes are very sensitive and are easily damaged by chemicals and penetrating objects
as well as harmful radiation. Safety spectacles/glasses offer basic protection from solid objects and
minor splashes. However, goggles offer far better protection by sealing against the wearers face.

Other PPE examples include hearing protection such as ear plugs and ear defenders, respiratory
protection such as face masks and respirators, head protection such as hard hats and hair nets, foot
protection such as steel toe cap boots and finally body protection such as lab coats/overalls/boiler
suits and high-visibility jackets.

4. Describe the precautions to be taken to prevent electrostatic discharge (ESD) damage to

electronic circuits and components (such as use of earthed wrist straps, anti-static mats, special
packaging and handling areas).

To avoid electrostatic discharge, the correct preparation of equipment and components should be
performed. Components should be organised and labelled in an appropriate storage area to keep
dirt and contaminates away. Additionally, static sensitive devices should be kept in special anti-static
cabinets or packaging to avoid electrostatic discharge.

The use of anti-static wrist bands avoids any damage to any of the components which could be
sensitive to electrostatic discharge. Also, the use of anti-static mats would be an idea to prevent any
rogue static charges.

The consequences of electrostatic discharge include damaged components, rendering them

unreliable or inoperable. Therefore, preventing ESD is very important.

5. Explain what constitutes a hazardous voltage and how to recognise victims of electric shock.

A hazardous voltage is any level of voltage that is considered dangerous to the person/persons
exposed to it. Living human tissue can be protected from damage by the insulating characteristics of
dry skin up to around 50 volts. If the same skin becomes wet, if there are wounds, or if the voltage is
applied to electrodes that penetrate the skin, then even voltage sources below 40 V can be lethal.

The main symptom of somebody who has encountered a severe electric shock is usually white or
very pale blue skin. The victim may also have a very low or absent pulse, burned skin and stiffness of
the body. Before any first aid is administered you must ensure the victim is no longer in contact with
the power source, or if they are turn the power source off.

6. Explain how to reduce the risks of a phase to earth shock (such as insulated tools, rubber
matting and isolating transformers).

One of the main ways to reduce the risk of shock include taking precautions to prevent people who
are not doing the testing coming into contact with exposed live parts. Another way is by protecting
and insulating both the equipment being worked on and the testing equipment.

It is also important to ensure that the people carrying out the testing work are suitably trained and
experienced so that they understand safe working practices and the equipment they will be working
on. It goes without saying that the correct tools must be used for the job at hand. Rubber matting
reduces the risk of shock, as well as correctly isolating transformers when not in use.
7. Explain how to use and extract information from circuit diagrams, block and schematic
diagrams, equipment manuals, data sheets, test procedures and instructions (to include symbols
and conventions to appropriate BS or ISO standards) in relation to work undertaken.

Schematic or circuit diagrams are a pictorial view of how an electronic circuit is wired together. Each
type of component is represented by its own symbol and the connections are shown by lines. Dots
indicate where the wires are connected together. Standards for drawing electronic circuits vary from
country to country, however there are two main standards: The British Standard BS3939 (also known
as IEC 60617) and the American ANSI standard YS32. Schematic diagrams help us to see how a circuit
actually works in theory. They can be a useful reference for ordering components, producing circuit
designs and fault finding.

A variety of constructional diagrams are used to help assemble an electronic circuit. These might
include assembly diagrams, exploded views, step-by-step guides, flow charts etc. These might
describe how to perform a specialised operation/connection or how to mechanically fix a
component or circuit board to an enclosure.

8. Describe the various types of circuit boards used (such as printed circuit board, thin film, thick
film and flexible film circuitry).

There are many different types of printed circuit boards. A printed circuit board allows components
to be connected together using tracks as well as physically supporting the components connected to
it. Tracks are very often made from copper, with the base board made from a range of materials
including fibreglass and paper.

Flexible PCBs are often used when many connections need to be made that bend around a product
or need to flex/bend during product use. A common application is the connection between the
screen of a laptop and the base which needs to flex when the lid is opened/closed.

Film circuit boards are very specialist types of PCB that have a very thin layer (or film) of tracks
deposited on a backing board such as glass, ceramic or plastic. They are generally used where
circuits must be extremely small and/or complex, for example in an LCD screen.

9. Explain how to recognise, read the values and identify polarity and any other orientation
requirements for all electronic components being used in the assemblies (such as capacitors,
diodes, transistors, integrated circuit chips, and other discrete through-hole or surface mounted
components).

Most components will have tell-tale signs of their polarity and/or values by the way they are
designed and what is printed on them. So for example, a diode has one end of the barrel printed in a
different colour representing the orientation. A diode will only allow the flow of current in one
direction, therefore the orientation will show which way this current will flow.

Most, if not all, polarised capacitors will be designed in such a way that you can easily identify which
way round the capacitor needs to be placed. So for example, the positive leg of a capacitor will have
a longer leg than the negative side, making it easy to identify.

With transistors, they are usually designed in a ‘D’ shape to represent which leg does what. It
identifies which is the emitter, the collector and the base. Usually, the base is the middle leg, the
collector is the leg at the top of the ‘D’ and the emitter is the bottom leg.

The values of capacitors and diodes will usually have the values printed on the side of them.
10. Explain how to check that components meet the required specification/operating conditions
(such as values, tolerance, current carrying capacity, voltage rating, power rating, and working
temperature range).

Fixed resistors have been manufactured with a set value that cannot be changed. The value of the
resistor can be identified by the four coloured bands around the barrel of the resistor which is
known as the resistor colour code. The first two bands give the numbers, the third gives the
multiplier and the last band tells you the tolerance. The multiplier is the number of zeros added to
the value and the tolerance is how accurately the resistor has been made. Identifying these values is
very important before applying the fixed resistor the circuit.

A diode has one end of the barrel printed in a different colour representing the orientation. A diode
will only allow the flow of current in one direction, therefore the orientation will show which way
this current will flow. The values of capacitors and diodes will usually have the values printed on the
side of them stating their voltage or power rating. Alternatively, a user manual could be consulted to
identify, for example, the proper working temperature range.

11. Describe the basic principles of operation of the electronic circuits being assembled, and the
purpose of the individual modules/components within the circuits.

With the amplifier and filter circuit, the circuit is configured to invert the signal, and then clip any
noise using the filter. Inside the inverting amplifier, the input resistor has a value of 1k ohms and the
feedback resistor has a value of 10k ohms. This means a gain of 10. As the input frequency increases,
the gain increases then rapidly decreases to a minimum of 480.0mV using a 35 kHz frequency.
Because the filter side of the circuit has 1 inductor with 2 capacitors below it, this filter is a low pass
filter. Please refer to worksheets for Assessed task 1 for more information.

The circuit used for the low-light alarm system comprises of 3 printed circuit boards. Firstly, a
transformer will step down the AC current from the mains. The Power Supply Board (PSU) will collect
and convert the AC current to a stable DC output. This makes the current more appropriate for the
remaining boards to handle. After the transformer has stepped down the AC current, it is then
passed through the rectifier bridge section of the circuit which produces a pulsed/raw DC output. It
then passes through large value capacitors which smoothes out the DC current. It now reaches the
regulator section of the circuit, where the DC output is regulated to an appropriate and required
level. This also eradicates any existing ripple making a stable DC output, achieving stabilisation.
Please refer to worksheets for Assessed task 2 for more information.

12. Describe the application and use of circuit protection equipment (such as fuses and other
overload protection devices).

Fuses are a type of protection device used in circuits to stop damage if something unusual happens.
They act like a weak link in a circuit so that if too much current flows through it they will quickly
break to prevent other components being harmed. These are good components to have if a short
circuit occurs as they will prevent damage to any other components. Fuses have a rating that’s
normally printed on them or stamped in to the end caps. This is the maximum current that can pass
through before they blow.

Another example of a circuit protection device is a heat sink. Heat sinks act a bit like a mini radiator,
allowing heat to be removed from a component. These tend to be mechanically attached to the
component and sometimes a sticky white thermal compound is used between the component and
the heat sink to help the heat transfer away more easily.
13. Describe the preparation requirements for components to be used in the assembly (such as
pre-forming component pins/legs).

When assembling circuits, preparation is key. In most instances, a preparation sheet is useful in
order to ensure covering all aspects of preparation. You must make sure that you have the correct
PPE to carry out the task in a safe manner and visually inspect your equipment to make sure that it is
all safe and in good condition. Set up your workstation so that everything you need is to hand and
neatly organised. The soldering iron is now turned on and left to pre-heat, ready for use.

Depending on what components are being used in the circuit, will depend on your next step. If you
are using resistors, you will probably need to bend the legs of the resistor into position in order to
apply to the board before soldering. In this case, you can easily bend the legs of the resistor using
long nose pliers. When applying polarised capacitors for example, you will need to ensure that the
correct sized leg is in the correct hole (ensuring the component is the correct way round).

14. Describe the methods of mounting and securing electronic components to various surfaces
(such as the use of manual soldering techniques, surface mount technologies and mechanical
fixing devices, use of heat sinks/shunts).

Surface mount technology is a method for producing electronic circuits in which the components are
mounted or placed directly onto the surface of printed circuit boards. In the industry it has replaced
the through-hole technology construction method of fitting components with wire leads into holes
in the circuit board. Both technologies can be used on the same board for components not suited to
surface mounting, such as large transformers and heat-sinked power semiconductors.

One method of applying a heat sink to a printed circuit board is by using thermally conductive tape.
The tape is applied to the base of the heat sink, and then attached onto the component board. It is
the most cost-efficient way to apply the heat sink; however the tape cannot provide mechanical
attachment for heavier heat sinks or high vibration environments. Other methods include epoxy
adhesive which is a liquid that bonds the heat sink to the board, wire-form clips which simply clip the
heat sink to the board and push pins which are used for larger heat sinks.

15. Describe the methods of attaching markers/labels to components or cables to assist with
identification (such as colour coding conductors, using coded tabs).

Wire or cable identification markers are designed to easily attach to wires and cables to help you in
identifying them. There are many different types of cable markers. The basic varieties include labels,
sleeves and tags. You can buy a range of kits of basic cable markers which suit a variety of
applications. Colour coding is the most common and identifiable method, helping to avoid a possible
mix up of circuits which could cause great damage. It also highlights individual functions so when
wiring is tested and repaired, it can be identified separating earth and neutral conductors. If, when
wiring, the conductors are unidentifiable then problems may emerge. This may include a wrong wire
fitting that would affect the whole installation, but also they are a health and safety issue in that
some may be more harmful than others and connected in the wrong way may be dangerous.

16. Describe the use of calculations and regulations, when selecting wires and cables and when
carrying out tests on electronic circuits.

When assembling an electronic circuit, you must firstly determine how much power the circuit is
going to consume. Power = Volts x Current (Amps). Once you know the power consumption, you can
determine what thickness of cable you need to use. Certain regulations need to be followed in
determining the dimensions of the cable depending on the configuration of the circuit. The
regulations can be found in the 17 th Edition IEE Wiring Regulations.

17. Describe the importance of making visual checks of the completed assembly (such as
examination for excessive solder or solder spikes which may allow short circuits to occur, correct
orientation of components for pin configuration or polarity, obvious signs of damage (such as heat
damage) or strain on terminations).

Before anything is ever plugged in or connected to a battery the first line of quality control is visual
inspection. Most basic assembly errors can be identified with these simple checks. Once any
problems have been identified, a course of appropriate action can be taken; for example replacing a
component, re-soldering a joint etc.

A large part of the visual inspection is to assess the quality of the soldered joints. Just one joint
poorly soldered can stop a whole product from working properly. In industry, a huge amount of time
and effort is taken to ensure that the soldering techniques used result in high-quality reliable joints.
It is extremely important that visual checks are made to ensure that all components are the correct
way round and the soldering is of a good standard otherwise the whole circuit will not work.

18. Describe the tools and equipment used in the electronic assembly activities (including the use
of cable stripping tools, crimping tools, soldering irons, specialist assembly tools).

When assembling electronic circuits, many different tools and equipment are used to achieve a fully
functioning circuit whilst working within a safe environment. A soldering iron is used to make
soldered joints. An extractor fan extracts irritant fumes from solder flux, keeping the user safe. Side
cutters are used to cut wires to size and trim component legs. Long nose pliers are used to form
components to the required shape as well as holding or positioning items. Wire strippers are used to
strip insulation from wires and cables. Screwdrivers and spanners are used to open/close cases and
enclosures as well as mechanical fixings of components and circuit boards. A trimmer tool is used to
make adjustments to electronic circuits. A de-soldering pump is used to remove solder when de-
soldering. When setting up the workstation, an anti-static mat is recommended to avoid electrostatic
discharge.

19. Describe the importance of ensuring that all tools are in safe and serviceable condition, are
used correctly and are returned to their correct location on completion of the assembly activities.

Any tools/equipment should be securely stored. They should be checked before each use with any
problems logged and taken out of service if necessary. This practice is to ensure the safety of the
user and other people around the user. Equipment should be periodically calibrated to ensure its
accuracy; this should be noted on a label on the device. Extra care should be taken when storing
tools that could be potentially dangerous, again ensuring everybody’s safety. When tools are
returned, they should be returned to their correct location in order to prevent any damage to them,
whilst keeping them safe from, for example, falling from height.

20. Describe the care, handling and application of electronic test and measuring instruments (such
as multimeter, oscilloscope, signal generators, stabilised power supplies, logic probes/analysers
and measuring bridges).

A multimeter can be used to measure several different electrical characteristics including a.c/d.c
voltage and current, resistance and continuity. The multimeter has probes which are insulated and
great care should be taken when working on live electrical circuits not to touch the metal part of the
probe or any of the exposed circuit connections. Before using a multimeter you should first select
the appropriate range and insert the probe leads in to the corresponding sockets. The range is the
highest value that the meter can read in that range. Exceeding this could damage the multimeter
and the circuit you are testing.

A power supply unit is used to provide power to a circuit when testing. Some power supplies have a
digital readout of the output voltage which can be used to set them. The voltage must always be set
correctly before connecting to the test circuit as excessive power could damage components on the
printed circuit board, or even cause harm if the output voltage is too high.

All test equipment and measuring instruments should be stored correctly and used in the correct
manner in order to prevent damage to them. For example, a signal generator has many different
knobs and dials on the face of the device. Being stored incorrectly can cause these dials to snap or
break deeming the device as unusable.

21. Explain how to check that test equipment is safe to use (such as condition of power cables,
using suitably fused test probes, clips and leads); how to check that equipment is within current
calibration approval dates, and PAT tested; checking that the test equipment is suitable for the
tests they are to carry out and can cover the range and values they are to measure.

Before using any test equipment, visual inspections should be carried out to check the overall
condition of the equipment. With electrical test equipment, power cables and plugs must always be
checked for any damage. When using a multimeter the appropriate range should be selected. The
range is the highest value that the meter can read in that range. Exceeding the selected range could
damage the multimeter and the circuit you are testing. Staying within the selected range ensures
that the multimeter is safe to use.

All electrical equipment and appliances needs to be PAT tested. Once test equipment has been PAT
tested, it will carry a label on it showing the date that it was tested and therefore the next inspection
date can be identified. Before any test equipment is used, these PAT test labels need to be checked
to ensure that the equipment is safe to use and it has not expired the test date.

22. Describe how to check that the test equipment is suitable for the tests you are to carry out and
cover the range and values you are to measure * You can check that your test equipment is suitable
for your test by checking the test equipment is suitable for the specific test your about to carry out
make sure your test equipment is measuring in the same unit as your actual test e.g if your test is to
get the voltage make sure your test equipment can measures voltage.

23. Explain how to connect to an approved power supply and, where appropriate, signal source;
identifying correct test points in the circuit; how to position test instruments into circuits without
damaging circuit components (such as using test probes, ensuring correct polarity, taking antistatic
precautions); setting instrument zero readings; obtaining instrument readings and comparing
them with expected results.

Before connecting to your circuit, you must make sure the power and signal source is switched off. If
the power supply is a variable supply, it must be set to the correct voltage before being connected.
The same needs to be done with the signal. The frequency and amplitude needs to be correct. The
ground clip/wire needs to be connected first, and it needs to be the last off when disconnecting.

To identify where the correct test points are within the circuit, you need to fully analyse the circuit
and looks for points that give you meaningful information. In some cases, the test points may be
labelled. Inputs, outputs and the power supply need to be looked at with respect to ground to
identify the correct test points.
Test instruments need to be positioned in a safe place within circuits in order to prevent damage to
the components. The use of test probes is recommended to make sure that the correct amount of
voltage is passing across the circuit. Too much voltage may cause components such as transistors to
fail and/or become unsafe. Another way to prevent damage to components is by the use of
antistatic equipment such as antistatic mats. These mats prevent electrostatic discharge keeping the
components safe. Also, by wearing an anti-static wrist strap will prevent damage to the components.

In order to set instrument zero readings, there is usually an adjustment device that you can set to
read zero for zero input. It is important when carrying out the testing and inspection of the
equipment that the test gear is reading zero. This means that any reading taken will be the true
reading of the circuit and not include the resistance readings of the meter being used for example.

24. Explain how to make adjustments to circuit components; making decisions on circuit
performance and faulty components; removal and replacement of faulty components.

Only a certain amount of components can be adjusted such as potentiometers, inductors, variable
capacitors and variable resistors. The adjustments can be made under live conditions but an anti-
static wrist strap must be worn to prevent damage to these components along with using an
insulated screwdriver.

If there are any doubts over circuit performance or faulty components, adjustments can be made. If
the circuit is not performing to standard, test equipment can be used to fault find and determine
which components need to be adjusted, removed or replaced. If a suspected faulty component has
been identified by visual/electrical inspection, or from a fault finding procedure, the component will
need to be carefully removed and the method of de-soldering is used to remove it. A soldering iron
is used to reheat the solder on the component and then the de-soldering tool is used to extract the
molten solder. The old component can be successfully removed and replaced. Once faulty
components have been removed, test equipment will need to be used once again to ensure the
circuit is working to its full potential.

25. Describe the fault finding techniques to be used when the equipment fails to operate correctly
(such as half split, unit substitution and input/output).

Half-splitting is a technique used in trouble shooting which reduces the average number of
measurements needed to isolate the faulty stage or component. If you have 10 stages in a circuit,
the first point to test would be between stage 5 and 6. If the signal is ok between these stages, then
everything from the stage 1 to stage 5 is ok and working and the problem lies between stage 6 and
10, therefore halving the test measurement of the fault path. This repeats until the fault has been
found.

Unit substitution simply means replacing a suspected faulty component with a known-to-be-working
alternative. The test on the circuit is repeated and if the fault has gone, then it was the correct
component that was removed which was the faulty one.

The input to output technique is fairly simple. After determining the systems function, the
input/start of the process is determined, followed by the output/finish of the process. Now each
input to output is tested for correct operation.

26. Describe the problems that can occur with the assembling and testing operations, and how
these can be overcome.
Heat is a major factor that needs to be considered when assembling and testing circuits. The tip of a
soldering iron is around 3000C and can cause burns to the skin. Soldering irons need to be used with
an appropriate holster/station. When using test equipment to test a circuit, the voltage must be set
accordingly to the circuits means otherwise overheating of components can occur and can become
dangerous to the touch. That and the components will probably fail anyway.

The soldering process gives off fumes from flux in the solder. In concentration, these can be harmful
to the user over prolonged periods of exposure. An extractor fan should be used whilst soldering to
eradicate these harmful fumes from the users face. In addition, a lab coat may be worn to prevent
damage and/or contamination of clothes.

Electric shocks, however big or small they are, can be harmful if experienced. To prevent electric
shocks, all equipment must be inspected before use and have valid (in date) PAT testing labels on
them to ensure they are safe to use.

Along with problems that can occur regarding our health and wellbeing, problems can occur with the
operation side of things. Before soldering components to the board, a visual check must be
performed to ensure the correct polarity of components, as well as checking that the components
values are all correct. If the board is soldered, and then a mistake in the components orientation is
spotted, the method of de-soldering can be used to rectify the mistake. In this case, prevention is
always best and this is why the visual inspections are always made to ensure everything is ok before
soldering.

27. Explain when to act on their own initiative and when to seek help and advice from others.

You should use your initiative providing it is safe, with training and procedure, and within your limits.
You may need help from others at times when people with more experience can assist you in solving
problems. In addition, you can use your initiative providing you are competent in the task you are
performing.

In relation to wiring and testing electrical circuits, you must be competent when handling live
electrics and ‘best-guessing’ is not the answer. Appropriate training and qualifications have to be
acquired to handle live electrics. For the best possible soldering standards when assembling a circuit,
high quality training must be given to make the user competent in soldering.

28. Describe the importance of leaving the work area in a safe and clean condition on completion
of the electronic assembly and testing activities (such as returning hand tools and test equipment
to the designated location, cleaning the work area, removing and disposing of waste).

It is important to leave the work area in a safe and clean condition on completion of activities
because it keeps everybody who enters the work area safe from harm. If the work area is kept
unclean, for example if liquids are left on the floor, people can slip over and cause serious harm.
When using test equipment and electrical equipment, wires must be placed in a safe place to ensure
that they are not a trip hazard.

Hand tools and test equipment needs to be put away after use in the correct location. This prevents
hand tools getting damaged or falling on somebody, and it prevents any damage to the test
equipment. Knobs and dials on the test equipment are more likely to be damaged or snapped off if
they are left out where people are working than they are if they are put away in a cupboard.

Components that are being used whilst assembling circuits need to be stored in their correct
locations as they could be affected by electrostatic discharge and therefore could be deemed
unusable or give false readings when the circuit is complete. Therefore, all components must be put
away carefully and in the correct locations.

When removing and disposing of waste, chemicals and substances need to be disposed of in the
correct way in a safe manner. The COSHH regulations state that all substances that are hazardous to
health need to be controlled. In this instance, the fumes from the flux in solder are being controlled
when we use an extractor fan to prevent breathing in these fumes. Other electrical waste such as
left over solder or cables/wires that are no longer being used need to be disposed of in the correct
manner such as being thrown in an electrical waste bin.

Keeping the work area safe and putting all tools and components away after activities is very good
practice for keeping organised. This means that when the next person wants to use the same
tools/components they know where they are and can be ensured that they are not damaged due to
correct storage.