Information Sheet 1.

1-1

Occupational Health and Safety Policies and Procedures in Consumer

Electronics Servicing

The most significant danger to people carrying out electrical testing work is that
they might suffer an electric shock. Any simultaneous contact of a part of the
body with a conductor that is live at a dangerous voltage, e.g. one that is
connected to the mains supply, while another part of the body is connected to
an earth, will result in an electric shock. There is also a risk of burn injuries
resulting from arcing when conductors are accidentally short circuited An
electric shock can lead to serious injury, sometimes fatal. Injuries can also occur
when a person reacts to an electric shock, for example by falling or touching
another hazard. Factors which are likely to increase the risk receiving an electric
shock.

Hazard Identification

Hazard identification is a key step in preventing injury and disease in the

workplace. Where there's a risk, you need to stop and think. You need to think
about what you are about to do, the potential risks and the likely effects on
yourself and other people.

Approach to Hazard Identification

1. Spot the hazards.-Be alert work! Notice potential hazards and work out
what the problem is.
2. Asses the risk-Talk to your supervisor about the hazard and work out a way
to solve the problem.
3. Make the changes-Follow through. Carry out the agreed actions in order to
solve the problem.

Electrical Hazards

1. It is important that every electrical worker works in a safe manner, not only
for his or her safety, but also the safety of others.
2. Working safely includes the work procedure, the type of tools used and the
type of clothing worn.
3. Accidents and deaths can also result from equipment becoming "live" due to
electrical faults, lack of maintenance or short circuit.

Serious injury can also occur if accidental contacts made with the two poles of a
supply, whether the supply is earth-referenced or not. In TVs, such supplies are
generated internally on printed circuit boards and can be contacted if boards are
handled while live or before stored charges have dissipated.
 .

Some equipment may have large areas of earthed metal that can be easily
touched. Touching exposed live conductors connected to the mains supply at
the same time as touching the earthed metalwork will result in an electric shock.

Isolation and Tagging -Isolation and tagging procedures cover basic safety
principles and isolation requirements to protect personnel and equipment. Any
faulty equipment should be tagged so that it cannot be used until it is replaced
or repaired.

RED and BLACK "DANGER" tags are used to warn workers about hazards
associated with equipment and machinery maintenance.

This tag is a notice to all persons to identify appliances or equipment that are
out of service for repairs and alterations. Placed at common isolation points of
the equipment that is unsafe or not to be operated.
The person working with the machine should hold the only key to the lock. A lock
must only be removed by the person who attached it to the equipment or
machinery.

Clothing provides protection from:

1. Electric arcing/flask burns
2. Flying objects; and
3. Electric shock.

Clothing
1.Ideally, clothing should cover the body completely
2. Made of cotton material.
3. Have non-conductive and concealed buttons;
4. Have sleeves to wrist length; and
5. Have legs which reach to the footwear

Personal Protective Equipment and Clothing

Every electrical worker should ensure that they always use approved safety
equipment in the workplace.

Hearing Protection -Hearing protection provide protection from excessive

noise from electric power tools you are operating;
1. Excessive noise from electric power tools on workmate nearby is operating.
2. Mechanical noise from machines and equipments.
Safety footwear
Footwear should be non-conductive
Safety footwear provides protection from:
1.Electric shock
2.Falling objects

Insulating gloves -Special gloves should be wear when accidental contact

with live conductors is possible, but they must never be the sole means of
insulation.

Face Mask-this protect your respiration inhaling chemical residue fog etc.

Hairnet- this is to avoid obstruction in your vision and make you comfort while
you are working

Insulating mats- Insulating mats should be used when working on live

conductors or where accidental contact is possible. They must never be the sole
means of insulation.
ESD table is use to protect from the effects of electrostatic damage of the
electronics equipments in the field service.

In electronics testing and servicing isolation power transformer is a 1:1

(under load) powertransformer used for against electric shock (leakage current).

.
Antistatic Wrist Strap Wear a ground strap. Anti static wrist strap is used to
avoid risk of electrostatic discharge from a human body to an electronic
component circuit.

GFCI (Ground Fault Circuit Interrupter) protected outlet to ensure

earth grounding the device will automatically shut down to isolate electrical
source in the equipment if a grounding system is not connected.
Three wire system (neutral mythology)design is to make sure that any user
who touches the exposed metal surfaces of two pieces of equipment at once will
not be subjected to an electrical shock

Earth Ground-ground wireprotects against current surge which is detrimental

to the equipment. It also guarantees in reducing leakage current that causes
electric shock.

Do not work when you are tired or taking medicine that makes you drowsy.

Do not defeat polarized plug

Use approved equipments

Do not defeat special connector or adapter

Use approved tools

Replace the exact fuse rating and specification

Never assume that a circuit is OFF. Double check it with an instrument that you
are sure is operational.

Avoid wearing bracelets or wrist watch

Buddy system while working electrical power lineSome situations require buddy-
system to guarantee that power will not turn ON while a technician is still
working.

Never tamper with or try to override safety devices such as interlock in the
cabinet or sliding door.

Never tamper overload protection, a type of switch that automatically removes

power when there is short circuit overload etc.

Keep tools and test equipments clean and in good working condition. Replace
the defective parts if necessary.

Avoid octopus setup

You must be certain these devices are discharged properly before you working
around them.

Avoid clever wirings

Use only approved Fire Extingusher

Use insulated ladder

Do not work in damp area

Use personal protective equipment and devices when working.

In case of fire find out where the circuit breaker is located and shut down the
energy source distribution.

Use safety belt

Ask for help in the near police or fire station emergency though land line,
cellular phone radio
Put or list down emergengy hotlines in your wallet or near work station

Use only exact specfication of components

Use only exact or approved replacement parts

Follow the proper waste segregation

Follow instruction in using chemicals and apply proper disposal ,some chemical
are toxics.

You should wash your hands thoroughly after handling materials in the
fabrication process like PCB designing
Safety Guidelines in Assembling and Disassembling Consumer
electronic Products and Systems

The danger to in most audio equipment and the other devices is the AC line
connection and getting sucked into any mechanical people traps. Before you
plug in the unit with any covers removed, make note and cover up any exposed
AC line connections. The rest of the circuitry is low voltage and while you can
destroy your equipment by your actions, you should be fairly safe.

Always keep one hand in your pocket when anywhere around a powered line-
connected or high voltage system.

Don’t wear any jewelry or other articles that could accidentally contact circuitry
and conduct current, or get caught in moving parts. Set up your work area away
from possible grounds that you may accidentally contact
Don’t work alone in the event of an emergency another person's presence may
be essential.

If you need to probe, solder, or otherwise touch circuits with power off,
discharge (across) large power supply filter capacitors with a 2 W or greater
resistor of 100 to 500 ohms/V approximate value (e.g., for a 200 V capacitor, use
a 20K to 100K ohm resistor). Monitor while discharging and verify that there is
no residual charge with a suitable voltmeter. In a TV or monitor, if you are
removing the high voltage connection to the CRT (to replace the fly back
transformer for example) first discharge the CRT contact (under the suction cup
at the end of the fat HV wire). Use a 1M to 10M ohm 5 W or greater wattage (for
its voltage hold off capability, not power dissipation) resistor on the end of an
insulating stick or the probe of a high voltage meter. Discharge to the metal
frame which is connected to the outside of the CRT.

Connect a high power resistor around 20K-100K ohms for proper discharging of
high voltage capacitor in a circuit .

For TVs and monitors in particular, there is the additional danger of CRT
implosion - take care not to bang the CRT envelope with your tools. An implosion
will scatter shards of glass at high velocity in every direction. There is several
tons of force attempting to crush the typical CRT. While implosion is not really
likely even with modest abuse, why take chances? However, the CRT neck is
relatively thin and fragile and breaking it would be very embarrassing and
costly. Always wear eye protection when working around the back side of a CRT.
Connect/disconnect any test leads with the equipment unpowered and
unplugged. Use clip leads or solder temporary wires to reach cramped locations
or difficult to access locations.

Connect/Disconnect Test Lead

Unplug the Equipment

If you must probe live, put electrical tape over all but the last1/16" of the test
probes to avoid the possibility of an accidental short which not protect you from
shock from many points in a line connected TV or monitor, or the high voltage
side of a microwave oven, for example. (Note however, that, a GFCI may
nuisance trip at power-on or at other random times could cause damage to
various components. Clip the reference end of the meter or scope to the
appropriate ground return so that you need to only probe with one hand.

Perform as many tests as possible with power off and the equipment unplugged.
For example, the semiconductors in the power supply section of a TV or monitor
can be tested for short circuits with an ohmmeter.

Waveform Analysis
Switching OFF

Desoldering Component

Use an isolation transformer if there is any chance of contacting line connected

circuits. Variac (tm) is not an isolation transformer! The use of a GFCI (Ground
Fault Circuit Interrupter) protected outlet is a good idea but will not protect you
from shock from many points in a line connected TV or monitor, or the high
voltage side of a microwave oven, for example. (Note however, that, a GFCI may
nuisance trip at power-on or at other random times due to leakage paths (like
your scope probe ground) or the highly capacitive or inductive input
characteristics of line powered equipment.

Isolation Transformer

GFCI

If circuit boards need to be removed from their mountings, put insulating

material between the boards and anything they may short to. Hold them in place
with string or electrical tape. Prop them up with insulation sticks - plastic or
wood.

Know your equipment: TVs and monitors may use parts of the metal chassis as
ground return yet the chassis may be electrically live with respect to the earth
ground of the AC line. Microwave ovens use the chassis as ground return for the
high voltage. In addition, do not assume that the chassis is a suitable ground for
your test equipment.

Information Sheet 1.1-2

Hand Tools
A hand tool is a device for performing work on a material or a physical system
using only hands. The hand tools can be manually used employing force or
electrically powered, using electrical current. Virtually every type of tool can be
a hand tool and many have also been adapted as power tools which get their
motive power from motors or engines rather than from human mechanical
action.

Slotted Screwdriver- is used to drive or fasten negative slotted screws.

.

Philip screwdriver used to drive or fasten positive tighter It is screwdriver that

could take greater torque and could provide tighter fastenings.
Long Nose- is used for holding, bending, and stretching the lead off electronic
component or connecting wires.

Side Cutter- is a wire-cutting plier, though they are not used to grab or turn
anything, but are used to cut wires.

Magnifier- is a convex lens which is used to produce a magnified image of an

object such as small electronics components in a PCB.

Paint Brush made of bristles set in handle, use for cleaning dirt.

De-soldering tool device for applying heat to melt solder in attaching two
metal parts for electrical work, wires are usually soldered to printed circuit
boards, other wires, or small terminals. A low-power iron (20-30 Watts) is
suitable for this works.

Soldering Iron –is used in removing soldered wires and components on printed
circuit boards for troubleshooting and repair purposes.
Soldering Iron Stand is a place where the soldering is safe guard This will
keep the soldering iron away from flammable material

IC Extractor Used to remove integrated circuits (I.Cs) without damaging the

pins

Alignment tool These are insulated, magnetic and metallic precision tool which
is used to align radio a video circuits.

Information Sheet 1.1-3

Electronic Test Equipment

Electronic test equipment (sometimes called "test gear" or "bench top") is used
to create signals and capture responses from electronic Devices Under Test
(DUTs). In this way, the proper operation of the DUT can be proven or faults in
the device can be traced and repaired. Use of electronic test equipment is
essential to any serious work on electronics systems.

Oscilloscope-.is a piece of electronic test equipment that allows signal voltages

to be viewed, into waveform usually as a two-dimensional graph of one or more
Color Pattern Generator-an instrument use to align color oscillation television
or any video system

Signal Generator-Used to generate RF signal for calibration of electronics

equipment especially RF circuits such as radio transmitter and receiver

Multi –Tester-Multi tester can measure various electrical quantities such as

voltage, current and resistance, for testing components.

High-Voltage Prob -high-voltage meter or probe is the tool needed to test

high voltage circuit such as the picture tube of a Monitor and Television.

Information Sheet 1.1-4

Electronics Symbols

Most symbols that you will encounter in laying out electronic diagrams are
accepted as standard, but in some cases some manufacturers modify symbols
and practices to suit a particular industrial policy while others use their own
symbols to represent unique or special component and devices. Do you know
that electronic symbols and their use in conjunction with recommended drafting
practices have been developed through the years, and have been standardized
by a number of different organizations? Among these are the American National
Standards Institute (ANSI), the Electronics Industries Association (IEA), the
Institute of Electrical and Electronics Engineers (IEEE), and the International
Electro technical Commission (IEC).
 Information sheet 1.1-5

Electronic Diagrams

When you purchase a brand new appliance or equipment, it is very important

that a diagram is included with the product to insure that there will be a
reference material in case the appliance or equipment becomes defective.

All electronic circuits from the simplest to the most complex design need
diagrams to be used as reference in designing, modifying, and troubleshooting
the circuit. The most common used electronic diagrams are schematic, pictorial,
wiring, and block diagrams. Each one of these diagrams has its own unique
characteristics in presenting the circuit.
To produce a quality and marketable electronic diagram, you have to follow the
Electronic Drafting Standards which is the process of illustrating various kinds of
circuits and wiring systems

The most common graphical languages used in the illustration of components in

circuits and wiring systems are block, schematic, wiring, and pictorial diagrams.

Rules for Drawing Symbols

One of the features of a quality electronic diagram is its appearance with

simplicity in design and easy-to-understand layout. To achieve this, you have to
follow the following standards in laying out electronic diagram.

1. The position of a symbol on a diagram does not affect its meaning.

2. The weight of a line used in drawing a symbol does not affect its meaning. In
some cases, a heavier line may be used to emphasize a particular symbol.
3. A given symbol may be drawn in any size that is suitable for use in any
particular diagram. However, when a symbol is enlarged or reduces
4. If necessary for contrast, some symbols may be drawn smaller or larger than
other symbols on a diagram. However, for simplicity, it is recommended that not
more than two different sizes of symbols be used on any one diagram.
5. In general, a connecting line should be brought to a symbol either vertically or
horizontally, but a connecting line brought to a symbol at an angle has no
particular significance unless otherwise noted.
6. The arrowhead of a symbol may be open ( ) or closed ( ) unless otherwise
noted.
7. The standard symbol for terminal (o) may be added to any symbol. But when
this is done, the terminal symbol should not be considered a part of the symbol
itself.

Pictorial diagram - It shows the pictures of the actual components and wiring
Connections although it does not provide the exact size of components. It shows
exact shape in proportion to the actual component or device

Pictorial Diagram of a Booster Amplifier

Schematic diagram - It shows the components used in their interconnection.

Each graphic symbol is also accompanied with a reference designation to
distinguish it from other similar symbols. It does not illustrate the physical size,
shape or chassis location of the component parts and devices.

Block Diagram – This form usually uses block of squares, rectangles or

triangles to represent circuits and simplified the principle of the entire system.

Block Diagram of a Television Receiver

Wiring diagram – It shows wiring connection in a simplified, easy to follow
manner. It may show either internal or external connections or both and is
usually drawn as simple as possible to trace out the connection of a circuit. The
components of the circuit are identified by name or are represented by means of
pictorial illustrations that do not follow any well-definedstandard form.

Wiring diagram of a car stereo and power amplifier

Flow Chartis a type of diagram that represents an algorithm, workflow or

process, showing the steps as boxes of various kinds, and their order by
connecting them with arrows. This diagrammatic representation illustrates a
solution model to a given problem.

Reference Identification and Numbering

The symbols used to represent various components on a circuit diagram or

circuit board is most often accompanied by a combination of alpha numeric
character that identify the components designation and specification but are
not themselves a part of the symbols
Components Reference ID
Resistor R
Capacitor C
Diode D
Transistor Q or TR
Integrated Circuit IC
Transformer T
Inductor Coil L
Variable Resistor VR
Switch S or SW

COMPONENT PLACEMENT GUIDE

Information Sheet 1.1-6

Electronics Components

An electronic component is a basic indivisible electronic component that is

available in a singular form. Electronic components are discrete devices or
discrete components, mostly industrial products, and not to be confounded with
electrical elements which conceptual abstractions are representing idealized
electronic components

A component may be classified as passive(resistive), reactive (electro -

magnetic, capacitive inductive ) and active (semi conductive).The strict physics
definition treats passive components as ones that cannot supply energy
themselves, whereas a battery would be seen as an active component since it
truly acts as a source of energy
.
A resistor is an electronic component that limits or regulates the flow of
electrical current in an electronic circuit. Resistors can also be used to provide a
specific voltage for an active device such as a transistor.

The passive component is characterized amount of resistance which is

measured in ohms (Ω), kilo-ohms (K), or mega-ohms (M).Physical size of
resistors determines power handling ability Commonly available as 1/8, 1/4,
1/2, 1 -10 watts much higher powers available , usually as wire wound or
ceramic encapsulated parts.

Resistor handling and installation

Resistors are not polarized and may be installed in either direction.
Resistors are not generally susceptible to ESD damage, so special precautions
are not required. Mechanical stress due to lead bending should be minimized

Resistor is use to limit the flow of current in a circuit

Resistor is use to drop the voltage in a circuit
Variable resistor is use as a potentiometer or rheostat in a circuit.

Resistors

Carbon Film Resistor made by depositing a thin carbon film on a ceramic

Wire Wound Consist of a cylindrical core which is wrapped or wound with wire.
The cylindrical core is typically made from a ceramic material
Surface Mounted Surface mounted technology resistors are utilized in many
LCD and TFT television sets, cellular phones etc.

Variable resistorscan change their value over a specific range. A

potentiometer is a variable resistor with three terminals

Capacitor –a capacitor(originally known as condenser) is a passive two-terminal

electrical component used to store energy in an electric field Capacitors are
commonly used to perform various functions in a circuit.
The component is characterized an amount of

Capacitance which is measured in farad (μF).Physical size of capacitors is

related to voltage handling ability – WVDC – working voltage DC Temperature
coefficient may also be important – can be + or – or nearly zero
Temperature coefficient depends upon dielectric material.

Capacitor handling and installation

Most capacitors are not polarized and may be installed in either direction.
Electrolytic capacitors are polarized and must be installed with proper polarity,
else catastrophic failure. Capacitors are not generally susceptible to ESD
damage, so special precautions are not required..Mechanical stress due to lead
bending should be minimize
Filter capacitor is use to remove voltage ripple and boosting D. C
component in a power supply to eliminate humming sound, noise motor boating

Coupling capacitor is use to coupled circuit to block D.C component in a

Audio/Video Circuit to obtain proper oscillation and amplification.

Variable capacitor is use to change the oscillating frequencies in the RF tank

of a radioreceiver to tune-in the desired radio station

Electrolytic Capacitors

Filtering – is use to remove voltage ripple in a power supply

It blocks D.C component in a audio/video circuit

Ceramic Filtering is use to remove voltage ripple in a power supply

Block DC component in a Audio/Video Circuit

Film Capacitor -Filtering is use to remove voltage ripple in a power supply

Block DC component in a Audio/Video Circuit
Trimmer and Padderused as tuning capacitor for radio receivers

Tantalum-Filtering is use to remove voltage ripple in a power supply Block DC

component in a Audio/Video Circuit

SMT Capacitor

Surface mounted technology capacitors are utilized in many LCD and TFT
television sets, cellular phones etc.

Inductor- (also choke, coil or reactor) is a passive two-terminal

electrical component that stores energy in its magnetic field.

Inductors are used extensively in analog circuit and signal processing. Inductors
in conjunction with capacitor and other components form tuned circuits (radio)
which can emphasize or filterout specific signal frequencies. Values specified in
henries (H), mill henries (mH) and micro henries (μH)..A coil of wire that may be
wound on a core of air or other non-magnetic material, or on a magnetic core
such as iron powder or ferrite.

Wire gauge and physical size of the coil determine the current handling
capacity. core material will have a temperature dependence. Air is best, followed
by iron powder, then ferrites.

Inductor handling and installation

Inductors are not polarized and may be installed n either direction. Inductors are
not generally susceptible to ESD damage, so special precautions are not
required. Mechanical stress due to lead bending should be minimized. Inductors
in timing or frequency determining circuits should be installed in a mechanically
rigid fashion

Static noise filter by using inductor

Other Uses

1.Intermediate frequencies amplifier for band filtering using inductor

2.Antenna balloon (matcher ) by using inductor
3.Oscillator by using variable inductor

Inductors

Molded inductor & air-wound inductor Molded chip inductors have outer
cases that have been molded using either injection of transfer molding. An
advantage of these kinds of inductors is that they have very precise dimensions.
These are also called encapsulated chip inductors.

Wire wound chip inductors have cores made out of wound wire. They are used in
many applications, including in cars, telephone communications, and mobile
technology.
Ferro Magnetic Ferromagnetic-core or iron core inductors use a magnetic
core made of a ferromagnetic or material such as iron or ferrite to increase the
inductance.

Air core inductorThe 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

Variable InductorA variable inductor can be constructed by making one of the

terminals of the device a sliding spring contact that can move along the surface
of the coil, increasing or decreasing the number of turns of the coil included in
the circuit.

Laminated Core InductorLow-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.

Radio Frequency Inductor At high frequencies, particularly radio frequencies

(RF), inductors have higher resistance and other losses. In addition to causing
power loss, in resonant circuits this can reduce the Q factor of the circuit,
broadening the bandwidth
 SMT Inductor

Surface mounted technology inductors are utilized in many LCD and TFT
television sets, cellular phones etc

Diode-A diode is a two-terminal electronic component with asymmetric transfer

characteristic with low (ideally zero) resistance to current flow in one direction,
and high (ideally infinite) resistance in the other A semiconductor diode, the
most common type today, is a crystalline piece ofsemiconductor material with a
p-n junction connected to two electrical terminals. Most modern diodes are
semiconductor devices, but are considered passive since they do not contribute
any amplification or gain to a circuit. May be classified by semiconductor
materialsilicon, germanium, gallium arsenide, etc. or classified by circuit
function

Diode Handling and Installation

Diodes are polarized and must be installed in with correct orientation. Many
diodes are modestly susceptible to ESD damage, so normal ESD precautions
should be taken. Mechanical stress due to lead bending should be minimized.

Rectifier diode is use to convert A.C-DC in a power supply circuit

Small signal detector or switching diode

Light-emitting diode (LED) is utilized for signal or power indicator

Zener Diode- is utilized for voltage regulation

Varactor diode -is utilized for electronic tune circuit

A transistor is a semiconductor device used to amplify and switch electronic

signals and electrical power. It is composed of semiconductor material with at
least three terminals for connection to an external circuit. A voltage or current
applied to one pair of the transistor's terminals changes the current flowing
through another pair of terminals. Because the controlled (output) power can be
higher than the controlling (input) power, a transistor can amplify
 a signal. Today, some transistors are packaged individually, but many more are
found embedded in integrated circuits.

The transistor is the fundamental building block of modern electronic devices,

and is ubiquitous in modern electronic systems. Following its development in the
early 1950s the transistor revolutionized the field of electronics, and paved the
way for smaller and cheaper radios, calculators, and computers, among other
things.

Transistor Handling and Installation

Transistors are polarized and must be installed in with correct orientation.

Most BJT transistors are modestly susceptible to ESD damage, so normal ESD
precautions should be taken.
MOSFET (IGFET) transistors are very susceptible to ESD damage, so rigorous
precautions should be taken.
Mechanical stress due to lead bending should be minimized.

Transistor Amplifier Circuit

Transistor as switch
An integrated circuit (IC), sometimes called a chip or microchip, is
a semiconductor wafer on which thousands or millions of tiny resistors,
capacitors, and transistors are fabricated. An IC can function as
an amplifier, oscillator, timer, counter, computer memory, or microprocessor. A
particular IC is categorized as either linear (analog) or digital, depending on its
intended application.

IC Handling and Installation

ICs are polarized and must be installed with correct orientation. Observe pin 1
location on sockets or circuits.
Treat all ICs as if they are very susceptible to ESD damage (very many actually
are), so rigorous precautions should be taken.
Leads generally should not be bent.

Pin identification and numbering convention

Pins are numbered sequentially in a counter clockwise direction.

Pin 1 is often identified with a dot or a dimple.

The pin 1 end of the chip is often identified with a notch.

Linear IC as Audio Amplifier

Digital IC as Processor
Linear ICs -have continuously variable output (theoretically capable of attaining
an infinite number of states) that depends on the input signal level. As the term
implies, the output signal level is a linear function of the input signal level.
Ideally, when the instantaneous output is graphed against the instantaneous
input, the plot appears as a straight line. Linear ICs are used as audio-frequency
(AF) and radio-frequency (RF) amplifiers. The operational amplifier (op amp) is a
common device in these applications.

SMT IC
Digital ICs- operate at only a few defined levels or states, rather than over a
continuous range of signal amplitudes. These devices are used in computers,
computer networks, modems, and frequency counters. The fundamental building
blocks of digital ICs are logic gates, which work with binary data, that is, signals
that have only two different states, called low (logic 0) and high (logic 1).

A microcontroller (sometimes abbreviated µC, uC or MCU) is a small computer

on a single INTEGRATED CIRCUIT containing a processor core, memory, and
programmable input peripherals. Program memory in the form of NOR
flash or OTP ROM is also often included on chip, as well as a typically small
amount of RAM. Microcontrollers are designed for embedded applications, in
contrast to the microprocessors used in personal computers or other general
purpose applications.

A microprocessor incorporates the functions of a computer’s central processing

unit(CPU) on a single integrated circuit(IC),or at most a few integrated circuits.It
is a multipurpose, programmable device that accepts digital data as input,
processes it according to instructions stored in its memory, and provides results
as output. It is an example of sequential digital logic, as it has internal memory.
Microprocessors operate on numbers and symbols represented in the binary
numeral system.
 Information Sheet 1.1-7
Resistor color coding
1. The 4-band code is used for marking low precision resistors with 5%, 10% and
20% tolerances. Identifying the value will become easy with a little practice, as
there are only a few simple rules to remember:
2. The first two bands represent the most significant digits of the resistance
value. Colors are assigned to all the numbers between 0 and 9, and the color
bands basically translate the numbers into a visible code. Black is 0, brown is 1,
red is 2 and so on (see the color code table below). So, for example, if a resistor
has brown and red as the first two bands, the most significant digits will be 1
and 2 (12).
3. The third band indicates the multiplier telling you the power of ten to which
the two significant digits must be multiplied (or how many zeros to add), using
the same assigned value for each color as in the previous step. For example, if
this band is red (2), you will multiply it by 10 2 = 100 (or add 2 zeros). So, for the
resistor we used in the previous example, the value would be: 12 x 100 = 1200Ω
(1.2kΩ).
Note: If the multiplier band is gold or silver, the decimal point is moved to the
left by one or two places (divided by 10 or 100).
4. The tolerance band (the deviation from the specified value) is next, usually
spaced away from the others, or it's a little bit wider. A color is assigned to each
tolerance: gold is 5%, silver is 10%. 20% resistors have only 3 color bands - the
tolerance band is missing.
So, for a 560 ohm, 5% resistor the color stripes will be green, blue, brown and
gold. Green and blue are the first significant digits (56); brown is the multiplier
(101 = 10) and gold is the tolerance (5%). 56 x 10 = 560Ω.
If the 3rd band would be red instead of brown, the multiplier would be (10 2 =
100) instead of 10 and the resistor value would be 56 x 100 = 5600 ohms = 5.6
k ohms.
If the multiplier band is gold or silver, then the decimal point is moved to the left
one or two places (divided by 10 or 100). For example, a resistor with green,
blue, silver and gold rings has a value of 56 x 0.01 = 0.56Ω.

The 5-band code

The 5 band code is used for marking high quality, precision resistors with 2%,
1% or lower tolerances. The rules are similar to the previous system; the only
difference is the number of digit bands. The first 3 bands will represent the
value, the 4th band will be the multiplier and the 5th stripe will give us the
tolerance.
Optional band
A few resistors have an additional band - often giving beginners a bit of trouble -
indicating either the reliability or the temperature coefficient.
The reliability band specifies the failure rate per 1000 hours (assuming that a full
wattage being applied to the resistor). This stripe is found primarily on 4-band
resistors made for military applications and seldom used in commercial
electronics.
The temperature coefficient is more commonly marked, especially on quality 5-
band resistors, as it starts to become an important factor for precision
components. For a resistor with temperature coefficient of 200 ppm, for
example, a change in temperature of 50°C causes a value change of 1%. The
most common values for this band are presented in the color chart above.

Examples:

Four band code:

Green, blue, red, with silver tolerance band: 56 x 100 = 5.6 k ohms, with a

tolerance of 10%
Brown, black, orange, gold tolerance band: 10 x 1000 = 10000 ohms (or
10K ohms), with a tolerance of 5%
Red, red, brown, silver tolerance band: 22 x 10 = 220 ohms (220 ohms),
with a tolerance of 10%
More 4 band resistor color code examples: E12 and E24 series.

Five band code:

Blue, brown, white, brown, red tolerance band: 619 x 10 = 6190 ohms
(6.19K ohms), with a tolerance of 2%
Red, red, brown, black, with a brown tolerance band: 221 x 1 = 221 ohms,
with a tolerance of 1%
Brown, black, black, red, with a brown tolerance band: 100 x 100 = 10000
ohms (10.0K), with a tolerance of 1%

Information Sheet 1.1-7

Capacitor Coding

Capacitors are elements of a circuit that react to rapidly changing signals, rather
than slowly changing or static signals. Capacitors can store the energy from
strong rapidly changing signals and return that energy to the circuit as desired.
The most common usage of capacitors is to absorb noise, which is by definition a
rapidly changing signal, and divert it away from the signal of interest. Different
capacitor values are needed to trap different types of noise. Use these tips to
learn how to read capacitor designations and determine the value of the
capacitor.

Small value ceramic, mylar, and polyester type capacitors have their values
stamped on their bodies as a numerical code, 102, 473, etc. in very small print.
These codes can easily be deciphered into a standard value in microfarads.

The first two digits of the code indicate the two significant digits of the value.
The third digit is the number of zeros to the right. Writing the first two digits,
then the zeros will yield the value in microfarads. If desired, that value can now
be converted to microfarads by moving the decimal point six places to the left.

1. Understand the units of measurement used for capacitors. The base unit of
capacitance is the Farad (F). This value is too large to be of use in a circuit.
Smaller denominations of capacitance are used by electronic circuits.

Read uF as microFarad. 1 microFarad is 1 times 10 to the -6 power Farad.

Read pF as picoFarad. 1 picoFarad is 1 times 10 to the -12 power

2. Read the value directly on larger bodied capacitors. If the surface of the body
is large enough, the value will be printed directly on the capacitor. For example,
47 uF indicates 47 microFarads.

3. Read the capacitance of smaller bodied capacitors as two or three numbers.

The designators uF or pF will not appear due to the small size of the capacitor
body.
Read two digit numbers as being in picoFarads (pF). For example, 47 would be
read as 47 pF.
Read three digit numbers as a base capacitance value in picoFarads and a
multiplier. The first two digits will indicate the base capacitor value in
picoFarads. The third digit will indicate a multiplier to be used on the base
number to find the actual value of the capacitor.

Use a third digit of 0 through 5 to place the corresponding number of 0s behind

the base value. A third digit of 8 means multiply the base value by .01. A third
digit of 9 means to multiply the base value by 0.1. For example, 472 would
indicate a 4700 pF capacitor and 479 would indicate a 4.7 pF capacitor.

Digit-Character-Digit. Some small capacitors are marked with codes like 1n0.
The digits are the values before and after the decimal point and the character
tells you the dimension; so the example given is 1.0 nF (nano-Farad).

4. Look for a letter code. Some capacitors are defined by a three number code
followed by a letter. This letter represents the tolerance of the capacitor,
meaning how close the actual value of the capacitor can be expected to be to
the indicated value of the capacitor. The tolerances are indicated as follows.
Read B as 0.10 percent.
Read C as 0.25 percent.
Read D as 0.5 percent.
Read E as 0.5 percent. This is a duplication of a D code.
Read F as 1 percent.
Read G as 2 percent.
Read H as 3 percent.
Read J as 5 percent.
Read K as 10 percent.
Read M as 20 percent.
Read N as 0.05 percent.
Read P as plus 100 percent to minus 0 percent.
Read Z as plus 80 percent to minus 20 percent.

Example 1:
You have a capacitor with "103" stamped on it.
The first two digits are: 1 0
The third digit is: 3 so add three zeros to the 1 0 --> 1 0, 0 0 0 pf
Now to covert the 10,000pf to microfarads:
Move the decimal point to the left six places giving 0.01 microfarads.

Example 2:
You have another capacitor with "104" stamped on it.
The first two digits are: 1 0
The third digit is: 4 so add four zeros to the 1 0 --> 1 0 0, 0 0 0 pf
Now to covert the 100,000pf to microfarads:
Move the decimal point to the left six places giving 0.10 microfarads.

Values greater than 1 microfarad are also coded this way.

Example 3:
Number stamped on capacitor: 223
Decoded value: 22 + 000 = 22,000pF = 0.022 microfarads

Below is a table showing standard codes for different tolerances:

These letter codes are usually stamped on the capacitor next to or below the
value.

C = +/- 0.25pF M = +/- 20%

D = +/- 0.5pF P = +100 - 0%
J = +/- 5% Y = -20 +50%
K = +/- 10% Z = -20 + 80%

Mathematical Prefix

Information Sheet 1.1-8

Soldering

Soldering is defined as "the joining of metals by a fusion of alloys which have

relatively low melting points". In other words, you use a metal that has a low
melting point to adhere the surfaces to be soldered together. Consider that
soldering is more like gluing with molten metal, unlike welding where the base
metals are actually melted and combined. Soldering is also a must have skill for
all sorts of electrical and electronics work. It is also a skill that must be taught
correctly and developed with practice.
The most common solder alloy used in electronics is Tin-Lead 60/40. This alloy is
recommended if you are new to soldering, but is hazardous.

Various lead-free alloys are becoming popular recently. These require higher
soldering temperatures and do not "wet" as well as Tin-Lead alloys. However
they are safer and can be more effective. 96.5 Tin/ 3.5 Silver is the most
successful and will produce a joint with less electrical resistance than any tin-
lead alloy.

Both lead and lead-free formulations are available online at places like
solderdirect.com and in your local Radioshack/Homedepot store.

Flux is an additive in solder that facilitates the soldering process by removing

and preventing oxidation and by improving the wetting characteristics of the
liquid solder. There are different types of flux cores available for solder wire.

Rosin is most commonly used by hobbyists. After soldering, it leaves a brown,

sticky residue which is non-corrosive and non-conductive, but can be cleaned if
desired with a solvent such as isopropanol (also called isopropyl alcohol or IPA).
There are different grades of Rosin flux, the most commonly used is "RMA"
(Rosin Mildly Activated).

No-clean fluxes leaves a clear residue after soldering, which is non-corrosive and
non-conductive. This flux is designed to be left on the solder joint and
surrounding areas, but should still be cleaned off as flux by its very nature is
corrosive.
Water-soluble fluxes usually have a higher activity (i.e is more aggressive) that
leaves a residue which must be cleaned with water. The residue is corrosive and
may also damage the board or components if not cleaned correctly after use.
 Information Sheet 1.1-9

Cabling and Wiring Techniques

Cabling and wiring is a process of putting or installing of electrical or

electronics wires. Properly choosing the colors for your wires can help you
decipher your wiring configurations.

Wiring of Audio System

Radio Transceiver Cabling and Termination

Cabling and Termination of TV Antenna

Cabling and Termination in Computer Network

Terminal Block

Audio System Harness

Use shielded in audio-video system to eliminate static and noise
interference

Connector and Terminal Lugs for Audio System

Audio –Video Harness

Information Sheet 1.1-10

 Power Supply Circuits

A low voltage power supply converts AC input voltage to DC output voltage.

Every circuit or device needs power supply to operate. A low voltage power
supply needs a rectifier to change AC power line to DC output, a filter to
smoothen pulsating DC and sometimes a voltage regulator to keep output
voltage constant. A transformer is often used to step-up or step-down AC
voltage at the input of the circuit.

AC Circuits Rectifier Filter Circuits Regulator

AC Circuits DC
Input Input

Power Transformer. When AC voltage needs to be more or less that of the

power line voltage, then a power transformer is needed to solve the problem.
The transformer is usually an isolation type step-down AC line to be in lower
application.

Rectifier Circuit. This circuit converts AC input voltage to DC output voltage.

Due to the capability of a diode to conduct current in one direction, it is the
perfect device to be used as a rectifier.

Filter Circuit. Although the output DC voltage of the rectifier has one polarity,
it still includes various amplitude variations called ripples. A filter capacitor can
eliminate practically all ripples.

Power Regulator. DC output usually suffers when maximum load is connected

to the power supply. This circuit maintains the DC voltage level to keep up with
the varying need for power.

Basically, the type of power supply is determined by the type of rectifier used.
There are three basic rectifier circuits usually used for power supply circuits,
namely: (a) half-wave rectifier; (b) full-wave, with center tapped transformer;
and (c) full-wave bridge type.

Half-Wave Rectifier
The circuit uses one diode directly connected to a transformer or power
line. When the AC input signal is in its positive alternation at point A, the diode
is set to forward bias, allowing current to flow through the diode, then to load
the resistor back to the coil at point B. When the negative alternation is applied
to point A, the diode is set to reverse bias, thus preventing any current flow
through the circuit.
Full-Wave with Center Tap Rectifier
This circuit uses two diodes connected at both ends of the coil and center
tap set to ground. Illustration below shows the basic diagram of this circuit type.

When the positive alternation of AC voltage is applied to point A, diode

one is set to forward bias, diode two to reverse bias. Current flows from point A,
passing the diode to load resistor to the center tap of the transformer. When AC
changes direction, diode one is set to reverse bias and diode two to forward
bias, thus allowing current to flow from point B to diode two, then loading the
resistor to the center top of the transformer.
The current utilized for each half of the alternation is only half of the total
current generated by the transformer. Although both halves of the wave form
are rectified, the current is cut into half.

Full-Wave Bridge Type

This circuit is full-wave and does not need a center tap. It uses four diodes.
With this connections, the circuit functions in full-wave operation without any
current loss. When the positive side of the wave form is applied to point A, diode
one and diode three are set to forward bias, and diode two and four are set to
reverse bias. The current flows through diode one to load resistor to diode three
to point B of the coil.
 When the negative side of the wave is applied to point A, diode one and
diode three are set to reverse bias, while diode two and four are set to forward
bias, allowing the current to flow from point B to diode four, to load resistor,
then to diode two to point A.

Filtering Pulsating DC

When pulsating DC is produced after the rectifier, eliminating the ripple is

the next problem. With the capability of the capacitor to store electrical energy
through its charging and discharging characteristics, bridge the gap between
two pulses. The charged and discharge time is important to remove all ripple in
the wave perfectly to produce a pure DC output. Illustration below shows the
details of the operation.

Job Sheet 1.1-1

Apply Occupational Health and Safety Procedures

Tools and Materials

Soldering Iron
Soldering Stand
De-soldering Tool
Face Mask
Printed Circuit Board Assembly
PCB Holder

Procedure
1. Heat up and apply tinning process.
2. Secure the soldering iron in a soldering stand
3. Wear a face mask properly
4. Put the PCBA in the PCB holder
5. Re-solder the components
6. Clean the workbench
7. Clean and maintain tools and equipments
 Job Sheet 1.1-2

Job Title: Preparing Soldering Tools and Materials

Information: This operation is very vital for beginner for assembling –
disassembling consumer electronics.
Tools and Materials:
Soldering Iron 30-40Watts
Soldering Stand
Soldering Lead 60/40 Tin /Lead
Sponge
Safety Precautions:
1. To avoid burns and injuries always put the iron in a stand when not is in
use.
2. To avoid burns and injuries never touch the tip of iron just to determine if
it is working.

Procedure:
Tinning the Soldering Tip
Before use, a new soldering tip, or one that is very dirty, must be tinned.
"Tinning" is the process of coating a soldering tip with a thin coat of solder. This
aids in heat transfer between the tip and the component you are soldering, and
also gives the solder a base from which to flow from.

Step 1: Warm Up the Soldering Iron

Warm up the soldering iron or gun thoroughly. Make sure that it has fully come
to temperature because you are about to melt a lot of solder on it. This is
especially important if the iron is new because it may have been packed with
some kind of coating to prevent corrosion.
Step 2: Prepare A Little Space
While the soldering iron is warming up, prepare a little space to work. Moisten a
little sponge and place it in the base of your soldering iron stand or in a dish
close by. Lay down a piece of cardboard in case you drip solder (you probably
will) and make sure you have room to work comfortably.
Step 3: Thoroughly Coat the Tip in Solder
Thoroughly coat the soldering tip in solder. It is very important to cover the
entire tip. You will use a considerable amount of solder during this process and it
will drip, so be ready. If you leave any part of the tip uncovered it will tend to
collect flux residue and will not conduct heat very well, so run the solder up and
down the tip and completely around it to totally cover it in molten solder.

Step 4: Clean the Soldering Tip

After you are certain that the tip is totally coated in solder, wipe the tip off on
the wet sponge to remove the entire flux residue. Do this immediately so there
is no time for the flux to dry out and solidify.

Job Sheet 1.1-3

Job Title: Soldering Printed Circuit Board Assembly

Information: This operation is very vital for beginner for assembling –
disassembling consumer electronics.
Tools and Materials:
Soldering Iron 30-40Watts
Soldering Stand
Soldering Lead 60/40 Tin /Lead
Sponge
Solder Bread Board
Assorted Electronic Components for
Incense
Flux
Soldering Paste
Lacquer Thinner
Cleaning Brush
PCB Holder or Vise

Safety Precautions:
1. To avoid burns and injuries never touch the tip of iron just to determine if
it is working. While soldering is not generally a hazardous activity, there
are a few things to keep in mind. The first and most obvious is that it
involves high temperatures. Soldering irons are going to be 350F or
higher, and will cause burns very quickly. Make sure to use a stand to
support the iron and keep the cord away high traffic areas. Solder itself
 can drip, so it makes sense to avoid soldering over exposed body parts.
Always work in a well lit area where you have space to lay parts out and
move around. Avoid soldering with your face directly above the joint
because fumes from the flux and other coatings will irritate your
respiratory tract and eyes. Most solders contain lead, so you should avoid
touching your face while working with solder and always wash your hands
before eating. Solders, especially lead-based solders, contain hazardous
materials. Wash your hands after soldering, and be aware that items
containing solder may require special handling if you dispose of them.
2. Soldering irons are very hot. Do not touch the tip with your skin. Also,
always use a suitable stand or holder to keep the tip up and off of your
work surface.
3. To avoid hazardous effects of lead smoked you should utilize a
facemask.

Procedure:
Step 1: Surface Preparation:
A clean surface is very important if you want a strong, low resistance solder
joint. All surfaces to be soldered should be cleaned well. 3M Scotch Brite
pads purchased from the home improvement, industrial supply store or
automotive body shop are a good choice as they will quickly remove surface
tarnish but will not abrade the PCB material. Note that you will
want industrial pads and not the kitchen cleaning pads impregnated with
cleaner/soap. If you have particularly tough deposits on your board, then a fine
grade of steel wool is acceptable but be very cautious on boards with tight
tolerances as the fine steel shavings can lodge between pads and in holes.
Once you have cleaned the board down to shiny copper you can use a solvent
such as acetone to clean any bits of the cleaning pad that may remain and to
remove chemical contamination from the surface of the board. Methyl hydrate is
another good solvent and a bit less stinky then acetone. Be aware that both
these solvents can remove ink, so if your board is silk screened, test the
chemicals first before hosing down the entire board.
A few blasts with compressed air will dry out the board and remove any junk
that may have built up in the holes.
It also never hurts to give the component leads a quick wipe down as well, to
remove glue or tarnish that may have built up over time.

Step 2: Component Placement

After the component and board have been cleaned, you are ready to place the
components onto the board. Unless your circuit is simple and only contains a few
components, you will probably not be placing all the components onto the board
and soldering them at once. Most likely you will be soldering a few components
at a time before turning the board over and placing more. In general it is best to
start with the smallest and flattest components (resistors, ICs, signal diodes,
etc.) and then work up to the larger components (capacitors, power transistors,
transformers) after the small parts are done. This keeps the board relatively flat,
making it more stable during soldering. It is also best to save sensitive
components (MOSFETs, non-socketed ICs) until the end to lessen the chance of
damaging them during assembly of the rest of the circuit
Bend the leads as necessary and insert the component through the proper holes
on the board. To hold the part in place while you are soldering, you may want to
bend the leads on the bottom of the board at a 45 degree angle. This works well
for parts with long leads such as resistors. Components with short leads such as
IC sockets can be held in place with a little masking tape or you can bend the
leads down to clamp onto the PC board pads.

Step 3: Apply Heat

Apply a very small amount of solder to the tip of the iron. This helps conduct the
heat to the component and board, but it is not the solder that will make up the
joint. To heat the joint you will lay the tip of the iron so that it rests against both
the component lead and the board. It is critical that you heat the lead and the
board, otherwise the solder will simply pool and refuse to stick to the unheated
item. The small amount of solder you applied to the tip before heating the joint
will help make contact between the board and the lead. It normally takes a
second or two to get the joint hot enough to solder, but larger components and
thicker pads/traces will absorb more heat and can increase this time.

Step 4: Apply Solder to the Joint

Once the component lead and solder pad has heated up, you are ready to apply
solder. Touch the tip of the strand of solder to the component lead and solder
pad, but not the tip of the iron. If everything is hot enough, the solder should
flow freely around the lead and pad. You will see the flux melt liquefy as well,
bubble around the joint (this is part of its cleaning action), flow out and release
smoke. Continue to add solder to the joint until the pad is completely coated and
the solder forms a small mound with slightly concave sides. If it starts to ball up,
you have used too much solder or the pad on the board is not hot enough.
Once the surface of the pad is completely coated, you can stop adding solder
and remove the soldering iron (in that order). Don't move the joint for a few
seconds as the solder needs time to cool and resolidify. If you do move the joint,
you will get what's called a "cold joint". This is recognized by it's characteristic
dull and grainy appearance. Many cold joints can be fixed by reheating and
applying a small amount of solder, then being allowed to cool without being
disturbed.

Step 5: Inspect the joint and cleanup

Once the joint is made you should inspect it. Check for cold joints (described a
little above and at length below), shorts with adjacent pads or poor flow. If the
joint checks out, move on to the next. To trim the lead, use a small set of side
cutters and cut at the top of the solder joint.

After you have made all the solder joints, it is good practice to clean all the
excess flux residue from the board. Some fluxes are hydroscopic (they absorb
water) and can slowly absorb enough water to become slightly conductive. This
can be a significant issue in a hostile environment such as an automotive
application. Most fluxes will clean up easily using methyl hydrate and a rag but
some will require a stronger solvent. Use the appropriate solvent to remove the
flux, then blow the board dry with compressed air.

Tips

Soldering is something that needs to be practiced. These tips should help you
become successful so you can stop practicing and get down to some serious
building.

1. Use heat sinks. Heat sinks are a must for the leads of sensitive
components such as ICs and transistors. If you don't have a clip on heat
sink, then a pair of pliers is a good substitute.
 2. Keep the iron tip clean. A clean iron tip means better heat conduction and
a better joint. Use a wet sponge to clean the tip between joints. Keep the
tip well tinned.

3. Double check joints. When assembling complicated circuits, it is good

practice to check joints after soldering them. Use a magnifying glass to
visually inspect the joint and a meter to check resistance.

4. Solder small parts first. Solder resistors, jumper leads, diodes and any
other small parts before you solder larger parts like capacitors and
transistors. This makes assembly much easier.

5. Install sensitive components last. Install CMOS ICs, MOSFETs and other
static sensitive components last to avoid damaging them during assembly
of other parts.

6. Use adequate ventilation. Most soldering fluxes should not be breathed in.
Avoid breathing the smoke created and make sure that the area you are
working in has adequate airflow to prevent buildup of noxious fumes.

Job Sheet 1.1-4

Job Title: De-soldering Electronic Board through Braid Copper

Information: This job simplifies the de-soldering or removing of small
components like integrated circuits and other small components

Tools and Materials:

Soldering Iron 30-40Watts
Soldering Stand
Soldering Lead 60/40 Tin /Lead
Sponge
Assorted Electronics Boards
Incense
Flux
Soldering Paste
Lacquer Thinner
Cleaning Brush
PCB Holder or Vise
Soldering Braid or Wick

Safety Precautions:
1. To avoid burns and injuries always put the iron in a stand when not is in
use.
2. To avoid burns and injuries never touch the tip of iron just to determine if
it is working.
Procedure:
1. Heat up the soldering iron and tinning processes.
2. Put the PCBA in the PCB holder.
3. Put small amount of soldering paste in a braid copper
4. Place the de-soldering braid on the joint. Place the tip of the soldering iron on
top of it.
5. Wait until the solder melts and get sucked up by the braid.
6. Wait for the part that was heated to cool. It will take about 30 seconds.
7. Apply lacquer thinner and remove the residue with the used of brush.

Job Sheet 1.1-5

Job Title: De-soldering Electronic Board through Soldering Sucker

Information: This job simplifies the de-soldering process with use of soldering
sucker bulky components can remove easily in the board.

Tools and Materials:

Soldering Iron 30-40Watts
Soldering Stand
Soldering Lead 60/40 Tin /Lead
Sponge
Assorted Electronics Boards
Incense
Flux
Soldering Paste
Lacquer Thinner
Cleaning Brush
PCB Holder or Vise
Soldering Sucker
Safety Precautions:
1. To avoid burns and injuries always put the iron in a stand when not is in
use.
2. To avoid burns and injuries never touch the tip of iron just to determine if
it is working.

Procedure:

1. Heat up the soldering iron and apply thinning processes

2. Put the printed circuit board assembly in the PCB holder.
3. Set the pump by pushing the spring-loaded plunger down until it locks.
4. Apply both the pump nozzle and the tip of your soldering iron to the joint. and
wait a second or two for the solder to melt.
5. Press the button on the pump to release the plunger and suck the molten
solder into the tool.
6. Repeat if necessary to remove as much solder as possible.
7. The pump will need emptying occasionally by unscrewing the nozzle.
8. Apply lacquer thinner and remove the residue with the used of brush.

Job Sheet 1.1-6

Job Title: De-soldering Electronic Board through Soldering Sucker

Information: This job simplifies the de-soldering process with use of soldering
sucker bulky components can remove easily in the board.

Tools and Materials:

Soldering Iron 30-40Watts
Soldering Stand
Soldering Lead 60/40 Tin /Lead
Sponge
Assorted Electronics Boards
Incense
Flux
Soldering Paste
Lacquer Thinner
Cleaning Brush
PCB Holder or Vise
Soldering Sucker

Safety Precautions:
1. To avoid burns and injuries always put the iron in a stand when not is in
use.
2. To avoid burns and injuries never touch the tip of iron just to determine if
it is working.

Procedure:

1. Heat up the soldering iron and apply thinning processes

2. Put the printed circuit board assembly in the PCB holder.
3. Set the pump by pushing the spring-loaded plunger down until it locks.
4. Apply both the pump nozzle and the tip of your soldering iron to the joint. and
wait a second or two for the solder to melt.
5. Press the button on the pump to release the plunger and suck the molten
solder into the tool.
6. Repeat if necessary to remove as much solder as possible.
7. The pump will need emptying occasionally by unscrewing the nozzle.
8. Apply lacquer thinner and remove the residue with the used of brush.

Job Sheet 1.1-7

Job Title: Wiring 3 Wires A.C Plug

Information: This job simplifies the wiring and termination.
Tools and Materials
3 Way Plug
3 Wire A.C Plug(brown,blue,green)
Long nose Pliers
Diagonal Cutter
Screw Driver Set

Procedure

1.Choose the specified wires and gauge

2. Remove wires insulation. Strip roughly 0.5 to 1cm off of the end of the blue,
brown and striped wires, so that the copper insides are clearly visible.

3. Loosen the Philip screw in the center of the plug, on the side with the three
pins poking out.
4.Take the back off of the plug (the part you loosened by undoing the screw).
5. Follow the diagram put all three wires through the cable grip, along with the
thick white cable, until the cable grip can be securely tightened onto the thick
white cable. The cable grip may have to be loosened with a Philip screwdriver in
order to fit the cable underneath it.

BROWN to the Live(L) terminal

BLUE to the Neutral (N) terminal
GREEN/YELLOW to the Earth (E) terminal.
6. Put the back of the plug back on once all the wires are in and tight, and all
the screws are securely done up.

Job Sheet 1.1-8

Job Title: Wiring Power Extension Cord

Information: This job simplifies the wiring and termination of power extension
cord.
Tools and Materials:

1. Standard/Flat Screw Driver

2. Philips Screw Driver
3. Long Nose Pliers
4. Side Cutting Pliers
5. Electrician’s knife/ Pocket knife
6. Continuity Tester or Multi-tester
Procedure:
1. Prepare the plan.
2. Gather all necessary materials, tools and equipment needed.
3. Insert cord into the male plug, split the cord wires about 8 centimeters long.
4. Remove insulation of both wires 1 centimeter long with a pocket knife as if
sharpening a pencil. Be careful not to cut any strand.
5. Scrape bare wire with the back of the knife until shiny. Twist the wire stands.
6. Tie the underwriter’s knot
7. Make a loop on terminal wires and connect the wires to the screw of the male
plug. The loop should go with the thread clockwise direction.
8. Split the cord wires at the other end about 4 centimeters long, then follow
procedure no. 4.
9. Connect the wires to the connectors.
10. Open the convenience outlet then remove the screw.
11. Insert the wire connectors to the screws, tighten it and return the cover.
12. Check the continuity and test the extension cord.
 Job Sheet 1.1-9

Job Title: Wiring Low Voltage Audio Circuit

Information: This job simplifies the wiring and termination in low voltage audio
circuit

Tools and Materials

Hook –Up Wires
Long nose Pliers
Diagonal Cutter
Screw Driver Set
Battery Terminal
DC Power Jack
Pin Headers
Soldering Iron (with stand)
Soldering Lead 60/40 tin lead content
Female PL-55 Mono Jack
Project Enclosure
Procedure
1. Refer to the diagrams wire and install the 9 volts battery connector to DC
power jack through the electronic soldering.

For low DC Circuit voltages use the following color codes:

Black – Negative
Red – Positive
Green – Ground

2. Assemble the connectors for input and output pin headers, using color code s
where shown in the pictorial and apply electronic soldering.

3 .Install and mount properly in the enclosure