PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

UNIVERSITI MALAYSIA PERLIS
2013/2014
(PLT 108) ENGINEERING SKILLS 2


MODULE PCB : PCB DESIGN



NAME :
ID NUMBER :
COURSE :
DATE :
CHECKED BY :
C03: Ability to apply and construct the basic skills and standard practiced of PCB and
electronic component fitting.

60
SUBJECT: ENGINEERING SKILLS 2

PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

PLT 108

Prepared by MOHD SHIHABUDIN ISMAIL Page 1 of 9
LEARNING
Students should be able to:-
1. Test or simulate the circuit on a Test PCB (with thru holes) before proceeding to
actual PCB.
2. Convert the circuit schematic diagram to PCB layout manually by sketching the
circuit layout on a sheet of paper as viewed from the component side.
3. Transform the circuit layout on the copper clad board.
4. Drill the mount points using hand-feed drilling machine.
5. Etch the board using acid etching method.




The list of the equipment required for this exercise.
Board design:
1. Paper and pencil
2. Ruler
3. Permanent black marker with fine
point
4. Tape
5. Scissors
6. Drill with tiny #65 twist bit (0.035"
which is good for most electronic
components)
7. Fine grade steel wool (0000 steel
wool) or thinner or acetone
8. Dust mask for protection from
copper dust when drilling
9. Copper clad PC board

Boards etching process:
1. Ferric Chloride (FeCl
3
) chemicals
CAUTION: FeCl
3
solution is toxic. It can cause
skin burning or irritation. Please take all
necessary precautions and use appropriate
safety equipments.
a) Rubber gloves
b) Safety glasses
c) Paper towels to clean up spillage
d) A small resalable plastic container to put
the FeCl
3
into for etching and storage
afterwards
e) A larger plastic container that the small
one well go into for water and storage of
materials afterwards.
f) Warm water, goes in larger container to
heat the FeCl
3
.
g) A well ventilated work area as the vapor
is also quite nasty and not good to
breathe in.
SUBJECT: ENGINEERING SKILLS 2

PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

PLT 108

LAB SHEET PCB DESIGN: LAB 5 Page 2 of 9
TASK 1: TESTING THE CIRCUIT ON A TEST PCB (WITH HOLES)
i. Test or simulate the given circuit on a test PCB (with holes). It is important to
make sure the circuit works before proceeding to the PCB design because any
mistakes on the PCB after it is sent in are not possible to fix.



Figure 1: Circuit diagram of Mobile Charger

List of components Quantity
1. Integrated Circuit LM317TIC 1
2. USB socket (female) 1
3. Resistor 16 1
4. Resistor 180 1
5. Resistor 1.2 k 1
6. Capacitor 1000 F 1
7. Transistor BC548 1
8. Diode (1N4007) 1
9. Zener Diode (6.8V) 1
SUBJECT: ENGINEERING SKILLS 2

PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

PLT 108

LAB SHEET PCB DESIGN: LAB 5 Page 3 of 9
10. Variable Resistor (2.2 k) 1
11. Connector socket (male & female) 2
12. Transformer Unit (230v to 12V) 1
13. Test PCB (with thru holes) 1


ii. Solder the component onto the test PCB neatly without any soldering defects
(such as solder horn, solder balls, cold solder etc).

Notes : Do not cut the component leg since you need to dismantle back the
components to be installed on the actual PCB later.


iii. After complete soldering, show to the lecturer for checking. Then test the circuit
by connecting it to the transformer unit available. Ensure the variable resistor
knob is adjusted to maximum before connected to transformer unit.

iv. Measure the voltage output of the circuit by using Voltmeter and record the
initial value. Adjust the variable resistor to adjust the voltage value to 5.0 V.
TASK 2: SKETCH THE CIRCUIT LAYOUT ON A PAPER
Convert the circuit schematic diagram to PCB layout manually by sketching the circuit
layout on a sheet of paper as viewed from the component side first, so as to avoid any
confusion. Please make sure to design the layout as compact as possible so that it well
fit on the board.


Figure 2: Example of circuit layout design on a paper

Copy the confirmed final lay out onto the transparency plastic.
SUBJECT: ENGINEERING SKILLS 2

PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

PLT 108

LAB SHEET PCB DESIGN: LAB 5 Page 4 of 9
TASK 3: TRANSFORM THE CIRCUIT LAYOUT ON THE COPPER CLAD BOARD
AND DRILL THE BOARD
Make a copy of the layout design which is reverse of the original.
i. Cut the copy of the layout out (on the transparency plastic) with scissors/ knife
(anti cutter).
ii. Tape the design (in reverse of the original) design onto the copper side of the
PCB.
CAUTION : Do not touch the copper side PCB by finger since it may affect the etching quality
later.
iii. Using the permanent marker pen, draw a solder pad and traces on the copper
plate through the opening that you have cut. Please make sure the pen leaves a
nice bold and thick line otherwise it will not resist the FeCl
3
as well. Confirm the
traces and solder pad are completely drawn by marker pen. Then, remove the
transparency plastic.

Figure 3: Drawing traces of layout on the PCB


iv. Drill a hole in the center of all the solder pads for the individual components
using #65 drill bit. Use a small punch if necessary for drill guide. Other drill bit
size might be used depends on the size of the components leg.

SUBJECT: ENGINEERING SKILLS 2

PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

PLT 108

LAB SHEET PCB DESIGN: LAB 5 Page 5 of 9




Figure 4 : Drilling holes in PCB

v. After you have drilled all the holes, clean off all the dust.


SUBJECT: ENGINEERING SKILLS 2

PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

PLT 108

LAB SHEET PCB DESIGN: LAB 5 Page 6 of 9
TASK 4: PCB ETCHING


Figure 5: Semi Auto Etching Machine

i. The etching process need to be carried out by using Semi Auto Etching Machine
(conveyor type). Refer to Figure 5.
Caution : The operation of this machine need to be under supervision by
technician. Temperature and timer need to be adjusted accordingly.
Note : FeCl
3
solution is already in the machine.
SUBJECT: ENGINEERING SKILLS 2

PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

PLT 108

LAB SHEET PCB DESIGN: LAB 5 Page 7 of 9

Figure 6: PCB inlet slot for Etching machine

ii. Insert the PCB through the PCB inlet of the etching machine as shown in figure 6.
iii. The etching process will be started automatically by the machine and take
around 5 minutes to complete.



Figure 7: PCB outlet slot for Etching machine

i. After about 5 minutes the board should be completely etched and will come out
through the outlet of the etching machine as shown in figure 7. Remove the PCB
from the outlet tray and then dry it off on the paper towel. Ensure only required
traces and copper pads remain on the PCB.

SUBJECT: ENGINEERING SKILLS 2

PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

PLT 108

LAB SHEET PCB DESIGN: LAB 5 Page 8 of 9
TASK 5: CLEAN THE PCB
i. Clean the marker off the traces using 0000 steel wool or thinner or acetone.

ii. Populate the board with the components.






SUBJECT: ENGINEERING SKILLS 2

PUSAT PENGAJIAN KEJURUTERAAN SISTEM ELEKTRIK

PLT 108

LAB SHEET PCB DESIGN: LAB 5 Page 9 of 9