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Manual Electrical
Manual Electrical
Table of Contents
Sl. No. Name of the Job Page No.
1. Soldering and De-soldering practice 2
2. To make a Half-Wave & Full wave Rectifier Circuit and 9
Analyses the Wave Forms with Cathode Ray
Oscilloscope (CRO).
3. TO make an electrical wiring for controlling two lamps 16
from a switch board.
4. To make the electrical connection of a fluorescent lamp 19
JOB-1
Materials Required:
Sl. No. Name of the Materials Rating/Size Quantity
1. Vero Board (1001501.6) mm 1 nos.
2. Soldering flux ISI mark As per requirement
3. Soldering wires Diameter (0.5-5) mm As per requirement
4. Connecting wires Single core, diameter As per requirement
(0.5-5) mm, copper/
Aluminum
Solder lead joins the component leads with the PCB contacts firmly. The
quality of the solder lead should be good enough to, make the soldering
process perfect. Rosin core solder is a good choice shown in Figure 3. Do not
use the Acid core solder used to solder electrical contacts and plumbing
metal joints since the acid content will corrode the copper tracks of the PCB.
Good solder contains 60% Tin and 40% Lead. Solder with 0.75 to 1mm
diameter is good. Some makes of solder contains a core of flux inside.
Good soldering requires clean soldering iron tip. If the soldering Iron is a
newly purchased one, first apply a layer of lead before starting the soldering.
This is called Tinning which will helps to transfer heat easily. After
prolonged use, the tip will become dirty which will make the soldering
process difficult. So before starting the soldering, clean the tip using a File
or Sand paper and make it glowing. After cleaning, wipe the tip with moist
cotton or sponge. Since the soldering process is intermittent, keep the
soldering iron tip on a heat sink. An old porcelain fuse carrier can be used
for this or purchase one soldering iron stand with heat sink. Figure 5 shows
the example of good soldering on PCB. The front view of the vero board is
shown in Figure 7 which is used for soldering purpose in the Electrical ,
Electronics and Computer shop at NIT Rourkela.
1. First clean the PCB joints well using a blade or knife to remove dirt
and corroded materials. If the joint is dirty, the solder joints will be
loose.
2. Clean the leads of components before placing on the PCB.
3. The leads will project out from the copper track side of PCB. Place
resistors slightly projecting from the surface of PCB to dissipate heat.
4. First solder resistors, then capacitors, diodes etc and finally
transistors and ICs.
5. Apply very little flux in the solder joints and make the soldering. The
soldering lead and the iron tip should be at an angle of 45 degree so as
the make the solder flow easily.
6. Do not keep the soldering iron tip more than 3 seconds on the
soldering joint when soldering CMOS components.
7. After soldering, check the solder joints carefully. Use a hand lens if
needed. The joints should be conical, uniform and shiny.
8. If the solder joint is Dry, that will considerably affects the working of
circuit. So double check all the joints and re-solder if necessary.
9. Cold solder is the term used to describe the solder joints without firm
connection. The cold solder will appear as a ball over the solder joint.
So if it appears remove the excess solder with the hot iron tip.
10. Trim the excess leads of the components with a Trimmer.
11. If static sensitive components are used, touch the soldering iron tip to
a metal object before soldering to remove the static charge
accumulated at the tip.
12. Wires should be soldered firmly to prevent loose contact. Before
soldering the wires, clean the bare wire with a blade to remove rust or
dirt. Apply some solder to the wire tip and make the soldering.
13. After completing the soldering, double check the joints for any
shorting of leads. This is essential for the transistors and ICs.
14. Clean the solder side of PCB using Spirit or PCB cleaning solution.
15. After connecting the power supply, just touch on the components. If
heat develops, disconnect the power supply immediately and check for
any shorting.
16. If AC is used in the PCB, do not touch any points when connected to
mains.
17. As a safety measure, wear a rubble foot wear during soldering. It is
better to use a plastic sheet on the floor so that the foot will rest on
the insulated sheet while soldering.
Step 1: Equipment
De-soldering requires two main things: a soldering iron and a device to
remove solder. Soldering irons are the heat source used to melt solder. Irons
of the 15W to 25W range are good for most electronics/printed circuit board
work. Anything higher in wattage and you risk damaging either the
component or the board. Note that you should not use so-called soldering
guns. These are very high wattage and generate most of their heat by passing
an electrical current through a wire. Because of this, the wire carries a stray
voltage that could damage circuits and components. The choice of your
solder removing device is also important. There are two main ones; vacuum
pumps (solder suckers) and solder wick. They both do the same thing, so
what you use will depend on your personal opinion or experiences. I suggest
keeping both on hand though, as you may find that each works well in
different situations. Solder suckers usually look like large syringes. There is
a spring loaded plunger, and a button to release it. The plunger is pushed
down. When you want to suck up the solder, you position the nozzle over
the molten solder and hit the button. The plunger moves up, creating a
vacuum and sucking up the solder. Solder wick, on the other hand, has no
moving parts. It looks like wick used in oil lamps, except that it is made of
copper. To use it, you put the wick over the joint and heat it. One thing to
note about solder wick is that it is expensive, and because it is expendable, a
solder sucker may be a better choice if you plan to do a lot of de-soldering. I
personally prefer to use a sucker to remove most of the solder, then finish
up with the wick.
Remember that when de-soldering, the resin in the solder and the coating on
the board may releases fumes. These fumes are harmful to your eyes and
lungs. Therefore, always work in a well ventilated area. Hot solder is also
dangerous. Be sure not to let it splash around because it will burn you
almost instantly. Eye protection is also advised.
JOB-02
Aim: To make a Half-Wave and Full Wave Rectifier Circuit and Analyses the
Wave Forms with Cathode Ray Oscilloscope (CRO).
Materials Required:
Figure9. Half-wave rectifier circuit along with input and output waveform
Theory:
= , =
Procedure:
Input:
Sl.No Time(T)
Output:
Sl. No. Time(T)
Conclusion:
Precautions:
Model Questions:
1. What is rectifier?
2. What is half wave rectifier? How does it work?
Materials Required:
Figure 10. Full-wave rectifier circuit along with input and output waveform
Theory:
= = , =
2
Procedure:
Output:
Sl.No Time(T) Vp Vpp Vrms
Precautions:
Model Questions:
1. What is rectifier?
2. What is use of Resistor in Rectifier Circuit?
3. What is the use of a Rectifier Circuit?
4. What is full wave rectifier? How does it work?
JOB-3
AIM: TO make an electrical wiring for controlling two lamps from a switch
board.
Materials Required:
PVC Pipe
Wooden Box
P N
220 V
Figure 11.Electrical wiring for controlling two lamps from a switch board.
Procedure:
Precautions:
Model Questions:
JOB-4
Materials Required:
Stater
Bimetal switch
Condensator
Fluorescent Tube
Tungsten Filament
Ballast
Wooden Box
PVC Pipe
PVC saddle clamp
Wooden Box
N P
220 V
Typical fluorescent tube is filled with inert gas and a small amount of mercury that creates vapor.
Generating fluorescent light occurs in two stages. First, electrons emitted from cathodes create an
electrical arc through mercury vapor. Then, resultant ultraviolet radiation strikes phosphor coating
which then gives off visible light. Bi-pin bases are necessary for preheat and Rapid-Start fixture designs.
1. Collect all the parts of the fluorescent lamp as well as toll required
for the electrical connection.
2. Connect all the parts through PVC wire and complete the circuit as
given in the Fig.12
3. Give supply voltage and test.
Conclusion:
Precautions:
Model Questions
JOB-5
Aim:To make electrical wiring for controlling different loads from a switch
board.
Materials Required:
F I
N
S S S
FP FP
S S
Figure 13. Electrical wiring for controlling different loads from a switch board; P: Phase, N: Nutral,
S: Single pole switch, I: Indicator, F: Fuse, G: Ground, FP: Five pin Plug, R: Regulator
Procedure:
Conclusion:
Precautions:
Model Questions
1. How much voltage is applied in the single phase supply?
2. what is the bus bar?
3. Why we use regulator?
4. What is the maximum load on switch board?
5. What do you mean by colour of wiring?
6. What do you mean by PVC?
7. State the meaning of SHORT CIRCUIT.
JOB-6
Aim:To control a lamp from two positions and from multiple positions.
Materials required:
Procedure:
Off On
Precautions:
Model Questions
1. How much voltage is applied in the single phase supply?
2. what is two-way switch?
3. How does a two-way switch work?
4. What is application of two-way switch connection?
5. What is the maximum load on switch board?
6. What do you mean by PVC?