Modul 04 Workshop Practice

KERTAS
PENERANGAN
MODUL 4
L03-04-24 WORKSHOP PRACTICE
161
GROUP CLUSTERING MODULE 4
L03-04-24-LA1 APPLY SAFETY WORKSHOP REGULATION
C05B.01/L4 Identify Safety and health regulation
L03-04-24-LA2 PERFORM WORKSHOP PRACTICE
C05B.02/L4 Design circuit using CAD software

C05B.03/L4 Use hand tools & power tools
C05B.04/L4 Perform soldering techniques
L03-04-24-LA3 EVALUATE WORKSHOP PRACTICE
C05B.05/L4 Fabricate circuit
162
INSTITUSI LATIHAN
JABATAN TENAGA MANUSIA
KEMENTERIAN SUMBER MANUSIA
MALAYSIA
KERTAS PENERANGAN
COURSE CODE
L03 DIPLOMA TEKNOLOGI TELEKOMUNIKASI
AND NAME
MODULE CODE
L03-04-24 WORKSHOP PRACTICE
AND NAME
LA1 APPLY SAFETY WORKSHOP REGULATION

LEARNING
LA2 PERFORM WORKSHOP PRACTICE
ACTIVITY (LA)
LA3 EVALUATE WORKSHOP PRACTICE
C05B.01/L4,
C05B.02/L4,
CU.WA NO./ C05B.03/L4,
LEVEL C05B.04/L4,
C05B.05/L4,
C05B.06/L4
PERFORM WORKSHOP PRACTICE USING ELECTRONIC TRAINER

TERMINAL SET, SOLDERING STATION, COMPUTER, UV EXPOSURE BOX,
PERFORMANCE ETCHING MACHINE, DRILLING MACHINE, COMPLETE TOOLS KITS,
OBJECTIVE PRINTED CIRCUIT BOARD SO THAT THE KNOWLEDGE AND SKILLS
RELATING IN WORKSHOP SAFETY SKILL APPLIED, PERFORMED
AND EVALUATE ACCORDING STANDARD SPECIFICATION AND
REGULATION
WIM/L03/12011/S04/P1(12016) MUKASURAT 163

LA1 APPLY SAFETY WORKSHOP REGULATION
1. INTRODUCTION TO WORKSHOP SAFETY
Workshop safety include:
 Safety Clothing
 Workshop Safety Hazards
 Safety Data Sheets and Labels
 Storage and Spills
A number of accidents could occur in a workshop. Typical workshop safety hazard

are:-
 Fire and explosion

 Asphyxiation
 Chemical burn
 Electric shocks
 Physical injury
L03-04-24-LA1-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 164

1.1. Basic Personal Protective Clothing
Personal protective clothing helps minimize personal injury in the event

of an accident. Basic protective clothing is:
 Overall
 Protective boots
 Latex gloves
1.2. Eye Protection
Eye damage can result from small particles, sharp objects, liquids,
gases or intense light. Typical eye protection is:
 Safety glasses
 Safety goggles
 Face shield
 Welding helmet

1.3. Hand Protection
Hands may be injured in a workshop by cuts, skin damage or chemical

burns. Gloves worn to help prevent injuries. Example of gloves that can be
used:
 Latex glove
 Rubber glove
 Leather glove
1.4. Ear and Respiratory Protection
Exposure to loud noises over long periods can damage the ears. Ear
defenders and earplugs can be used to protect ears. Respiratory equipment
required during some tasks, or breathing difficulties, headaches, dizziness or
sickness may occur.
1.5. First Aid
First aid is the assistance given to any person suffering a sudden

illness or injury, with care provided to preserve life, prevent the condition from
worsening, and/or promote recovery.
It includes initial intervention in a serious condition prior to professional
medical help being available, such as performing CPR while awaiting an
ambulance, as well as the complete treatment of minor conditions, such as
applying a plaster to a cut. First aid is generally performed by the layperson,
with many people trained in providing basic levels of first aid, and others

willing to do so from acquired knowledge. Mental first aid is an extension of
the concept of first aid to cover mental health.
The key aims of first aid can be summarized in three key points,
sometimes known as 'the three P's':-
 Preserve life: the overriding aim of all medical care which includes
first aid, is to save lives and minimize the threat of death.
 Prevent further harm: also sometimes called prevent the condition
from worsening, or danger of further injury, this covers both
external factors, such as moving a patient away from any cause of
harm, and applying first aid techniques to prevent worsening of the
condition, such as applying pressure to stop a bleed becoming
dangerous.
 Promote recovery: first aid also involves trying to start the recovery
process from the illness or injury, and in some cases might involve
completing a treatment, such as in the case of applying a plaster to a
small wound.
1.6. Fire Extinguishers
Different classes of fire extinguisher
 Class A
 Class B
 Class C
 Class D
 Class E
Typical fire extinguisher types:
 Water
 Foam
 Dry powder/chemical
 Carbon dioxide ( Co2 )
 Halon

Hazardous materials container/ packaging has product warning label
including:
 What product is
 Manufacturing details
 Hazards types
 Potential hazards types
 protection

LA2 PERFORM WORKSHOP PRACTICE
LA3 EVALUATE WORKSHOP PRACTICE
1. DESIGN CIRCUIT USING CAD SOFTWARE (ALTIUM DESIGNER 15)
1.1. PREPARING FILE ‘ELECTRONICS DESIGN’ (Altium)
To prepare file for Electronic design, on the computer desktop screen, double
click Shortcut Altium Designer 15.
Or on computer screen, click at windows task bar,
[Start] ->[All Program] –> [Altium Designer] –>[Altium Designer]
L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 169

Window as below will appear:
1.2. PREPARING PROGRAM FILE
1.2.1. Preparing new project file
KlikFile – New – Project…
Window as below will appear:

Next window that will appear:
Klik pada PCB
Project
Klik pada
<Default>
Namakan Fail PCB

Project
Klik pada Browse

untuk simpan fail di
tempat yang
sesuai
Klik OKjika selesai

Right click at PCB BAR GRAPH LED.PrjPcb - Add New to Project – Schematic

Right click at Sheet1.SchDoc - Save As…
Save at the assign folder.

1.3. ALTIUM DESIGNER CONFIGURATION
Click at Design – Document Options

At Sheet Option choose paper size – Standard Style – A4, A3, atau A2 and
ext.
At units choose Metric Unit System

1.4. START DRAFTING SCHEMATIC CIRCUIT.
To get componenet from the library, klik at Libraries then click

Search – contains – write the component name
Choose Plech L7805ABV and insert at Schematic circuit.

Click at Place Wire to make a connection wire
Double click at the component to display Component Properties, change the value for:-
1. Designator
2. Comment
3. Value

Once finish drafting the schematic circuit, click Tools- Annotate Schematics
Annotate schematics functionality is to assign dedicated numbers for each
component on the PCB circuit.
Click Update Change List

Click OK
Click Accept Changes (Create ECO)

Click Excecute Changes
Then close the window until schematic window appear
Once finish drafting the schematic circuit, Klik Save

1.5. STARTING DRAFTING PCB LAYOUT
Prepare PCB Layout file

Click File – New From Template – PCB Board Wizard
Below window will appear
Click Next
Choose Board Unit
Choose Board Unit

Choose Metric ,
Click Next

Choose Board Profiles
Choose Custom ,
Click Next
Choose Board Details

Choose PCB Size
Width :100.00mm
Height :90.00 mm
Keep Out Distance

:0.00mm
Click Next
Choose Board Layers
Click Next

Choose Via Style
Click Next
Choose Component and Routing

Technologies
Choose Through –Hole Components
Click Next
Choose Default Tracksdan Via

Sizes
Choose the suitable size
Minimum Track Size :0.8mm
Click Next
Click Finish

Window as below will appear
Transfer the file Free Documents to

PCB_Project1.PrjPC
Window below will appear

1.6. TRANSFER COMPONENT FROM PCB TO PCB LAYOUT.
To transfer Schematic file to PCB layout, a few steps need to be taken. Go to

Schematic circuit design – Update PCB Document PCB1.PcbDoc
Click Validate
Changes

Click Execute
Changes
Click Close

Transfer the
component to PCB
Board

1.7. TRANSFER AND MODIFY COMPONENT FOOTPRINT
To transfer and modify component footprint at PCB Board:
Double click at the component, window as below will appear.
Click at Lock Primitives
Change the component

footprint fit to the real
component.

To measure the component leg:
Click at Report – choose Measure Distance or push Ctrl + M
Make measurement of
the distance between
component leg

Modify Pad size dan Hole size at component leg
Click at component leg, window below will appear.
Click Find Similar

Objects..
Choose Pad Size

and hole size that
suitable
X Size : 2mm
Y Size : 2mm
Choose Same at
X Size (All Layers):
Y Size (All Layers):

To make the connection wire:
Click at Interactively Route Connections, below window will appear.
Choose Bottom Layer at the bottom
Make a connection wire according to the circuit, as below.

1.8. CONVERT FILES PCB LAYOUT INTO GERBER FILES
convert Files PCB Board into Gerber Files
click File – choose Fabrication Outputs – Gerber Files; it will shown as below
General
Select Milimeters
○ 4:4
Layers
Select Milimeters
Drill Drawing
Slelct Plot all used layer pairs
Illustration as shown
Convert Files PCB Board into NC Drill Files
click File – choose Fabrication Outputs – NC Drill Files;
illustration as picture below
illustration as shown

Convert Files PCB Board to PDF Files

cilck File – select Smart PDF;
illustration as shown
for View 3D
click View meu – select Switch To 3D; illustration as shown

2. Analyse PCB
After finish done pcb routing on PCB, next is analyse PCB

Click Tools—Design Rule Check
click Rule to Check


Check each rule.
Check each rule violation.


If rule violation does not couse any problem to the PCB, changes to the PCB design
is not needed. If rules violation create problem to PCB functionality or performance,
changes need to be done.
2.1. CREATE NEW COMPNENT IN LIBRARY
If component used is not listed in the library, user may create new component
in the library. To create new component in the library:
Click at Project – New – Library – Schematic Library;
Below window will appear.

New component information can be inserted in the library.

Below are steps in inserting new footprint information in the library.

3. Soldering techniques
3.1. Basic hand soldering
3.1.1. MULTICORE SOLDER

Multicore solder is the most common type for hand soldering has
a composition of Tin (Sn60) and Lead (Pb40), with a diameter of 0.71
mm. It contains internal core of non-corrosive Rosin Mildly Activated
(RMA) flux. It has a ‘plastic’ stage between the melting and solidifying
stages
Dry joints’ are caused through:

 movement of joint during ‘plastic’ stage
 thermal stress
 PCB contamination
 oxidisation
3.1.2. TIPS
Appropriate tip size and width is determined by the size of the
connection to be made. The ideal tips are 2/3 to equal the diameter of
the pad. The tips should be correctly 'tinned’ at all times, by adding a
small amount of solder to the hot tip

3.1.3. LEAD FORMING
Minimum distance from the end of the component body to the

start of the lead bend is usually 2 lead diameters or 1.5mm for hand
bending methods. Without undue pressure hold the component lead
with the pliers and bend the lead protruding beyond the pliers with a
finger until a 90 degree angle is formed. If damaged discard
component.
3.1.4. COMPONENT MOUNTING
Radial leaded loaded slightly off the PCB (0.3 - 3.0mm). Axial-
leaded loaded with the body of the component very close to the PCB
(0.3 - 3.0mm
3.1.5. BENDING AND MOUNTING OF COMPONENTS
Component need to be mounted centrally between the holes.

Resistors mounted so colour code orientated in the same direction. The
polarised components should be orientated so that polarity symbols (+
or - ) and component value are visible

3.1.6. LEAD TERMINATIONS
TYPE 1 FULLY CLINCHED –

 bend the lead flat against the pad
 trim the lead to a length of between
 1-2 lead diameters
 Used in High Quality/High Reliability
 military or life support applications
 difficult to rework
TYPE 2 SEMI-CLINCHED –
 bend the lead to an angle of approx. 45
 Cut to a minimum of 0.5mm and a max. of 1.5mm, or between 1-
2 lead diameters
 Used for commercial applications
 ease of de-soldering
TYPE 3 RIGID LEAD TERMINATION –

 straight through termination
 Cut to a length of min. 0.5mm and max. of
1.5mm, or between 1-2 lead diameters

3.1.7. CONSTRUCTING A GOOD SOLDER JOINT
 Figure a) the amount of solder applied is minimal and may result in

a poor electrical connection over time.
 Figure b) shows the optimal solder joint that has good wetting
between component lead and PCB pad.
3.1.8. CLEANING
Cleaning is a process of removing contaminates before and after

soldering. It is to ensure good mechanical/electrical connection. There
are three different methods in cleaning:
 Mechanical - scourers or bristle brush

 Chemical - solvents eg. Isopropyl Alcohol
 Thermal - solder pot

3.1.9. BASIC SOLDERING PROCEDURE
 iron temperature is set at approx. 350

 soldering iron tip size is suitable
 solder sponge is damp
 tip is clean and shiny (wipe & tin)
 Apply flux (RMA) to help ‘wetting’ if necessary
 soldering iron at a 45 angle
 heat the lead and the pad simultaneously
 flowing solder around the joint forms a heat bridge
 remove soldering iron and solder simultaneously (prevents ‘spiking’)
 clean the PCB with Isopropyl Alcohol and a bristle brush
 wipe or pat dry with a lint free tissue to remove traces of residue.
Use appropriate safety equipment

 fume extractors
 hand cleaners
 goggles

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KERTAS

L03-04-24-LA1 APPLY SAFETY WORKSHOP REGULATION

C05B.01/L4 Identify Safety and health regulation

L03-04-24-LA2 PERFORM WORKSHOP PRACTICE

C05B.02/L4 Design circuit using CAD software

L03-04-24-LA3 EVALUATE WORKSHOP PRACTICE

C05B.05/L4 Fabricate circuit

LA1 APPLY SAFETY WORKSHOP REGULATION

PERFORM WORKSHOP PRACTICE USING ELECTRONIC TRAINER

WIM/L03/12011/S04/P1(12016) MUKASURAT 163

1. INTRODUCTION TO WORKSHOP SAFETY

Workshop safety include:

A number of accidents could occur in a workshop. Typical workshop safety hazard

 Fire and explosion

L03-04-24-LA1-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 164

Personal protective clothing helps minimize personal injury in the event

1.2. Eye Protection

L03-04-24-LA1-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 165

Hands may be injured in a workshop by cuts, skin damage or chemical

1.4. Ear and Respiratory Protection

1.5. First Aid

First aid is the assistance given to any person suffering a sudden

L03-04-24-LA1-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 166

1.6. Fire Extinguishers

Different classes of fire extinguisher

Typical fire extinguisher types:

 Carbon dioxide ( Co2 )

L03-04-24-LA1-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 167

 Potential hazards types

L03-04-24-LA1-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 168

1. DESIGN CIRCUIT USING CAD SOFTWARE (ALTIUM DESIGNER 15)

1.1. PREPARING FILE ‘ELECTRONICS DESIGN’ (Altium)

Or on computer screen, click at windows task bar,

[Start] ->[All Program] –> [Altium Designer] –>[Altium Designer]

L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 169

1.2. PREPARING PROGRAM FILE

1.2.1. Preparing new project file

KlikFile – New – Project…

Window as below will appear:

L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 170

Namakan Fail PCB

Klik pada Browse

Klik OKjika selesai

Next window that will appear:

L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 171

Next window that will appear:

L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 172

Next window that will appear:

Next window that will appear:

Save at the assign folder.

L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 173

1.3. ALTIUM DESIGNER CONFIGURATION

Click at Design – Document Options

L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 174

At units choose Metric Unit System

L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 175

To get componenet from the library, klik at Libraries then click

Choose Plech L7805ABV and insert at Schematic circuit.

L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 176

L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 177

Click Update Change List

L03-04-24-LA2/LA3-IS WIM/L03/12011/S04/P1(12016) MUKASURAT 178

Click Accept Changes (Create ECO)