PARTS OF A COMPETENCY-BASED LEARNING

MATERIAL PACKAGE
References/Further Reading
Performance Criteria Checklist
Operation/Task/Job Sheet

Self Check Answer Key

Self Check

Information Sheet
Learning Experiences
Learning Outcome Summary

Module Content
Module Content

List
Module
of Competencies
Content

Module Content

ELECTRONICS PRODUCTS
ASSEMBLY AND SERVICING In our efforts to standardize CBLM, the
NCII above parts are recommended for use
in Competency Based Training (CBT)
in Technical Education and Skills
Development Authority (TESDA)
Technology Institutions. The next
sections will show you the components
and features of each part.
 Competency Based Learning Materials

Sector: ELECTRONICS
Qualification Title: ELECTRONICS PRODUCT ASSEMBLY SERVICING NCII

Unit of Competency: ASSEMBLY OF ELECTRONIC PRODUCTS

Module Title: ASSEMBLING ELECTRONIC PRODUCTS

HOW TO USE THIS COMPETENCY-BASED LEARNING MATERIAL

Welcome!

The unit of competency, “Assemble Electronic Products”, is one of the competencies of

EPAS NC II, a course which comprises the knowledge, skills and attitude required for an
EPAS NC II course.

This module, “Assemble Electronic Products”, contains training materials and activities
related to Prepare to assemble electronic products, Prepare/ Make PCB modules, Mount and
solder electronic components, Perform electronic products assembly, Test and inspect
assembled electronic products for you to complete.

In this module, you are required to go through a series of learning activities in order to
complete each learning outcome. In each learning outcome are Information Sheets, Video
Clips, PowerPoint Slides, Self-Checks, Task Sheets, Job Sheets. Follow and perform the
activities on your own.

If you have questions, do not hesitate to ask for assistance to your trainer.

Recognition of Prior Learning (RPL)

You may already have some of the knowledge and skills covered in this module because you
have:
✔ Been working for some time.
✔ Already have complete training in this area.

If you can demonstrate to your trainer that you are competent in a particular skill
or skills, talk to him/her about having them formally recognized so you don’t have
to do same training again. If you have a qualification or Certificate of Competency
from previous training shows it to your trainer. If the skills you acquired are still
current and relevant to this module, they may become part of your evidence you
can present RPL. If you are not sure about the currency of your skills, discuss it
with your teacher.

After completing this module ask your trainer to assess your competency.

The results of your assessment will be recorded in your Progress Chart and
Accomplishment Chart.
 EPAS NC II
COMPETENCY-BASED LEARNING MATERIALS

List of Competencies

No. Unit of Competency Module Title Code

ELC724335
Assemble Electronic Products
1. Assembling Electronic Products

MODULE CONTENT

UNIT OF COMPETENCY : ASSEMBLE ELECTRONIC PRODUCTS

UNIT MODULE : ASSEMBLING ELECTRONIC PRODUCTS
MODULE DESCRIPTOR : This unit covers the knowledge, skills and attitudes
required to assemble electronic products and
systems for consumer/ industrial uses/applications.
It consist of competencies in identifying and
repairing electronic components and circuits,
preparing/making printed circuit board (PCB)
modules, mounting and soldering of components,
assembling electronic products and performing
mechanical and electrical/electronic tests.

NOMINAL DURATION : 40 hours

QUALIFICATION LEVEL : NC II
PREREQUISITE :

SUMMARY OF LEARNING OUTCOMES:

Upon completion of this module the students/trainees must be able to:

LO1.Prepare to assemble electronic products

LO2.Prepare/ Make PCB modules
LO3.Mount and solder electronic components
LO4.Perform electronic products assembly
LO5.Test and inspect assembled electronic products

SUMMARY OF ASSESSMENT CRITERIA:

1. Complete check-up of industrial electronic components, products and systems is
conducted and defects are identified, verified and documented against customer
description.
2. Repair/maintenance history is verified in line with the company procedures.
3. Service manuals and service information required for repair/maintenance are acquired as
per standard procedure.
4. Workplace is set/prepared for repair job in line with the company requirements.
5. Necessary tools, test instruments and personal protective equipment are prepared
in line with job Requirements
6. Materials necessary to complete the work are obtained in accordance with job requirements.
7. Consumer electronic products and systems are installed in accordance with manufacturer’s
instructions, requirements, and without damage to the surrounding place or environment
8. Devices are tested in accordance with standard procedures.
9. Final inspections are undertaken to ensure that the installed devices conforms to technical
requirements.
10. Unplanned events or conditions are responded to in accordance with established procedures
11. Work site is cleaned and cleared of all debris and left safe in accordance with the company
requirements
12. Report on installation and testing of equipment is prepared according to company’s
procedures/policies.
13. Systematic pre-testing procedure is observed in accordance with manufacturer’s instructions.
14. System defects/Fault symptoms are identified using appropriate tools and equipment and
troubleshooting Techniques and in accordance with safety procedures
15. Test instruments required for the job are used in accordance with user manuals.
16. Circuits are checked and isolated using specified testing procedures
17. Identified defects and faults are explained to the responsible person in accordance with
enterprise or company policy and procedures
19. Control settings/adjustments are checked in conformity with service-manual specifications.
20. Results of diagnosis and testing are documented accurately and completely within the
specified time.
21. Customers are advised/informed regarding the status and serviceability of the unit
according to procedures.
22. Personal protective equipment is used in accordance with Occupational Health and Safety
practices.
23. Electro-static discharge (ESD) protection procedure is followed in accordance with
current industry standards.
24. Defective parts/components are replaced with identical or recommended appropriate equivalent
ratings
25. Repaired or replaced parts/components are soldered/mounted in accordance with the
current industry standards.
26. Control settings/adjustments are performed in conformity with service-manual specifications
27. Repair activity is performed within the required timeframe
28. Care and extreme precaution in handling the unit/product is observed as per procedures
29. Cleaning of unit is performed in accordance with standard procedures
30. Excess components and materials are disposed of based on WEEE directives and 3Rs waste
management Program
31. Repaired units are reassembled according to procedures
32. Reassembled units are subjected to final testing and cleaning in conformity with
manufacturer’s specifications
33. Service completion procedures and documentations are complied with based on manual.
34. Waste materials are disposed of in accordance with environmental requirements.
 LEARNING OUTCOME SUMMARY

LEARNING OUTCOME 1 PREPARE TO ASSEMBLE ELECTRONIC PRODUCTS

CONTENTS:
 Applied safety rules and procedures
-OH&S policies and procedures

ASSESSMENT CRITERIA:
1. Assembly workplace is prepared in accordance with OH&S policies and procedures
2. Established risk control measures for work preparation are followed.
3. Work instructions are obtained and clarified based on job order or client requirements
4. Responsible person is consulted for effective and proper work coordination
5. Required materials, tools and equipment are prepared and checked in accordance with
established procedures
6. Parts and components needed to complete the work are identified, prepared and obtained
according to requirements
CONDITION:
The students/trainees must be provided with the following:
May include:
ESD-free work bench with mirror
Variable power supply Oscilloscope, digital
Variable transformer High-grade magnifying glass with
Soldering iron lamp
Hot air soldering station Flashlight/headlamp
Table top reflow oven Cleaning brush
Desoldering tools Soldering wire
Screwdriver (assorted) SMD soldering paste
Wrenches (assorted) Stranded/solid/hook-up wires
Allen wrench/key Assorted electronic components
Function/Signal generator Assorted electronic sensors Mufti-
testers (analog/digital)
Utility knife/stripper
Pliers (assorted)

ASSESSMENT METHOD:
 Oral Questioning or Interview
 Practical Demonstration
 Third-party workplace reports of on-the-job performance by the candidate
 Learning Experiences

Learning Outcome 1
PREPARE TO ASSEMBLE ELECTRONICPRODUCTS

Learning Activities Special Instructions

1. Read Information Sheet 1.1 Applied safety If you have some problems on Information Sheet
rules and procedures 1-1, don’t hesitate to approach your facilitator. If
you feel you are knowledgeable on the content of
Information Sheet 1-1, you can now answer Self-
Check 1-1.

2. Answer Self Check 1.1 Compare your answer with the answer key 1-1. If
you got 100% correct answer in this self-check,
you can now move to the next information sheet. If
not review the information sheet and go over the
self- check again.

INFORMATION SHEET 1.1

APPLIED SAFETY RULES AND PROCEDURES

“OH&S POLICIES AND PROCEDURES”

What is occupational health and safety?

1. Occupational health and safety is a discipline with a broad scope involving many
specialized fields. In its broadest sense, it should aim at:
2. The promotion and maintenance of the highest degree of physical, mental and social
well- being of workers in all occupations;
3. The prevention among workers of adverse effects on health caused by their
working conditions;
4. The protection of workers in their employment from risks resulting from factors
adverse to health;
5. The placing and maintenance of workers in an occupational environment adapted to
physical and mental needs;
6. The adaptation of work to humans.

In other words, occupational health and safety encompasses the social, mental and physical well-
being of workers, that is the “whole person”.

Successful occupational health and safety practice requires the collaboration and participation of
both employers and workers in health and safety programmes, and involves the consideration of
issues relating to occupational medicine, industrial hygiene, toxicology, education, engineering
safety, ergonomics, psychology, etc.
Occupational health issues are often given less attention than occupational safety issues
because the former are generally more difficult to confront. However, when health is addressed,
so is safety, because a healthy workplace is by definition also a safe workplace. The converse,
though, may not be true - a so-called safe workplace is not necessarily also a healthy workplace.
The important point is that issues of both health and safety must be addressed in every
workplace. By and large, the definition of occupational health and safety given above
encompasses both health and safety in their broadest contexts.
Poor working conditions affect worker health and safety

1. Poor working conditions of any type have the potential to affect a worker's health and safety.
2. Unhealthy or unsafe working conditions are not limited to factories — they can be found
anywhere, whether the workplace is indoors or outdoors. For many workers, such as
agricultural workers or miners, the workplace is “outdoors” and can pose many health and
safety hazards.
3. Poor working conditions can also affect the environment workers live in, since the working
and living environments are the same for many workers. This means that occupational hazards
can have harmful effects on workers, their families, and other people in the community, as well
as on the physical environment around the workplace. A classic example is the use of
pesticides in agricultural work. Workers can be exposed to toxic chemicals in a number of ways
when spraying pesticides: they can inhale the chemicals during and after spraying, the
chemicals can be absorbed through the skin, and the workers can ingest the chemicals if they
eat, drink, or smoke without first washing their hands, or if drinking water has become
contaminated with the chemicals.
The workers' families can also be exposed in a number of ways: they can inhale the pesticides
which may linger in the air, they can drink contaminated water, or they can be exposed to
residues which may be on the worker's clothes. Other people in the community can all be
exposed in the same ways as well. When the chemicals get absorbed into the soil or leach into
groundwater supplies, the adverse effects on the natural environment can be permanent.
Overall, efforts in occupational health and safety must aim to prevent industrial accidents and
diseases, and at the same time recognize the connection between worker health and safety, the
workplace, and the environment outside the workplace.

Why is occupational health and safety important?

Work plays a central role in people's lives, since most workers spend at least eight hours a day in
the workplace, whether it is on a plantation, in an office, factory, etc. Therefore, work
environments should be safe and healthy. Yet this is not the case for many workers. Every day
workers all over the world are faced with a multitude of health hazards, such as:
 Dust
 Gases
 Noise
 Vibration
 Extreme temperatures

Unfortunately some employers assume little responsibility for the protection of workers' health
and safety. In fact, some employers do not even know that they have the moral and often legal
responsibility to protect workers. As a result of the hazards and a lack of attention given to health
and safety, work-related accidents and diseases are common in all parts of the world.

Costs of occupational injury/disease

How much does an occupational disease or accident cause?

Work-related accidents or diseases are very costly and can have many serious direct and
indirect effects on the lives of workers and their families. For workers some of the direct costs of
an injury or illness are;
 The pain and suffering of the injury or illness; the loss of income
 The possible loss of a job; healthcare costs.

It has been estimated that the indirect costs of an accident or illness can be four to ten times
greater than the direct costs, or even more. An occupational illness or accident can have so
many indirect costs to workers that it is often difficult to measure them. One of the most obvious
indirect costs is the human suffering caused to workers' families, which cannot be compensated
with money.
The costs to employers of occupational accidents or illnesses are also estimated to be
enormous. For a small business, the cost of even one accident can be a financial disaster. For
employers, some of the direct costs are:

 Payment for work not performed;

 Medical and compensation payments;
 Repair or replacement of damaged machinery and equipment;
 Reduction or a temporary halt in production;
 Increased training expenses and administration costs;
 Possible reduction in the quality of work;
 Negative effect on morale in other workers.
 Some of the indirect costs for employers are:
 The injured/ill worker has to be replaced;
 A new worker has to be trained and given time to adjust;
 It takes time before the new worker is producing at the rate of the original worker;
Time must be devoted to obligatory investigations, to the writing of reports and filling out of forms;
Accidents often arouse the concern of fellow workers and influence labor relations in a negative
way; poor health and safety conditions in the workplace can also result in poor public relations.

Overall, the costs of most work-related accidents or illnesses to workers and their families and to
employers are very high. On a national scale, the estimated costs of occupational accidents and
illnesses can be as high as three to four per cent of a country's gross national product. In reality, no
one really knows the total costs of work-related accidents or diseases because there are a multitude
of indirect costs which are difficult to measure besides the more obvious direct costs; Health and
safety programs.

For all of the reasons given above, it is crucial that employers, workers and unions are committed
to health and safety and that: workplace hazards are controlled - at the source whenever
possible; records of any exposure are maintained for many years; both workers and employers
are informed about health and safety risks in the workplace; there is an active and effective
health and safety committee that includes both workers and management; worker health and
safety efforts are ongoing.
Effective workplace health and safety programs can help to save the lives of workers by reducing
hazards and their consequences. Health and safety programs also have positive effects on both
worker morale and productivity, which are important benefits. At the same time, effective programs
can save employers a great deal of money.
 GENERAL SAFETY RULES
By maintaining a safe working practice you will protect not only your own safety but that of others
who will come into contact with your work.
 Always ensure grounding straps and leads are intact and securely connected.
 Always use the correct fire extinguisher. Water can conduct electric currents, Carbon
dioxide (CO2) and appropriate Halogenated extinguishers should be used and in some
cases foam is appropriate.
 Always ensure interlock switches are operating properly
 Always ensure your tools and test equipment are kept clean, in good working order
and always use the appropriate tool for the job.
 Always discharge capacitors in a circuit. Some capacitors such as those in a power supply
will hold a lethal charge long after the power has been removed.
 Always familiarize yourself with the safety precautions associated with any
solvents or chemicals you are about to use. Many give off strong fumes which can
ignite or cause drowsiness.
 Always use appropriate tools, equipment and protective clothes, Buy the best you can afford.
 Always use the recommended replacement component, many devices have built in
safety measures and narrow tolerance bands.
 Always wear protective equipment, protective boots, hard-hats, goggles, overalls etc
when they are needed.
 Always remove all rings, bracelets, medallions or anything which could get caught in
moving machinery or may conduct electricity.
 Always read the manufacturers data and information sheets. They are an invaluable source
of information and safety procedures for the equipment under test.
 Always when working with electricity, keep your left hand in your pocket where
possible to avoid providing an electrical path through your chest and heart.
 Do not work when you are tired or taking medicine which makes you drowsy or affects
your reactions and concentration.
 Do not work under poor lighting conditions
 Do not work in areas which are damp
 Never use an extension or adapter to overcome grounding straps or earth leads.
 Never work in wet clothing
 Never assume a circuit is off. Always check for power with the appropriate instrument.
 Never meddle with safety devices
 Never override interlock safety switches.
 Never remove equipment grounding straps or leads.

Hazard identification, risk assessment and control measures introduction

Hazard identification (HAZID) and risk assessment involves a critical sequence of information
gathering and the application of a decision-making process. These assist in discovering what
could possibly cause a major accident (hazard identification), how likely it is that a major accident
would occur and the potential consequences (risk assessment) and what options there are for
preventing and mitigating a major accident (control measures). These activities should also
assist in improving operations and productivity and reduce the occurrence of incidents and near
misses.
There are many different techniques for carrying out hazard identification and risk assessment at
an MHF. The techniques vary in complexity and should match the circumstances of the MHF.
Collaboration between management and staff is fundamental to achieving effective and efficient
hazard identification and risk assessment processes.

Hazard identification
The Regulations require the employer, in consultation with employees, to identify:
 all reasonably foreseeable hazards at the MHF that may cause a major accident; and
the kinds of major accidents that may occur at the MHF, the likelihood of a major accident
occurring and the likely consequences of a major accident.

The importance of getting the hazard identification right

Major accidents by their nature are rare events, which may be beyond the experience of many
employers. These accidents tend to be low frequency, high consequence events as illustrated in
Figure 1 below. However, the circumstances or conditions that could lead to a major accident may
already be present, and the risks of such incidents should be proactively identified and managed.

Figure 1: HAZID focus on rare events

HAZID must address potentially rare events and situations to ensure the full range of major
accidents and their causes. To achieve this, employers should; identify and challenge
assumptions and existing norms of design and operation to test whether they may contain
weaknesses; think beyond the immediate experience at the specific MHF; Recognize that
existing controls and procedures cannot always be guaranteed to work as expected; and learn
lessons from similar organization and businesses.
Some significant challenges in carrying out an effective HAZID are: substantial time is needed to
identify all hazards and potential major accidents and to understand the complex circumstances that
typify major accidents; the need for a combination of expertise in HAZID techniques, knowledge of
the facility and systematic tools; the possibility that a combination of different HAZID techniques
may be needed, depending on the nature of the facility to ensure that the full range of factors (e.g.
human and engineering) is properly considered; obtaining information on HAZID from a range of
sources and opinions; and ensuring objectivity during the HAZID process.
Com care must be satisfied that hazard identification has been comprehensive and the risks are
eliminated or controlled before granting a license or certificate of compliance to operate an MHF.
 SELF CHECK 1.1
Fill in the Blank Direction:
Choose the correct answer from the choices inside the box. Write your answer in your answer
sheet.
 OHS
 HAZID
 RISK MANAGEMENT
 CO2
 MHF
 COM
1. Hazard identification (HAZID) and risk assessment involves a critical
sequence of information gathering and the application of a decision-making process
2. Occupational Health and Safety
3. How likely it is that a major accident would occur and the
potential consequences
4. Always use the correct fire extinguisher. Water can conduct electric
currents, Carbon dioxide (CO2) and appropriate Halogenated extinguishers should be
used and in some cases foam is appropriate
5. Major Hazards Facility

ANSWER KEY TO SELF CHECK 1.1

1. OHS
2. HAZID
3. RISK MANAGEMENT
4. CO2
5. MHF
6. COM
LEARNING OUTCOME 2 PREPARE/ MAKE PCB MODULES

CONTENTS:
 PCB problems and solutions
 PCB characteristics

ASSESSMENT CRITERIA:
1. PCB layout is verified for conformity with the schematic diagram in accordance with the layout
rules
2. PCB layout is transferred to copper-cladded board following acceptable methods and
standards
3. Visual inspection is performed based on standards procedures.
4. Thru-hole is drilled based on standards procedures
5. PCB is cleaned based on standards procedures
6. Functionality of PCB is tested and visual inspection is performed based on standards
procedures
CONDITION:
The students/trainees must be provided with the following:

May include:
ESD-free work bench with mirror
Variable power supply Oscilloscope, digital
Variable transformer High-grade magnifying glass with lamp
Soldering iron Flashlight/headlamp
Hot air soldering station Cleaning brush
Table top reflow oven Soldering wire
Desoldering tools SMD soldering paste
Screwdriver (assorted) Stranded/solid/hook-up wires
Wrenches (assorted) Assorted electronic components
Allen wrench/key Assorted electronic sensors
Function/Signal generator
Mufti-testers (analog/digital)
Utility knife/stripper
Pliers (assorted)

ASSESSMENT METHOD:
Oral Questioning or Interview Practical
Demonstration
Third-party workplace reports of on-the-job performance by the candidate

LEARNING OUTCOME SUMMARY

Learning Experiences
Learning Outcome 2

Prepare/ Make PCB modules

Learning Special Instructions
Activities
Read Information Sheet 1.1 If you have some problems on
Applied safety rules and Information Sheet 1-1, don’t hesitate to
procedures approach your facilitator. If you feel you
are knowledgeable on the content of
Information Sheet 1-1, you can now
answer Self-Check 1-1.
2. Answer Self Check 1.1 Compare your answer with the answer
key 1-1. If you got 100% correct answer in
this self- check, you can now move to the
next information sheet. If not review the
information sheet and go over the self-
check again.

INFORMATION SHEET 1.2-1

PREPARE/ MAKE PCB MODULES

PCB PROBLEMS AND SOLUTIONS

PCB Assembly problems and its solutions

PCB Assembly problems and its solutions

In PCB Assembly, there is a set of process that is constantly being followed. One process cannot be
skipped; one cannot be switched to be performed over the other. For an SMT component populated PCB, it
is always going to be the following processes (arranged in order):
 Solder Paste Printing
 Automatic Placement
 Reflow
But even if the processes are followed, certain problems arise when a populated PCB is inspected. In
here, we are going to tackle some of the PCB Assembly problems that are commonly encountered and
discuss how to solve and prevent from happening again:
 Solder bridging
Solder bridging is a phenomenon where at least two neighboring component pins have short circuited by
way of an unnecessary solder. This phenomenon may be due to the following: excess solder volume,
inaccurate placement of the machine, or the plain mismatch of the PCB footprint. To solve this problem,
the engineers or assemblers should do the following: reduce the solder volume by changing the printing
machine settings or go far as changing stencil mask opening.

Learning Activities Special Instructions

Reading /Discussing and Demonstrating the information Sheet You are required to Read Information Sheet
and answer self-check and compare answer
5.1 Silk screen etching of PCB
using answer key, to measure your
5.2 Photo transfer etching of PCB understanding on the topic, to gain
 9.1 Prepare supplies, materials and equipment remarkable training performance, review of
the information sheet is encourage.
9.2 Familiarize with the diagram and the product
The Task Sheet and Job Sheet will help you
to practice your skills, Please Review
Perform Task Sheet procedures before performing Task or Job
Sheets.
5.1 Silk screen etching of PCB
The performance criteria checklist will guide
5.2 Photo transfer etching of PCB and help you evaluate your work as you are
9.1 Prepare supplies, materials and equipment practicing your skill.
9.2 Familiarize with the diagram and the product After performing every Task/Job Sheet
please evaluate your performance using
Evaluate Performance using the Performance Criteria Performance Criteria Checklist.
5.1 Silk screen etching of PCB When you are ready, present your work to
5.2 Photo transfer etching of PCB your trainer for final evaluation and recording.

9.1 Prepare supplies, materials and equipment If you have questions and clarification don’t
hesitate to ask your trainer.
9.2 Familiarize with the diagram and the product

After performing the activities of LO2, you may

proceed to LO3

INFORMATION SHEET 1.2-1

Procedure in PCB designing
Learning Objectives:

After reading this INFORMATION SHEET, YOU MUST be able to:

1. Acquire knowledge how to design printed circuit board.

2. Perform Printed circuit board designing using the circuit diagram of variable regulated AC/DC power supply.

3.Understand the importance of printed circuit board designing in making PCB module

Introduction

A printed circuit board (PCB) has components inserted into the hole and soldered to form its circuit connection. Its
main purpose is to reduce the space and to troubleshoot easily when problem arises.

The printed circuit board (PCB) has conductors that are thin strip of copper, usually bonded to a baseboard called
substrate. There are two very common substrate materials used in printed circuit, the phenolic and epoxy plastic.
 PCB (Printed Circuit Board) Plain Circuit Board

Copper Side

Substrate Side

Printed Circuit Board In PCB designing, we should not focus only on the size of the pathways linking to the
other component, but also on the types, kinds, and characteristics of component. Here are the other design
factors needed:

1. PCB size and shape. The PCB must be big enough for the entire component to be mounted where it is
anticipated.

2. Position of the Terminal. Input, output and supply voltage if possible should be placed near the border for
easier way during troubleshooting or minor repair.

3. 3.High Temperature Dissipation. Too much heat is the number one problem of all components. Bigger
space is needed so that heat sink can be provided to the component. This will protect the component from
burning up.

4. Accessibility of Components. This component that is adjustable or variable (example: potentiometer,

trimmer resistor or capacitor) should be placed near the border to make the troubleshooting or minor repair
easier.

5. Space for Bolt and Nut. The designer should place an allowance for mounting the PCB with bolt and nut
in securing the entire board to the chassis.

6. Different Types of Circuit Should be grouped according to its Application. This will enhance the circuit
operation and will prevent it from distortion generated by other circuit. This is the reason why the circuit of
the power supply is far from the audio circuit.

Procedure in PCB designing

1. Prepare the tools and materials needed in lay outing and designing a PCB

Tools and materials needed: 

 Ruler

 Utility cutter 

 Permanent marker 

 Pencil and Eraser 

 Graphing paper and a piece of bond paper (short)

 Masking Tape

2. Prepare the schematic diagram of the circuit.

 Schematic diagram of Variable regulated AC/DC power supply

3. Make the PCB design. Arrange the components terminals on a graphing paper or a piece of paper to
show/illustrate the interconnection of the components based on the schematic diagram given.

A. Component Placement Guide B. PCB Design

 C. Actual Component Placement Guide

4. Finalized your design with the actual size of the component, terminals and size of the PCB (1 ½ ” x 2”) to
check the spacing of the components. It should not be on top of the other components.

5.Let your work check by the trainer.

SELF-CHECK 1.2-1

Direction: Identify the following items.

1. A board that is open with electronic components is mounted and soldered.
2. A conductor where the component’s terminal lead is soldered.
3. It consists of a thin copper layer which is firmly bonded to an insulating base material. It is sometimes
called as a component side.
4 -5. The two types of substrate materials used in a present circuit.

ANSWER KEY 1.2-1

1. PCB
2. Substrate
3. Copper foil side
4. Epoxy
5. Phenolic
 ACTIVITY SHEET 1.2-1
Title : Procedure in PCB designing

Performance Objective : Given the ACTIVITY SHEET 1.2-1, you should be able to perform
procedure in PCB designing for variable regulated AC/DC power supply
circuit diagram.

Supplies/Materials : Activity Sheet 1.2-1, piece of paper pencil or ball pen, circuit diagram of
variable regulated AC/DC power supply

Equipment : N/A

Steps/Procedure :

Procedure in PCB designing

1. Prepare the tools and materials needed in lay outing and designing a PCB

Tools and materials needed:

• Ruler
• Utility cutter
• Permanent marker
• Pencil and Eraser
• Graphing paper and a piece of bond paper (short)
• Masking Tape

2. Prepare the schematic diagram of the circuit.

3. Make the PCB design. Arrange the components terminals on a graphing paper or a piece of paper to
show/illustrate the interconnection of the components based on the schematic diagram given.

4. Interconnect the traces to the pads/terminals of the components depending on the connections of the
components to one another. Make sure that the traces will be the same as the connection of the schematic
diagram.

5. Finalized your design with the actual size of the component, terminals and size of the PCB (1 ½ ” x 2”) to
check the spacing of the components. It should not be on top of the other components.

6. Let your work check by the trainer.

7. Discuss your answers with the trainer 8.Apply the safety precautions following the OH&S policies and
Procedure

Assessment Method:

Demonstration

PERFORMANCE CRITERIA CHECKLIST 1.2-1

Did you…. YES NO

1. Interconnect base on the schematic diagram?
2. Used appropriate tools and materials in PCB designing?
3. Position the terminals not overlapping to each components?
4. Used correct PCB size?
5. Position the terminal of the input, output and auxialliary components accessible?
6. Provide space for the bolts and nuts?
7. Provide proper grounding on your design?
 INFORMATION SHEET 1.2-2
Procedure in PCB Lay-Outing
Learning Objectives:

After reading this INFORMATION SHEET, YOU MUST be able to:

1. Acquire knowledge how to layout printed circuit board.

2. Perform Printed circuit board layout using the circuit diagram of variable regulated AC/DC power supply.
3. Understand the importance of printed circuit board layout in making PCB module

In every electronic activity specially PCB layout can be performed (using CAD ) or in combination with an
Auto router, The results are usually still achieved using at least some manual routing – simply because the
design engineer has a far better judgment of how to arrange circuitry. Surprisingly, many auto routed boards
are often illogical in track routing – the program has optimized the connections an sacrificed any small
amount of order that may have been put in place by manual routing. Generally auto routed boards are
somewhat harder for a technician to repair debug; for this reason. Historically, PCBs used to be laid out by
using stick on paper shapes and ape on mylar drafting film, - that really WAS manual routing.

Procedure in Lay-Outing

1. Using a permanent marker, art transfer or masking tape for layout the design on the PCB. Follow the
procedure on how to trace the path of the connection traces from the schematic diagram.

2. Be wise on positioning the terminals or the pads of the components and avoid shorting the traces of the
connections.

3. Double check your design, make sure that all of the connections are the same as the connections on the
schematic diagram.

4. Make sure that the components size are seized so the components will not be on top of the other in
mounting procedure.

5. Let your trainer check your design work before the etching process.

SELF – CHECK 1.2-2

Direction: Answer the following questions and write your answers in separate sheet of paper.
1. What should be consider in PCB layout? 2
2. This will protect the component from burning up?
3. The _______ layout must be accessible to all Components?
4. The layout should place an allowance for mounting the PCB?
5. What do you call the status where excessive heat is the number one problem of all components

ANSWER KEY 1.2-2

1. Size
2. Space
3. PCB
4. Bolts and Nuts
5. High Temperature Dissipation
 ACTIVITY SHEET 1.2-2
Title : Procedure in PCB Lay-Outing

Performance Objective: Given the ACTIVITY SHEET 1.2-2, you should be able to perform procedure in
PCB lay outing for variable regulated AC/DC power supply circuit diagram

Supplies/Materials : Activity Sheet 1.2-2, piece of paper pencil or ball pen, circuit diagram of variable
regulated AC/DC power supply

Equipment : N/A

Steps/Procedure:

Procedure in PCB Layouting

1. 1 Using a permanent marker, art transfer or masking tape for layout the design on the PCB. Follow the
procedure on how to trace the path of the connection traces from the schematic diagram.

1. 2 Be wise on positioning the terminals or the pads of the components and avoid shorting the traces of the
connections.

1. 3 Double check your design, make sure that all of the connections are the same as the connections on
the schematic diagram.

1. 4 Make sure that the components size are seized so the components will not be on top of the other in
mounting procedure.

1. 5 Let your trainer check your design work before the etching process.

Assessment Method:

Written - Oral Questioning

Performance Criteria checklist

PERFORMANCE CRITERIA CHECKLIST 1.2-2

Did you.... YES NO

1. Finalized your layout with the actual size of the component, terminals
and size of the PCB?
2. use appropriate materials in lay-outing your design on the PCB?
3. position the terminals or the pads of the components to avoid shorting
the traces of the connections?
4. Double check your Layout or make sure that all of the connections
are the same as the connections on the schematic diagram?
5. measure the actual size of the component so it will not be on top of each other?
 INFORMATION SHEET 1.2-3
Procedure in PCB ETCHING
Learning Objectives:

After reading this INFORMATION SHEET, YOU MUST be able to:

1. Acquire knowledge how to etch printed circuit board.
2. Perform Printed circuit board etching using the materials needed in PCB etching.
3. Understand the importance of printed circuit board etching in making PCB module

Printed Circuit Board Etching is where the excess copper is removed to leave the individual
tracks or traces as they are sometimes called. Buckets, bubble tanks, and spray machines are tools to do
different ways of etching but most firms currently use high pressure conveyors spray equipment. Spray
etching is fast Ammonia Cal etching solutions when sprayed can etch 55 microns of copper a minute. Less
than 40 seconds to etch a standard 1 Oz, 35 micron circuit board.

Many different chemical solutions can be used to etch circuit boards ranging from slow controlled speed
etches used for surface preparation to the faster etches used for etching the tracks. Some are best used in
horizontal spray process equipment while others are best used in tanks. Enchants for PTH work have to be
selective and be nonaggressive to tin / tin lead plating, which is used as the etch resists. Copper etching is
normally exothermic where high speed etching is carried out solution cooling is normally required. This is
normally done by placing titanium water cooling coils into the enchant. Almost all etching solutions liberate
toxic corrosive fumes. Extraction is highly recommended. All enchants are corrosive and toxic mainly due to
the high metal content. P.P.E. Personal Protection Equipment must always be used. Spent solutions should
always be disposed properly and not to be spilled down local drains where they can pollute local sewage
works and rivers.

Printed Circuit Board Etching

It is the removal of unwanted portion or layer of conductive materials (that is copper) bonded to an insulating
base called substrate. By using a chemical reaction to the copper called ferric chloride, it liquefies the
uncovered surfaces of the designed copper clad board that creates a PCB.

Tools and Materials Needed In PCB Etching

1. Designed PCB
2. A bottle of the Ferric Chloride. (The quantity of bottle will depend upon the area of the PCB).
3. Plastic Basin. It is the medium of ferric chloride
4. Popsicle sticks (2 pieces). It is used for hauling the designed PCB.
5. Old newspaper. It is placed under the plastic basin for the prevention of accidental spill of chemical over
the table.
6. Apron
7. Piece of Cloth
8. Plastic Varnish 1 bottle
9. Lacquer Thinner
10. Surgical Gloves
11. Knife or Cutter
PROCEDURE IN PCB ETCHING
1. Prepare the necessary tools and materials needed in PCB etching.
2. Wear your apron and surgical gloves in order to prevent accidental splash of the solution on your clothes
or on your skin.
3. Pour the ferric chloride in the plastic basin.

Pouring of Ferric Chloride

4. Etch the PCB by immersing it in a basin filled with ferric chloride until the uncovered part of the copper
clad is totally etched. Ferric chloride

Immerse PCB in plastic basin filled with ferric chloride

5. After 10 - 15 minutes, check the PCB if all the parts needed to be removed are totally etched (using the
two Popsicle sticks in hauling). If not yet, return it into the plastic basin filled with ferric chloride. After 3 - 5
minutes check it again.
6. Haul the PCB from the plastic basin and wash it in a free flowing water to remove the remaining residue
in the PCB.
7. With a clean and dry piece of cloth, wipe the wet PCB
8. Pour a little amount of lacquer thinner on a clean dry piece of cloth and wipe the markings of the
permanent marker pen in the copper clad. (Note: In doing this, you should wear your surgical gloves.)
9. Aided by bright light, inspect the PCB for possible hairline break or short. If there is a hairline path
between the copper conductors, cut it by a knife or cutter. And if there is a break between the copper
conductors, solder it.
10. Apply plastic varnish to the newly etched PCB to prevent corrosion or rust, and let it dry before touching
it.

Techniques to correct PCB Hairline Break or Short

A. Hairline Break. It is an open copper foil in the Printed Circuit Board. Most of the time this is due to
improper PCB designing or etching. To eliminate the hairline break, just place a hook up wire and solder it.

B. Hairline Short in the PCB Conductor. It arises if the printed circuit board designing or etching is done
improperly. To eliminate the hairline short, you should cut it with a knife.

SELF CHECK 1.2-3

 Procedure in PCB ETCHING

Direction : Answer the following questions and write your answers in separate sheet of paper,
1. What is the method called by removing unwanted copper in the PCB?
2. What material is used, that protects parts of the laminate from the acid and leaves the desired copper
layer untouched?
3. At least how many minutes the PCB is in the basin with acid?
4. What is the chemical solution use in PCB Etching?
5. What are the safety equipment and use when we do the process of etching?

ANSWER KEY 1.2-3

1. Etching
2. Masking tape
3. 20 minutes
4. Ferric Chloride
5. Goggles, mask, gloves , apron

ACTIVITY SHEET 1.2-3

Title : Procedure in PCB Etching
Performance Objective: Given the ACTIVITY SHEET 1.2-3, you should be able to perform procedure in
PCB Etching for variable regulated AC/DC power supply circuit diagram

Supplies/Materials : Activity Sheet 1.2-3, ferric chloride, basin, designed PCB, rags, water, popsicle stick,
newspaper, utility cutter and PPE.

Equipment : N/A

Steps/Procedure:

Procedure in PCB Etching

1.Prepare the necessary tools and materials needed in PCB etching.

2. Wear your apron and surgical gloves in order to prevent accidental splash of the solution on your clothes
or on your skin.

3.Pour the ferric chloride in the plastic basin

4.Etch the PCB by immersing it in a basin filled with ferric chloride until the uncovered part of the copper
clad is totally etched.

5.After 10 - 15 minutes, check the PCB if all the parts needed to be removed are totally etched (using the
two Popsicle sticks in hauling). If not yet, return it into the plastic basin filled with ferric chloride. After 3 - 5
minutes check it again.

6.Haul the PCB from the plastic basin and wash it in a free flowing water to remove the remaining residue in
the PCB.

7.With a clean and dry piece of cloth, wipe the wet PCB.

8.Pour a little amount of lacquer thinner on a clean dry piece of cloth and wipe the markings of the
permanent marker pen in the copper clad. (Note: In doing this, you should wear your surgical gloves.)

9.Aided by bright light, inspect the PCB for possible hairline break or short. If there is a hairline path
between the copper conductors, cut it by a knife or cutter. And if there is a break between the copper

PERFORMANCE CRITERIA CHECKLIST 1.2-3

Did you.… Yes No

1. Use appropriate PPE while performing the etching activity?
2. Etch your designed PCB following the procedure correctly?
3. Fix any hairline short or hairline break on your PCB?
4. Apply proper safety precaution while performing the activity?
5. 5. Use appropriate tools while performing the activity?

INFORMATION SHEET 1.2-3

Procedure in Learning Drilling
Learning Objectives: After reading this INFORMATION SHEET, YOU MUST be able to:
1. Acquire knowledge how to drill printed circuit board.
2. Perform Printed circuit board drill using the Mini – drill.
3. Understand the importance of printed circuit board drill in making PCB module

Drilling is a cutting process that uses a drill beat to cut a hole of circular cross section in solid
material, the drill beat is rotary cutting tools, often multi point, the beat is pressed against the work piece and
rotated at rates from hundreds to thousands of revolution per minute. This forces the cutting edge against
the work piece, cutting off chips (swerve) from the hole as it is drilled. Exceptionally, specially-shaped bits
can cut holes of non-circular cross section; a square cross-section is possible,

How to set – up Mini Drill

1.Loosen the chuck by using a long metal tool and change the drill bit. This is done in a counter clockwise
movement.
2.Insert the drill bit 1mm diameter in size and attach it to the chuck of the unit.
3.Turn the long metal tool clockwise to tighten the jaw of the unit. Be sure that the drill bit is well secured on
the chuck.
4.Before inserting the 12 volts adaptor, you should turn off the unit.
5.Test the rotation of the unit if it is well aligned. If not, align it following the steps no. 1 and 2.

How to Use a Mini Drill

To control the unit, hold the mini - drill at the lower part and firmly position your arm. Then with the mini drill
held perpendicularly to your work surface, lightly press downward to the holes to be drilled in the PCB but
be sure that the PCB has a piece of wood under it to avoid damaging the table. With practice, you will be
able to get the procedure correctly

PROCEDURE IN DRILLING
1. Prepare all the materials needed.
- Mini drill
- Designed etched
2. Mark where the holes are to be drilled.
3. Using the mini drill, bore hole perpendicularly to the surface of the PCB.
4. Clean the surface of the PCB and look for open line or short circuit.
5. Apply varnish on the clad surface to prevent it from corrosion

SELF CHECK 1.2-4

Direction : Answer the following questions and write your answers in separate sheet of paper.
1. What is the material use in PCB drilling?
2. What do you called the process of cutting using the drill bit?
3. Mark where the __________ are to be drilled?
4. What should be the position of the hole to the surface of the PCB? 5. What liquid form is used to prevent
it from corrosion?
5. What chemical is applied to prevent corrosion to the PCB?

ANSWER KEY 1.2-4

1. Drill/ Small Drill
2. Drilling
3. Hole
4. Perpendicularly
5. Varnish

ACTIVITY SHEET 1.2-4

Title : Procedure in PCB Drilling
Performance Objective : Given the ACTIVITY SHEET 1.2-4, you should be able to perform
procedure in PCB Drilling for variable regulated AC/DC power supply circuit
diagram

Supplies/Materials : Activity Sheet 1.2-4, 12v Mini Drill designed etched PCB, and PPE.

Equipment : N/A

Steps/Procedure:

Procedure in PCB Drilling

1. Prepare all the materials needed. - Mini drill - Designed etched PCB
2. Mark where the holes are to be drilled.
3. Using the mini drill, bore hole perpendicularly to the surface of the PCB.
4. Clean the surface of the PCB and look for open line or short circuit.
5. Apply varnish on the clad surface to prevent it from corrosion.
6. Apply the safety precautions following the OH&S policies and Procedures

Assessment Method:

Written - Oral Questioning

Performance Criteria checklist

PERFORMANCE CRITERIA CHECKLIST 1.2-4

Did you.... Yes No

1. Use appropriate PPE while performing the drilling activity?
2. Drilled your designed etched PCB following the procedure correctly?
3. Clean your PCB after drilling?
4. Apply proper safety precaution while performing the activity?
5. 5. Use appropriate tools while performing the activity?

BIBLIOGRAPHY

Personal experience based on Industry Standards

Online Resources : https://en.wikipedia.org/wiki/Drilling

https://en.wikipedia.org/wiki/etching
https://en.wikipedia.org/wiki/designing
1. Plan for keeping employees safe and healthy.
2. Outline managerial commitments to workplace safety.
3. List company health and safety principles.
4. Mandate all employees to follow the policy.
5. Specify employee health and safety responsibilities.