Introduction to Soldering and De-soldering

Basic Electrical Engineering

UNIT-6

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What is soldering ?

⇒ Soldering is a joining process used to join different types of metals

together by melting solder.
⇒ Solder is a metal alloy usually made of tin and lead which is melted
using a hot iron.

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Key components for soldering operation

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Flux and its usage
Flux is a substance which is
1 Nearly inert at room temperature

2 Preventing oxidation of the base and filler materials

3 Strongly reducing at elevated temperatures

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 Soldering iron vs soldering gun
⇒ Soldering iron is much lighter than gun.
⇒ Easier to work with especially over long periods.
⇒ A soldering iron doesn’t need to be turned off on repeatedly because
it stays hot longer, which contributes to a smoother workflow.
⇒ Soldering irons are less effective when working on heavier jobs; irons
have less voltage than soldering guns.
Precaution during soldering
1 Only work in an environment that is well light and ventilated.
2 Always unplug the soldering iron when it is unattended.
3 Be careful to keep clothes, hair, power cables and skin etc away from
the soldering iron tip and the metal shaft.
4 Be careful when placing the iron to it’s stand, make sure it is secure
and does not fall off.

5 Always handle the iron by the plastic handle.

6 Point the circuit away from yourself and others whilst trimming down
component legs, and be careful of any sharp bits of metal whilst
handling the circuit or components.
Subject: ICT Workshop Dr. Varun Ku 6/ 9
Basic soldering guide

1 Make sure soldering iron tip is clean and tinned with solder.
2 Heat the pad and component legs with tip of the iron simultaneously,
and be careful not to burn the printed circuit board or any plastic or
insulation.
3 Whilst the iron is still in contact with the area, apply a small amount
of solder to the join, and hold the iron on until the solder flows
properly.
4 Check to make sure the solder joint is nice and shiny and that it does
not bridge any connections.
5 Clean off the soldering iron and tin the tip, try to keep the tip well
tinned with a nice shiny layer of solder at all times.
Desoldering
Desoldering is the process of removing solder and components from a
circuit board, typically for repair, replacement, or troubleshooting. It
involves heating the solder to a molten state and then removing it
2
using various tools and techniques.
Why Desoldering is Necessary:
Repair and Replacement:
3
When components fail or need to be replaced, desoldering allows you
to remove the old component and prepare the circuit board for a new
one.
4
Troubleshooting:
Desoldering can be used to isolate and remove components to
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pinpoint the source of a problem in a circuit.
Salvaging:
Desoldering can be used to remove components from a broken circuit
board for reuse or recycling.
Breadboard Wiring
• A breadboard is a rectangular plastic board with a bunch of tiny holes in it. These holes let
you easily insert electronic components to prototype (meaning to build and test an early
version of) an electronic circuit, like this one with a battery, switch, resistor, and an LED.
• No soldering is required so it is easy to change connections and replace components. Parts
are not damaged and can be re-used afterwards.
• The connections are not permanent, so it is easy to remove a component if you make a
mistake, or just start over and do a new project. This makes breadboards great for beginners
who are new to electronics.
• The most common sizes you will probably see are "full-size," "half-size," and "mini"
breadboards. Most breadboards also come with tabs and notches on the sides that allow you
to snap multiple boards together.

General Purpose PCB

Printed circuit Board commonly abbreviated as PCB is the base(literally) of electronics.

The PCB provides support as well as electrically connects various Electronic Components in the circuit.

For testing or for mounting your components you can either design and manufacture a custom PCB or
else you can mount it on a zero PCB and accordingly make the connections.

General Purpose PCB are perfect if you have not finalized the design or you are making the circuit just
once like for a school or college project.

Types of General Purpose PCB

Single Sided Paper Phenolic

This is made of FR1 or FR2 type of copper clad (Paper phenolic) and are mostly used by students as
they are low cost and easily available.

In this type you can mount the components on one side and solder from the other side of PCB. Copper
is available only on one side of the PCB.
Single Sided Glass Epoxy

This is made of FR4 type of copper clad (glass epoxy) used by students, as well as in Industry these PCB
are more sturdy as compared to Paper phenolic type.

In this type you can mount the components on one side and solder from the other side of PCB. Copper
is available only on one side of the PCB

Double Sided Glass Epoxy

This is made of FR4 type of copper clad (glass epoxy) these are mostly used in Industry. In this type you
can mount the components on both side as well as you can solder from both sides of PCB. Copper is
available on both side of the PCB.

Flexible PCB

These are new types of PCB not easily available in the market. These PCB's are flexible like a cloth and
thus can be used where you can't use a Paper phenolic or glass epoxy PCB. These PCB are flexible thus
you can easily adjust the circuit on it even in a small constraining place.

Advantages of using General Purpose PCB

• Low cost.

• Perfect for Prototyping and testing small circuits.

• Perfect for all who are starting with Electronics.

• Short Design Time

• You can change the circuit at any time

Disadvantages of using General Purpose PCB

• Cannot be used for Mass Production.

• Difficult to Repair or Troubleshoot.

• Soldering skills required.

• Difficult to use for complex circuits.

 Electrical Wiring
• A process of connecting various accessories
for distribution of electrical energy from
supplier’s meter board to home appliances
such as lamps, fans and other domestic
appliances is known as Electrical Wiring.
• The wiring system selected will depend to a
large extent on the types of service required.
 Factors Affecting the Selection of
Wiring
1. Durability

2. Safety

3. Appearance

4. Cost

5. Accessibility

6. Maintenance Cost
 Types of Internal Wiring
• Cleat wiring
• Casing and capping wiring
• Batten wiring
a) CTS or TRS or PVC sheath wiring
b) Lead sheathed or metal sheathed wiring
• Conduit wiring
a) Surface or open Conduit type
b) Concealed or underground type Conduit
 Cleat Wiring
• In this system of wiring, cables are supported
and gripped between porcelain cleats and
6mm. above the wall or roof.
• The main part is base, which is grooved to
accommodate the cables, the other part is the
cap which is put over the base
• Cleats are placed above the wall or roof at an
interval of 30 to 60 cm.
• The cables recommended for this type of
wiring are VIR or PVC cables and any other
approved insulated cables.
Advantages
1. It is the cheapest system.
2. Installation and dismantling is easy.
3. Less skilled persons are required.
4. Inspection is easy.
5. Alterations and additions are easy.
Disadvantages
1. It is purely temporary wiring system.
2. Appearance is not good.
3. Cables are exposed to atmosphere and there
is a possibility of mechanical injury.
4. This system should not be used in damp
places other wise insulation gets damaged.
 Casing and Capping Wiring
• It consists of rectangular blocks made from
seasoned and knots free wood (preferably teak-
wood).
• The casing has usually two (or three) ‘U’ shaped
grooves, into which the VIR or PVC cables are
laid in such a way that the opposite polarity
cables are laid in different grooves.
• The casing is covered by means of a rectangular
strip of the same width as that of casing known
as capping and is screwed to it.
• This system of wiring is suitable for low voltage
installations.
Advantages
1. It provides good insulation as conductors are
apart.
2. It provides good mechanical strength.
3. Easy to inspect by opening the capping.
Disadvantages
1. It is costly system now – a – days because it
needs seasoned, knot free wood.
2. There is every risk of fire.
3. The labor cost is more because it requires
skilled carpenters.
4. This system can not be used in damp places.
 CTS or TRS or PVC Sheath Wiring
• CTS cables are available in single-core, twin-core or
three-core with a circular or oval in shape.
• CTS cables are sufficiently chemical proof, water
proof, steam proof.
• The cables are run or carried on well seasoned,
perfectly straight and well varnished (on all four sides)
teak wood batten of thickness 10 mm. at least.
• The width of the batten depends upon the number and
size of cables to be carried by it. Battens are fixed to
the walls or ceilings by means of gutties or wooden
plugs.
• The cables are held on the wooden batten by means of
tinned brass link clips spaced at an interval of 10 cm.
• .This system is suitable for low voltage installations..
Advantages
1. It’s appearance is good, if carried properly.
2. It’s life is sufficiently long.
3.It can withstand the action of most chemicals such as
acids and alkalies.
4. It’s installation is easy and quick compared to casing-
capping.
5. It is cheap compared to casing – capping, metal conduit
and lead sheathed wiring.
Disadvantages
1. This system of wiring is not recommended in situations
exposed to sun and rain, unless preventive steps are
taken.
2. It can not be used in damp places.
3. Good work man ship is required to make a sound job.
4. Only suitable below then 250V.
 Metal Sheathed Wiring
• In lead sheathed or metal sheathed wiring the
cables used are insulated wires, TRS or PVC,
with metal outer covering of about 1 mm.
thick. The metal covering is known as
sheathing and is made of lead – aluminium
alloy containing about 95% of lead. The metal
sheathed cables are run on wooden batten
and are fixed to it by link – clips. The whole
metal sheathing efficiently earthed as per
IS732-1983
Advantages
1. It provides protection against mechanical
injury.
2. It can be used in damp situations.
3. It can be used in situations exposed to-sun,
and rain provided no joint is exposed.
4. It has longer life.
Disadvantages
1. It is costly system of wiring.
2. It is not suitable where chemical (acids and
alkalies) corrosion may occur.
3. In case of insulation damage, the metal sheath
become alive and gives shock.
 Conduit Wiring System
Conduit wiring system consists of either VIR or
PVC cables taken through tubes or pipes and
terminated at the outlets or switches / sockets. The
tube or pipe is known as “conduit”. Conduit wiring
may run over the surface of the walls and ceiling
or may be concealed under masonary work.
Types of Conduits
1. Rigid steel / metal conduit.
2. Rigid PVC / non-metallic conduit.
3. Flexible steel conduit.
4. Flexible PVC / non-metallic conduit.
Surface Conduit Wiring
All steel conduits should be coated or finished
with galvanized or enameled surface. Conduit
accessories must be of threaded type. No steel
conduit less than 12.7 mm. in diameter
should be used.
The conduit should be laid over the wooden
gutties, and should be fixed to the wall by
means of saddles at an interval of not more
than 1.2 m.
Concealed Conduit Wiring
The conduits (metal or PVC) are embedded along
walls or ceiling in plaster at the time of building
construction. The conduits are fixed by means of
saddles not more than 60 cm. apart. The VIR or
PVC cables are drawn into the concealed by
means of GI wire of size 18 SWG.
PVC conduits are increasingly being used in place
of steel conduits. PVC conduits are less expensive
and the labour time saved may be as much as
25% to 50% compared to the time taken when
installing steel conduits. PVC conduits are
resistant to acids alkalies, oil and moisture.
Advantages
1.It provides protection against mechanical
damage.
2. Metal conduits provides protection against fire
due to short circuit etc.
3. The whole system is water proof.
4. It’s life is long.
5. Replacement of defective wiring is easy.
6. It is shock proof if earthing is done properly.
7. PVC conduit wiring (particularly concealed) is
cheap.
8. PVC conduit wiring requires less time.
9. Concealed conduit wiring appearance is very
good.
Disadvantages
1. PVC conduit does not provide protection
against fire.
2. Metal conduit wiring is very costly.
3. Metal conduit wiring requires more time.
4. Metal conduit wiring needs skilled labour.
5. Very hard to find the defects in the wiring.
6. Very complicated to manage additional
connection in the future.
 General Rules for Wiring
The following general rules should be kept in mind
while executing the electrical wiring work:
1. The current rating of the cable / conductor should be
slightly greater (at least 1.5 times) than the load
current.
2. Every live wire / line should be protected by a fuse of
suitable rating as per load requirements.
3. Every sub-circuit should be connected with the fuse
distribution board.
4. All metal coverings used for the protection of earth
must be connected to earth.
5. No switch or fuse is used in earth or neutral
conductor.
6. Every apparatus should be provided with a separate
switch.
7. No additional load should be connected to the existing
installation until it has been satisfied that the installation can
safely carry the additional load.
8. All the switches and starters should be accessible to the
operator.
9. A caution notice (danger plate) should be fixed on very
equipment.
10. In any building light wiring and power wiring should be kept
separately.
11. When the installation has been completed it should be tested
before giving the supply and the leakage in the wiring should
not exceed 1/5000 of the maximum current of the load.
12. In 3-phase, 4 – wire installation the load should be
distributed almost equally on all the phases.
13. In case of 3-phse, 4-wire system, at the main board,
indication should be done in Red, Yellow and Blue. Neutral
should be indicated in black.
 Electrical Energy Distribution Systems
• As per the recommendations of ISI the maximum
number of points of lights, fans and socket
outlets cannot be exceed beyond 10 and the
maximum load that can be connected in such a
circuit is 800 watt. Hence in case of more load or
more points to be connected to the supply
system, then it is to be done by having more than
one circuit through
(a) Distribution board system
(b) Tree system
(c) Joint box system
(d) loop – in – system.
General Requirements of Electrical
Installation
a) Layout wiring
b) Conductors
c) Rating of lamp, fan and socket outlet point
d) Joint box and looping in system
e) Reception and distribution of main supply
f) Arrangement of apparatus on switchboards
g) Single phase supply
h) Three phase, four wire supply
i) Sub distribution board
j) Sub circuits
k) Diversity
l) Diversity factor for sub circuit
Layout Wiring
Conductors
Rating of lamp, fan and socket outlet point
Joint box and looping in system
Reception and distribution of main supply

 At the entry level there should be a circuit breaker or linked

switch on live conductor.
 No break in the neutral wire in the form of switch or fuse
throughout the installation
 All main switches should be either metal clad enclosed or of
any insulated enclosed pattern and should be fixed at close
proximity to the point of entry of supply.
Reception and distribution of main supply
Reception and distribution of main supply

Metal clad switchgear should preferably be mounted on any one

of the following type of boards
Hinged type metal boards
Fixed type metal boards
Teak wood boards
Arrangement of Apparatus on
Switchboards
Arrangement of Apparatus on
Switchboards
 Single Phase Supply

The consumer’s main switch fuse is connected after the meter

and feed a distribution fuse board. It is important to note that
fuses should be connected only in live wire and never in the
neutral wire. Similarly all switches installed on live wire only
and never on the neutral wire.
Simple diagram of Single Phase Installation
 Single Phase Installation with a number of sub-
distribution boards having a common main switch fuse
 Single Phase Installation with a number of sub-distribution
boards each connected to the mains through a separate fuse
 Service Connection
The line bringing electric power from supplier’s low voltage
distribution up to the energy meter installed at the consumer’s
premises is called the service connection.
The electric supply authority supplies power to the consumers
through a low voltage three phase four wire distribution system
called the secondary distribution system.
Large consumers supplied at higher voltages through three-wire
high voltage distribution system called the primary distribution
system (6.6, 11, 33 kV)
Service connection may be by mean of underground cables or by
mean of overhead conductors or cables.
Underground Service Connection
 Overhead Service Connection
This system is used when the consumer’s premises are more
than 45 meter away from the supplier’s distribution pole.
a) PVC or weather proof cable service line
b) Bare conductor service line
PVC or weather proof cable service line
Bare conductor service line

Service connection through GI Pipe

Bare conductor service line

Service connection with

PVC or weather proof cables
Service Mains
 Sub Circuits
-After the main switch the supply is taken to the various load
points.
-In the given circuit same circuit contains light, fan and power
circuit which has various drawbacks.
-Dividing the wiring into a number of smaller circuit is called sub-
circuit.
 Sub Circuits
Sub-circuit divided into two parts:
a) Light and fan sub-circuit
b) Power Sub-circuit
Location of Outlets.
Location of Control Switches
Location of Main Board and Distribution Board
 Guidelines for Installation of Fittings
• Switches, socket outlets and light points
• Fans
• Fuses and switches
• Earthing installation
Load Assessment
 Estimating and Costing of Electrical
Installation
• Quantity and specification of material
• Price list
• Labour charges
• Overhead charges
• Contingencies
• Profit purchase system
 Electrical Installations for Residential
building: Estimating and Costing of Material

• Choice of particular type of wiring depending upon a particular

use, financial implication and personal preferences.
• Installation work should be as per Indian Electricity Rules 1956.
• The planning and designing of electrical wiring should be done
before civil work start.
• Layout of electrical wiring prepare in advance and handed over
the civil engineer to make necessary provisions in the building
for electric work.
Example of Estimating and Costing of materials
Installation Plan
Schematic and Wiring Diagram
 Electrical Installations for Commercial
Building

Electric service and supply

• Supply authority supplies power to the consumer through low
voltage i.e. 415V/240V three phase four wire distribution
• Large consumers are supplied at higher voltage: 6.6, 11, 33 kV
three wire high voltage feeder
 Internal Distribution

• Small residential installation

• Medium Large Installation
• Large Installation
Large Installation