Fabrication and testing a Printed Circuit Board for a rectifier

circuit

Objective:

To fabricate and test a PCB for a rectifier circuit.

Software Required:

Any software used for PCB design. Example: Cadence – OrCad, ExpressPCB.

Circuit Diagram:

Procedure:

At first, the diagram given below is drawn using ExpressPCB software.

A. Procedure to draw the PCB layout in ExpressPCB:

1. Open a new file in ExpressPCB.

2. Go to view and then options to fix the measurement system either inches or mm.
For this project all the measurements are in mm.

3. Then go to Layout and then Board Properties to select the no of layers. For this
case, 2 layers option is selected.

4. Then fix the board size by selecting the locus of right hand bottom corner point. Here
the size is 85mmX50mm. That means x = 85mm, y= 50mm.

5. Then select the option place a trace, which is available in the left corner of the
window. The width of the selected trace is 3.05mm. The drop and down button is
available on the top to select the width of the trace. The current carrying capacity of the
board is proportional to the width of the trace. To know the current carrying capacity of
the traces go to http://www.expresspcb.com/tips-for-designing-pcbs/

6. Place the traces as per the diagram.

7. Go to the component option, then component manager and then Connector - Wire
connection (0.052 inch hole) to select the wire connectors for placing 4 nos. of diodes.
For this layout, 8 nos. of connectors are required which is marked as W in the above
diagram.
8. Go to the option Place a pad (through hole or surface mount) to place holes for
input and output banana connectors. After selecting this option one drop and down
button will appear on the top of the window. From that button select 7.62mm round pad
with 4.24mm hole.

10. Go to Place a circle or arc option to place arcs at the corners of the circuit in order
to ensure the connectivity at corners. However this step is optional.

9. Then save the file with an extension of .pcb.

Link for free download of ExpressPCB: http://www.expresspcb.com/

B. Procedure to prepare Printed Circuit Board using wet process:

I. Coating of liquid photo resist on PCB using Photo Resist Dip Coating Machine
(PRDC)

A. Take a board of specific size from the laboratory store.

B. Ensure the work area is a yellow room and the tank of PRDC machine has been filled
with liquid photoresist.

C. Clamp PCB firmly on hanger provided.

D. Ensure machine is plugged in. Switch on DOWN movement switch. The motor will
come on and the PCB will be lowered into the uncovered Resist tank.

E. When the board reaches to the bottom, the limit switch will stop downward
movement. Switch on the UP movement switch after few minute and bring the PCB
back up to the starting mark.

F. After excess photoresist drips off, unclamp board for further processing.

Caution

Clamp the PCB firmly on the hanger.

II. Curing wet Photoresist on PCB using PCB curing (Oven) Machine

A. Clamp the PCB to the oven lid firmly, lower in to protocure chamber, so that it sits
firmly.

B. Switch ON the protocure mains and see that the mains indicating lamp (Red colour)
glows and air circulating fan starts.

C. Switch ON the temperature switch (Yellow) for the heater to switch ON.
D. The thermostat is preset (normally 200-2500C).

E. Depending on the time required (4-5 min) in the chamber set the timer rotary switch
to ON position.

F. On completion of the time, the timer will switch off and remove the PCB carefully.

III. Exposure of PCB in to Double sided U.V Exposure

A. Unclamp and lift lids unlatch and lift the top glass slowly and lock at rest position.

B. Put the stainless steel ‘C’ type stand in side. Ensure glass is clean, before setting the
PCB and phototool (Film negative for transfer) aligned and as much to the centre of the
glass as possible. Place film firmly and aligned with the PCB. Bring down the top glass
over the PCB and lock.

C. Start power switch ON to start the unit.

D. Select the change over switch for top or both (preferably both) to start the top tube or
both U.V. tubes.

E. Set the process timer knob from 0 to 10 min (generally set 3-5 min).

F. The timer will automatically count down to 0. After time has lapsed the U.V. lights will
automatically switched off.

G. Unclamp the lid and remove PCB for further processing. Keep film in a clean paper
for further processing.

Caution

Keep the glass clean for clear image transfer.

IV. Washing of PCB with LPR developer

A. Keep the developer liquid in a pot and keep the PCB inside the liquid for 3-5min.

B. Then wash the PCB in water for 2-3 min.

C. Apply LPR dry blue on to the PCB and keep for 2-3 min.

D. Wash the PCB again using water.

Caution

LPR developer solution is evaporating in nature, so keep the jar closed always.

Don’t touch the dry blue with bare hands.

V. Etching Process

A. Clam the PCB onto the jig connected to the lid of the machine. Once it is securely
clamped, lower the tank, so that lid fits properly.

VI. Drilling in to PCB

A. Select proper drill bit to make hole on the PCB.

B. Switch on the drill machine and adjust the knob position to desired r.p.m.

C. Fabrication of the components on to the PCB

I. Fabricate the components on the PCB using soldering rod and wire.

D. Testing of PCB

I. Connect the input with a 230/12 volts transformer.

II. Check the output voltage in oscilloscope.

III. Store the graphs with the average and rms values of input and output.

Results and Analysis:

Compare the experimental results with the theoretical results.