1. Soldering PCBs – Siren Kit Week 1 of 2
Nick Carter
May

2. Activity Plans Soldering a Siren Kit (Elenco SP-1)
Week Make a European Police Siren PCB – part 1
Learn Soldering on PCB Breadboard (This is a custom breadboarding kit)
Learn how and practice
Learn to solder wires in PCB
Get parts kit and look at it
Learn about soldering Resistors and Capacitors and solder some
Solder Resistors (11), Capacitors (6) and wire jumpers (2), Potentiometer (1)
Week Make a European Police Siren PCB – part 2
Complete Resistor and Capacitor component soldering – and links (if not done)
Learn about Semiconductors soldering and solder them
Solder Transistors (2), LEDs (2), Integrated Circuit (1)
Learn how the circuit works at high level
Solder Speaker and Battery
Test the Circuit
Learn Unsoldering
Change 2 resistors to change the Tone
Troubleshoot & fix if necessary.

3. Introduction to Soldering (PCB Bread boards)
Peeuuu!
Cool
HOT
Nick Carter 4/21/2016

4. ONLY TOUCH or HOLD THIS PART
Safety Rules
ALWAYS wear SAFETY GOGGLES
Soldering Iron CAN BURN YOU BADLY
Soldering iron CAN BURN YOUR CLOTHES
Soldering iron - in the HAND or in the STAND
PUT it back in the STAND when not soldering
Cool
HOT
VERY HOT MELTS METAL
ONLY TOUCH or HOLD THIS PART
Hot like boiling water
OW!
OW!

5. Solder and the Joint
Solder is a metal mixture, mostly tin, that melts at 400 deg F (like your kitchen oven on MAX.)
Parts connected by solder are JOINED together. It is Solder joint. They are joined in 2 ways:
Solder makes a MECHANICAL CONNECTION fastening parts together – used for copper water pipes and electrical circuits
Solder makes an ELECTRICAL CONNECTION between the parts – used for electrical circuits
To make a good joint, the solder needs to stick to the parts (wet the parts). Wetting is also called “tinning”. It is good to have parts tinned and silvery before soldering.
The iron tip needs to be hot, clean and silvery
The parts need to be clean so solder will stick to them
The parts need to be hot before applying solder
Solder contains a chemical – FLUX - that cleans the parts.
It makes the smoke you will see. Do not breath this  Peeuuu!

6. Soldering is Joining Things Together We make a solder joint like this
Mechanically join the parts or hold them together.
They should not move while solder cools.
Heat both parts with the soldering iron.
3 to 5 seconds depending on size of wires
Too much heat can damage components
If the component has more than 2 leads, after 1, go solder a different component and come back so that the component does not overheat
Poke the solder wire onto the hot joint and it will melt and wet the parts we want to join
Add solder wire until parts are wetted and holes are filled.
Take the iron and solder wire off the parts so they can cool (Solder first, or it may stick to the joint)
Let the parts cool before moving them.
A good solder joint will be shiny. If it looks grainy, melt it and let it cool again.

7. Soldering PCB – Looks Like This
Cool
HOT
3. Push Solder into joint
1. Heat both parts with Iron
2. Wait until parts are hot (3-5 seconds)
4. Solder wets both parts
5. Take away solder and iron and let joint cool
OOPS Note:
If you take away the iron before the solder, the solder may stick to the joint.
If this happens put the iron on again to melt it and take away the solder.

8. PCB Breadboards
There are several kinds. Try to find most suitable for what you are building.
1 pad per hole – make connections with wire
Groups of pads/holes connected together
Has special patterns for surface mount or special components
Has holes in groups that can be separated by cutting between them to make smaller groups

9. PCB Breadboard examples Not always pretty, but functional
VERO board
Has drill-like tool to cut breaks
Added wires to join components

10. Your Practice Bag Contains
Solder
Copper Braid
Small PCB Breadboard
Stripped copper wires
One has long bare end

11. Soldering Practice 1 - Solder Bridges
Heat pad, apply solder, make nice low blob.
Heat next pad over, apply solder, make blobs join
If they don’t join add more solder
This is a “solder bridge” joining the pads
Remove the bridge by wiping tip of iron between pads
Make another bridge and remove it
Use the “Solder Wick” copper braid to suck up the extra solder so you separate pads again
Push braid on extra solder with iron tip and wait until it heats and sucks up the solder them remove it.
Braid gets hot so I made “handles” 
FYI Another tool for removing solder is a solder sucker
Solder is nice and shiny

12. Soldering Practice 2 – Component Wires
Take a jumper wire and feed bare ends of wire through 2 holes and bend apart to stop it falling out, heat wire and pad, apply solder, melt it to wet all parts and cover the pad. Leave other pad unsoldered
Apply the iron and count 3 seconds to heat the wire and pad then apply solder – it should flow and wet the pad and wires to join them
Do this for 3 wires next to each other – use the one with long end last.
Bend the long unsoldered wire ends to go across the other unsoldered pads with wires Solder all 3 pads and make sure all wires are joined. This is how you use this breadboard to make circuits.
Trim wire ends.
Hold then cut.
Top side
Bottom side
Bend this
long wire across
on underside

13. This will work , but……. What could be better with this?
Joining wire can touch unused pads
- Use pliers to form wire before soldering
Bare wire should be on underside.
- Push wires through more
Solder does not cover wire and pad,
- needs longer heat up time and more solder

14. Planning your Circuit
This is like designing a printed circuit board and you can make the design into one later
If you have several holes connected together, match up a group of holes with each of the component connections using a hole for each component wire.
How many holes for these circuit connections A, B, C, D, E and F? How far apart should we make them?
LED D
Battery + B A C
4.7K
100 E
NPN
4.7K F
Battery -

15. Some Free Design Tools (I have only tried Eagle CAD and 123D)
Stripboard Magic
Fritzing (for regular breadboards)
Eagle CAD – put your component ends on same places as board holes. You can use layout tool but make the breadboard instead of PCB
123D Layout, Simulate, PCB layout not good yet. Working on Eagle CAD file import/export

16. What is in SIREN Parts Kit DO NOT OPEN SMALL BAGS YET
Instruction Manual – Do not need this yet
Lots of good information here
Use for reference and more detailed learning
Several Bags - DO NOT OPEN YET
Circuit board
Bag with Semiconductors and Copper braid.
Bag with card with resistors and capacitors.
Speaker
9V battery snap with wires
Coil of solid wire
Tube of Solder

17. Soldering Resistors and Capacitors -1
Polarity
Resistors go either direction
Wire jumpers also.
Capacitors go any direction - UNLESS MARKED
Do not bend lead
close to this part
– it can break
Negative Sign
Ceramic disc capacitor
Goes either direction

18. Soldering Resistors and Capacitors -2
Bend leads over at about 45 degrees so component does not fall out when you turn the board over to solder.
Solder it
Trim leads
Do not bend lead
close to this part
– it can break
Bend
Good joint
Too cold
Too little solder
Too much Solder

19. Solder Resistors, Capacitors and Wires to the PCB
Take out the following from the bags
Solder tube
Bag with resistors and capacitors on card
Check none are missing. Check all have proper value - colors match bands and card label.
Printed Circuit Board (PCB)
Get 2 wire links from me ( I cut/stripped them already)
Solder wire links first
Take one component from the card at a time starting at resistor end, insert, bend leads, recheck the Component number against card,
Make sure electrolytic capacitor + and – matches PCB
Turn board over, solder leads.
Trim leads. Can be done as you go or if the leads are not in the way you can wait and trim several at a time.
HOLD THE END OF THE LEAD WHEN YOU CUT IT OR IT MAY HIT SOMEONE!!

20. Clean-Up and Storage
Finish soldering and trimming any component you started
Put everything back in the ZIPLOC bag
solder
unsoldered components,
PCB
Anything else you got out of the bag, e.g. Manual unless you read it at home – but it is downloadable online.
Make sure your name is ON the bag or on paper IN the bag

21. BAG CHECK Make sure your bag has Your Name Circuit board
Bag with Semiconductors and Copper braid.
Bag with card with unsoldered resistors and capacitors.
Speaker
9V battery snap with wires
Coil of solid wire
Tube of Solder