130 ELECTRONICS ENGINEERING WORKSH SL. RKSHOP, EXPERIMENT NO: § 4- DATE: INTERCONNECTION METHODS AND. SOLDERING PRACTISE ‘0 familiarize with soldering, RJ 45 crimping tool and wire wrapping Components require Wire stripper, soldering iron, solder flux, knife, tweezers, long nose plier, modular crimping tool, RI 45 cable, wire wrap tool, sufficient amount of wire Theory Soldering: Itis the process of joining together two metallic connectors at relatively low temperature of 270°C to 350°C .The joint where the two metal conductors are to be joined or fused in heated with a device called soldering iron. Then the alloy of tin (68%) and lead (37%) called solder is applied which melts and covers the joint. The solder cools and solidifies quickly. Soldering kit: It consist of soldering iron soldering paste(flux) and soldering lead Soldering Iron: Soldering iron consists of mainly four parts: 1. Heating 2. Soldering bit or tip 3. Handle 4. Connecting wire Soldering irons available in different sizes and watts such as low, 25W, 35W, 60W, 100W, 250W etc.All parts are replaceable. The wattage depends upon the current consumption and heat requirements, There are generally three types of soldering bits available “They are pencil bit, oval bit and bent bit. Selection of bit depends upon the place and heat requirements the oval bit is made up of copper which is a good conductor of heat. ———— Dept of ECE Universal Engineering College Page 31(CS ENGINEERING WORKSHOP SSS 454; ing lead solder) . ; oan as up of an alloy of Jead (Pb) and Tin (Sn).It is lable in the form of wire (The percentage of tin and lead is I tn ly equal but more the amount of tin the better 1s the © 1 Pee with 60% Tin and 40% Lead is ee older. An alloy range of 1 rPPPALS: efficiency of si used and has melting 93°C to 273 °C- soldering Paste (Flux) For a good soldering the surface oxides must be removed during the soldering process.Fiux is the cleaning agent § to remove oxidation during soldering Heating @ metal cause js oxidation prevents soldering from reacting rapid oxidation th e chemically with a metalFlux cleans the metal by removing the oxide layer Crimping ru-45 connectors are normally used in telephone and network cable. Occasionally they are used for serial network connections .When the RJ-45 connectors first came into use 290 they were primarily used for telephones. The great advances in ' technology ereated a need for another size connectors and the 5 RI-45 was adapted to fit. € 7 Wrapping ‘ ‘Wire Wrap is a method to construct electronic circuit board Electronic components mounted on an insulating board are interconnected by lengths of insulated wire run between their terminals, with the connections made by wrapping ‘ several turns around a component lead or a socket pin, Wires can be wrapped by hand or by machine and can be hand modified afterwards. Procedut : Soldering . al the parts must be clean and free from dirt and grease 1 i 4 + A small quantity of flux may be applied on the surfaces to be soldered Sepualbealvenal Egnecdng Gage ane iversal Engineeri fF ECE,Uni neering Colleg Page 32;CTRONICS ENGINEERING WORKSHOP © Clean the tips of soldering iron with a damaged spoon © Add a tiny amount of fresh solder to the cleaned surfaces to be soldered ¢ Heat slightly all parts of the joint with the soldering iron © Continue heating and then slightly apply sufficient solder to form an adequate joint © Remove and return the soldering iron safely to its stand © Allow two or three sec to set the joint © Do not remove the joint parts until the solder has cooled Crimping © Remove the outer coverage using crimping tool and separate the coloured wires inside the RJ 45 cable © Remove the middle insulation and the level the coloured wires « Put the cable in RJ45 connector © Crimp the connectors using the crimping tool until it is properly connected Wrapping ¢ Remove the insulation of the wire © Put the wire into the lower holes of wrapping tool «Put the second wire to the holes of wrapping tool © Rotate the wrapping tool until the wires are properly wrapped Familiarized soldering process, crimping tool and wrapping processes Dept of ECE,Universal Engineering College Page 33,