SUBJECT: CE318F – SAFETY MANAGEMENT

A JOB HAZARD ANALYSIS

JOB TASK: Making a Printed Circuit Board (PCB)

A printed circuit board, or PCB, is used to mechanically support and electrically connect electronic

components using conductive pathways, tracks or signal traces etched from copper

sheets laminated onto a non-conductive substrate. It is also referred to as printed wiring board (PWB)

or etched wiring board.

JOB STEPS:

Below are the steps on how to make a PCB:

1. Make a circuit layout using the Proteus Professional program. Print the layout in a photo paper

using laser printing. After printing, cut the circuit layout and remove the excess photo paper.

2. Using an iron-saw cut a piece of copper clad sheet with the size of the circuit layout previously

printed in the photo paper. Smoothen the sides and remove the dirt from the copper clad sheet

by sanding but be careful not to remove the copper coating in the copper clad sheet.

3. Place the photo paper and the copper clad sheet together. Make sure that the printed circuit

layout is facing the copper clad sheet.

4. Using an electric iron, iron the photo paper into the copper clad sheet for about 20 minutes until

the photo paper sticks to the iron clad.

5. After ironing, soak the copper clad sheet in the ferric chloride solution in a small container for

about 30 or more minutes until the unnecessary part of the paper is dissolved and only the

copper pathways or tracks remain in the copper clad sheet. Gently shake the container for faster

effect. After soaking, remove the copper clad sheet and wash it with water.

6. Sand the copper clad sheet gently to remove the paper that remains in the copper pathways or

tracks. Be careful not to remove the copper tracks in the copper clad sheet.

7. Using a small electric drill, make very small holes in the copper clad sheet as indicated in the

circuit layout where the different components will be placed. Voila! The PCB is done.

JOB HAZARD AND CONTROL:

TASK DESCRIPTION:

Cutting the circuit layout from the photo paper using a cutter or scissors.

HAZARD DESCRIPTION:

Using bladed instruments might cut or wound the finger or hand if used carelessly.

HAZARD CONTROL:

Use the cutter or scissors with extra care. Put it in the right place after use to avoid accidents. If using a cutter, retract the blade to its case or handle after use.

TASK DESCRIPTION:

Ironing the photo paper into the copper clad sheet using an electric iron until the photo paper sticks to the iron clad.

HAZARD DESCRIPTION:

Losing grip and dropping the iron to your foot.

Possibility of electric shock when the wire conductor is accidentally touched while plugging the electric iron into the wall socket.

During ironing, the hot metallic bottom of the electric iron can cause burn in the skin.

During ironing, the copper clad sheet gets hot making it hard to touch or to hold with the bare hands which can cause burn in the skin if incorrectly handled.

HAZARD CONTROL:

While using the iron, hold it carefully to avoid dropping it into the floor or onto your own foot/feet.

Be extra careful in plugging the iron by making sure you are not to touch the conductor while plugging it to the wall socket.

Do not touch the bottom of iron when using it to avoid unnecessary burns in your skin.

Use any heat insulator in your hand to hold the hot copper clad sheet or use any clamp that will hold the copper clad sheet while ironing.

TASK DESCRIPTION:

Soaking the copper clad sheet in the ferric chloride solution in a small container for about 30 or more minutes until the unnecessary part of the paper is dissolved and only the copper pathways or tracks remain in the copper clad sheet.

HAZARD DESCRIPTION:

Iron (III) chloride is toxic, highly corrosive and acidic. It is harmful by inhalation, ingestion and in contact with skin. It also makes nasty stains in the clothes or furniture.

HAZARD CONTROL:

Since it is corrosive, it can cause burns in your skin. Use gloves for handling protection.

Use an apron or similar clothing protection to avoid staining your clothes.

Don't expose the compound to a lot of light, since it decomposes to HCl (Hydrogen chloride) which could potentially be dangerous.

Wash your hands thoroughly with soap and water.

When you think it is still reusable, store or put it away from the reach of children. Otherwise, dispose it in the ground.

TASK DESCRIPTION:

Making very small holes in the copper clad sheet as indicated in the circuit layout, where the different components will be placed, using a small drill.

HAZARD DESCRIPTION:

The rotating needle might cause injury if use improperly or carelessly.

HAZARD CONTROL:

Read the input voltage rating of the drill before use. Always use an adapter if the drill requires.

Hold the drill handle tightly while making holes in the PCB.

Turn off the drill when not in use.