Rajib Hasan

Rajib Hasan is a U.S.-focused solar energy analyst and residential & commercial solar PV consultant with over 8 years of experience in rooftop system design, solar installation cost analysis, AHJ permitting processes, NEC compliance, and net energy metering (NEM). He works closely with American homeowners and businesses to evaluate solar installers, navigate federal and state incentive programs, and make data-driven, long-term solar investment decisions.Expertise Areas:

S. residential & commercial solar installation costs
AHJ permitting & utility interconnection processes
NEC (National Electrical Code) compliance
Net Energy Metering (NEM 2.0 & NEM 3.0)
Federal solar tax credits (IRS Sections 25D & 48)

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Printed circuit boards can go wrong over time because of wear and tear. They start malfunctioning, demanding repair and replacement. Hiring a professional for this job is very costly and time-consuming. But you can save yourself from this hassle by knowing how to repair a printed circuit board (PCB) safely. However, you will have to carefully diagnose and fix the damage to make it function again. But how do you do this complex task? Our easy, step-by-step guide is here for you. In this article, we will let you know how to repair a printed circuit board. We have covered everything from simple to complex troubleshooting of the circuit board. Let's dive in. Can a PCB be Repaired? The straightforward answer is yes if there is any physical damage. However, the full restoration will depend on the level of damage. Firstly, you will need to identify the root cause of the failure. Then, you will have to adopt a repair technique according to the damage level and type. This can range from eyelet replacement to laminating repair, pad or trace lifting, etc. You will need to execute a high level of technical expertise with enough patience. You will also need a degree of hand-eye coordination. How To Repair a Printed Circuit Board (PCB)? PCB is designed very smoothly using PCB design software. Now, let's start with the most important part: the PCB repair itself. Ten easy steps will allow you to regain the functionality of your printed circuit board. Follow the steps with caution and safety. Step 1: Map Out the Circuit Board Start by properly understanding the PCB schematics. Introduce yourself to the different components and sections. Know about the location of the power supply, ground connection, filters, capacitors, dividers, etc. This will help you troubleshoot easily without harming the other parts. Step 2: Visually Inspect the Surface Elements Search for the damage indicators using a magnifying glass or microscope. You should look for the signs of: Cracks or tears Cold joints Burnt/melted parts Lifted/missing parts Overlapping/missing components Dulled traces Excessive solder Tombstoning in solder joints. After visual inspection, use an oscilloscope to probe the signal strengths and waveforms at different points. This will help you test for the continuity of the circuit across the board. Finally, a multimeter is used to measure current, resistance, etc. Step 3: Gather the Tools and Other Materials That You’ll Need After detecting the issues, you have to select the repair methods. Then, you will need to gather the tools and materials accordingly. It will ensure a quick and uninterrupted repair process. Most PCB repair needs the following tools and materials: Tweezers Hot air gun Paper clip Soldering gun Adhesive copper tape Scissors or craft knife Pen Flathead screwdriver or sharp knife or sandpaper Cotton swabs and rubbing alcohol Are you done gathering the materials? Now, you’re ready to start the repair process. Step 4: Remove the Damaged Pad or Component Now, turn to remove the damaged components. Firstly, fix the PCB on a convenient surface to prevent it from moving around while working. Now, take the hot air gun and hold it 6 inches from the failed component. Turn it on and wait for a few seconds. Then, use tweezers to lift the component away. Use the hot air gun again if it does not come out in the first attempt. Use a sharp knife to remove the heat-damaged pads. You must try your level best to free the board from any residue with the least damage. So, be cautious and avoid applying excessive pressure to prevent any additional damage to the PCB. Step 5: Clean the Track and Remove Solder Clean the electronic circuit board and ensure proper adhesion and a solid connection for the new component or pad. You can use a sharp knife to remove any unwanted solder. You can also use a sharp-pointed screwdriver or sandpaper with a very fine grit. You should transform the track into a fully exposed one that is free of existing solder. It should look shiny and clean no matter what tool you use. Then, clean the component placement area more subtly. For this, dip a piece of cotton in rubbing alcohol and wipe off any residue present. Last, mark the end of the cut track using a pen. It will play the role of a guide for placing the new component or pad accurately. Step 6: Place Your Copper Tape Over the Track This step is important to make a strong connection for the new component or pad. In this phase, you will need to place your sticky copper tape over the top of the area you have prepared. Start by cutting a piece of copper tape slightly longer than the track. Then, place it over the track. Make sure this tape overlaps with the track and covers the existing through-hole and a portion of the area surrounding it. The ends of the tape should flush with the edges of the PCB. Step 6: Solder/ Weld The Joints Pick your solder gun to solder the joints of the new copper tape and the track on your repaired board. Start applying a small quantity of solder to a pad and heat it until it melts. Next, softly press the tip of the soldering gun against the copper tape. Make sure it remains static until the solder cools down and makes a strong bond. Repeat this procedure on the remaining pad, making sure both joints are properly soldered. Note that copper tape melts very fast at soldering temperatures, so begin this process only when you can finish this process in one go. Use as little heat as possible and work quickly. Step 7: Restore the PCB Through-Hole If necessary, you will need to restore the through-hole before soldering the new component. Use a sharp knife to remove any debris or obstructions from the hole. Ensure that it is completely clean and free from dirt or solder. Next, take a cotton swab and dip it into rubbing alcohol. Use it to clean any contaminant from the through-hole. Lastly, use a paper clip or a similar tool to resize the hole. Gradually widen it to match the size of the component lead. Step 8: Place and Solder Your Component Insert the component lead into the through-hole for a secure fit to solder the new component onto the PCB. Flip the PCB to work on the soldering side. Then, use a soldering gun to solder to one pad, melting it for bonding. Softly press the soldering gun’s tip to the pad to connect the lead. Hold until the solder sets and forms a strong connection. Repeat the process on the other pad. As we previously suggested, you should shorten the healing time as much as possible. Step 9: Trim Excess Tape From the Repaired Area After ensuring that the new component is in place, you can trim any excess tape from the repair areas. Just take a pair of scissors or a craft knife to trim the extra tape. Stay vigilant lest you cut any of the tracks or pads. Lastly, ensure a net and tidy appearance while maintaining the integrity of the circuitry. Step 10: Test the Board After finishing the PCB repair, use a digital multimeter to test electronic components on a circuit board and their functions, voltage, current, etc. Then, place the circuit board back in the device to test its operation. If you notice any issues, troubleshoot and check the solder joints, traces, and components. Remember that the board you just repaired may restore functionality to your PCB, but the pads, tracks, and connectors will never get back to their original, intact condition. 5 Signs Your PCB May Need Repair or Replacement Early detection is the key to an easy repair process. Let's look at five common red signals that indicate the need for PCB repair or component replacement. Visible Physical Damage or Corrosion Chips, cracks, and bent components indicate serious damage to your PCB. Also, subtle signs of corrosion, discoloration, moisture damage, and greenish or white deposits are some red signals. They demand quick cleaning, repairs, and replacements. Intermittent or Total Loss of Power Loss of power signals to the damage of multiple components in the PCB. Any kind of connection/cable-related interruption, broken input/output areas, fuses, voltage, or regulator problems need immediate attention. Overheating or Burn Marks on the PCB Frequent overheating can indicate damage to highly sensitive components, including capacitors, resistors, and diodes. If your workplace lacks ventilation and/or airflow, take overheating seriously. Malfunctioning or Non-Responsive Components Your devices' malfunctioning can mirror the malfunctioning of your PCB components. It can be a result of poor soldering or damaged traces. So, whenever you notice the usual unresponsiveness, use a multimeter to test your components. Frequent Circuit Shortages or Open Circuits Beware if your device becomes unstable and unpredictable during regular use. Faulty component connections or open/ short circuits can cause this. You should immediately address the issue to prevent permanent discontinuity. 10 Reasons for The Failure of The PCB Circuit Board If you know the reasons behind the failure of your PCB, the repair process will be much faster. Here are the ten reasons behind PCB damage. Physical Damage It is the most prominent reason for PCB failure. Physical damage can result from shock, pressure, falling, violent vibration/ crash, or manual PCB disassembly, leading to functional disruption. Trace Damage Traces are the paths made of silver and copper. Overheating, short circuits, dust contamination, power surges, or lightning strikes can damage traces. It hampers the electrical circulation, leading to malfunction. Poor Fabrication Misinterpretation of drawings can lead to wrong Printed Circuit Board design. It can lead to incorrect component assemblies, such as improper trace routing or an excessive number of bends. Therefore, leakage during the soldering process can create a big mess. This improper assembly and soldering will cause signal loss between the components. Component Failure It can happen because of excessive heat, aging, or electrical faults. Also, components can be loose or disconnected due to pressure, shock, or crashes. As a result, they require replacement, reattachments, or repair. Plating Voids Plating is a sensitive process of creating a conductive layer of the PCB surface. In this process, small empty spaces or gaps can develop within the layers. These voids can cause incomplete electrical connections, circuit breaks, corrosion, or the deterioration of the PCB. Acid Traps Sometimes, the etchant solution gets trapped in the sharp angles of the PCB. This creates acid traps that corrode the copper traces and pads, ultimately leading to complete PCB failure. Solder Mask Delamination Solder mask delamination means the partial or complete peeling off of the PCB's protective layers. Poor quality materials or mishandling, such as exposure to moisture, heat, or chemicals, are the common reasons behind it. Sometimes, mechanical damage also causes delamination and harms the PCB. Environmental Factors Environmental factors like excessive heat and humidity can cause the expansion and melting of the components. Additionally, exposure to chemicals, air, water, and other contaminants causes rust on the metal parts. Dust, fiber, hair, and insects during manufacturing can also cause quick PCB damage. Static Electricity Damage. Static electricity is the main cause of the damage to PCB during the assembly process. Whenever a PCB comes in contact with static electricity, it reacts adversely. Even a minor amount of static electricity can damage a PCB. Overheating Damage Some PCB assembly puts the components so close to one another. This can generate high temperatures and burnout between the components while running. Additionally, if the outside temperature is above 170 degrees, the PCB components will be damaged. How do You Repair PCB Soldering Errors? Soldering errors are a prime cause of PCB malfunction. Here are six effective ways to repair your PCB's soldering error. Method 1: Desoldering Sucker Desoldering sucker uses a spring-loaded vacuum to draw the solder upwards when it is heated. However, it can only remove the uncovered solder in a tiny amount. So, you will need to repeat the process several times to move the component. You will also need to remove the components covering the contact area. Method 2: Solder Wicking It is a pre-fluxed copper braid, also known as wick, solder braid, and desoldering wick. It removes excess solder. It also fixes solder bridging without harming the entire board or other components. Like the desoldering sucker, it can only remove the uncovered solder. Method 3: Hot Air Welding Station It works by melting the solder in the repaired area with its hot air. After this, you can remove the component using a vacuum lifter or tweezers. However, a long heating time can melt the copper plating and damage the circuit board. So, complete the task with as little heating time as possible. Method 4: Hot Plate It is a faster tool than the others. You just have to put the PCB on it, and it will melt all the solder joints at once, so you can remove multiple components at once. However, a large melting range can damage the entire circuit board or other good components. Method 5: Desoldering Station It comes with a soldering iron tip with a small hole in the middle. This will help you draw the solder as it melts. The only problem is that it will only remove the uncovered solder. Method 6: Hot tweezers It consists of thermal tweezers clamped over the soldering iron. The hot tip of the tweezers heats up and melts the solder by transferring the heat directly to the component. This tool is the safest for avoiding harming other components because it can melt the target component more precisely. How to Repair PCB Pads? PCB pads have several problems like lifting, corroding, or breaking down. Here are two methods to repair the PCB pads Lifted Pads Start by cleaning the pads with a cotton swab dipped in PCB-safe solvents. Smudge conductive epoxy on the pads. Then, press it down for equal adhesion. Give the epoxy some time to cure. Then, you can start the soldering process. Broken Or Contaminated Pads Firstly, remove the damaged pad. Then, scuff the solder mask of the pad to make the connected trace visible. Now, clean the space with a swab and solvent. Take a new pad and connect it to the trace. Then, apply conductive epoxy and hold it in place. Lastly, add the epoxy between the line and pads and cure before soldering. How to Repair Holes in PCB? PCB repair tools for holes or vias damage: Microscope Knife Wet wipes Hammer Flux Calipers (or drill guage template) Eyelet kit Eyelet forming tool Drill and Drill bits or ball mill Cleaning solvent, Weld and Welding iron. Step-by-step process of repairing holes in PCB Start by drilling in order from small to large. Continue until you find the drill that is slightly larger than the plated hole opening. Drill the plating hole smoothly with a hand drill. Make sure you drill perpendicular to the plane of the PCB. Use the drill template gauge to find the right size of the hole’s outside diameter. Ensure the correct eyelet size. Keep the flange side of the eyelet on the swage tool. Ensure the circuit board is level. Use a 90-degree pick to evenly “roll” out the flange. Use a hammer to create a flat surface. Apply liquid flux and weld the pads to the substitution eyelet. It will help to make an electrical connection. Make sure the solder “wicks” up to 75% of the sides of the flange. Do an electrical test to ensure connections are in place. How to Repair PCB Trace? Traces are the highly conductive track. They connect the microchips and other important components on a PCB board. Trace can fail due to corrosion, improper storage or leaks in the battery or electrolytic capacitor. Here are the PCB track repair steps: Firstly, identify the faulty trace. Then, spot the joints and pads on each extremity. Wipe off grease and dirt with a lint-free cloth dampened with rubbing alcohol. Clean until the copper color is completely visible. Carefully trim off any loose trace to avoid damaging other components on the PCB. Check for enough visible traces at the lifting end. If present, weld a wire jumper from that location to the other end of a connection pad or joint or trace. If it is not present, weld from one joint or connection pad to another. This will help you achieve the effect of completely replacing the trace path. How to Repair PCB Gold Finger? There are three main issues with PCB gold finger repair. They are, Scratched and Worn Gold Fingers Gold finger with Solder Contaminated Goldfinger Here is how to repair the scratched, torn, contaminated, or damaged edge contacts to functional durability and conductivity. Clean and check the areas that need re-plating. The degree of spatter or damage on the gold-plated surface will determine the need for replating. Stick the tape on and near the area where the solder splattered. Apply the solution to remove the residual solder. Check if you need to replace the pad. If needed, use a new gold-plated pad as a replacement. Rinse off the solution residue on the PCB. Then, inspect the board after it is fully dry. Connect a bus in the immediate vicinity of the re-plating area. If necessary, conduct an electroplating process with nickel and gold plating solutions. For this, use a small power supply with a cotton swab connected to the electrodes. Lastly, check the area after the plating is complete. Necessary Safety Measures when Repairing PCBs Repairing is not only about the safety of the PCB; it's about your safety as well. Before starting the process, you will need to take care of a few things for a safe operation. Here are the safety precautions you must take while fixing your PCB. Wear safe explosion-proof glasses. You can not prevent the solder from splattering while repairing the PCB. When the soldering iron melts the tin wire, some liquid will be splashed. Explosion-proof glasses are a must-wear item to save your eyes from these harmful objects. Discharge the Electronics Remember to unplug the electronic equipment before repairing an electronic circuit. Start your process after ensuring that the PCB board, especially the power supply and capacitor, is completely discharged. Also, remove the extra supplementary battery to prevent short circuits and protect your safety from electrocution. Wear an Antistatic Wrist Strap Electrostatic discharge (ESD) can generate static electricity. Anti-static wrist straps will help you avoid this electricity and dissipate excess charges. You should also wear anti-static hats and shoes. This combo will ensure your overall safety. Reduce Environmental Pollution Dirt on hands and the edges of the PCB, such as water and salt, can cause corrosion and short circuits. So, before repairing the PCB, clean your hands and use electronic safety hand sanitizer. You should also clean the edges of the PCB to ensure its cleanliness and safety. You can also wear work gloves for better protection. Designate a Clean Workspace You should repair your PCB in an extremely clean environment with sufficient light and ventilation. Also, ensure your workspace is free from all kinds of static electricity sources. Conclusion These are all the basics of repairing a printed circuit board. With the necessary knowledge and skills, you can fix your PCB safely. However, you will have to be very attentive, patient, and detail-oriented to get the work done perfectly. Repairing a printed circuit board is a very sensitive and delicate task. With practice and time, you will become an expert like a professional. To gain quick expertise, follow our step-by-step guide repeatedly and accurately. Do not forget to be cautious about not harming the good components while repairing the bad ones. FAQs Why Do You Need to Know Circuit Board Repairing? It saves you money and hassles when going to the professional. It helps regain your PCB's optimal functionality, saves time on replacements, and minimizes waste. For DIY enthusiasts, hobbyists, and engineers, repairing yourself will give you a sense of confidence, skill development, and accomplishment. It will help to handle the further damages more quickly and efficiently. It will stimulate your interest in exploring the elementary to advanced issues of PCB. What are the Most Common PCB Repair Techniques? The most common techniques for PCB repairs are Solder Joint Repairs, Trace Repairs, Recapping, and Ball Grid Array Repairs. Sometimes, you may need to combine two or more techniques or replace one. Can I Repair a PCB with Multiple Issues? Yes, you can repair a PCB with multiple issues. However, this will depend on the scope of the repair and the extent of the damage. If there are too many issues, a replacement will save you time and cost. How Much Does PCB Repair Cost? The cost fluctuates depending on the damaged components. However, the average cost of repairing a PCB is between $50 and $150. How do you repair a circuit board without a solder? Solder is not the only option for attaching wires to a circuit board. You can also repair a printed circuit board with wire wrapping or conductive adhesive like epoxy. How Do I Find a Circuit Board Repair Service Near Me? You can search for a circuit board repair near you online or ask for a recommendation. Do not forget to check the customer reviews shared on the repair service website. They will help you choose the right repair service. What are the issues with repairing a PCB board yourself? The main issue is that repairing a PCB board yourself can downgrade its reliability. The repair attempt and its heating and cooling cycle can lessen the life expectancy of the components and the board itself. So, always verify the PCB's reliability and status after repairing a PCB board. How-to-Repair-a-Printed-Circuit-Board

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