EVALUATION OF SOLDER-TIP

FUME EXTRACTION SYSTEM

By: Gener Arciaga

Date: 2010-12-22

Gener Arciaga, Process Engineer 2010-12-22

 EXECUTIVE SUMMARY:

This evaluation is a continuation of the previous fume-extraction systems that were

evaluated (see “EVALUATION OF FUME EXTRACTORS USED FOR HAND-SOLDERING PROCESS” dated 2010-10-29.)

In this evaluation, a demo system for a soldering-tip extraction was set-up at Light
mark PCBA Assembly line. The system seemed to work very well in extracting fumes
at the tip of the soldering iron.

The tip extraction works well when the extraction tube is directly on top of the
soldering iron tip and the smoke is following a laminar flow pattern. However, during
the soldering process the soldering iron can be orientated sideways. Solder fumes
generally tend to go upwards so when the tip extraction is sideways, it cannot suck
the smoke from the tip. Another observation was that fume extraction efficiency is
affected by the rapid hand-movement of the operator. Operators tend to move the
soldering iron away from the joint rapidly after forming the solder joint. In this
manner, the laminar flow of the smoke is disturbed and goes to different directions,
thus the extraction tip cannot suck all the smokes.

After 1 week of operation, operators noticed a decrease in sucking pressure. The

extraction tube was filled with solder balls and solder splatters inside and some foam
fibers (wet foam to clean soldering iron tip). After another week of operation, the
motor pump over-heated and broke down because the hoses were totally blocked.

On top of these issues, operators found the tip extraction attachment interfere with the
movement and cleaning of the soldering iron tip.

Overall, the solder-tip fume extraction system did not meet the expectations.

Gener Arciaga, Process Engineer 2010-12-22

PROJECT:

Evaluation of Solder Tip Fume Extraction System

OBJECTIVES:

1. To evaluate the overall effectiveness of Metcal solder tip fume extraction

system.

BACKGROUND:

Several standard fume-extractors were already evaluated (see previous report dated
2010-10-29). None of them so far has effectively extracted solder fumes that met the
objective of these studies.

Gener Arciaga, Process Engineer 2010-12-22

EVALUATION/ACTIVITY MADE:

A demo unit which consists of the main filter unit - Metcal BVX-208, BTX-CK4-50
and AC-FX1 kit. The system was set-up at the Light mark Assembly Line for 3
soldering stations. Operators were asked to use the system for the next 1-3 weeks.

Main Hose from Vacuum

Pump BVX-208

Fume-Extraction
Tube attached to the
soldering iron

Gener Arciaga, Process Engineer 2010-12-22

RESULTS AND ANALYSIS:

During the first use of the system, there were adjustments made on how far the
extraction tube must be from the tip of the soldering iron. If the fume extraction tube
is too close to the tip, two issues came up – (1) tube interferes with the cleaning of
the tip and (2) soldering iron is limited to use only one side of the tip. If the fume
extraction tube is about 1-inch away from the tip, the solder fumes cannot be
sucked. So the fume extraction tube was moved around half-inch away from the
soldering iron tip that causes the less interference with tip cleaning and still can suck
up solder fumes.

1st week of operation:

• Difficulty in handling: Soldering irons cannot be turned easily because of the

weight of the hoses and the limitation to use of only 1 face of the solder tip.

• Difficulty in cleaning: Tube position interferes with the cleaning of the tip.

• Accumulation of solder balls/splashes inside the tube: Solder balls and

solder splashes were being sucked too and stick inside the inner wall of the
tube.

• Loss of sucking pressure: Due to reduced diameter caused by the sticking

solder balls/solder splashes inside the tube, the sucking pressure was
reduced.

• Fume extraction tube orientated sideways: Smoke tend to go upwards, thus

tube extraction cannot suck all the fumes effectively.

• Rapid movement of soldering tip: Solder operators tend to move the tip away
from the joint quickly after the solder joint is formed. The laminar flow of the
smoke is disturbed, thus smoke went to different locations and the tube
extraction tube cannot suck all the fumes effectively.

Gener Arciaga, Process Engineer 2010-12-22

 2nd week of operation:

• One soldering station was totally not sucking any more fumes.

• Users asked removal of the system from the workstation.

Investigation of the cause of loss of sucking pressure

The clogged fume extraction tube was replaced with a new fume extraction tube
(spare) but there was still no sucking pressure felt from the tip. The other soldering
stations with fume extraction tip were removed and the 2 open ports were plugged
to hopefully increase pressure. This did not help either. The main hose was
removed from the main pump and it was discovered that the main pump is turned-
on but is not running.

The main hose was shortened with only one solder fume extraction tip connected.
Since the supplied pump was not working anymore, the main hose was connected
to the existing BVX-200. Still, there was no sucking pressure from the tip of the
fume extractor tube. The secondary hose was removed from the main hose port
and found out the port was blocked with solder and foam lump (see pictures below)
that was why there was no sucking pressure.

5mm

Port is blocked with

solder/foam lump

Gener Arciaga, Process Engineer 2010-12-22

 Further investigation revealed the amount of solder balls and some contaminants
were stuck inside the main hose (see pictures below) which may eventually clog the
whole system given that the system was just in operation for 2 weeks.

Below are the pictures of clean and clogged fume extraction tubes:

Clean Tube After 2 weeks of use

This fume extraction system can suck anything (fumes, dirt, fibers, solder balls,
solder splashes) that gets close to the tip of the tube because it is always sucking
100% of the time as long as the main vacuum pump is on.

Gener Arciaga, Process Engineer 2010-12-22

CONCLUSION AND RECOMMENDTATIONS

Solder Tip fume Extraction system is not a very effective system in extracting fumes
from a soldering workstation specific to Light mark assembly. It has plenty of
disadvantages than benefits.

This confirms the industry’s and vendor’s consensus that very few companies buy
this system because it has lots of issues from the operator’s usage perspective, not
to mention the effectiveness of the system to suck fumes and probably the cost of
maintaining this system.

It is recommended to investigate a custom-designed fume extraction system

designed for Light mark assembly application.

- End of Report -

Gener Arciaga, Process Engineer 2010-12-22