Fume extraction systems are meant to ensure healthy working environment for the operators, but the system doesn’t add any market value to the product, limiting its adoption in the industry. Here is an article on Fume extraction systems, why it’s a must on a workbench and solutions available in market.
Electronics production is heavily concerned with soldering components on to printed circuit boards (PCBs). A small part of the operation is automated, using wave soldering machines, with the majority being manual as operators add individual components using hand soldering irons. Further hand soldering and desoldering is frequently used in rework stations to carry out repairs and upgrades. All of this soldering activity generates fumes which can cause long term, serious harm to operators if inhaled. Employers may face expensive compensation claims as a result. Most countries recognize this and enforce legislation to ensure that employers protect their employees from these harmful effects. Even in regions without such legislation employers have an ethical duty to provide such protection. In this article we look at the nature of the risk, the relevant legislation, and how fume extraction can be managed safely, effectively, energy-efficiently and in compliance with regulatory demands. There are many applications where fume extraction is necessary for health concerns and safety plus laws pushed it. Manufacturing and assembly operations rework centers, hand soldering stations ect, anywhere where there are harmful fumes and particles in the air that can be detrimental to worker health and safety. Traditionally used leaded solder used to be highly dangerous for operators heath. Lead-free soldering is not that much but considerably hazardous as with any type of welding or soldering applications there will be smoke and fumes. These fumes contain a variety of toxins depending on the materials being used and highly hazardous for operator. And here is why Fume extraction systems became must for any SMT or soldering workstation. According to the application, one installs a small affordable bench top fume extractor. These are smaller, direct plug units that can maintain a clean air workspace for up to 8 – 10 employees per machine which can be the perfect solution to many applications including solder, rework, manicure work, ect. A bench top fume extractor uses filters and suction to keep harmful fumes and particles out of the air and contained until disposed of. They are easy to set up and maintain, and can quickly be moved to any location that needs fume extraction. Large scale soldering or welding operations, or even a large salon/cosmetology school may find more of a benefit in a whole building fume extraction system where a central unit is installed and the building is outfitted with ducting and vents that maintain a constant level of air filtration. This can be a costly option due to the amount of work that goes into installation, but may be the best solution for operations where fumes are constant, the volume of fumes are high, or where the number of employees is such that individual extraction units are impractical. These units pull fumes and particles through vents installed in the building, the air gets filtered and processed in the main unit and can then be discharged into the atmosphere or recycled back into the building.
Choosing the Appropriate Solder Fume Extractor
Whether you’re looking for a one- or two- solder tip workstation solution, or a larger system for a production cell, there are a number of key elements to consider. These can help to identify the most suitable choice of manufacturer and model for your application. For all systems, the highest priority is naturally the effectiveness of the extraction and filtration performance in protecting workers from harm and their employers from non-compliance issues or compensation claims. Features such as high volume extraction, and a wide range of easily-fitted extraction arms, nozzles and accessories to optimize workstation configuration are important. However, each different system also has other considerations of its own. For volume extraction, economy and convenience of set-up and use can be important. Volume extraction systems should be mobile to maximize utility and minimize installation costs. Maintenance costs are also reduced if the arms and nozzles do not need daily cleaning, and energy costs are saved if the cleaned air is re-circulated back into the work area rather than using external air that needs heating or cooling – note however that an exhaust to atmosphere option may be needed for situations where recirculation is not allowed. Using highly reliable, maintenance-free turbines and motors, and generally investing in products with high-quality components also reduces maintenance costs as well as possible downtime. Filter exchange should be as easy as possible too. Remote control and automation also improves efficiency; cost savings can be made through automatic air flow control which intelligently regulates the airflow at each workstation, regardless of how many workstations are connected. This increases filter lifetime and saves energy. Filter condition monitoring ensures that clogged filters are noted and exchanged before they can excessively degrade the extractor’s operation. An RS232 serial port on the extraction unit provides an opportunity to integrate the extractor’s software with a plant wide management system or other process equipment. There are other issues that relate to the utility of the systems. If the extraction unit is centralized, what is the maximum bridging distance in meters to the work areas, and how many work stations will it support? If the extraction units are on wheels they can be re-deployed with minimal effort as production requirements change. The acoustic noise generated should be checked if the extraction unit is to be sited near workers.
What type of soldering are you doing?
The type of soldering [e.g. Hand Soldering, Wave Soldering, Reflow Soldering, Production Soldering, Maintenance Soldering, Pipe Soldering, Mechanical & Aluminum Soldering, Resistance Soldering, Stained Glass Soldering, etc.] being performed by the operator directly determines the size, configuration, and air volume that the fume extractor will require in order to be effective. Certain applications can release more fumes or may be spread out over a larger surface area; this may require a more powerful fume extraction unit
How often do you solder?
Do you solder 8 hours a day, 5 days a week? Or do you solder for a half an hour once a week? The amount of time spent soldering should be taken into consideration when choosing an appropriate fume extractor. Extractors with more powerful fans, larger filter media, and pre-filtration should be selected if soldering is performed on a regular basis.
How big is your workspace?
Can your bench top workspace accommodate a fume extractor, depends highly on your workbench set-up. Small footprints are an extremely important factor for bench top solders fume extractors. If you don’t have room on your bench top, would you prefer a wall-mounted unit to hover over your work area or a floor unit that reaches your work area via flexible hose?
How many operators are soldering at once?
Is there one or multiple operators soldering, many companies’ offers multi-operator fume extraction units that equally share air volume through separate self-supportive or “python-style” flex hoses.
ESD-Safe Fume Extraction
For those working on applications that need to be protected from Electrostatic Discharge, such as electronic soldering, this feature may be a primary requirement as you search for a solder fume extractor. If your process calls for an ESD-Safe unit, suitable products are available from many companies.
Type of Solder
In addition, the type of solder being utilized is important in determining the appropriate filtration media. For example, is lead-based solder being utilized? If so, a HEPA filter is critical to use in order to capture the lead particulate.
Tip and Volume Solder Fume Extraction Systems by BOFA
BOFA’s range of Tip and Volume fume extraction systems are designed for electronics soldering applications that generate fume comprising; resin acid particulate and gaseous organic compounds within the Electronics sector. Solutions are available for manual and automated processes including: wave solder, reflow, selective solder and conformal coating applications. T1, TVT2 and T15 offer tip extraction for lead free soldering applications. These are high volume units that are designed to extract and filter the fumes and debris. The systems are ideally suited for soldering iron tip extraction, vac pens, flexi fume arms and any other number of applications that requires close proximity micro extraction.
The T30A, T60 and T100 are designed to extract and fumes and debris through small bore hoses and attachments. Ideal for soldering iron tip fume extraction. Due to high concentration of debris generated from up to 100 operators, these systems have been designed to keep the unit compact, but still utilize a comprehensive filter system. With this in mind, the units incorporate a facility for retaining a high concentration of particulate within the filter enclosure. These systems have a built in silencer that has a collar to allow for redirection or external venting of filtered air if required. The V200 / V250 volume fume extraction units have been designed primarily to extract the fumes generated during hand soldering in the electronics industry. These portable systems come complete with extraction arms and installation kit that contain everything required to set up one or two operators with ease. Minimal installation allows the units to be moved with the work bench when factory layouts need changing due to production challenges. The low noise levels and fully comprehensive filtration units are ideal for factories with changing production demands.
Our larger volume extraction units have the capacity to be used on all manufacturers of automated soldering systems such as reflow ovens. Large filter capacity and vast carbon filters ensure long filter life and optimum extraction even when lead free solder is used. Adjustable and regulated air flow control ensures consistent temperatures within the solder machine/reflow oven, throughout the life of the filters. Easily accessible filters are accommodated by the uniquely styled V2000 ‘clam shell’ and V4000 ‘gull winged’ doors, which allow for maximum space and ease when changing filters.
Solder Fume Extractors by Sentry Air Systems Inc.
Bench top Fume Extractor Winged Sentry: Model # SS-200-WS
Sentry Air offers several different styles of source-capture fume extractors for solder fume control, solder pot and wave soldering fumes. Configurations include bench top, wall-mounted, portable, and floor models. These compact and energy-efficient systems feature quiet operation, convenient mobility, and high efficiency filtration media including HEPA and/or Activated Carbon. ESD safe units are available for those concerned with electrostatic discharge while working with sensitive electronic equipment. Modular design and sturdy construction make Sentry Air’s Solder Fume Extractors a convenient and effective solution for solder fume control needs. Typical uses may include: solder pot fume control, solder smoke, lead-based solder fume removal and a variety of other soldering processes. The Winged Sentry is a compact bench top fume extractor that offers a unique and customized design. It features adjustable “wing flaps” to assist in directing fumes towards the unit’s inlet and into the filter chamber. The operator can place these wings in the most effective position for their particular application, or they can be positioned flat against the sides of the unit to conserve space.
Appropriate filtration media is installed in the Winged Sentry based on the application being performed by the operator. HEPA [up to 99.97% efficient on particles 0.3 microns and larger], ASHRAE [up to 95% efficient on particles 0.5 microns and larger], Activated Carbon, and specialty-blended media [i.e. Acid Gas, Mercury, Aldehyde, Ammonia] are the most common filters for this unit. The Winged Sentry is an optimal choice for fume extraction in applications such as soldering, capsule filling, solvent and epoxy fume, powder filling, R&D, light grinding and a variety of applications involving chemical fumes and dusts. The Winged Sentry provides a highly energy-efficient, quiet and economical solution to many fume extraction needs. An optional transparent hinged lid [SS-200-WSL] is available to further enclose the source capture area. This unit is also available with a more powerful fan and filtration system [SS-300-WS].
OK International
Two Station Design for Dynamic Fume Extraction BVX-201
OK International has been a leading manufacturer of tools for the electronics assembly workbench for almost 60 years. And, under the Metcal brand names, OK International has been an innovator in efficient, cost-effective systems to protect operators from hazardous fumes. For the safety of your operators and working environment, Metcal offers a full line of solder fume extractors. From volume to tip to bench-top fume extraction, Metcal has systems to purify the air by filtering harmful smoke and particulates from the working area. Fume extraction systems are also useful for extracting potentially noxious fumes from the use of certain adhesives and chemicals on the workbench.
While lead-free solder is good for the environment, it increases the need for fume extraction. Metcal fume extractor systems have a highly efficient filter to remove all the toxic solder fumes and keep workers healthy. These systems offer innovative designs in small, portable units that are quiet and easy to set up but deliver the power to extract all harmful fumes.
The BVX-200 Series Fume Extraction Systems are revolutionary two-arm units that combine powerful fan p performance with efficient filtration, quiet operation and complete portability. They can be placed under or next to the bench-top and fitted with either two 50mm (2″) diameter BVX arms or one 63mm (2.5″) diameter arm.
Using the proven fan motor, the BVX-200 Series Fume Extractions Systems add a proprietary one-stage impeller design that doubles the total free-blowing airflow.
The result is a maximum free-blowing airflow of 250m /h (150cfm), with a maximum suction force of 850 Pa (3.5″WC). This suction force provides ample capability in reserve to handle any clogging that may occur during the normal life of the filter. The BVX-201 Fume Extraction System is designed mainly for solder fumes and incorporates both pre- and main filters which can be changed independently to maximize the working life of each filter and lower the total cost of ownership. The main filter has a HEPA efficiency of 99.97% at 0.3 micron, plus an activated carbon filter to remove additional gases. For applications that require a high capacity of gas filtration, such as cleaning with solvents or conformal coatings, the BVX-203 Fume Extraction System features a deep-bed gas filter.
Conclusions
Soldering activities, whether on a large scale unit such as a wave soldering machine or with a soldering iron at an individual work station, create fumes due mainly to the rosin flux within the solder. These fumes present a health hazard to workers if inhaled, as they can trigger asthma and cause other health problems. Accordingly legislation exists to guide employers and protect workers from this risk.
