Contemporary Controls Successfully Completes its Lead-Free Conversion Process
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Downers Grove, Illinois (June 8, 2006)-The deadline for the Restriction of Hazardous Substances (RoHS) Directive is July 1, 2006, and Contemporary Controls' Downers Grove, Illinois, plant has successfully met the challenge. George Thomas, President of Contemporary Controls, thanks his entire manufacturing and engineering
staff for their efforts in making the necessary conversion to lead-free products. "It took the thoroughness and the cooperation of everyone in operations to make compliance possible," says Thomas. "This process involved the purchase of new equipment, the specifying of alternate components, revised bill of materials, revised work instructions as well as in-depth training for the employees. It was a significant effort."
Neil Maloney, Manufacturing Engineer, said the The Association Connecting
Electronic Industries (IPC) aided us in our goal. "As members of IPC, we could rely on them for guidance through some of the darker areas along our path to RoHS compliance," said Maloney. "The IPC did much investigating in lead-free solder alloys, manufacturing processes, and material declaration that were necessary for us to just keep up with the changing European marketplace."
The process began with the engineering department assessing the company's current products and determining if they could be manufactured employing new parts and
surface finishes that were compliant with the RoHS directive. Once the assessments were completed and the new components were effectively sourced, the company's factory floor had to be converted to a lead-free environment.
Maloney said this approach involved the purchase of a new Vitronics® XPM820 reflow oven because of the higher temperature and tighter process control required for lead-free. The oven is designed with 8 heating zones and 2 cooling zones in order to attain the required 217°C temperature and to acquire the proper ramp rate for lead-free soldering. "We had to purchase a larger reflow oven (8 heating zones instead of the previous 4)) to heat up products to higher temperatures than before, when our leaded solder was melting at 183°C. This higher temperature makes it imperative that the components are rated to handle the additional thermal load. Not only that, but the increased number in thermal zones are necessary to ensure that the components are not heated too quickly to the point of having components explode-right in the oven."
Next, the Electrovert Astrapak wave solder machine was converted by refitting pumps and changing solder pots to titanium and replacing the tin/lead solder with the new Tin Silver Copper (SAC) alloy solder.
Maloney said lead-free solder has a different odor than our leaded alternative. "Personnel had to enclose the area behind our solder pots with a curtain and an exhaust system so the odor wouldn't be prevalent in our manufacturing area during weekly solder pot maintenance," he explained.
John Magagnini, Manufacturing Supervisor, said production facility employees attended classes to learn no-lead soldering techniques. According to him, "You must be very patient when lead-free soldering because it doesn't melt or flow as nicely as leaded solder.
The operator must be trained properly to know what is an acceptable or an unacceptable solder joint. When the operator makes a correct lead-free solder joint, visually it may seem to be unacceptable. The operator learns to retrain his or her eyes to know what is right or wrong."
The company's manufacturing facility in China underwent a change to lead-free production less than a year ago. However, Maloney said, the Downers Grove facility is in the unique position that we need to support all our legacy products and our legacy products are leaded. Some of these products will not or cannot be converted. Therefore,
after July 1, 2006, both leaded and unleaded products will be available. The customer must decide if a leaded product is acceptable for his application.
For more information on the company's RoHS Compliance Plan, visit our website at http://www.ccontrols.com/rohs.htm.
Contact:
George Thomas,
President
1-630-963-7070 x 100
gthomas@ccontrols.com
