I would not have used ORL0 flux on braided wire shielding, but rather ROL1.

This sort of looks like corrosion of telephone subscriber wires, i.e. the
wires inside the customer's premises between the telephone jack and the
"Network interface device."

Is there any voltage on the shieiding wrt ground or the signal wire?  Is
the shielding covered with any insulation (it looks like it is bare)?

Karen Tellefsen - Electrical Testing
[log in to unmask]
908-791-3069


Steve Gregory <[log in to unmask]>

Good Morning!

We've just had something come-up that really has a few of us scratching
our heads around here.

To preface this; we have a mechanical assembly building where we put
cabinents and boxes together plus do some cable and harness assembly.
Yesterday one of engineers called me and said that they were seeing some
green stuff on some of the cables that we've built and said that I
should come and take a look at it. While I was walking over to the other
building it was thinking to myself; "I hope that somebody didn't get a
hold of the wrong flux or something...".

When I got there, I was really suprised at what I saw:

http://stevezeva.homestead.com/files/Green_Junk_1.jpg

http://stevezeva.homestead.com/files/Green_Junk_2.jpg

http://stevezeva.homestead.com/files/Green_Junk_3.jpg

http://stevezeva.homestead.com/files/Green_Junk_Close.jpg

The photos that you see come from a cable assembly that is about 3-feet
long, and we're seeing it on cable assemblies that are longer. The wire
in the assembly is a PTFE insulated single conductor shielded and
jacketed cable. The conductor and shield is silver plated OFHC copper.
The photos are taken from a section in the middle of the wire well away
from any area that soldering has been done. The shields of all the wires
in the bundle get soldered together at each end using a ORL0 wire solder
and flux. The green substance appears throughout the wires. In "Green
Junk 3", you can see how the green is with a group of the strands of the
braided shield and how it spirals around the wire.

It goes without saying that I'm contacting the wire manufacturer, and
I'm sending out a cable assembly for analysis. But have any of you ever
seen this before?

Steve




Enthone GmbH  Geschäftsführer: Knut Balzer, Luc de Croo, Jürgen Dietrich  Amtsgericht Düsseldorf  HRB 45276
USt-Id-Nr. DE 811 205 946 


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