Steve,
Just a wild idea, started off by Dewey's witticism - is there any chance that the green stuff is just dye in the insulation material?
Bev
RIM
-----Original Message-----
From: TechNet [mailto:[log in to unmask]] On Behalf Of Steve Gregory
Sent: Tuesday, June 09, 2009 10:23 AM
To: [log in to unmask]
Subject: Re: [TN] Green Junk in Wire
Hi Karen,
The wire is PTFE Insulated, and these wires have not had any voltage applied.
We've been using this flux and building these cables for quite some time, and have not seen this before. The only thing that has really changed is with the batches of wire.
The flux complies with what is called out in 3.3 of J-STD-004. Can you elaborate on why you would use a ROl1 over a ORL0?
Steve
-----Original Message-----
From: Karen Tellefsen [mailto:[log in to unmask]]
Sent: Tuesday, June 09, 2009 9:04 AM
To: TechNet E-Mail Forum; Steve Gregory
Subject: Re: [TN] Green Junk in Wire
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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