My reply did not say to reduce the solder to just below the melting point, on the contrary you want to be just slightly above the melting point for safety and quick rise to process temperatures while using much less electricity and not turn on the boost heater.  

If  your looking for large energy savings you may want to consider the large fune extraction systems instead of exhausting all your heat and air conditioning to the outside. The modern reflow ovens have flux fume extraction systems like on the Vitronics XPM series that makes the external fume extration system more feasible and less costly due to less frequent filter exchanges. 

The Wave solder machines can be equipped with VOC free fluxesa and use bubble-jet spray fluxer or the electrovert Ultrasonic spray fluxer to reduce flux useage and the environmental benefits of water based fluxes. 

 Another area to look at is the receiving and shipping docks. 

1. The factory area should have double isolation doors with security badge reader to separate it from the dock.  

2. Human nature - Doors that are manually opened are left open for many more hours than those with electric door openers. 

3. Forced hot air from the buildings heating system is the least efficient in dock areas, as all the heat is gone as soon as you open the doors. The Gas/IR tube hears can be aimed at the cement walls and floors to heat the surfaces as well as the people. IR  heating is much more efficient. 

4. The are energy monitoring systems that are connected to all the circuit breakers to monitor power consumption. The rate paid is the highest combined peak rate. They explained that by having a controllers monitoring everything from vending machines to air conditioners versus process critical machines the system makes sure the peaks surges don't occur at the same time by delaying or reducing power via ladder logic based on priority. The end result is that the electrical rate per kilowatt is reduced. 

Of course for this investment the company must own the building versus lease. 

 - The new system from a Massachusetts company, incorporates small sniffer tubes to measure air quality and minimize the exchange of fresh hot or cold air into the factory or office building. Again by reducing the air exchange, we loose less heat and air-conditioning. 



This probably more information and beyond the scope of your project but I figured with the focus of Green technologies, the system we put in 25 years ago may be of interest to you and other technet people. 



 John Goulet 

MFG/Process Engineer  


----- Original Message ----- 
From: "Rex Waygood" <[log in to unmask]> 
To: [log in to unmask] 
Sent: Wednesday, September 22, 2010 3:29:01 AM 
Subject: Re: [TN] Energy Usage of Equipment 

I cannot answer your question yet but I wanted the same answers. 
Originally I looked for industrial 3 phase power meters but these were very expensive. 
Due to the appearance on the market of domestic energy meters (some energy supply companies give them away free) it is possible to buy low cost three phase energy meters. 
So for about £65 we purchased a CC128 ENVI from http://www.greenandeasy.co.uk/ (see energy saving devices)  with 2 extra CTs. The manufacturers website is http://www.currentcost.com/ . 
We are only just using it but it was purchased to answer the questions about the most cost effective way to run our equipment. Had we had it a week earlier we would probably have discovered the reason for our wave's overshoot ourselves. 
Regards 
Rex 

Rex Waygood 
Technical Manager 
  
Hansatech EMS provides value manufacturing through engineering and quality 
  
Hansatech EMS Limited 
Benson Road 
Nuffield Industrial Estate 
Poole 
Dorset 
BH17 0RY 
  
+44 (0)1202 338200 


-----Original Message----- 
From: TechNet [mailto:[log in to unmask]] On Behalf Of Blair Hogg 
Sent: 21 September 2010 21:24 
To: [log in to unmask] 
Subject: [TN] Energy Usage of Equipment 

Oh wise and informative Technetters, 

John Goulet posted a few days ago about using a thermal blanket and reducing the temperature of the wave solder bath to just below MP in order to reduce wear on the heaters while keeping costs low. 

Does anyone have any information on how much power is consumed by the typical wave solder pot in heating the solder from ambient, and how much is required to run steady state? What about reflow ovens? 

We are looking at our energy costs here and ways to reduce. Currently we shut the machines overnight, and they turn on by timer 2 hours before the shift starts. We are a one shift operation. 

Thanks, 

Blair 

--------------------------------------------------- 
Technet Mail List provided as a service by IPC using LISTSERV 15.0 To unsubscribe, send a message to [log in to unmask] with following text in the BODY (NOT the subject field): SIGNOFF Technet To temporarily halt or (re-start) delivery of Technet send e-mail to [log in to unmask]: SET Technet NOMAIL or (MAIL) To receive ONE mailing per day of all the posts: send e-mail to [log in to unmask]: SET Technet Digest Search the archives of previous posts at: http://listserv.ipc.org/archives Please visit IPC web site http://www.ipc.org/contentpage.asp?Pageid=4.3.16 for additional information, or contact Keach Sasamori at [log in to unmask] or 847-615-7100 ext.2815 
----------------------------------------------------- 

______________________________________________________________________ 
This email has been scanned by the MessageLabs Email 

______________________________________________________________________ 
This email has been scanned by the MessageLabs Email Security System. 
For more information please contact helpdesk at x2960 or [log in to unmask] 
______________________________________________________________________ 

--------------------------------------------------- 
Technet Mail List provided as a service by IPC using LISTSERV 15.0 
To unsubscribe, send a message to [log in to unmask] with following text in 
the BODY (NOT the subject field): SIGNOFF Technet 
To temporarily halt or (re-start) delivery of Technet send e-mail to [log in to unmask]: SET Technet NOMAIL or (MAIL) 
To receive ONE mailing per day of all the posts: send e-mail to [log in to unmask]: SET Technet Digest 
Search the archives of previous posts at: http://listserv.ipc.org/archives 
Please visit IPC web site http://www.ipc.org/contentpage.asp?Pageid=4.3.16 for additional information, or contact Keach Sasamori at [log in to unmask] or 847-615-7100 ext.2815 
----------------------------------------------------- 

______________________________________________________________________
This email has been scanned by the MessageLabs Email Security System.
For more information please contact helpdesk at x2960 or [log in to unmask] 
______________________________________________________________________

---------------------------------------------------
Technet Mail List provided as a service by IPC using LISTSERV 15.0
To unsubscribe, send a message to [log in to unmask] with following text in
the BODY (NOT the subject field): SIGNOFF Technet
To temporarily halt or (re-start) delivery of Technet send e-mail to [log in to unmask]: SET Technet NOMAIL or (MAIL)
To receive ONE mailing per day of all the posts: send e-mail to [log in to unmask]: SET Technet Digest
Search the archives of previous posts at: http://listserv.ipc.org/archives
Please visit IPC web site http://www.ipc.org/contentpage.asp?Pageid=4.3.16 for additional information, or contact Keach Sasamori at [log in to unmask] or 847-615-7100 ext.2815
-----------------------------------------------------