Steve--

 At our company, we made the jump from the foam bubble "Lawrence Welk" type
fluxer - to the "Al Capone" machine gun type spray fluxer earlier this year.
I do not envy your dealings with the QA crowd.
   We have a new Electrovert machine with the "Supa-flux" and we had lots of
perceived dewetting problems fron the inspectors. We solved this by getting
a wide dispersion nozzle for the fluxer, and slowing down the reciprocating
spray head to a minimum speed. This put enough flux through the holes on the
boards to let enough solder wick up through the holes to tranquilize the QA
people. You may also want to try a lighter flux, but you run the risk of
getting the whole production choir to sing a loud chorus of "We've never
done it this way before." Try a bigger nozzle first.

Good luck

Neil Maloney
Service Technician
Contemporary Control Systems
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