Hi, Chuck, I can't answer for the electronic side of your problem, though it does sound like you have a problem with uncoated boards, humidity and ionic contamination. You may have to kill one bird with two stones - if you need to put a barrier coating between the boards and the atmosphere (conformal coating), you will have to get the boards clean enough for a coating to stick. If you're using a no-clean soldering process, you will still have to clean the boards, and by cleaning them sufficiently for conformal coating, you may find that your ionic contamination problem disappears, in which case you may choose not to coat. Coating is good until you need to rework a board, and then it becomes a pain as it has to be removed and that's usually messy and time-consuming. However, if coating proves to be your answer, an acrylic varnish such as Humiseal 1B31 should do the trick. It can be applied by brush, dipping or spraying, and dries in ambient atmospheric conditions. Make sure the board is dry before coating. Pete Duncan Chuck Mays <com@INVETECH To: [log in to unmask] .COM.AU> cc: (bcc: DUNCAN Peter/Asst Prin Engr/ST Aero/ST Group) Sent by: Subject: [TN] Ionic contamination limit for PWA with TechNet 0402 sized components <[log in to unmask] ORG> 05/28/01 12:04 PM Please respond to "TechNet E-Mail Forum."; Please respond to Chuck Mays I've checked the technet archive and have not found a similar problem, so here goes. I have a problem with a small mobile product that is failing in field trials. One area we have considered is a combination of RH and the level of ionic contamination affecting high impedance areas of the PWA to cause the problem. (The problem exhibits itself as a RAM corruption and the S/W engineers are busily making sure it isn't their problem.) An external lab checked a sample of the PWA's using the Omega method and found the average level to be about 18 ug/sq.in. (I'm aware that 10 ug/sg.in. is the recommended limit.) The PWA uses 0402 sized resistors and is the finest pitched assembly that the manufacturer in China who builds this and other boards for us uses. A no clean process is used. The other products built for us by this manufacturer are OK in terms of ionic contamination and field performance. Most of the failures in field trials have occurred not too far from the bay in one of the suburbs of Sydney where the field trials are in progress. The temperature is not high (15 - 20 degrees C), but we are now in the rainy season. One day, when it rained in the suburb nearer the bay, and not in the other field trial areas, 6 of the field trial units failed in the one area. My questions are: 1. Does anyone have experience that indicates that the 10ug/sq.in. level for ionic contamination is OK for PWAs that use 0402 sized components? Or does experience indicate that a lower level is more appropriate and if so, what level? (It don't know the exact pitch of this board, but am waiting for the answer.) 2. Is it possible to determine an impedance above which one should be concerned with a level of ionic contamination for a given voltage? 3. If it turns out that for this design, RH and the level of ionic contamination are causing the problem, can the situation be improved by conformally coating the board or areas of the board? (If so, can someone please point me to the applicable standards for conformal coating? Thanks.) Best Regards, Chuck Mays Invetech Operation Pty Ltd [log in to unmask] Tel 613 9211 7700 Fax 613 9211 7702 The information contained in this message and any attachments is confidential and intended for the named recipient(s). If you have received this message in error, please contact the sender by return e-mail and destroy the message and any attachments. 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