SOP for SOLDERING

Soldering Safety Guidelines:

General safety Precautions:
1. Working with solder, flux and cleaners:
• Use lead free or low-lead solder if possible.
• Do not flick or shed the solder on the floors/benches.
• Always wear eye protection to avoid solder debris.
• Wear gloves while soldering and wash hands with soap and water after removing gloves.
• Keeping cleaning solvents like flux cleaner and iso-propyl alcohol in dispensing bottles to
avoid inhalation hazards.
• Read the manufacturer’s instructions and MSDS (Material Safety Data Sheets) for all
materials before beginning work.
2. Personal Safety:
• Do not eat or drink around the soldering station area.
• In order to prevent burns from splashes of hot solder or other debris wear long sleeve shirts
and pants while soldering.
• Avoid inhalation of soldering smoke/fumes. Keep the fume extractor as close as possible to
the object where solder is applied.
• Do not forget to clean your work area with a wet wipe after soldering to avoid lead surface
contamination.
3. Soldering Iron safety:
• Clean the soldering iron with lead-free tip cleaner.
• Do not touch the soldering iron tip. It’s very hot (7200F) and it will burn.
• Keep the cleaning sponge wet during use.
• Do not put down the soldering iron on the work bench.
• If not in use, rest the soldering iron on its stand.
• Turn of the soldering station before you leave.
4. Electrical Safety and fire prevention:
• Examine equipment for cracked cords before soldering.
• Prevent damage to electrical cords during soldering. Keep them away from heated tips.
• Become familiar with fire extinguisher location in the room.
• Work on a fire-proof or non-flammable surface that is not easily ignited.
5. First Aid:
• In case of burns, cool the affected area with cold water for 15 minutes.
• Get medical attention if the condition is severe.
6. Lab staff responsibilities:
• Clean your work benches every month with TSP based cleaners.
• Educate students about the safety procedures that must be followed while soldering.
• Set up a schedule to dispose the contents of dross containers every four months.
• Set up a date to clean the general lab area every four months.

Potential Hazards:
Fumes from Heated Lead solder:
Lead is a known neurotoxin and can pose significant chronic health risk. Solder contains 37-
40 % lead
and lead is considered toxic. If lead-containing solder is handled and treated properly, there is
a minimal hazard to any person working with solder.
Fumes from fluxes:
• Flux allows the solder to flow more smoothly. Soldering may involve the use of flux
paste or liquid, or the solder itself may have a rosin core. When the flux is heated it
converts to a gaseous or vapor state.
• There is a possibility that the person soldering is exposed to soldering fumes, if proper
ventilation is not used. Even those who solder occasionally should make a habit to use
fans or fume extractors.

The available types of flux in the market are:

➢ Rosin fluxes- Contact with rosin-based solder flux, flux residues, and the fume itself
can cause dermatitis. Wear long sleeved clothing and gloves can prevent skin contact.
Always use brush to apply Flux.

➢ Organic and Inorganic water soluble fluxes: These fluxes are lead free and toxic free.
But they contain organic salts and acids which may produce mild allergic irritation of
the skin and respiratory tract.

Rosin Flux Liquid Flux

 Wax Flux:
• Consistency: Typically has a thicker, paste-like consistency that resembles
wax. It can be applied directly to surfaces and tends to stay in place during the
soldering process.
• Application: Often comes in a jar or stick form, allowing users to apply it with
a brush or by dipping components into it. Its viscosity helps it adhere well to
surfaces, making it ideal for applications where precision is needed.
• Liquid Flux:
• Consistency: Fluid and thinner than wax flux, which allows for easy application
but can run off surfaces if not used carefully.
• Application: Available in bottles or pens, liquid flux can be sprayed or brushed
onto components. It is often used for larger areas or when a more uniform
application is necessary.

Recommended Lead Work Practices:

The OSHA Lead standard (CFR 1910.1025) addresses worker exposure to lead as an
airborne contaminant. Based on standard soldering iron temperatures of 620⁰ F- 700⁰F and the
melting point of lead (621⁰ F), with a vapor pressure of 0.0 mm Hg and a boiling point of
3164⁰F, it is unlikely that lead fume will be generated during electronic soldering, unless the
solder is heated to extreme temperatures. Even when there is no exposure to lead fumes, there
is still a need for safe work practices to prevent employee exposure to lead from other exposure
routes described above.

Steps to Select Solder Bit’s for specific application:

Choosing the right soldering iron tip is crucial for achieving optimal results in various soldering
tasks. Different applications require specific tip shapes, sizes, and materials to ensure effective
heat transfer and precision. Here are the steps to select the appropriate solder bits for your
specific application:
1. Identify the Application Type
• General Purpose: For versatile tasks, consider using a chisel tip, which is suitable for
a wide range of soldering jobs, including through-hole and surface mount soldering.
• Precision Work: If you need to work on fine details or small components, opt for
a conical tip or needle tip, which allows for greater control and precision.
• Drag Soldering: For drag soldering techniques, a bevel tip or J series tip can be
effective due to their shape that facilitates solder flow across multiple joints.
2. Consider Component Size
• Small Components: Use smaller tips (0.2mm to 1.0mm) for delicate work on
microelectronics or densely populated PCBs.
 • Large Components: Larger tips (2.0mm and above) are better suited for soldering
larger components or areas, such as connectors or ground planes.
3. Evaluate Heat Transfer Needs
• Larger tips generally have higher thermal mass, allowing them to maintain temperature
better during soldering of larger joints. This helps in transferring heat quickly and
efficiently.
• Smaller tips may cool down quickly when applied to larger surfaces; thus, ensure that
the selected tip matches the thermal requirements of your task.
4. Assess Material Compatibility
• Some soldering tasks may require specific materials due to the type of solder being used
(e.g., lead-free vs. leaded). Ensure that the tip material is compatible with the solder to
prevent rapid wear or oxidation.
5. Temperature Control
• Different tips may require different temperature settings based on their size and
application. Larger tips may need higher temperatures, while finer tips can often operate
at lower temperatures.
• Always refer to the manufacturer's recommendations for optimal temperature settings
based on the selected tip.
6. Regular Maintenance Considerations
• Choose tips that are easy to clean and maintain. Regular cleaning helps prevent
oxidation and buildup of flux residues, which can affect performance.
• Ensure that you can easily tin the tips to maintain their efficiency and prolong their
lifespan.
7. Test and Adapt
• If possible, test different tips on sample projects before committing to a specific type
for larger tasks. This allows you to assess how well each tip performs under your typical
working conditions.
Steps to Select Temperature for Specific Soldering:
Selecting the appropriate temperature for soldering is crucial for achieving reliable and
effective solder joints. The right temperature depends on several factors, including the type of
solder, the components being joined, and the soldering technique used. Here are the steps to
determine the optimal soldering temperature for your specific application:

1. Understand Solder Types

• Lead-Based Solder: Typically melts at lower temperatures (around 180-190°C or 360-
370°F). A common working temperature is between 300°C and 350°C (572°F to
662°F).
• Lead-Free Solder: Generally, requires higher temperatures (approximately 220-250°C
or 428-482°F) due to its higher melting point. Set your iron to around 350°C to 400°C
(662°F to 750°F) for effective soldering.

2. Consider Component Sensitivity

• Heat-Sensitive Components: For delicate components like transistors or ICs, use lower
temperatures (around 250°C to 300°C or 482°F to 572°F) to prevent damage.
• Robust Components: Larger components or those designed to handle heat can tolerate
higher temperatures without risk of damage.
3. Evaluate Soldering Iron Quality
• The quality and type of soldering iron affect temperature control. High-quality,
temperature-controlled soldering stations allow for precise adjustments and consistent
results.
• If using a low-quality iron, you may need a higher setting to compensate for poor heat
transfer.
4. Assess Joint Size and Complexity
 • Small Joints: For tiny connections, a lower temperature is often sufficient, as less heat
is required to melt the solder.
• Large Joints: Larger connections require higher temperatures to ensure adequate heat
transfer and melting of the solder.
5. Adjust Based on Speed of Work
• If you are soldering quickly, a higher temperature may be necessary to ensure that the
solder flows properly before the joint cools down.
• Conversely, if you are working slowly, a moderate temperature can help avoid
overheating components.
6. Monitor Ambient Conditions
• The ambient temperature of your workspace can impact soldering efficiency. In cooler
environments, you might need slightly higher temperatures to achieve effective solder
flow.
7. Start with Manufacturer Recommendations
• Always refer to the datasheets or technical specifications provided by component
manufacturers for recommended soldering temperatures. These guidelines help prevent
damage during the soldering process.
8. Experiment and Adjust
• Start with a baseline temperature based on the factors above and adjust as necessary
based on your experience. If the solder does not flow well, increase the temperature
incrementally; if components are burning, reduce it.

Steps to Solder Cell Tabs and Balancing Connector to Make a Battery Pack
Creating a battery pack by soldering cell tabs and a balancing connector involves careful
assembly and soldering techniques to ensure safety and functionality. Below are the detailed
steps to guide you through this process:
1. Gather Necessary Materials and Tools
• Materials:
• Lithium-ion or NiMH Etc, cells with pre-attached solder tabs
• Balancing connector (typically JST or similar)
• Solder (preferably rosin core)
• Flux (optional but recommended)
• Heat shrink tubing or electrical tape for insulation
• Tools:
 • Soldering iron (70 watts or higher recommended), (Temperature at 350°C –
360°C for Tab and 320°C – 350°C for Balancing Connector)
• Soldering tip (wide tip preferred for better heat transfer)
• Wire cutters/strippers
• Pliers
• FR4 Sheet Thick Tool for providing Support and Spacing Between Tabs.

• Tape (e.g., painter’s tape) for holding cells in place

2. Plan the Configuration

• Determine the arrangement of your cells (in series, parallel, or a combination) based on
your desired voltage and capacity.
• Identify where the balancing connector will be placed in relation to the cells, ensuring
it can connect to each cell's positive and negative terminals.

3. Prepare the Cells

• Clean the solder tabs of each cell with isopropyl alcohol to remove any oxidation or
contaminants. Provide rubber bands to stack Cells and insert FR4 Spacer.

• Apply a thin layer of flux on each tab to enhance solder adhesion.

Tin the Solder Tabs
• Heat your soldering iron and apply a small amount of solder to the tip.
• Touch the soldering iron to each tab briefly, then apply solder until it is evenly coated.
This process, known as "tinning," prepares the tabs for better connection.
Position the Cells
• Use tape to hold the cells in place according to your planned configuration. This
stabilizes them while you work on soldering.
• Ensure that tabs are oriented correctly for soldering without risking short circuits.
Solder Cell Tabs Together
• Heat your soldering iron and apply it to the first tab connection you want to make.
• Press the two tinned tabs together and apply solder until it flows into both tabs, creating
a solid joint. Avoid prolonged contact with the cell to prevent overheating.
• Allow each joint to cool naturally without moving it.
• The Final Quality should be similar to below Fig.
4.Connect the Balancing Connector and Cable Routing
• Identify the correct pins on the balancing connector corresponding to each cell’s
positive and negative terminals.

• Solder wires from the balancing connector to the respective tabs on each cell, ensuring
that you maintain proper polarity.
• Use flux as needed during this process for better adhesion.

8. Insulate Connections
• Once all connections are made, slide heat shrink tubing over each joint and use a heat
source (like a heat gun) to shrink it down, ensuring that no exposed metal is left.
• Alternatively, use electrical tape and Kapton tape to secure terminals.

9. Final Assembly
• After all connections are secured and insulated, check that everything is properly
aligned and that there are no short circuits.
• Ensure that all connections are firm and that there are no loose wires or tabs.
11. Testing
• Before final installation in your device, test the battery pack with a multimeter to ensure
proper voltage output across the pack and verify that the balancing connector functions
correctly.
• Final QC after the testing has to be done.