This is where the Glaubitz company from Zittau comes into play. The company has established itself as a provider of vehicle electronics repairs since 1996. Today, around 100 employees take care of the functional restoration of around 900 different types of devices. These range from engine and transmission control units, air conditioning control units and power steering systems to mass air flow meters, ignition distributors and even classic car electronics. Glaubitz now supplies more than 30,000 customers worldwide - primarily automotive workshops.

Repairs to control units are not only a cost-effective alternative to new parts, but also offer an opportunity to protect against misdiagnosis, as around 15 to 20 percent of devices sent in are fault-free. The ECU (Electronic Control Unit) service is also an option if, for example, new parts are no longer available on the market.

Depending on the type of device, the repair takes between one and four working days. As the control units are always supplied complete with housing, in many cases these have to be milled open or protective coatings and potting gels removed. Traditionally, the control units consist of PCB circuit boards, but are increasingly being manufactured on a ceramic carrier basis. Each control unit is processed at a specially equipped workstation, a test bench. A visual inspection, an input test, troubleshooting, repair with a 24-month warranty and an output test are carried out on this test bench.

Pollutants in the air

Milling, drilling and soldering work is therefore carried out at almost 50 test stations every day, but this causes an unpleasant side effect: airborne pollutants such as soldering fumes or very fine dust. The smaller the particles stirred up, the more harmful they are, as they can not only cause respiratory or brain diseases in employees, but also affect the function of the repaired control parts. For example, if aerosols or solvent residues in the soldering fumes settle on the electronic components, they can impair the conductivity of the component connections or cause corrosion.

From 1998, fans and open windows were supposed to provide fresh air. However, this proved to be an impractical solution in the long term, which is why those responsible at Glaubitz began to think about effective air pollution control. The primary concern was employee protection. Due to relatively small workspaces, pollutants spread quite quickly. In addition, there are legal requirements, such as those of the employers' liability insurance associations, which regulate the maximum particle load at workplaces.

In 2009, an LRA 1000 extraction and filter unit was purchased to remove soldering fumes. Prior to this, the company had contacted and evaluated various suppliers of extraction and filter systems. The contract was awarded to ULT from neighboring Löbau. "Geographical proximity played a subordinate role in the selection of a suitable provider," explains Andreas Ullmann, Managing Director of Glaubitz. "The price-performance ratio and the very good advice during the initial purchase convinced me at the time."

The filter system was and is operated as a central extraction system, which is connected to around 25 workstations via piping. Each workstation is equipped with an Alsident 50 extraction arm in ESD design to ensure that pollutants are captured at their source. In 2016, a second extraction system of the same type was added, which currently ensures clean air at a further 12 test stations. Both systems run throughout the entire working day. If the extraction system is not required at the respective workstations, the relevant employee can stop the air extraction using a throttle valve in the extraction arm.

One exception is in the area where instrument clusters are processed and repaired. Very small quantities of soldering fumes are produced here, which is why the central extraction system is not used. Instead, two small mobile units of type LRA 200 are used, each of which removes pollutants from three workstations.

Proven over the years

Site manager Michael Kaplan, responsible for building technology, sums up: "After six years of completely trouble-free operation of our first LRA 1000, the decision to purchase another system and two smaller LRA 200s was very easy. The reliable and low-maintenance units are the ideal way for us to implement the required health and safety regulations." So far, there have been no problems with the extraction systems - neither during operation nor during maintenance work. "The simple operation and low-noise operation of the ULT systems have proven themselves in daily use," adds Friedrike Föst, Team Leader Soldering Technology. All in all, it is not only those responsible for occupational health and safety who have satisfied faces. The employees at the test benches, who process orders from all over Europe, are also breathing freely.

Stefan Meißner, Head of Corporate Communications ULT / am