Circuit Board Repair Guide > Conductor Repair Procedures > Conductor Repair

How to Repair a Damaged Conductor Using a Foil Jumper

Repair Circuit Boards | Repair SMT Pads | Repair BGA Pads | Repair Lands | Repair Edge Contacts
Repair a Conductor | Plated Hole Repair | Base Board Repair | Replace Solder Mask or Coatings

This conductor repair procedure is used on printed circuit boards to replace damaged or missing circuits on the printed circuit board surface using a foil jumper bonded with liquid circuit board epoxy.

Caution
The circuit widths, spacing and current carrying capacity must not be reduced below allowable tolerances.

IPC Acceptability References
IPC-A-600 2.0 Externally Observable Characteristics
IPC-A-610 10.0 Laminate Conditions
 
Related Procedure References
CTC 1.0 Foreword - Circuit Board Repair Guide
CTC 2.1 Handling Electronic Assemblies
CTC 2.2.1 How to Clean a Circuit Board
CTC 2.2.2 Cleaning Circuit Boards, Aqueous Batch Process
CTC 2.5 Baking and Preheating of Printed Circuit Boards
CTC 2.7 Epoxy Mixing and Handling
IPC 7721 4.2.1 Conductor Repair, Foil Jumper, Epoxy Method

 
Damaged conductor needs replacement
Damaged Conductor
Tools and Materials
Abrader - Mild abrasive for removing oxides and contaminates from conductive surfaces.
Alcohol Swabs - Self-saturating Isopropyl alcohol swabs. Squeeze handle to release alcohol.
Circuit Bond Pack - Clear, superior strength epoxy in two-compartment plastic package.
Circuit Tracks - Rectangular shaped pure copper conductors for making circuit board repairs.
Cleaner - General purpose cleaner for removing contamination.
Cleaning Brushes - Disposable brushes for use with solvents for cleaning and application of coatings.
Color Agents - Use to tint the color of epoxy used for solder mask repair or circuit base board repair.
High Temperature Tape Discs - High temperature polyimide tape discs, .50" diameter.
Knife with #16 Blades - A must-have tool for precise cutting, scraping and trimming.
Microscope - It is a challenge to undertake precision repair without a good microscope.
Micro Drill System - Versatile power tool for milling, drilling, grinding, cutting and sanding circuit boards.
Micro Probes - Use to dispense a minute amount of adhesive and for micro-positioning of small objects.
Mixing Picks - Unique mixing sticks have a paddle shape on one and sharp pick on the opposite end.
Oven - General purpose oven for drying, baking and curing epoxies.
Scraper - Hardened stainless steel tip for scraping solder mask and removing defects.
Soldering Iron, Solder and Flux - A well maintained soldering iron is a must at every tech bench.
Wipes - Nonabrasive, low-linting wipes for cleanup.

4.2.1 Conductor Repair, Foil Jumper, Epoxy Method

Printed Board Type: N/A  |  Skill Level: Advanced  |  Conformance Level: Medium  |  Rev.: E  |  Rev. Date: Jul 7, 2000

Scrape off solder mask or coating

Fig. 1: Scrape off any solder mask
or coating from the ends of the remaining circuits.

1.  Clean the area.
 
2.  Remove the damaged section of circuit using a knife. The damaged circuit should be trimmed back to a point where the circuit still has a good bond to the PC board surface.

Note
Heat can be applied to the damaged circuit using a soldering iron to allow the circuit to be removed more easily.
   
3.  Use a knife and scrape off any solder mask or coating from the ends of the remaining circuit. (See Figure 1).
   
4.  Remove all loose material. Clean the area.

Note
It is essential that the board surface be smooth and flat. If the base material is damaged see appropriate procedure.
   
5.  Apply a small amount of liquid flux to the ends of the remaining circuit. Tin the exposed end of each circuit using solder and a soldering iron.
   
6.  Clean the area.
   
7.  Select a Circuit Track to match the width and thickness of the circuit to be replaced. (See Table 1) Cut a length approximately as needed. The Circuit Track should overlap the existing circuit a minimum of 2 times the circuit width.
   
      Table 1 - Common Circuit Track Sizes
   
     
Part No. Thickness Width
115‐5204 .002" .004"
115‐5206 .002" .006"
115‐5208 .002" .008"
115‐5210 .002" .010"
115‐5312 .003" .120"
115‐5315 .003" .015"
115‐5520 .005" .020"
115‐5530 .005" .030"

Note
The new circuit may be trimmed from copper sheet.

Place new Circuit Track in position

Fig. 2: Place the new Circuit Track
in position and hold in place with
High Temperature Tape.

8.  Gently abrade the top and bottom surface of the Circuit Track with a buffer to remove the protective coating.

Note
A thin protective coating is applied to the Circuit Track to prevent oxidation.
   
9.  Clean the Circuit Track.
   
10.  If needed, the ends of the Circuit Track may be tinned with solder prior to lap soldering it in place.
   
11.  If the Circuit Track is long or has bends, one end may be soldered prior to forming the new shape. Place the Circuit Track in position. The Circuit Track should overlap the existing circuit a minimum of 2 times the circuit width. The Circuit Track may be held in place with High Temperature Tape. (See Figure 2).
   
12.  Apply a small amount of liquid flux to the overlap joint.
 
Bend Circuit Track using wood sticks

Fig. 3: Bend Circuit Track using 2 wood sticks.

13.  Lap solder the Circuit Track to the circuit on the circuit board surface using solder and a soldering iron. Make sure the Circuit Track is properly aligned.

Note
If the configuration permits, the overlap solder joint connection should be a minimum of 3.00 mm (0.125") from the related termination. This gap will minimize the possibility of simultaneous reflow during soldering operations. Refer to 7.1 Soldering Basics.
   
14.  Bend the Circuit Track as needed to match the shape of the missing circuit. (See Figure 3).

Note
Two wood sticks can be used to make sharp bends in the replacement Circuit Track. Use one stick to hold the Circuit Track at the bend location and use the other wood stick to form the shape as needed.
   
Wide circuits folded to produce sharp bend

Fig. 4: Wide circuits that cannot
be easily formed may be folded
over to produce a sharp bend.


15.  Wide circuits that cannot be easily formed may be folded over to produce a sharp bend. (See Figure 4).
Form final shape of Circuit Track

Fig. 5: Form the final shape of the
Circuit Track then hold in place
with High Temperature Tape
while soldering.


16.  Form the final shape of the jumper and hold in place with tape. Lap solder the Circuit Track to the remaining circuit on the circuit board surface using solder and a soldering iron. Make sure the Circuit Track is properly aligned. Remove the tape used to hold the foil jumper. Clean the area. (See Figure 5).
   
17.  Mix the Epoxy. If desired, add color agent to the mixed epoxy to match the circuit board color.
 
Coat top and sides of Circuit Track with epoxy

Fig. 6: Coat the top and sides of
the Circuit Track with epoxy.
18.  Coat the top and sides of the Circuit Track with epoxy. The epoxy bonds the Circuit Track to the circuit board surface and insulates it. A wooden stick sharpened at one end may be used to apply and spread the epoxy. (See Figure 6).
 
19.  Cure the epoxy per Procedure 2.7 Epoxy Mixing and Handling.

Caution
Some components may be sensitive to high temperature.
 
20.  Apply surface coating to match prior coating as required.
 
Evaluation
 
1.  Visual examination for alignment and overlap of foil jumper
 
2.  Visual examination of epoxy coating for texture and color match.
 
3.  Electrical tests as applicable.



How to purchase.                                                           View cart Minimum order $50 + shipping
Image Description Part No., Price and Quantity
Abrader 115-3136 Abrader, 115-3136

Mild abrasive is ideal for removing oxides and other contaminates from conductive surfaces prior to soldering, coating or plating. Housed in a push-stick type applicator.

Enlarge
115-3136

$7.95 each

 
Alcohol Swab Alcohol Swabs (package of 50), 235-1000-50

Self-saturating foam swabs filled with 99% Isopropyl alcohol. Ideal for removing flux residue and cleaning surfaces prior to soldering, coating and application of epoxy. Overall Length: 4.125". Squeeze handle until it "pops" releasing alcohol into the tip.

Enlarge
235-1000-50

$39.00 pkg/50

 
Liquid circuit board epoxy Circuit Bond Pack  MSDS, 115-3302

Clear, low viscosity, superior strength epoxy, precisely measured out into a two-compartment plastic package so it's easy to use and there's no measuring (2 gram). Shelf life: 6 months minimum.

Enlarge
115-3302

$12.95 each

 
Circuit Track 115-5204 Circuit Track, .002" x .004", x 36" Long, 115-5204

Rectangular shaped pure copper wire used to repair damaged conductors on circuit boards. Size .002" x .004" (.051 mm x .102 mm). Length 36" (914 mm). Packaged in a small bobbin spool.

Enlarge
115-5204

$39.95 each

 
Circuit Track 115-5205 Circuit Track, .002" x .005" x 36" Long, 115-5205

Rectangular shaped pure copper wire used to repair damaged conductors on circuit boards. Size .002" x .005" (.051 mm x .127 mm). Length 36" (914 mm). Packaged in a small bobbin spool.

Enlarge
115-5205

$39.95 each

 
Circuit Track 115-5206 Circuit Track, .002" x .006" x 36" Long, 115-5206

Rectangular shaped pure copper wire used to repair damaged conductors on circuit boards. Size .002" x .006" (.051 mm x .152 mm). Length 36" (914 mm). Packaged in a small bobbin spool.

Enlarge
115-5206

$39.95 each

 
Circuit Track 115-5208 Circuit Track, .002" x .008" x 36" Long, 115-5208

Rectangular shaped pure copper wire used to repair damaged conductors on circuit boards. Size .002" x .008" (.051 mm x .203 mm). Length 36" (914 mm). Packaged in a small bobbin spool.

Enlarge
115-5208

$39.95 each

 
Circuit Track 115-5210 Circuit Track, .002" x .010" x 36" Long, 115-5210

Rectangular shaped pure copper wire used to repair damaged conductors on circuit boards. Size .002" x .010" (.051 mm x .254 mm). Length 36" (914 mm). Packaged in a small bobbin spool.

Enlarge
115-5210

$39.95 each

 
Circuit Track 115-5312 Circuit Track, .003" x .012" x 36" Long, 115-5312

Rectangular shaped pure copper wire used to repair damaged conductors on circuit boards. Size .003" x .012" (.076 mm x .305 mm). Length 36" (914 mm). Packaged in a small bobbin spool.

Enlarge
115-5312

$39.95 each

 
Circuit Track 115-5315 Circuit Track, .003" x .015" x 36" Long, 115-5315

Rectangular shaped pure copper wire used to repair damaged conductors on circuit boards. Size .003" x .015" (.076 mm x .381 mm). Length 36" (914 mm). Packaged in a small bobbin spool.

Enlarge
115-5315

$39.95 each

 
Circuit Track 115-5520 Circuit Track, .005" x .020" x 36" Long, 115-5520

Rectangular shaped pure copper wire used to repair damaged conductors on circuit boards. Size .005" x .020" (.127 mm x .508 mm). Length 36" (914 mm). Packaged in a small bobbin spool.

Enlarge
115-5520

$39.95 each

 
Circuit Track 115-5530 Circuit Track, .005" x .030" x 36" Long, 115-5530

Rectangular shaped pure copper wire used to repair damaged conductors on circuit boards. Size .005" x .030" (.127 mm x .762 mm). Length 36" (914 mm). Packaged in a small bobbin spool.

Enlarge
115-5530

$39.95 each

 
Cleaning Brush Cleaning Brushes (package of 100), 235-2106-100

Disposable brushes for use with solvents for cleaning and application of coatings.



Enlarge
235-2106-100

$29.95 pkg/100

 
Color Agents for Circuit Boards Color Agent, Green, 115-9348

Use to tint epoxy for solder mask and base board repair. Color agent may also be applied directly to the circuit board surface for color matching. Supplied in 1 oz. (29 ml) collapsible metal tubes. MSDS

115-9348

$19.95 each

 
Color Agents for Circuit Boards Color Agent, Light Green, 115-9358

Use to tint epoxy for solder mask and base board repair. Color agent may also be applied directly to the circuit board surface for color matching. Supplied in 1 oz. (29 ml) collapsible metal tubes. MSDS

115-9358

$19.95 each

 
High Temperature Tape Discs 235-3050 High Temp. Tape Discs, .50" Diameter, 235-3050

High temperature tape discs are made of polyimide film with 1.5 mil of silicone adhesive that will not leave any residue. They can withstand temperatures of up to 500°F (260°C).
235-3050

US $5.95 pkg/60

 
Knife 355-0614 Knife with #16 Blades, 355-0614

A must-have tool for precise cutting, scraping and trimming. Includes five #16 blades.


Enlarge
355-0614

$9.95 each

 
Micro Probe 355-3102-5 Micro Probes (package of 5), 355-3102-5

These super-sharp probes are manufactured from high quality stainless steel. They include a plastic grip for easy handling. These inexpensive, disposable probes are ideal for dispensing a minute amount of epoxy, and for micro-positioning of small objects.

Probe Tip - .006" Diameter x .50" long

Enlarge

355-3102-5

$4.95 pkg/5

 
Mixing Pick Mixing Picks (package of 100), 115-3315-100

Unique mixing sticks have a paddle shape on one end for mixing, and sharp pick on the opposite end.


Enlarge
115-3315-100

$9.50 pkg/100

 
Scraper 335-3197 Scraper, 335-3197

Hardened stainless steel tip for scraping solder mask and removing defects.



Enlarge
335-3197

$9.95 each

 

Products above ship direct from manufacturer and are special order/non-returnable. Will ship within 3 business days.



2CheckOut.com Inc. is a payment facilitator for goods provided by ELAB (Engineering Lab). View cart

Payment methods accepted: American Express, Visa, MasterCard, Discover, Diners Club, JCB and Paypal.

Depending on issuing bank, charges on credit card statements should appear as 2CO.COM*ELAB.

If you use Paypal, your credit card statement will show Paypal*2CheckoutCO as the merchant.

Import duties and Value Added Tax will be collected at time of delivery for all shipments outside the USA.



Links to Related Products


Circuit Track Kit used to repair damaged PCB tracks   Circuit Track Kit 201-3130
Thanks to Circuit Tracks, it's now easier than ever to repair damaged circuits. Circuit Tracks are rectangular shaped conductors made of 99.9% pure copper. The rectangular ribbons closely conform to the original conductor dimensions. The replacement Circuit Track is bonded in place using a prepackaged epoxy which is included in this kit. The Circuit Track Kit is a great time and labor-saver and an easy solution to repairing missing or damaged circuits and conductors.


Circuit board epoxy for ciruit repair   Circuit Bond Kit 115-1322: Liquid circuit board epoxy
Circuit Bond Kit contains 10 packages of clear, low viscosity, superior strength epoxy ideal for circuit board use. The epoxy is precisely measured out into two-compartment plastic packages. This adhesive is easy to use and there's no measuring.

Color Agents for Circuit Boards
Matching epoxy to the color of the circuit board being repaired is easy when you use a color agent. Color agents may also be applied directly to the circuit board surface for color matching.



Copyright and Disclaimer Notice Copyright CircuitMedic, Haverhill, MA 01835 USA

Related Items
4.2.2 How to Repair a Damaged Conductor Using a Foil Jumper & Film Adhesive | 4.2.4 How to Repair a Damaged Conductor Using a Surface Jumper Wire