Operating instructions ERSA soldering station
Contents 1. Introduction..................................................................................................................... 4 1.1 Supply unit.............................................................................................................. 4 2. Technical data................................................................................................................. 5 3. For your safety.........................................................................................
Contents 6.4.3 6.5 6.6 6.7 6.8 6.9 Password lock.......................................................................................... 25 6.4.3.1 Setting the password.............................................................. 25 6.4.3.2 Changing the password......................................................... 27 6.4.3.3 Input of values without deactivating the password................. 27 6.4.3.4 Forgotten password............................................................... 28 6.4.
Operating instructions 1. Introduction We appreciate your decision to purchase this high-quality soldering station. The iCON 1 from ERSA is a top-of-the-line micro- processor-controlled soldering station. It is designed for use in industrial production, repairs and in laboratories. 1.1 Supply unit The use of a microprocessor facilitates operation and sets new standards for the functions available at the soldering station.
Operating instructions 2.
Operating instructions Soldering iron i-Tool Description Operating Voltage Maximum heating power Mean heating power Value Unit 24 VAC 150 W 80 W Heating-up time to 350°C / 662°F approx. 10 sec Weight (without supply line) approx. 30 g Other Supply line 1,2 m, highly flexible, heat resistant, antistatic Type: Antistatic in accordance to MIL-SPEC/ESA-Standard The handle features an integrated identification and standby function. 3.
Operating instructions 3.1 Pictograph and symbol explanations In this instruction manual, pictographs are used as hazard notes. Special information or orders and prohibitions to prevent personal injury or extensive material damage are supplemented by a pictograph and in the text with hierarchically structured bold words: Warning! Is used to warn of an imminent danger. Possible consequences can be death or personal injury. Attention! Is used to warn of a possible dangerous situation.
Operating instructions 3.2 Intended use ERSA heating tools may only be used for the processing of soft solder. In special cases, however, if stated explicitly in the operating manual of the respective tool, some tools can also be used to work plastics. If the tool is not used as intended or tampered with, the manufacturer cannot be held liable for any warranty and liability claims on part of the purchaser. Attention! Check all components before use.
Operating instructions Attention! Never leave your hot heating tool unattended. Remember that the tool insert needs a certain amount of time to cool down to a safe temperature even after you have switched the device off. Caution! Keep your workplace tidy. An untidy workplace increases the risk of accidents. Attention! Lead alloyed solders are toxic. Solders containing lead are toxic if they enter human body. For this reason, it is strictly forbidden to eat, drink or smoke.
Operating instructions Warning! Protect connection cables. Do not use the connection cable to pull out the plug or as a means of carrying the device. Make sure that connection cables are not exposed to heat and do not come into contact with oil or sharp edges. Damaged connection cables represent a potential cause of fire, short-circuits and electric shocks. Damaged connecting cables can cause fire, short circuits, and electric shock, consequently they must be replaced immediately.
Operating instructions 4. Transport, storage and disposal The i-CON 1 are each delivered in a stable box enclosure. Only use the original packaging for transport and interim storage of the systems. Do not move jerky or drop the i-CON 1. The i-CON 1 must be protected from weather influences such as rain, fog, sea air, etc. If the units will be stored for a longer period of time under humid conditions, then the i-CON 1 must be packed air-tight with desiccating agents in the enclosure.
Operating instructions 5. Commissioning 5.1 Before starting operation Please check the contents of the packaging for completeness. For more information read the chapter on [Spare Parts]! Should the listed components be damaged or incomplete, then please contact your supplier.
Operating instructions 5.2 Switching on for the first time Be sure to do the following to ensure the safe and long-lasting operation of the soldering tool: _ OFF 0 3BA00180 • 28.04.2008 • Rev. 1 _ ■ Check whether the supply voltage matches the value stated on the rating plate. ■ Switch off the soldering station with the power switch a. ■ Check the right fit of the soldering tip. ■ Connect the soldering tool with the control station b and put the soldering iron in the holder.
Operating instructions 6. Functional description 6.1 Operation The soldering station is switched on and off by the mains switch on the front side a. 0 _ ON The soldering station is controlled via a rotary encoder b with pushbutton function. It is called i-OP. The i-OP makes it possible to select desired functions or to change values. Clockwise turning results in higher values and counter-clockwise turning in lower values. Slow turning effects change in increments of one.
Operating instructions 6.2 The Work mode After the station has been switched on, the switch-on dialog is displayed for approx. 2 seconds. This dialog shows the station name a and the software version b of the i-CON 1.
Operating instructions 6.3 Parameter mode The following settings can be made in parameter mode: • Nominal temperature (150-450°C/302-842°F) • Calibration temperature (-70…+50°C/-126…+90°F) • Tip offset (Function reserved) • Energy function (3 stages) • Standby-Time (0-60min) • Standby-Temperature (150-300°C). Please proceed as follows to activate the parameter mode: ■ Hold the i-OP depressed for about 2 seconds, or press the i-OP two times quickly in succession.
Operating instructions Proceed as follows in order to change a parameter value: ■ Push the i-OP for approx. 2 sec. or two times quickly in succession to open the parameter mode. ■ Select the desired parameter by turning the i-OP. ■ Press the i-OP to activate the cursor, pressing the i-OP subsequently de-activates the cursor. If the cursor is activated, the value of the parameter is changed accordingly when the i-OP is turned.
Operating instructions 6.3.1 i-Set-Tool With the i-Set Tool (option) it is possible to save the settings (including password) of the station. Also you can write back the saved settings into the station. This way, the basic settings can be transferred quickly to several soldering stations. Please observe the i-Set Tool´s manual for this purpose. How to use the i-Set Tool: ■ Disconnect the soldering tool from the soldering station and connect the i-Set Tool.
Operating instructions 6.3.2 Set temperature The set temperature is the desired soldering tip temperature. In the work mode, the soldering tip temperature can be directly changed by turning the i‑OP. Confirm this by pushing the i‑OP. 6.3.3 Calibration temperature Use this function to calibrate the soldering tip temperature. It makes it possible to adjust the display value and actual tip temperature. The adjustable calibration range is -70...+50°C/-126...+90°F.
Operating instructions 6.3.4 Tip offset (Function reserved) 6.3.5 Calibrating the i-CON 1 Use the calibration temperature (see 6.3.6 “Calibration” temperature) to exactly synchronize the actual tip temperature with the displayed temperature. The following procedure must be observed for the calibration: 3BA00180 • 28.04.2008 • Rev. 1 ■ Input of desired set temperature (Chapter 6.3.2 “Set temperature”). ■ Set the calibration temperature (Chapter 6.3.6 “Determination of calibration temperature”).
Operating instructions 6.3.6 Calibration temperature ■ Determine the soldering tip temperature with a calibrated measuring device (e.g. ERSA DTM 100). ■ Compare the two displayed values of i-CON 1 and the measuring device. ■ Calculate the temperature difference: ∆T = Ti-CON 1 – Tmeasuring device ■ Set the calculated temperature difference ∆T (with algebraic sign via the rotary motion at the i-OP) in the menu item [Calibrate].
Operating instructions 6.3.8 Standby-Time The standby period is the time from the last work with the soldering tool to the point when the standby temperature is activated. The setting range is between 20 seconds and 60 minutes. The input [0] deactivates the standby function. For small soldering points or soldering works which are performed with very little motion, a sufficiently high standby-time should be selected.
Operating instructions 1 6.4 2 Configuration mode In the configuration mode, the following settings are possible: • Temperature window (monitoring) • Device number • process alarm (acoustic temp. monitoring) • Idle state • password • temperature unit • language selection of the station 0 _ 0 _ 0 2s To reach the configuration mode, keep the i-OP pushed for 5 seconds when you switch on the i-CON 1. 2 1 0 2s 0 3BA00180 • 28.04.2008 • Rev.
Operating instructions ■ turn the i-OP to select the menu option, then press: • [CHANGE] opens the menu [Configuration] • [ABORT] aborts the process • [DEFAULT] restores the factory settings. If the password lock is active, the soldering station cannot be reset to its delivery status (default) without the password. 6.4.1 Temperature window For the connected soldering tool a temperature window with an upper and lower range can be defined.
Operating instructions 6.4.3 Password lock The data of the station can be protected by a 4-digit (0001-9999) password. This way, settings/changes can be prevented. The station does not come with activated password lock; this is indicated by “0000” in the password input field. The symbol a signalizes that the station is protected. Factory setting: [0000] = unlocked. Please memorize your selected password thoroughly or note it down at a safe spot. Only ERSA can deactivate a forgotten password.
Operating instructions ■ Confirm your input by pushing the i-OP. The first [Password activation] image is displayed: ■ Select the [ABORT] item to quit the process. The password lock will not be activated in this case. ■ Note down the adjusted password, select the [>>>] item (continue), confirm by pushing the i-OP. Either Or The second [Password activation] image is displayed: ■ Enter your password again and Confirm your input by pushing the i-OP.
Operating instructions 6.4.3.2 Changing the password The password is set in the configuration mode. If a password has already been set, the code is displayed as astersiks. If the user wants to change a password, the active password lock must first be revoked by entering the current password. After the correct input, the new password can be set. If the numerical entry has been completed with the PUSH-function, a note is displayed indicating that the password lock is activated.
Operating instructions 6.4.3.4 Forgotten password If you have forgotten your password, it can only be de-activated by ERSA Service. In such a case, please refer to the company ERSA, indicating your address, name, invoice and serial number of the soldering station (see type plate). The password lock may also be de-activated with the i-Set Tool. Please observe the corresponding hint at section 6.4.3 to this purpose! 6.4.
Operating instructions 6.4.6 Adjustable shut-down function (idle state) The adjustable shut-down function (idle state) serves the purpose of energy saving and prolonging the lifetime of soldering tip and heater. In idle state the tools cool down to room temperature. The bottom line in the display then shows the text [Shut Down]. You can end the idle state at any time by actuating the i-OP.
Operating instructions 6.4.7 Device number This function is only required, if the i-CON 1 is equipped with a serial PC-interface (Option). An unambiguous device number must be assigned for identification, to enable the PC to correctly allocate the connected station. Please proceed as follows to set the [Unit number]: ■ Open the configuration mode and choose the option [Unit number]. ■ Activate the menu [Unit number] by turning the i-OP.
Operating instructions 6.5 Factory settings (“default”) The following lists shows the settings with which the station was programmed in our works. These settings can be restored via the “default function” in the “Configuration” mode. The only exception is the setting of the password which is not deleted via the default function. 3BA00180 • 28.04.2008 • Rev.
2s Operating instructions 0 6.6 0 _ _ Contrast Follow these steps to adjust the contrast of the display to the respective work environment: ■ Switch on the station and rotate the i-OP immediately. This activates the [Contrast] mode. 1 2 3 0 0,5 s 0 _ 0 3BA00180 • 28.04.2008 • Rev. 1 ■ Adjust the desired contrast by turning the i-OP. ■ Confirm your input by pushing the i-OP.
Operating instructions 6.7 Replacing the soldering tip Replace the soldering or desoldering tip when they are worn. Before replacing the soldering tip: ■ Switch off the station and let the soldering tip cool off. Attention! Only replace the tips when they are cold - burn hazard! 72°F _ 40°C OFF When the tip has cooled off, proceed as follows: 6.7.1 3BA00180 • 28.04.2008 • Rev. 1 i-Tool ■ Loosen the soldering tip by turning the knurled nut counter-clockwise.
Operating instructions ■ Carefully push the soldering tip out of the collar. Do not bend! Attention! Do not press on top of the tip! Risk of injury! ■ Carefully pull the new soldering tip into the retainer, until it engages. Do not bend! ■ Slide the new soldering tip and the collar onto the heating element. ■ Screw the tip tightly onto the soldering iron by turning the knurled screw clockwise.
Operating instructions 6.8 Changing the Heating Element Before changing a heating element: ■ 72°F _ Attention! Only replace the heating elements when they are cold - burn hazard! 40°C OFF 6.8.1 3BA00180 • 28.04.2008 • Rev. 1 Switch off the station and let the soldering tip cool off. Subsequently remove the soldering tip as described above.
Operating instructions ■ Slide the new heating elment into the handle Pay attention that the slot a in the heating elment matches the pin b in the handle. ■ 3BA00180 • 28.04.2008 • Rev. 1 Firmly push the heating element into the handle.
Operating instructions 6.9 Sensitive components Many components may be damaged by electrostatic discharge (please observe the warnings on the packaging or ask the manufacturer or supplier). These components can be protected by an ESD-secure workplace (ESD = electrostatic discharge). The soldering station can be easily integrated into such an environment. The soldering tip can be connected at high resistance (220kΩ) to the conductive workbase via the potential equalization jack (1).
Operating instructions 7. Error diagnosis and remedy 7.1 General Errors If the soldering station does not operate as expected, check the following items: 3BA00180 • 28.04.2008 • Rev. 1 • Is main voltage present? Correctly connect the mains lead to the device and socket. • Is the fuse defect? The fuse can be found at the rear side of the device in the mains connecting socket. • Note that a defective fuse may also indicate a deeper cause of error.
Operating instructions 7.2 Other Errors Other errors may also occur, indicating possible defects in the soldering tool. These errors are: • The station permamently only displays the room temperature. This indicates a fault on the heater or in the supply line. If the station is in idle state, the room temperature will also be displayed after a few minutes! • 3BA00180 • 28.04.2008 • Rev. 1 The display is switched off and no longer displays anything, but the mains switch continues to be illuminated.
Operating instructions 7.3 Continuity check for i-Tool If the soldering tip is not heated up after the previously mentioned points have been checked, you can check the heater resistor and the temperature sensor with an ohmmeter for conductance. 7.3.1 Heating element The continuity resistance between measuring points a and b should be approx. 3,5 - 4,5 Ohm (at cool soldering iron). In the event of interruption, the heating element is to be replaced (g = potential equalization). 7.3.
Operating instructions 7.5 Error Messages The i-CON 1 carries out an automatic error diagnosis. The result of a diagnosis is displayed as an error code: The triangular pictograph a appears in the display of the soldering station. The error code b is displayed as a number between 2 and 99. Additionally, an information text 3 is displayed in the bottom line. The error codes are listed in the following table. Error messages have to be confirmed with the i-OP.
Operating instructions Code 2 4 7 8 9 71 98 99 3BA00180 • 28.04.2008 • Rev. 1 Test in display [CALIBRATION FATAL ERROR !] [RT-compensation] [HE MISSING ? SENSOR ?] [HEAT ELEMENT?] Cause Station no longer calibrated Measurement reading of KTY not ok Heating element is not installed correctly Thermocouple error Heater defect [DATA LOST!] Parameter/Configuration data destroyed [iTOOL AND HE DEFECTIVE/ EXCHANGE] Both the electronics and the heating element of the i-Tool are defective.
Operating instructions 8. Maintenance 8.1 Important care jobs To ensure a long service life of your station, a few points must be observed. ■ Make sure that the soldering and desoldering tip is always tinned. A soldering tip which is always clean will become passive within a short time. If you always leave a small amount of solder at the soldering tip when you stop soldering, the service life increases substantially.
Operating instructions 9. Replacement parts Replacement parts Descriptiont Order-no. i-CON 1 electronic station, 80 W, antistatic, compl. with 1 i-Tool soldering iron and holder 0IC 1100A Soldering stations Single parts 3BA00180 • 28.04.2008 • Rev.
Operating instructions Replacement parts 3BA00180 • 28.04.2008 • Rev. 1 i-CON 1 / 45 Descriptiont Order-no.
Operating instructions 9.1 ERSADUR Long-Life Soldering tips (i-Tips) i-Tips [P] Ø 5,2 i-CON 1 / 46 5,2 0102PDLF10 Ø 0102PDLF08L 9,5 ,3 29 5,2 5,2 5,2 ,5 13 0102PDLF04L Ø Ø ,5 30 11 0102PDLF06L Ø 1,0 Ø 0,8 3BA00180 • 28.04.2008 • Rev.
Operating instructions i-Tips [C] 0,2 4,5 0,8 0,6 5,2 Ø 5,2 5,2 Ø 35 Ø 5,2 30 Ø ,5 ,5 30 0,6 Ø ,2 26 1,2 23 0102CDLF04 0102CDLF12 ,5 30 5,2 5,2 0,8 0,8 0102CDLF18L Ø 35 5,2 5,2 0,8 ,4 14 Ø Ø ,5 30 1,8 9,5 0102CDLF16 Ø ,5 30 1,6 9,5 1 9 0,4 2,4 2 0102CDLF20 0,8 1,7 45 i-CON 1 / 47 0 3BA00180 • 28.04.2008 • Rev.
Operating instructions i-Tips [C] ,5 45 ,5 45 ° 40 10 8,6 48 2 Ø1 26 0102CDLF120C ,2 13 20 24 0102CDLF100 0102CDLF200 i-Tips [S] 30 ° 0102SDLF04 9,5 0102SDLF06 ,7 0,6 12 1,8 ,7 ° ,2 45 Ø5 33 0102SDLF18 3BA00180 • 28.04.2008 • Rev.
Operating instructions i-Tips [A] 0102ADLF15 4 9,5 0102ADLF20 2,3 9,5 0102WDLF16 5,2 5,2 1,6 ,5 30 5,2 Ø 30 3,5 9,5 0102WDLF23 0102WDLF35 i-Tips [Z] 48 0102ZDLF150 3BA00180 • 28.04.2008 • Rev.
Operating instructions i-Tips [B] 5,2 45° Ø ,5 30 4 2 9,5 0102BDLF20 Consideration! Before you start to solder please remove the possibly existing hose protection nozzle. 3BA00180 • 28.04.2008 • Rev.
Operating instructions 10. Warranty © 05/2008, ERSA GmbH • 3BA00180 Rev. 1 Heating elements and soldering or desoldering tips are treated as wearing parts, and are therefore not subject to the warranty. Any return of goods must be accompanied by a written description of the material or construction fault that has occurred as well as a confirmed purchase invoice. ERSA created these operating instructions with careful attention to detail.
