Transcript
Energy Efficient & Technologically Advanced Soldering
Energy Efficient & Technologically Advanced Soldering
Overview
Energy Saving
ESD Safe
FEATURES
EOS Safe
Process Safe
Improved Productivity
MultiTool Connectivity
Standby time Offset (temperature offset) Temperature version °C/°F Password (lock function) Temperature window (WINDOW) Factory Setting - FSE COST BENEFIT
Moderate station cost Low running cost via LT tips Long life heater - NiCr Technology Minimal energy consumption IMPACT OF TECHNOLOGY & DESIGN
ESD Safe design EOS / Potential balancing possible Power on demand Calibration not required* Multi tools compatibility ERGONO MI CS
Lightweight Easy change of tips Features easy to program IN PROCES S SAFET Y
Temperature lockout Parameter lockout
Prepared by : Ganesh Mahendran / Eddine Zergdjenah
Calibration Free
Introducing
WSD81i
Energy Efficient & Technologically Advanced Soldering
‘Low cost’...really? Many users are prompted to exact purchase of so called low cost stations, or low initial purchase price. However, it’s best to understand what one is actually paying for. Consider a common brand in the market as a comparison. Brand
Low Cost Stations (LC)
Weller (W)
Model
X
WSD81i
Country of Origin
X
Germany $$
$
Market Price USD$ - Station*
W vs LC
LC
$
$
Control Electronics
Digital
Digital
Same
Heating Technology
PTC Ceramic
Nichrome heating
W
Soldering Iron - Power (W)
70W
80W
W
Act. Power during start up (W)
170W
90W
W
Act.Idle Power after start up (W)
60W
25W
W
Performance - Heat up to 380C
70secs (170 Watts)
15secs (90 Watts)
W
Market Price USD$ - Tips*
Temperature Response (Slug*)
Slug
1
2
Secs
23.8
23.6
3
Slug
22.6 Secs
Same
1
2
3
14.1
13.1
14.1
W
Multi tool connectivity
No
Yes
W
EOS / Potential Balancing
No
Yes
W
Prepared by : Ganesh Mahendran / Eddine Zergdjenah
Energy Efficient & Technologically Advanced Soldering
Why choose Weller 1
vs
Low Cost Stations
Energy saving: Low power consumption during start up and after start up when iron is not in used. Power on demand: which sense the thermal requirement for each solder joint size. Variable and adequate power according to the application. Reducing power consumption. No high steady Power if it is not required.
Low Cost: Conventional soldering irons are fixed power systems that store energy in their tips. They do not adjust power in response to thermal demand. Steady and high power consumption when it is not necessary.
2
Weller using Platinum Temperature Sensor: Resistance-temperature relationship holds true over extended periods of time. The most accurate sensor offering a brief response time, a high resistance against vibration and temperature shocks and the best longterm temperature stability. There is no temperature drift through aging. No need for calibration.
Low Cost: Thermocouple long-term stability is somewhat worse (temperature shift over time), the measuring accuracy is slightly poorer. Calibration has to be done regularly
3
Heater technology: Nichrome specific high precision heating bifilar wire wounded around a pure silver core for best thermal conductivity heats faster, evenly and recovers better than ceramic heater. The drop in temperature is significantly lower. See “slug” test on page 4. Storing energy into a large silver core offers best thermal conductivity, maximum energy storage and higher life of Heating Element
Low Cost: Slower heat up time and high drop in temperature are usually a strong indicator of the heaters capability and higher energy load. Ceramic heaters generally tend to be more frail & brittle - Increase cost of heater change / annum
4
Soldering process: Iron works on “precise tip temperature setting and automatic power on demand” principle. Goal is to solder joint quality as per IPC within the fastest period at lowest temperature. Controlling solder tip temperature with adequate heat transfer is essential for creating reliable solder joints and avoiding damages on SMD sensitive component.
Low Cost: Operators adjusting station temperature to maximum to compensate low temp. recovery. Reducing tip lifetime, high energy cost, may cause change in electrical characteristics, damage to electrical parts (such as loosening of terminations), softening of insulation, opening of solder seals and weakening of mechanical joints, risk of pad pattern lift up...
5
EOS – Electrical Over Stress / Potential balancing possible: Unique grounding management possibility to prevent noise, i nterference & undesirable current to component. EOS safe soldering iron. See page 6.
Low Cost: The vast majority of conventional irons have no separate//independant grounding wire and therefore no alternative to be connected directly to the main ground via low impedance; “Hard Grounding”. Safe soldering process is not secured. Transient/voltage signals providing from power line ground can damage sensitive components.
6
Multi tools Connectivity: Connectivity of several tools possible. Iron, heated tweezers, preheating platte, soldering bath. One station controlling various soldering/dessoldering tools.
Low Cost: Nil
Prepared by : Ganesh Mahendran
Eddine Zergdjenah
Energy Efficient & Technologically Advanced Soldering Temp C
1 2
3
Weller LT A 1.6D Weller LT B 2.4D Low Cost 1.6D Low Cost 2.4D
“Slug testing. This is one of the most reliable ways to test the performance of the heating capability of the soldering tool” Time (secs)
A slug test is a particular type of performance
Weller
Low Cost
test where a load to be heated is added to the soldering tip and simulating high rated
Slug
1
2
3
Slug
1
2
3
repetitive soldering operations. The change
Secs
23.8
23.6
22.6
Secs
14.1
13.1
14.1
in temperature is monitored through time.
Point 1,2,3. Best thermal conductivity, faster heat, evenly and temperature recovering better than ceramic heater. The drop in temperature is significantly lower and the process time is shorter
» Temperature drop » Heavy ground, should not go mass, multilayer beyond the process applications require window POD ( Power on » Weller heating Demand ). Wellers technology is offers this desgined to keep the » Goal is to solder temperature within joint quality as per the process window IPC within the fastest period
Key factors in heating / soldering 1
Tip initially contacts the solder joint. Tip mass losses heat 2
Weller heating element technology keeps temperature within its process window. Heat transfer is automatically regulated.
Solder joint completed, tip begins to recover 3
Tip tempeature has recoved, stabilize till next joint 4
Critical is the recovery time at each joint
Prepared by : Ganesh Mahendran
Low Cost Station: The right amount of heat into the tip to maintain the same temperature for high mass or simply consecutive soldering tasks is not secured. To compensate the loss of temperature, operators tend to increase the setting temperature which leads to high energy consumption, shorter tip lifetime and excessive temperature to component. Eddine Zergdjenah
Energy Efficient & Technologically Advanced Soldering
The Weller Advantage » Weller soldering irons work on “precise tip temperature setting and automatic power on demand” principle. » The basic rule of thumb when using a soldering iron is that it is best to use the minimum temperature possible and the precise amount of thermal energy when soldering , allowing reflow in a reasonable time but posing minimum threat of damage to the component/PCB. » Control of the soldering temperature and accurate management of heater power is the key strategy when performing isolated or high rated repetitive soldering operations. » The temperature is adjustable by one degree step and controlled with self-regulation. One soldering tip can be precisely adjusted for different temperature recommendations.The ideal temperature/duration ratios maximize productivity and solder joint reliability. Weller Tip OC
Low Cost Tip Tip O C
Weller (Joules)
Low Cost System (Joules)
High performance heat up Low energy consumption
Low performance heat up High energy consumption
Durability, Reliability & Repeatability » Weller offers high process stability and transparency at low Running Cost » A ceramic heating element is brittle and very sensitive against mechanical shock. It can snap by dropping it on a hard surface or if an operator puts some pressure on the tip. Repeated knocking to remove access solder also could cause it to snap. The cost for maintenance and replacement is significantly higher. » Weller specific high precision heating wire is bifular wound around a silver core, so it heats from the outside in and distributes ideally the heat through high conductivity of the silver core. The heater heats up the large Silver core body; part of the iron, with high thermal conductivity and heat capacity, which in turn conducts heat to the tip rapidly. » Weller long lasting heating element withstands tens of thousands of heating and cooling cycles without the potential for cracking or breaking.
Prepared by : Ganesh Mahendran
» The true net value of Weller soldering solution and the key criteria are the protection of components and the reduction in the need for tip or heating element replacement. Durability is key. » Temperature control enables users to set the lowest possible operating temperature, reducing considerably iron tip oxidation and increasing tip lifetime. » Weller Silver Line Technology offers real cost-effectiveness by considering all the costs - the upfront price of the system plus the cost of running it. » This technology offers a resistant heater, long tip life with low tip prices compared to all powered soldering irons using expensive heating cartridge tips with fixed temperature or ceramic heating element. » The iron is designed ready for implementation of EOS / Potential balancing which helps provide in-process security for assembly.
Eddine Zergdjenah
Energy Efficient & Technologically Advanced Soldering
EOS & Potential Balancing with WSD81i » Weller unique iron tip grounding management prevents noise, interference and » undesirable current flow (Electrical Over Stress/EOS) providing from power line ground » EOS : Any electrical energy that damages or causes possible failure » to component. » Weller offers superior protection against transient electrical energy . » Transient electrical energy can be caused by both internal and power line ground transients
Independent potential grounding line
1.Weller station is not transient generating by itself (zero switching voltage). Zero voltage switching attempts to switch power to the heater when the power cycle is essentially at zero voltage. 2.Noise on ground - whatever signal is present on ground, it will not be present on the tip of the iron Low cost stations: The vast majority of conventional irons have no separate/independent grounding wire and therefore no alternative to be connected directly to the main ground via low impedance; “Hard Grounding”. Safe soldering process is not secured.
Available grounding/potential balancing - WSD81i » a) Hard grounded (normal state) » b) Potential balance – with plug and balance wire to connect the iron tip to the common ground point » c) Potential free – with plug » d) Soft grounded: with plug and soldered resistor grounded via selected resistor
IPC J-STD-001E: 3.9 Soldering Tools and Equipment “Soldering irons, equipment, and systems shall be chosen and employed to provide temperature control and isolation from electrical overstress or ESD” All Weller electronic soldering equipment meet or exceed the stringent requirements for protection against electrical overstress (EOS) or electrostatic discharge (ESD) damage to ESD sensitive (ESDS) devices.
Weller Soldering Tips Designed at Weller’s German Research and Development Centre, Weller tips meet most thermal requirements in terms of design and durability. Coupled with the excellent heating technology from Weller, these tips provide a low cost and effective soldering results from a wide selection of tips.
Prepared by : Ganesh Mahendran
Eddine Zergdjenah
