Xg Classic Sgs-2000 Series Standard / Esd Model

Transcript

Thank you for purchasing one of the XG Classic Soldering Systems. This temperature controlled soldering system is an electronic device developed to meet the present and future needs of the production of electronic industry. Please read this manual before operating the unit. Store the manual in a safe, easily accessible place for future reference. This publication may not include some last minute technical changes and/or revisions to the unit. Changes are periodically made to the information described here. Future editions of this manual will incorporate these changes. This manual is provided for information purposes only. All information included herein is subject to change without notice. Spike is not responsible for any damages, direct or indirect, arising from or related to the use of this manual. Patent No: 013171461, 01217422X, 012179477 ! WARNING Spike (Changzhou) Electronics Co., Ltd. Normal use of this product could expose the user to solders containing lead which is known to the State of California to cause cancer and birth defects, or other reproductive harm, or other Proposition 65 listed chemicals. 4FT13-1300-034 Made in China XG Classic SGS-2000 Series Standard / ESD Model Temperature Controlled Soldering System Operation Manual XG SGS-2000 Series Temperature Controlled Soldering System Operation Manual Table of Contents Packing List............................................................ 2 Precautions............................................................ 2 Features................................................................. 4 Name of Parts......................................................... 6 Operating the Classic Series Soldering System.......... 7 1. Control Base 2. Iron Holder 3. Soldering Iron 4. Turn on the Power Switch Care and Maintenance of Soldering Iron.............. ...... 11 1. Working Temperature 2. Use and Care of Tips Calibrating Iron Temperature.................................... 13 1. Tools Required 2. Steps of Calibrating Iron Temperature Checking for Breakage of the Heating Element & Cord Assembly .......... .................. .................. 14 1. Broken Heating Element 2. Broken Soldering Iron Cord Replacing Fuse........................................................ 16 Troubleshooting Guide......... ....... ............... .............. . ..... 17 Specifications ........................ ............................ .... ........ 18 Control Base Soldering Iron Soldering Iron Temperature Curve .................. ...... .. . ........ 19 Schematic Diagram ........ ........................... ........... . ......... 19 Parts and Accessories ........... .................... .................. . ... 20 Soldering Tips ....................... ........................... ........... . .... 24 1. Packing List Please Check the contents of the XG Classic package and confirm that all the items listed below are included. Control Base Iron Holder Soldering Iron Cleaning Sponge Hex Wrench Documentation Package 1 1 1 1 1 1 ! CAUTION When seeking Tip replacements, select Spike genuine Soldering Iron Tips. Please refer to the instruction on how to use, and care of Tips. If an incompatible Tip made by another manufacturer is used, the original performance of the Soldering System may not be obtained. We take no responsibility for any problem caused by using products or parts made by another manufacturer. Precautions In this operation manual, “Warning” and “Caution” are defined as follows: ! WARNING: Misuse may potentially cause death of, or serious injury to, the user. (Figure 1) ! CAUTION: Misuse may potentially cause injury to the user or physical damage to the objects involved. For your own safety, be sure to comply with these precautions. 2. ! CAUTION When the power is on, the Tip temperature is between 392 F-896 F ( 200 C-480 C ). Since mishandling may lead to burns or fire, be sure to comply with the following precautions. Do not touch the metal parts near the Tip. Do not use the product near inflammable items and/or explosives. Advise other people in the work area that the unit can reach a very high temperature and should be consid ered potentially dangerous. Turn the power off while taking breaks and when fin ished using the unit. Before replacing parts or storing the unit, turn the power off and allow the unit to cool to room temperature. To prevent damage to the unit and ensure a safe working environment, be sure to comply with the following precautions. Do not use the unit for applications other than soldering. Do not turn on the power when the Soldering Iron is not connected to the Control Base to prevent any damage to the unit. Do not rap the Soldering Iron against any hard surface to shake off soldering residual, or otherwise subject the iron to severe shock. Do not modify the unit. Use only genuine Spike replacement parts. Do not wet the unit or use the unit when your hands are wet. The soldering process will produce smoke, so make sure the work area is well ventilated. 3. Features XG Classic is one of a series of high quality soldering systems featuring: High Efficiency and Low Interference Switching technology designed circuit, allowing maximumefficiency reaching at least 80% High power factor: Q 90% Minimal interference, effectively restraining EMI and RFI with zero voltage switching High Temperature-Fidelity, Rapid Heat up and Recovery Applying high open loop gain to improve the temperature adjusting accuracy This system allows the closest possible monitoring of extremely small temperature variation of the Tip, thus result ing the Soldering Iron to be in a state of constant temperature for working purposes Rapid heat up and recovery 4. Safe and Reliable Sensitive protection against short circuit Variable input voltage does not affect working temperature The sealed Iron Receptacle is convenient and safe for operation. The Iron Holder Cover is designed to prevent the Soldering Iron being accidentally touched The power unit and the control system is isolated from each other, only about 24V is used to drive the Heating Element The Soldering Iron is attached to the Base using a heatresistant Cord Assembly and a five-pin, heavy duty Plug The Tip is grounded to ensure working voltage to ground less than 2 milivolts Original Design with Comfortable and Unique Style This compact unit of modern style takes up little space on the workbench. Stackable as shown so that two or more Control Bases and/or an Iron Holder can be put onto each other for more convenience. Combinatory so that the Control Base and the Iron Holder can be used together or separately at ease (See Figure 2) Melt Solder flows into Iron rack and will not spray or overflow onto the workbench, and the Iron Holder can be easily cleaned The metal Control Base housing is molded that it can stand high impact and it has an excellent heat dissipation ability and serves as a shield against radiation of EMI and/or RFI Convenience and Ease A unique electronic control circuit is employed enabling the user to adjust Tip temperature from 392 through 896 ( 200 - 480 ) without changing Tip or Heating Element This system is equipped with a locking feature to allow the operator the ability to set and lock the system at a specific temperature Thinner grip makes the Soldering Iron easier and more comfortable to use Convenient to use and easy to clean a b c d Products of a Series for Your Selection Several models to meet different working requirement: Classic and Digital Control with ESD safe style More Tips are available (Figure 2) 5. Name of Parts Power Plug & Cord Assembly Soldering Iron Fuse & Fuse Box Back Panel Iron Holder Cover Power Switch Cleaning Sponge Pool ESD Socket Iron Holder Control Base Front Panel Temperature Control Knob Hex Wrench Heating Indicator CAL Cleaning Sponge Iron Cord Assembly & Plug (Figure 3) Receptacle 6. Operating the XG Classic Soldering System 1. Control Base 1) Front Panel (See Figure 4) Front Panel Name Plate Temperature Scale Temperature LED Indicator CAL Pot Plug Control Knob CAL Pot Plug: For calibrating Iron temperature. 2) Back Panel (See Figure 5) Five Pin Plug Receptacle (Figure 4) Five-pin Receptacle: For connection with the Soldering Iron. Temperature Control Konb: To allow the operator to adjust temperature. The temperature scale on the Front Panel in white is the Celsius, while in gold, the Fahrenheit. LED Indicator: Indicating the working condition of the Soldering System. Back Panel Fuse Box Power Switch Power Cord Assembly ESD Grounding Socket (Figure 5) Power Switch: Switch to “ O” to turn off the Soldering System, while “I” to turn on the Power Supply. Fuse Box: Refer to “Replacing Fuse”. ESD Grounding Socket: For connecting with protective device against ESD designed for ESD Safe models (Such as ESD Wrist Ring). 7. 3) Lock Temperature Set the Temperature control Knob to the desired temperature. (Please refer to “ Care and Maintenance of Soldering Iron-Working Temperature ” and “Calibrating Iron Temperature”). Lock the Knob: XG Classic Series are equipped with a Temperature Control Konb Lock. After setting desired temperature, tighten the Hex Nut on the underside of the Potentiometer Mount using the supplied Hex Wrench. Turn the Nut clockwise to tighten the Knob Lock. (See Figure 6) Temperature Contorl Knob Potentiometer Mount ! CAUTION : Do not overtighten the knob Lock. Do not attempt to turn the Knob when the Konb Lock is set. 2. Iron Holder ! CAUTION: Before using the unit, dampen the Sponge with water and squeeze it dry. Failure to do so may result in damage to the Soldering Tip. 1) The Iron Holder can be used together with the Control Base or separately as wished. To stack up with the Control Base, just slide the Iron Holder slot (See Figure 7a) from the back of the Control Base. See Figure 2 and Figure 7. The locking device will lock its position to maintain the firm hold with the Control Base. Counterclockwise Clockwise Front Panel Locking Hex Nut (Figure 6) 8. Iron Holder Slot Back Panel (Figure 7a) (Figure 7) (Figure 8) 2) With a little push, the Iron Holder can be easily pulled off the Control Base. (See Figure 7) 3) To clean the Holder, simply take the Holder off the Control Base, open the Cover, and pour out the residual & wipe the Holder clean with a soft dry cloth. (See Figure 8) 3. Soldering Iron ! CAUTION: Be sure to turn off the Power Switch before disconnecting the Soldering Iron. Failure to do so may damage the PWB. 1) Connect the Cord Assembly to the Receptacle as shown in Fig. 11. 2) Place the Soldering Iron in the Iron Holder. See Fig.12. Please refer to Care and Maintenance of Soldering Iron for more details. 4) Dampen the small Cleaning Sponge with water and then squeeze it dry. Place it in one of the openings of the IronHolder. (See Figure 9) 5) Add water daily to approximately the level as shown in Figure 9. The small Sponge will absorb water to keep the large Sponge above wet at all times. 6) Dampen the large Cleaning Sponge and place it in the Cleaning Sponge Pool of the Iron Holder. The large Sponge may be used alone (without small Sponge & water). 7) For your convenience, 4 verticle holes are designed on the Iron Holder for lron Tips. (See Figure 10) (Figure 9) (Figure 10) ! CAUTION: The Soldering Iron must always be placed in the Iron Holder when not in use. (See Figure 12). 4. Turn on the Power Switch ! WARNING: Be sure to ground the unit. 1) Plug the Power Cord into the power supply. Make sure the Power Switch is at the “O” (Off) position. (See Figure 5) 2) Turn on the power switch. The Heating Indicator lights orange when power is on. The Indicator blinks green and orange, when the temperature of Heating Element of the Soldering Iron reaches the set temperature. (See Figure 13) Wait for about half a minute and the unit is now ready to perform soldering work. (Figure 13) Front Panel 10. (Figure 11) (Figure 12) 9. Heating Indicator Care and Maintenance of Soldering Iron 1. Working Temperature A low temperature will slow the rate of flow of solder. A high temperature will burn the flux in the solder, which in turn will emit a heavy white smoke resulting in a dry joint, or damage to the soldered components or parts. When the Tip working temperature is set within the correct parameters suited to the particular solder being used, a good joint is assured. The most common solder alloy used in the electronic industry is 60% tin, 40% lead. The typical working temperature of the solder is detailed below but it can vary from manufacturer to manufacturer. Melting Point Normal operation Production line operation Desoldering operation for small joint Desoldering operation for large joint 419 F (215 C) 608 F (320 C) 716 F (380 C) 608 F (320 C) 752 F (400 C) The temperature above 770 F ( 410 C ) should not be used for normal soldering functions, but can be used for short period of time when excessive heat is required. 2.Use and Care of Tips Tip Temperature High soldering temperature can degrade the Tip. Use the lowest possible soldering temperature. The excellent thermal recovery characteristics of this system ensures efficient and effective soldering even at low temperature. This also protects the soldered items from thermal damage. When Not in Use Clean the Tip regularly with the supplied Cleaning Sponge, as oxides and carbides from the solder and flux can form impurities on the Tip. These impurities can reduce the Tip’s heat conductivity or result in defective joints. Before Use and After Use Wipe the Tip clean and coat the Tip with fresh solder. This helps prevent Tip oxidation. Always keep the 11. Tip tinned before returning to Holder, switching off or storing for any period of time,wipe only before using. Maintenance 1. When using the Soldering lron continuously, be sure to loosen the Tip and remove all oxides at least once a week. 2. This helps prevent seizure and reduction of the Tip temperature. Set the temperature to 482 F ( 250 C ). 3. When the temperature stabilizes, clean the Tip with the Cleaning Sponge and check the condition of the Tip. If black oxides appear on the solder-plated portion of the Tip, apply new solder (containing flux). Wipe the Tip on the Cleaning Sponge. Repeat until the oxides are completely removed. Coat with new solder. 5. If the Tip is deformed or heavily eroded, replace with a new one. 6. If any oxide film does form, this can be cleaned by carefully rubbing with a 600-800 frit fine emery cloth, isopropyl alcohol or the equivalent, then wrap rosin-core solder around the newly exposed surface and reheat, flood the tinned area with rosin-core solder after wrapped rosincore solder melted. ! CAUTION Do not keep lron set at high temperature for long period of time as this will break down the surface of the Tip. Do not give any excessive pressure on a Tip or rubbing a Tip on a joint during making a joint, it does not improve heat transfer but only damages the Tip. Do not use fluxes containing chloride or acid, use only rosin or resin activated fluxes. Never remove Tip oxides with files. 12. Calibrating lron Temperature ! CAUTION: The Soldering System should be recalibrated after changing the lron, or replacing the Heating Element or Tip. The initial temperature calibration of this Soldering System has been set at the factory in accordance with various industrial standards. No further calibration is necessary by the user within about 6 months after first use if no part change is needed. 1. Tools Required 1) Digital thermometer with leads and alligator clips or digital thermometer equipped with surface contact sensor specifically for Soldering lron temperature measurement. 2) Test Tip fitted with thermocouple or SGT-710B standard Tip for ceramic Heater. 3) 2.3-3mm (3/32” ) small flat screwdriver. 4) Multimeter 2. Steps of Calibrating lron Temperature 1) Connect the Cord Assembly Plug to the Receptacle on the Control Base. (See Figure 11) 2) Set the Temperature Control Knob to 750 ( 400 ). 3) Remove the CAL Pot Plug on the Front Panel (See Figure and turn on the Power Switch. 4) Wait until the temperature stabilizes. Use a small flat (-) or philips (+) screwdriver to adjust the screw (through the CAL hole behind the Front Panel at the Base) until the Tip thermometer indicates the temperature to be 750 ( 400 ). Turn the CAL Screw slightly clockwise to raise the temperature or counterclockwise to lower the temperature. 5) Reposition the CAL Pot Plug. ! CAUTION: The Soldering System should be recalibrated at the factory or service agent if the 200 temperature scale needs to be set. CAL Front Panel Clockwise Counterclockwise CAL Pot Plug (Figure 14) 13. Checking for Breakage of the Heating Element & Cord Assembly Disconnect the Plug and measure the resistance value between the connecting Plug Pins as follows. (See Figure 15) a b c Between Pin 4 & 5 (Heating Element) Between Pin 1 & 2 (Sensor) Between Pin 3 & Tip 2.5-3.5 W (Normal) 43-58 W (Normal) About 2 W 3 2 4 Measure when the Heating Element is at room temperature (See Figure 17) 1) Resistance value of Heating Element 2.5-3.5 W 2) Resistance value of Sensor 43-58 W. If the resistance value is not normal, replace the Heating Element. 5 1 1. Broken Heating Element Disassembling the Iron unit (Please see Figure 24 for details.) 1) Turn Nut (2) counterclockwise and remove the Tip Enclosure(3), the Tip (4). 2) Turn Nipple (5) counterclockwise, remove it from the lron. 3) Pull both the Heating Element (7),Terminal Board (8) and the Cord Assembly (12) out of the Handle (9) (toward the Tip of the lron). (Figure 15) (Figure 16) If the values of ‘a’ and ‘b’ are outside the above value, replace the Heating Element (sensor) and/or Cord Assembly. If the value of ‘c’ is over the above value, remove the oxidization film by lightly rubbing with fine sand-paper or steel wool the points as shown in Figure 16. 14. 2) Measure the resistance value a, b, and c to confirm tha tthe leads are not twisted and that the Grounding Spring is properly connected. Heating Element After replacing the Heating Element: 1) Measure the resistance value between Pin 4 & 1 or 2 Pin 5 & 1 or 2 If it is not , the Heating Element and Sensor are touching. This will result in damage of PWB. 2) Check the resistance value between the Pin of the Plug and the Wire on the Terminal. Sensor (Figure 17) 2. Broken Soldering lron Cord There are two methods of testing the Soldering lron Cord. 1) Turn the unit ON and set the Temperature Control Knob to its maximum on the dial 896 ( 480 ). Then wiggle and kink the lron Cord at various locations along its length, including the strain relief area.(See Figure 18). If the LED Heater Indicator flickers, the Cord needs to be replaced. (Figure 18) Pin 1: Black Pin 2: White Pin 4: Red Pin 5: Blue Pin 3: Green The value should be 0. If it is greater than 0 or is Cord should be replaced. , the ! CAUTION: The LED Indicator will flicker even with a normal lron Cord if the temperature reaches 896 ( 480 ). 15. Replacing Fuse Turn loose the Fuse Cover counterclockwise and remove the blown Fuse, change a new one with the same rated Fuse. (See Figure 19). Check the Specifications on page 18 for Fuse rating. Back Panel Fuse Fuse Box Cover Counterclockwise (Figure 19) 16. Troubleshooting Guide 4 ! WARNING: Disconnect the Power Plug before The Tip is not wet 5) Is the Tip temperature too high?( 770 [ 410 ]) servicing. Failure to do so may result in electric shock. If Power Cord Assembly is damaged, it must be replaced by the manufacturer, or its service agent to avoid personal injury or damage to the unit. 1 2 3 Problem Check The Heater Indicator is not lit up 1) Is the Power Cord and/or connecting plug disconnected? Connect it 2) Is the Fuse blown? Determine why the Fuse was blown and eliminate the cause, then replace the Fuse A. Is the inside of the Soldering Iron short-circuited? B. Is the Grounding Spring touching the Heating Element? C. Is the Heating Element Lead Wire twisted and shortcircuited? D. Is the PWB already damaged? The Heater Indicator is lit up but the Tip does not heat up Set an appropriate temperature A. Refer to “Use and Care of Tips” B. Working surfaces not well tinned during idling periods C. Lack of flux in soldering, wicking, repairing and touchup operations D. Wiping Tip on high sulphur content Sponges, dirty or dry Sponges and rags E. Contacting with organics, such as plastic resins, silicone grease, and other chemicals F. Impurities in solder and low tin 6) Is the Tip clean? Cause & Action Refer to “Checking for Breakage of the Heating Element & Cord Assembly” 3) Is the Soldering lron Cord broken? 4) Is the Heating Element broken? The Tip heats up intermittently 5 The Tip temperature is too low 7) Is the Tip coated with oxides? Refer to “are and Maintenance of Soldering lron.” 8) Is Iron temperature calibrated correctly? Refer to “Calibrating the Iron Temperature.” 9) Is the Tip seized? Is the Tip swollen because of deterioration? Replace the Tip and the Heating Element. 6 The Tip cannot be pulled off 7 The Tip does not hold to the desired temperature Check 8) 8 The Tip temperature is too high Check 8) Check 3) 10) The indicator is not lit at all or it stays orange for long period of time PWB is damaged 17. Specifications Control Base Model # SGS-2000 SGS-2005 SGS-2010 SGS-2015 Description Standard ESD Safe Standard ESD Safe Power Consumption AC 200-240V ~ 50Hz 6W Output Voltage 24V Temperature 392-896 F (200-480 C) Dimension of Control Base L x W x H = 5.7 x 4.3 x 1.8” (145 x 110 x 45mm) Dimension of Iron Holder L x W x H = 5.7 x 3.6 x 2.8” (145 x 91 x 70mm) Weight (Ele. Cord not included) 2 lb (< 1kg) Fuse 250V-T-1A ( F5 x 20) AC 90-125V ~ 60Hz 60W 250V-T-2A ( F5 x 20) Soldering Iron Model # SGI-900 Input Voltage 24V Tip to Ground Resistance < 2W Tip to Ground Potential < 2mV Heating Element Ceramic Heater ESD Safe No SGI-901 Yes The above specifications and design are subject to change without notice. 18. Soldering lrom Temperature Curve Schematic Diagram H: 65sec AC Input 500 EMC Filter Rectified Phase Correction Filter Zero Voltage High Frequency Switch Transformer Circuit 450 D: 60 400 350 Starting Circui O: 180sec 300 High Frequency Rectified Circuit Low-pass Circuit D: 18 250 Heating Element 200 T: H: O: R: D: 150 100 Test Criteria 1. Soldering Tip: SGT-716D 2. Epoxy Resin Board 3. Solder: F 1.6 5mm 4. Cycle: Every 3 Seconds Room Temperature 25 Heat-Up Time Operating Time Thermal Recovery Time Temperature Drop Grounding Setting COMP Temperature Sensor 50 1 2 3 4 5 (Figure 20) 6 7 Minute (Figure 21) 19. Parts & Accessories Control Base M3 X 5 Philips Tapping Screw (1) M3 X 10 Philips Tapping Screw (2) M3 X 10 Philips Tapping Screw (8) (Figure 22) 20. Part List No Remark Name Art. Number PWB (Printed Wire Board) Control Base 1 SGX-201 PWB 1 SGX-101 Control Base Housing 2 SGX-222 Basic PWB 2 SGX-117 PWB Insulator 3 TME-01 Module P 3 SGX-119A Transistor Fastening Plate 4 TME-02 Module C 4 SGX-126 Front Panel Assembly 5 SGX-281 Potentiometer 5 SGX-126A Front Panel SGX-126P Front Panel Plate 6 ESD Safe SGX-126PS Front Panel Plate 7 SGX-141 Potentiometer Mount 8 SGX-143 Temperature Control Knob 9 SGX-146 Five-Pin Socket 10 SGX-149 CAL Pot Plug 11 SGX-151 Water Resistant O Ring 12 SGX-163 Back Panel Assembly 13 SGX-163A Back Panel 14 SGX-170 Power Cord Assembly 15 SGX-180 Cord Stopper 16 SGX-185 Power Switch 17 SGX-190 Fuse Box 18 SGX-192 Fuse 19 SGX-195 ESD Grounding Socket 20 SGX-380 ESD Plug & Clip Optional 21. Parts & Accessories Iron Holder and others 1 6 5 4 3 2 3 11 10 9 1 M3 X 8 Tapping Screw(2) 5 8 4 7 2 12 (Figure 23) 22. (Figure 24) Parts & Accessories Iron Holder 1 SGX-301 Iron Holder 2 Soldering Iron 1 SGX-326 Iron Holder Lower Cap 3 SGX-351 Cleaning Sponge 4 SGX-360 Hex Wrench 3 5 SGX-391 Operation Manual 4 2 5 SGI-905 Soldering Iron SGI-906 Soldering Iron SGI-930 Nut SGI-935 Tip Enclosure Soldering Iron Tip SGI-941 Nipple See Soldering Iron Tips ESD Safe SGI-941S Nipple 6 SGI-945 Spring 7 SGI-950 Heating Element 8 SGI-955 Terminal Board 9 SGI-960 Handle SGI-960S Handle SGI-971 Handle Cover 10 ESD Safe Model ESD Safe SGI-971S Handle Cover 11 SGI-975 Iron Cord Bushing 12 SGI-980 Soldering Iron Cord Assembly SGI-980S Soldering Iron Cord Assembly ESD Safe ESD Safe 23. Soldering Tips For normal joint soldering, please use SGT-700 series. If you need special types of tips, please contact us. 24. SGT-700 Tip outside diameter O 6.5