SOLDERING GUIDE

32

Soldering Technology - a never ending story for more than 5,000 years

Man had scarcely learned howto use metals for his purposeswhen the desire to join themarose in him. Many of thepieces of jewelry, tools andweapons we know from theBronze Age were given theirutility and beauty by soldering.Today, it is difficult to saywho first discovered how to”glue” metals. One thing iscertain, the goldsmiths ofancient Egypt knew how tojoin gold more than 5,000years ago. Their colleagues in Troy were also master solderers long before theancient Teutons could evendream of such handicraft.Soldering ”came of age” whentin was discovered as a solder-ing metal. After all, that was4,000 years ago.

with seams which could with-stand 18 Atm (!), and conjuredup stoves and tubs made ofbronze, not to mention thearts of their goldsmiths andarmorers.The last century, in particular,not only witnessed an increasedimprovement in the craftman’ssoldering skill, but also ourunderstanding was refined in respect to the scientificinteractions which take placeduring soldering. Consequently, soft solderingdeveloped into an independentfield of production engineeringin the electronics industry. It combines the disciplinesof mechanics, chemistry,physics and metallurgy, toan equal extent.Ernst Sachs, founder ofERSA (a name comprised of the beginning letters of his first and last names) contributed to this.

In 1921, 80 years ago, he de-veloped the first electric andmass-produced solderingiron for industry. Driven by adesire to innovate, we havedevoted ourselves to the con-tinuous development andperfection of soldering tech-nology. With the world’s largestspectrum of soft solderingproducts and 80 years ofindustrial experience, ERSAis synonymous with expertiseand quality. Our range of handsoldering tools begins withthe smallest, 5-watt needleand covers everything fromconventional hand solderingequipment, countless custom-ized solutions for specialapplications, to the 550-wattworkshop soldering iron. Moreover, ERSA’s electronicallytemperature-controlled soldering stations nowrepresent, in the same way,the standard for the entireindustry as the complete lineof wave, reflow and selectivesoldering systems.

ERSA quality products havetheir home in a miriad of places. From hobby shops for Tiffany soldering, to electric hardware shops, upto toughest OEM factoryapplications, our productrange is designed to meetevery soldering need.This versatile soldering guideshould help you find yourway into the ”world of solder-ing” - and perhaps we canignite a ”soldering fire” inyou, just as it has burned for 80 years in our hearts.

ERSA’s state-of-the-art center forsoldering techno-logy in Wertheim

Soldering iron heated by fire: Soldering technology around 1536

From then on, the world’ssoldering technology was onits way upwards. It first spreadaround the Mediterranean.The Cretians showed it to theEtruscans, who then taught itto the Romans, Tunesians,Spaniards, followed by manyothers, including the lessdeveloped cultures of thetime - the Swiss, Bohemians,Hungrians, Teutons andScandinavians. The art of soldering wasimproved and sophisticatedfrom culture to culture, generation to generation. Looking back, the mostimpressive achievements canbe attributed to the ancientRomans. They soldered 400 kmlong water pipes made of lead

54

In the industry, at home, and everywhere - the art of soldering

soldering tip

flux

oxide layer

soldering direction

melted solder

hardened solder

printed conductor base material

Flux reaction during soldering on a printed conductor when a soldering wire with flux core is used

The prepared parts and the solder are heated

The melted solder flows into the solder gap and fills it The hardened solder joins the parts

Soldering is when two metallicworkpieces are joined with theaid of molten metallic bindingmaterial (solder). The trick liesin having the melting point ofthe solder lower than that ofthe metal to be joined. If thispoint is below 450°C, the pro-cess is termed soft soldering. If it is above the value, it is hardsoldering. Opposed to this,when welding, the metals to bejoined are brought to their ownmelting point by heating andthe material is then ”fused”.In soft soldering, the joints bet-ween the metals to be joinedare filled with an alloy made oflead and tin. It is important thatthis alloy does not simply stickto the surface of the foreignmetal after cooling, instead itmust unite with the metal. Forthis purpose, a small quantityof the foreign metal must be

dissolved and unite with thealloy, i. e. form mixed crystalsin the so called ”intermetalliczone”. Tin is responsible for this,whereas lead is charged withmaking the solder easy to meltand ensures the mechanicalstability of the joint. A solder joint consists of fivezones:

Basic materialZone of mixed crystalsHardened solderZone of mixed crystalsBasic material

Cross section of a solder joint

With ERSA’s high quality soldering tools, anyone can practice the art of soldering...

Soft soldering is an indispen-sable part of modern technology.It is the preferred means ofproducing reliable electricalconnections. Such connectionsare required in householdappliances just as much asthey are in computers or spaceshuttles. In other words, almostnothing works nowadays with-out soft soldering. Just ask your electrician, TV-serviceman, vehicle mechanicor dentist about soldering. Even the bosses at IBM, Siemens,Rolls Royce or NASA will giveyou the same answer.

... for hobby-applications ... and service-use

... for Tiffany-soldering ... for industrial use

A soldering iron around thehouse may not put a carpenterout of work, but replaces a goodnumber of other craftsmendealing with electrical and sanitary installation, radio, TV,lighting and communications

technology, electronics, etc. In addition, there are a varietyof hobby applications in whichthe use of a soldering iron is byno means subject to limitations,when it comes to imaginationand versatility.

For maximum tensile strength,which is synonymous to bestsolder joint quality, it is import-ant that the intermetallic zoneis neither too small nor toothick. The ideal parametersare 0.5 µ intermetallic pro-duced at 220°C to 280°C,within about two seconds.With a higher rate of intermet-allic material, the solder jointbecomes brittle and porous,with less than 0.5 µ we haveno tensile strength and there-fore a bad or ”cold” solderjoint.

ERSA SolderWell Technology

soldersoldering tip

12

3

2

1

1

2

3

2

1

But what exactly is the ”art of soldering”?

76

What do you need for soldering?

Heat is required in order tomelt the solder. It’s the job ofthe soldering iron to providethis heat. Temperatures of200-450°C are needed, depend-ing on the solder joint and the

solder used. The usual tempe-rature in the electronics fieldlies between 250°C and 350°C.In order to have the propertemperature for every soldering application, the

soldering tip tip spring heating element handle connection wires connection cable

thermal rating of the solderingiron is important. You mustchoose one which lies withinthe desired temperature rangeor choose an adjustable solder-ing iron or soldering station.

The technical requirementsare proper shape, perfectheat conduction, flawlesscomposition and reliabledurability and must also feature precise sensitivity. For this reason, one cannotbe demanding enough whenselecting a soldering tip.

The soldering tip is theactual ”heart” of the solder-ing iron. It is responsible forthe transfer of heat from theheating element through thesolder to the soldering joint.Different soldering tips areavailable depending on thetype of soldering iron used,what is being soldered and

how often soldering occurs.The most important groupsare nickel-plated copper solder-ing tips, non-scaling (coated)soldering tips and ERSADUR-soldering tips. Its compositionand quality are the deci-sive factors for the suc-cess or failure of asolder joint.

Some shapes and dimensionsof ERSADUR-soldering tips for the widest range of applications

Cross section of an ERSADUR soldering tip

The base material made of highlyconductive electrolytic copperensures unhindered heat transferfrom the heating element to theERSADUR coating

The ERSADUR coating (100to 300 micron) of iron plating at the tip(depending on the type oftip) is factory pre-tinned.

Nickel coating

Nickel coating

Chrome plating preventscorrosion and soldercollecting on undesiredspots

Iron coating

Traditional soldering tipsare made of copper, whichconducts heat well and isinexpensive, but not withoutdisadvantages. The tip oxi-dizes heavily when heatedand copper particles are setfree into the solder until ithas been ”corroded” entirely.Lots of care is required tokeep the tip functional.

ERSADUR-soldering tips, onthe other hand, have beendesigned for continuous operation and high quality.The special process to achievethis was developed by ERSAand is protected by a patent.

ERSADUR soldering tips aregalvanically plated with aniron coating which is thenshielded against oxidationand corrosion by a layer ofchrome. The heating elementof the soldering iron is pro-tected against overheating

and premature wear thanksto perfect heat transfer.

ERSADUR stands up to thevarious demands found insoft soldering technologywith a comprehensive rangeof soldering tips.

This range extends from solder-ing shaft diameters of 0.2 mm(for microelectronics) to 17 mm.

ERSADUR soldering tip careProvided that the ERSADURsoldering tips are properlycared for, tip life can be exten-ded. The following stepsshould be taken:

ERSADUR tips should alwaysbe coated with solder. With-out this coat, they becomepassive and will no longeraccept solder. In this case, thetip can be reactivated withflux and solder.

How to take soldering quality to the top - ERSADUR soldering tips2. The soldering tip for transferring heat from the heating element to the joint

1. The soldering iron for heat

Pre-tinning of a soldering tipInternally heated silver soldering tip

To do this, wrap flux core sol-der around the soldering tipand heat the iron. In additionto this, the hot tip should becleaned regularly with a moistsponge.

Spare sponges are availablein specialized trade.

Note: Good soldering is based upon the proper solder-ing iron, a clean soldering joint, a perfect solder-ing tip, the correct flux and solder, as well as the proper soldering time.

FOR HEALTH AND ENVIRONMENT

9

And of course a safe environment

8

Further materials needed for soldering

Metallic bonding agents,usually in the form of a wireor bar, are available in diffe-rent alloys and compositions.

Soft solders usually consistof a mixture of tin (Sn) andlead (Pb). Possible additivesare antimony, copper, silver,zinc and cadmium.

The composition of the alloydetermines the melting tem-perature and the physical properties of the joint.

The most commonly used solders in the electronic indu-stry are the alloys L-Sn 63 Pband L-Sn 60 Pb.

ERSA soft solders for the widest range of applications

1.2.3.4.

Alloy

L-Sn 60 PbL-Sn 60 Pb 38 Cu 2L-Sn 63 Pb 37L-Sn 62 Pb 36 Ag 2

Flux type

1.1.2 (F-SW 26)1.1.2 (F-SW 26)1.1.3 (F-SW 32)1.1.3 (F-SW 32)

Melting point/zone

183°C - 190°C183°C - 190°C183°C eutectical179°C eutectical

Application

1.-3. for general soldering work inelectro-technology and electronics

1.+3.particularly suitable forERSADUR-soldering tips

4. especially for SMD-technologylow flux contentfor low-residue soldering

Flux is used to attain thebest possible contact bet-ween the solder and metal. It ensures metallically cleansurfaces on the parts to besoldered, eliminates oxidesand impurities which can hinder soldering and preventsthe formation of new oxideswhen soldering. There aredifferent types of flux: acid

flux (for plumbing work) andacid-free products (for elec-trical and electronics work). Flux cored solder (solderingwire) with one or more fluxcores is the primary type ofsolder used in electronicalengineering. Bar solder is used mainly for plumbing, as well as in radiator andbody work.

4. Flux for improved contact

Solder wire with one or more flux cores

3. Solder for the connection

Consider this while soldering:• The breathing zone is close

to the soldering activity andsolder is held in the hand.This presents the risk ofcontaminating the air, orhands and objects whichare touched.

• Flux vapours can damageyour health and must bekept away from the brea-thing zone.

ERSA CLEAN AIR solder fume extraction systems ensure fresh air at the workbench

Safety first, especially whilesoldering. The VDE and GSsigns ensure the electricalsafety of soldering tools. Theuse of the VDE sign obligatesthe manufacturer to monitorproduction in accordancewith test guidelines and toconduct tests which conformto the regulations determinedby the VDE testing institute.

5. A safe and healthy working environment• One should never eat, drink or

smoke in rooms where solder-ing is performed. Traces oflead which remain on the handscan enter the human bodythrough food or cigarette smoke.

• Hands should be washedthoroughly after soldering.

• Soldering refuse is hazardouswaste and should not bedeposited in normal house-hold garbage.

Attention: Never do this while soldering!

1110

Highest quality - through best preparations and ideal parameters

PreparationThe most important prerequi-site for the success of a goodsoldering joint is absolute cleanliness. The conductorsand components must befree of dirt, oil and oxidation.These can be removed withsolvents or flux. ERSADUR soldering tipsshould be cleaned with adamp sponge when hot, priorto soldering. Please do notfile them as you would coppertips. This would damage theprotective coating and renderthe tips unusable.

Soldering processThe soldering process has threephases: wetting, flowing, bond-ing. Here, the working tempera-ture is the most important criteria.The best temperature is thelowest at which the three phasescan be performed without difficulty. This requires some

experience. A temperaturecontrolled soldering systemfacilitates work significantly.

After cleaning, place the solder-ing iron on the soldering joint.Then place the solder wire(with flux core) between the

tip and the soldering joint andmelt it. Continue to add solderwire until the entire joint hasbeen covered. Then immediatelyremove the soldering tip inorder to avoid overheating of themolten solder. Allow the solderto harden, avoiding vibrations.

Soldering quality

A good solder joint can berecognized with bent connec-tion wires on the PCB wherethe contours of the solderedconductor are still visible. This is assuming that not toomuch solder is applied.

Another indication is the melt-ing angle. Based on the factthat excellent melting of thesolder pads occurs, intermet-allic zones (mixed crystals)are created and can be recog-nized by the small meltingangle.

A melting angle of up to 25° indicates good solderquality, angles of up to 50°are acceptable in the field ofhand soldering.

right! wrong!

right! wrong!

right! wrong!

Another quality indicator iswhat the solder surfaceactually looks like. It shouldbe even, non-porous and shiny.

Brittle surfaces indicate toohigh soldering temperaturesor too long soldering times.

The only absolute qualityindicator for an ideal solderjoint is production of inter-metallic material. In this diffusion zone, inter-metallic compounds of copperand tin are produced (mixedcrystals, see page 5). Theycan only be seen by distroy-ing the joint and making across section. If the diffusion zone is toothick, the soldered joints have

no tensile strength and becomebrittle. At higher solderingtemperatures, the chemicalreaction rate is higher, whichproduces more intermetallicmaterial.

As a result, perfect solderjoints have to be made at lowworking temperatures withinshort soldering times.

As soon as the last solderjoint is produced, the ironshould be put back into theholder. But don’t clean the tip beforeputting it away, becauseremaining solder on the tipprevents oxidation.

Soldering time

The soldering operationshould be completed withinapprox. 2 to max. 5 seconds. When soldering electronicparts you will, with a bit ofexperience, only need a second

- the famous solder second.A soldering time of more than5 seconds is inadmissibleand indicates that the solder-ing iron is too cold or notpowerful enough.

25°

1312

Tiffany work - or plumbing solder work

Plumbing soldering work

If metal sheets or pipes haveto be joined, the metal at thesoldering joint must be bare. For this reason, it must becleaned thoroughly. After-wards flux, soldering paste orliquid flux is applied and thesoldering joint is heated withthe tip of the soldering iron.Then add the solder to fill thesoldering seam. Once the solder has harde-ned, remove the aggressiveflux residue, which causescorrosion.

Iron position when soldering a wide seam

iron positionwhen soldering anarrow seam

Tiffany work (Soldering glass)

Soldering glass objects generally involves three stages of work:

• spot soldering• rough soldering • fine soldering.

Before the actual solderingcopper foil is glued on theglass edges. Then the spotsoldering is carried out. Tospot solder, the process bywhich the glass parts arefastened or connected, take adrop of solder with the tip ofthe soldering iron andcarefully apply to the solderjoint. Each spot solderingoperation should only takeabout a second. During rough soldering, thegap between the glass is filledwith solder, after flux hasbeen applied. To achieve this, the solderingtip and the solder are allowedto contact above the joint. The speed of the solderingmovement and the applicationof solder to the soldering tipmust be coordinated precisely.Always drag the soldering

1st step: spot soldering

seam to be soldered shouldalways lie horizontally. The soldering tip is pulledslowly and evenly withoutinterruption along the seamfrom the beginning to the end.

2nd step: rough soldering

iron, never push it. Only inthis way a semicircular seamis obtained with an adequateamount of solder. The visualquality of the joint is impro-ved by fine soldering. The

Desoldering: the perfect toolfor all applicationsThe most important thing forsuccessful desoldering is thecorrect tool. You can choosebetween desoldering wicks (viacapillary action), mechanicaldesoldering pumps or elec-tronic temperature regulateddesoldering systems. These are divided in desolder-ing systems with conductiveheat and those with hot air.

Removing heated and melted solder by means of a mechanical desoldering pumpTemperature controlled desoldering iron

Desoldering

Reheating is not recommen-ded for reparing a faulty sol-der joint. It is better to remo-ve the solder by means of adesoldering tool or with adesoldering wick and to re-solder the joint.

When using a desolderingpump the solder joint has tobe heated with the solderingiron until the solder has mol-ten. Then remove the solder-ing iron and place the desol-dering pump on the joint andextract the solder.

In the case of heated desol-dering irons, the hollow desol-dering tip should be placedon the solder joint ensuring asound thermal contact. Oncethe solder has melted, it isextracted. Desoldering is also

Desoldering with desoldering pump

circuit board or components,can be achieved with tempe-rature controlled desolderingirons (see p.24/25).Basically, you have to distin-guish between desolderingthru-hole components andSMD components .

Desoldering with temperature-controlled desoldering iron

dependent upon proper tipselection. The inner diameterof the desoldering tip shouldbe roughly the same size asthe hole in the circuit boardor slightly larger.The best desoldering results,with least damage to the

the ironheats theentire over-lapped width

the melted solder flowsinto the gap and fills it

soldering tip desold. tip

Correct desoldering is not difficult

Tiffany soldering with the ERSA ANALOG 80 T Tiffany station

soldersolderingtip

glass

solder

glass

soldersoldering tip

soldering tip

soldering tip

solder

solder

heateddesold.tip

1. 2.

copper foil

copperfoil

1514

SMD-Technology - great tools for small components

SMD-solderingThe constantly growing impor-tance of this technology, com-bined with its highly-integratedmicro-sized components, placesgreat demands on SMD solderingequipment. The tools requiredinclude at least one set of finepointed tweezers for positioning,an ultra-fine soldering iron with ERSADUR soldering tip(beginning with 0.2 mm) and thin SMD-solder wire(Sn62Pb36Ag2, 0.5 mm)with an acid-free flux core. With the revolutionary ERSASolderWell technology, com-mon solder wire and the rightERSA SolderWell tip are all youneed. For detailed informationplease refer to our processdescriptions (see page 35).

Hot air soldering and desold. of SMDs

ERSA SolderWell Technology for Fine-Pitch installation within seconds

SMD-soldering with the ERSA Micro tool and an ultra-fine pencil-point soldering tip

right! clean solder joint wrong! wrong!

wrong! wrong! wrong!

SMD-desoldering within 3 seconds - thanks to the ERSA desoldering tweezers

SMD-desoldering with tweezers

SMD desolderingTo desolder and repair adamaged SMD component,the suitable tool is needed toremove the component fromthe PCB. Desoldering twee-zers or a hot air iron can beused. If conductive tweezersare used, it is most essentialto choose the correct desol-dering inserts. After havingdesoldered the component,the PCB has to be cleaned(e.g. with a No-Clean desol-dering wick). Afterwards, the new component can bepositioned and soldered. Forfurther details, please refer toour process description”SMD-Removal” on page 35).For the soldering and desol-dering of BGA componentsplease refer to our semi-auto-matic IR 500 A Rework Cen-ter on page 28.

Heat solder and remove ERSA desoldering tweezers ERSA hot gas nozzle

desoldering wicksoldering tip

desoldering tip hot gas nozzle

C.CAPAC./MELF SOT&DPAK TSOP/SOIC PLCC/LCCC BQFP/PQFP

For desoldering MELFs For desoldering SOICs For desoldering QFPs and PLCCs

Some examples of SMD-components Some examples of different desoldering tip shapes

1716

Soldering irons from 5 to 550 watts - meeting demands for various applications

Fine soldering ironERSA MINOR

Miniature soldering iron witha rating of 5 watts and a tiptemperature of 440°C.

The ideal tool for ultra-finesoldering of microcircuitsand microscope soldering. 6 V transformer-operated(e.g. ERSA SNT 30/6) or 6 V battery-operated.

The reduced distance bet-ween handle and curved soldering tip takes particularaccount of ergonomic require-ments.

ERSA Minor, in addition tothe electronics industry applications, is used for clockproduction or repair, for photo-graphic industry and dentalengineering applications.

ERSA MINOR: an ultra-fine soldering iron weighing incredible 6 g

Fine soldering ironERSA Multitip-seriesA particularly short, light andeasy-to-handle soldering ironwith a minimum distancebetween the soldering tip andthe front of the handle. Inter-nally heated soldering tips en-sure ultimate performance.With their rating of 8, 15, and25 watts, the Multitip line isdesigned to solder small andmedium-sized joints such asdistribution strips and hobbyapplications. The industriallyproven PTC heating elementsin the 15 and 25 watt irons en-sure high-speed series solder-ing due to the short heatingtimes. The handy solderingand desoldering sets executedin 15 and 25 watts, with inte-grated desoldering pump, sol-der wire, and additional tip areideal for multi-purpose tasks.

ERSA Multitip - internally heated fine soldering iron for small joints

Universal soldering ironERSA 30 S / ERSA 50 - 150The best-selling and mosttried and tested ERSA solder-ing iron with 30 and 40 wattratings. The practical stick-onsupport disk ensures a maxi-mum of ergonomics. This universal soldering iron isdesigned for multi-purposeuse in the crafts, service andhobby sector. A practical sol-dering set with desolderingpump and additional solderingtip is also available for this ver-satile soldering iron to handlenumerous soldering and desol-dering challenges on the go. The 50, 80 and 150 watt ver-sions, supplied with a bentsoldering tip, are ideal to sol-der copper conductors from2.5 up to 6 mm2 cross sec-tions (no figure).

ERSA 30 S universal soldering iron - one for all!

Workshop and hammer solder-ing irons ERSA 200 to 550

Thanks to their stretchedform, these powerful work-shop soldering irons with250 and 350 watt ratings areideal for internal solderingwork in containers, car bodyconstruction and for radiatorrepair. They easily fit in anyclamping device and can beused to heat branding ironsfor wood or plastic branding purposes.

The hammer-shaped solder-ing iron series with 200, 300and 550 watt ratings, is par-ticularly suitable for sheet tin-ning and installation work, aswell as collector and copperrail soldering.

Mul

titip

line

, 8/1

5/25

WM

inor

, 5 W

ERSA

30

S, 3

0/40

WER

SA 2

50/3

50, 2

50/3

50 W

åERS

A 20

0/30

0, 2

00/3

00 W

ERSA

550

, 550

W

1918

Always a quick trigger: Special soldering irons and off the line soldering

ERSA high-speed soldering: press the button and go

An unusually light and trans-former-independent soldergun with PTC heating ele-ment providing high heat-uprating. The ERSADUR long-life soldering tip is onlyheated as long as the buttonis pressed. Thanks to the

very short heating times it isideal for high-speed seriessoldering. The heat supplycan be adapted to thesoldering require-ments by perio-dically pressingthe button. The

Internally heated fine solde-ring iron ERSA Multi-Pro

The ERSA Multi-Pro is aninternally heated fine solder-ing iron with extremely heatresistant cable. It can beoperated with the entire 832and 842 ERSADUR solderingtip line with tip turn protec-tion. Tip shapes range from0.4 mm diameter pencilpoint and all chisel shapes to9.8 mm angled face types.Furthermore IC and SMDdesoldering tips are availa-ble. Due to this wide rangeof soldering tips, the Multi-Pro can be used for manydifferent applications, forboth conventional solderingand SMD soldering anddesoldering.

ERSA Multi-Pro - internally heated fine soldering iron

ERSA Independent 75Since this soldering iron doesnot dependend on a cable, any-thing can be soldered in anyway, anywhere, at any time. Incomparison to electric solder-ing irons, the rating can beadjusted steplessly from 15 to75 W. The large selection ofsoldering tips opens up manyapplications apart from con-ventional soldering such asSMD soldering, micro weld-ing, shaping and cutting ofplastics and processing ofheat-shrinkable sleeves.

ERSA Independent 130The “larger edition” of theERSA Independent 75, withits rating of 25-130 W, ismost suitable in situationswhere sophisticated solder-ing solutions are required offthe line, as for example ser-vicing, installation, repair andmaintenance.The integrated piezzo ignitiontogether with the fact that theiron operates on commericalbutane gas ensures easyhandling and high reliability.

internally heatedsoldering tip ensureshigh performance.The Multi-Sprint isideal for assembliesand repairs requiringa rating from 15 -100 W.

ERSA Multi-Sprint, 75 W

ERSA

Mul

ti-Pr

o, 2

5 W

ERSA

Inde

pend

ent 1

30, 2

5-13

0 W

ERSA Mobil toolThe ERSA Mobil tool is anextremely light, compact andextremely flexible and efficientbattery-powered soldering ironwhich is perfectly suited forhardly accessible fine solder-ing joints. It is operated withcommercial 1.5 V round cells.Due to the patented heatingsystem, extremely short heatup times are provided. TheMobil tool can be obtained asa set consisting of 2 solder-ing tips, one tip exchangerand 3 batteries.

ERSA

Inde

pend

ent 7

5, 1

5-75

WER

SAM

obil

tool

, 6 W

2120

ERSA soldering stations: temperature control for beginners and high-tech industry

with a high-resistanceconnection, which is installed tothe front potential equalizationsocket. The funnel-shaped tool holderis attachable both to the left or the right side of thestation.

ERSA MS 250 S - one station, two irons, millions of applications

The ERSA MS 250 S providesthe demanding hobby electricianwith temperature control andalternative connection facilitiesfor two different soldering irons.The 25 watt Multitip solderingiron is ideal for standard soldering tasks.

Fine joints, as on SMDs, arebest done with the 6 wattMinitype iron. The internally heated ERSADUR-soldering tips combine highperformance with a long service life. The soldering tip is supplied

ERSA Minityp for fine solder joints

ERSA Multitip for high heat applications

seconds from room tempe-rature to 280°C.

The large selection of long-life internally heated ERSA-DUR-soldering tips make thisversatile soldering stationsuitable for most solderingapplications.

The model ERSA ANALOG 60 Ais completely antistatic accor-ding to MIL-SPEC/ESA-stan-dards.

ERSA ANALOG 60 - the industrially-proven soldering station

The electronically temperature-controlled ERSA ANALOG 60soldering station is the stan-dard model in ERSA’s newseries of soldering stations.

The ceramic PTC heating ele-ment functions simulta-

neously as a temperatureprobe (RESISTRONIC-tempe-rature control system).

The high heat up rating of190 watts guarantees theimmediate supply of heatand a heat up time of 60

ERSA ANALOG 60 Profi-Set in a case

tweezers ERSA Pincette 40provides rapid and safe remo-val of all SMDs.

The extensive soldering iron tiprange includes, among others,the super fine 0.2 mm pencil tip,

ERSA MICRO-CON 60 iA - the intelligent champion

Multifunctionality and intelli-gence are two of many high-lights of our top-of-the-linesoldering station. This micro-processor-controlled and fullyantistatic soldering stationcombines top notch technolo-gy and yet has minimal spacerequirements.

The ERSA SENSOTRONICmicroprocessor control withFuzzy-logic ”intelligence” pro-vides amazing heat-up timesand repeatable solder jointquality.

The ERSA MICRO-CON 60 iAhas automatic identification of

four connectable solderingand desoldering tools: theincluded soldering iron ERSATech tool, two other solder-ing iron alternatives, and de-soldering tweezers.

The ERSA Tech tool ensures re-producible solder joint qualityat lowest production tempera-tures. The ERSA Power toolsoldering iron with its heat-uprating of 290 watts is ideal forextreme high-mass and multi-layer applications. The SMD-soldering iron ERSA Microtool meets miniature and Fine-Pitch soldering applicationdemands and the desoldering

Software monitors and docu-ments real-time temperatureprofiles of up to 32 stations.

Supervisor can set, display andchange working temperaturefrom a remote PC.

ERSA MICRO-CON Process Control Software (option)

PC networking model with ERSA CIA 32ERSA CIA 32 interface adapter

the 17 mm thermal power tip,and the ERSA MicroWell, ERSATechWell and ERSA PowerWelltips for rapid installations of ul-tra Fine-pitch (TAB) componentsat production temperatures.

Several user-friendly menuelevels, 8 presettable temperatu-res, 4-digit password lockout orstand-by function are somemore exemplary features of thisextraordinary soldering station.

2322

ERSA DIGITAL 2000 A: intelligent and multifunctional

Further features are: set valueadjustment, the possibility toselect °C or °F on the tempe-rature unit, selection of astand-by period between 0 to60 minutes, offset and cali-brating function, as well asthe possibility to block any

ERSA DIGITAL 2000 A - User-friendly and multi-functional 80 W soldering station

The ERSA DIGITAL 2000 A isan intelligent, microprocessor-controlled soldering station.Outstanding flexibility andmulti-functionality sets thissystem apart from others.The ERSA DIGITAL 2000 A isfully antistatic according toMIL-SPEC/ESA standardsand has a potential equaliza-tion jack with a high-resis-tance connection to the sol-dering or desoldering tip.

The following tools can beoperated with this station: • Tech tool• Micro tool• Power tool• Pincette 40• X-Tool

The soldering station auto-matically identifies the tools

when they are connected andadjusts automatically accor-ding to the tool's require-ments.

Apart from multi-functionali-ty, simple and comfortableoperation is another highlightof the station.

adjustments by a 3-digit password. The station's heatingsystem can be adjusted to thecorresponding applicationwith the help of the integrated"Energy Function".

To increase user-friendliness,the soldering station alsoincludes 4 programs. Eachprogram can be configuratedindependently and differently

Structure of the Tech tool withERSADUR-silver based tip

Pre-tinned zone

K-type thermal couple

Heating zone of high powerceramic element

High temp stainlessstell tip housing

Primary point of measurement

Secondary zoneof measurement

6 layersilver based tip

Tip changefinger grip

Power tool

Performance curve with thePTC heating element

• ERSA Tech tool solderingiron for maxium precision

• Power soldering ironERSA Power tool

• SMD soldering ironERSA Micro tool

• SMD-desoldering tweezersERSA Pincette 40

• Desoldering ironERSA X-Tool

ERSA Tool Selector - one tool for many stations

The Tool Selector is connec-ted to the MICRO CON 60 iAor DIGITAL 2000 A instead ofthe soldering or desolderingiron.It is possible to alternatelyselect from the four connec-ted tools without having topull plugs. As soon as a newtool is selected, the program(parameter set) changesautomatically.

The following soldering toolscan be connected:

with the above mentionedfunctions. Each solderingiron has its own program,and when the tools are chan-ged, the soldering stationautomatically switches to thecorresponding program.

Consequently, the DIGITAL2000 A is perfectly suitedfor operation with the ToolSelector. If only one soldering

iron is required, all pro-grams are available for thisiron.

The temperature is controlledby a digital PID algorithm,optimized for precise andquick temperature control.

SMD-soldering with the Micro tool Power tool soldering iron forincreased heat supply

Conventional desoldering with theERSA X-Tool

Control unit of the DIG 2000 A with five different soldering and desoldering tools

Application

2524

Temperature controlled or mechanical desoldering solutions

built-in solder collector - allthese outstanding featuresmake for an unrivaled high-tech tool.

ERSA X-tool - electronic temperature controlled desoldering station

The new ERSA X-Tool is ahigh-tech tool to desolderwired components from one-sided, two-sided or multilayercircuit boards.

In order to prevent anydamage to the circuit boardsor components, the high per-formance of the X-Tool 120 W(preheating power 260 W)guarantees efficient desolder-ing with an ideal dwell time

even under maximum loadlasting over an extendedperiod. The heat energy storedin the solder tip; the powerfulheating elements in conjunc-tion with an extraordinarilyproficient heat transfer owingto outstanding structural qua-lities of the removable desol-dering tip; and the presenceof a temperature sensor veryclose to the desoldering tip -all these combine to ensurepeak performance at all times.

In addition to this is the instantavailability of the vacuumimmediately after pressingthe button; the ergonomicform and user-friendliness ofthe tool, easy exchange of theinserted desoldering tip, andthe easy removal of the resi-dual solder with the aid of a

integrated temperature probe.The desoldering iron consists ofa desoldering head attached tothe soldering iron with a specialscrew fitting. The solder com-partment incorporates a heat-resistant glass tube and holder.A knurled screw provides easyand quick removal of soldergathered in the solder compart-ment. The device is galvanicallyisolated from the mains supplyby means of a safety transfor-mer and operates at a low volta-ge of 24 V. The electronics con-trol offers a zero crossing ener-gy supply.A potential equalization socketensures easy integration of thedesoldering iron (or solderingiron) into the potential equaliza-tion of the workplace.

ERSA ELS 8000 - Electronic temperature-controlled modularsoldering and desoldering station

The electronically temperature-controlled ERSA ELS 8000 sol-dering and desoldering stationis suitable for a wide range of ap-plications for industrial, labora-tory and repair work. The supplyunit incorporates a high-powervacuum/compressor unit tomake the station independentfrom a compressed air supply.The temperature of the solde-ring tip can be adjusted step-lessly between 150 and 400°C.

The soldering iron is extremelypowerful, thanks to its ceramicheating element featuring a highPTC (Positive TemperatureCoefficient) 290 W heat uprating and a rating of 80 W at350°C. Outstanding features ofthe internally heated ERSADUR-long-life soldering tips are theremarkable thermal conductionand long service life. The desol-dering iron is fitted with a PTCceramic heating element with

Desoldering pumpsERSA VAC and Soldapullt

Outstanding features of theindustrially proven desolder-ing pumps from ERSA are thehigh pumping performanceand low backlash desolderingproperties. The antistatic models allow carefree desoldering of electrostatically irritableassemblies. After melting the solder witha soldering iron, it is quicklyand completely sucked off. The long, slim desolderingtips also make work onclosely assembled boardspossible.

Special desoldering head for ”hot tasks”

2726

ERSA SMD-Rework solutions - as easy as 1•2•3

ERSA SMT UNIT 60 A - soldering and desoldering station for SMTFine-Pitch removal and installation within seconds

The SMT UNIT 60 A from ERSAwill handle virtually any solder-ing job - whether it is SMDsoldering, desoldering or repair

work. The electronically tem-perature-controlled antistaticstation has two separately con-troled tools: the ultra-light

ERSA Micro tool SMD solder-ing iron and the versatile ERSAPincette 40 desoldering twee-zers. An extensive range of evergrowing soldering and desol-dering tips for SMD compli-ments these tools. The ERSAMicro tool has a range of long-lasting ERSADUR-solderingtips beginning at 0.2 mmmaking it ideal for very fineand compact soldering work.In addition, the revolutionaryERSA MicroWell tip enablesthe installation of Fine-PitchSMD’s within seconds. Thedesoldering tip range of theERSA Pincette 40 desolderingtool covers everything fromMELFs and MINIMELFs toSOIC packages, QFPs andPLCC 84.

ERSA Rework 80 - the complete SMD/rework solution

The multifunctional, electron-ically temperature-controlledERSA Rework 80 solderingand desoldering station is theall-round station for repairwork on SMD and mixedtechnology assemblies. The supply unit provides aconstant high output of powerand has an integrated vacuumpump and SMD-placer.

The hot air control unit preciselymeters the hot-air stream of thehot air iron and also controls thetemperature. The electroniccontrol unit with digital displaymonitors the temperature ofthe SMD-soldering iron and de-soldering tweezers. All 4 toolscan be used at the same timeand controlled separately.

The highly accurate hot-airstream of the hot-air iron allowsfor work on either single ormulti-lead components. Therevolutionary ERSA Micro

tool and the ERSA MicroWelltip let Fine-Pitch componentsbe installed in a matter ofseconds.

The SMD-desoldering twee-zers give the capability todesolder everything fromMEFs and MINIMELFs to SOICpackages and PLCC’s. TheVAC-Pen vacuum placer ena-bles precise handling of SMTcomponents.

ERSA SMD 8012 tip holderCompletely equipped tip hol-der for SMD-soldering anddesoldering tips. Organizes theworkbench and saves space.

SMD desoldering SMD positioning

ERSA modular system withoptional kit for thru-hole

soldering and desoldering

SMD soldering Hot air SMD soldering and desoldering

ERSA SMD 8013

Installation of Fine-Pitch componentsUpon the first sight the solder-ing of Fine-Pitch componentsby hand seems to be a toughjob, but with the right equip-ment it is really easy: InsertERSA MicroWell soldering tip(1) into the ERSA Micro toolsoldering iron (2) and set a tiptemperature of 285-295 °C.

Then position the component(3) and fix two corner pins.

Apply flux (see page 30) to thepins on all sides of the compo-nent. Clean the front and con-cave of the MicroWell tip witha damp sponge.

Fill the concave with solderwire to slightly above the rim(4). Do not overfill the tip.

Holding the Micro tool verylightly in your hand set the

filled tip with the ERSAMicroWell side parallel to thePCB down onto the flat exte-rior portion of the pins (5)and slowly pull the tip acrossthe pins towards you (6). Inthis way the single solderingjoints form optimally andevenly.

Repeat steps (5) and (6) tosolder the remaining sides.

1 2 3

4 5 6

2928

the component. Furthermorevisual images of interior fil-lets of, e. g. PQFP and PLCCcomponents can be obtainedquickly and easily.With images from particularlyevery angle and an enormousmagnification range this fle-xible solution for the work-bench offers a multitudeof applications such as theinspection of solder pastedeposition, stencil thickness,via-hole diameters, adhesivedots or component coplanari-ty before soldering. The MAGNISCOPE unit pro-vides top views with up to700 x magnification.ERSA’s vision for the futureof quality assurance aretotal hardware/softwaresolutions. With theERSA ImageDoc Quali-ty Assurance Soft-ware, a tool wasdeveloped revo-lutionizingprocesscontrol together withthe ERSA inspectionsystems.

SMD solutions from the expert for the experts

ERSA SMD soldering equipment grants every wish

The enormous influence ofSurface Mounted Technology(SMT) on industrial PCB pro-duction challenges bothusers and manufacturers ofSMD equipment.

The new line of ERSA SMDhand soldering equipment

was developed in order toenable reproducible qualityat the workbench due toprocess contol.

We know the productionparameters and realize themvia on-line process control. Our wide product range in-

Fine-Pitch soldering and desoldering

cludes a large selection ofsoldering and desolderingtools, soldering/desolderingtips and modular systems. Starting from Fine-Pitch toceramic hybrids to MINIMELFson multi-layer boards, ERSASMT equipment meets allyour requirements.

ERSA SolderWell technology

Visual inspection systems made by ERSA

To see is to survive

The miniaturization trend andgrowing competitive pressureincreasingly challenge theelectronics industry. Inspec-tion of solder joints and PCBshas become an essential partin Total-Quality-Management. So far, it was only possible toexamine solder joints superfi-cially or the entire PCB was

desroyed. ERSA recognizedthis need and, with theERSASCOPE InspectionSystem, engineered the firstoptical system to visually inspect hidden solder jointsunder the component withoutdestroying it.The optical unit offers across-sectional visual imageof BGAs, Micro-BGAs andFlip Chips by looking under

The operator dependent decisi-on making process which wassubjective, based on the kno-wledge of the individual nowbecomes objective throughthe various “expert databases”.The ImageDoc Softwareallows for inspection and

measurement, classification,analyses, action and docu-mentation. With featues suchas the integrated problem/solution database, automaticmeasurement, referencepictures etc. the systembecomes an invaluable pro-cess control tool.

ERSASCOPE

ERSA IR 500 AThe ERSA IR 500 A is a com-plete stand-alone system de-signed for every rework appli-cation. The user-friendly ope-rating instructions will assistand ensure that all operatorsconduct process controlledrework in minutes. The inte-gration of the revolutionaryERSA MICRO-CON 60 iAoffers the expansion of theunit to include a total of up to5 various tools to handle everyrework, repair and solderingapplication. An extremely pre-cise X/Y/Z-placer (PL500A) isoptionally available.

PL 500 A / IR 500 A and monitor

3130

Anything you need for soldering: process materials and practical accessories from ERSA

Solder wire dispenser ERSA SR 100This solder wire dispenser isthe ideal addition to any solder-ing workbench. It is designedto handle different reel sizes(250/500/1,000 g). The variablesolder wire guide accommo-dates different solder wire diameters and allows thesolder wire feed to be adjustedquickly to the correct positionwithout the need to move theERSA SR 100. The ERSA SR 101 add-on is for using asecond solder wire reel.

ERSA solder bathsElectrically heated meltingpots, ideal for dip-tinningwick ends, connection wiresand cable plugs.They areavailable for 40 up to 11,000 gof solder.

ERSA solder wireIn accordance to various soldering applications, ERSAsolder wire is available in different alloys and diameters.

ERSA holdersFor safe and ergonomic positioning of the solderingiron while heating-up orhaving a break.

ERSA desoldering wicksERSA desoldering wicks areindispensable for effectively andgently removing flux and solderresidue via capillary action.

ERSA SMD-solder paste and flux creamIdeal for SMD-soldering evenon finest PCBs, especially forERSA SolderWell soldering.

ERSA tip exchangerFor safe and rapid changing ofnearly all ERSA soldering anddesoldering tips. Especially designed for series 212 and 422.

ERSA spongesSponges to clean the hot sol-dering tip from solder residuesright before soldering.

ERSA solder wire feed unit

The ERSA LVE electric solderwire feed unit feeds solderwire precisely and functionsas your missing ”third” handduring soldering work. The solder wire feed can beadjusted continuously.

The solder wire is fead to thesoldering tip in a teflon tube,which ensures that it will notjam during operation. There is no longer need to go through the laborious process of threading the wire into the feed when changing the solder wire reel.

The solder wire can also betriggered by means of theoptional foot pedal switch.

Cut, weld and seal with thisplastics welding device

This plastics welding deviceis used to cut, weld and sealthermoplastic foils, tissuesand sealing profiles. Rope ends are securedagainst untwisting thanks toautomatic bonding during thecutting process. Where precise working tem-peratures are required, werecommend the use of a sol-dering station together withadequate inserts.

Temperature measuringdevice ERSA DTM 100This tool is ideal for calibrat-ing temperature values inaccordance with ISO 9000ff.Thanks to its innovative technology, the temperaturemeasuring device measurestemperature quickly andaccurately even on the finestof soldering tips.

33

ERSA CLEAN AIR solder fume extraction

32

ERSA Tiffany solutions

room temperature to 280°Cin only 60 seconds and only weighs an incredible 50 grams.

The many internally heatedERSADUR-long-life soldering tips, designed in accordance with Tiffanyrequirements, have an amazingly long service life.

Their special design allowsoptimal heat transfer, accord-ing to the selected workingtemperature, resulting innicely built-up or flat edges.

ERSA ANALOG 80 T - ERSA Tiffany station for professionals

Thanks to the precise tem-perature control, overheating ofglass parts and copper foils canbe ruled out when using ERSATiffany soldering stations.They offer enormous powerreserves comparable to thoseof uncontrolled soldering irons.

The ERSA SENSOTRONICtemperature control system,with the thermocouple in thefront of the soldering tip, provides extremely high tem-perature stability. With 290watts, the powerful ERSAsoldering iron heats up from

The auxiliary equipment usedin soft soldering, such as fluxesor glues, release noxious gaseswhen heated. Irritation of theeyes and mucous membrane,dizziness and allergies are onlysome of the associated healthhazards. It is important to inter-cept the harmful particles asnear as possible to their sourcein order to reduce healthhazards.

ERSA CLEAN AIR extractionsystems perfectly follow thisprinciple: Solder fume canbe easily extracted directly atthe soldering tip by means ofthe EASY TIP extractionsystems.EASY ARM extraction systemsextract solder fumes via anextraction arm. Various ex-traction nozzles and hoodsare available to optimally

adapt this arm to the respec-tive conditions at the work-bench.The particle filters used havea filtration efficiency betterthan 99.9 % according DOPtesting regulations. Dange-rous gases are filtered up to99 % with activated carbonfilters.Detailed information can beobtained on request.

ERSA CLEAN AIR TIP EXTRACTION Activated carbon filters dangerous gas

832 GD 832 MD832 LD

ERSA ANALOG 80 T for Tiffany solderingFirst class with heavy mass:ERSADUR Tiffany solderingtips

ERSADUR soldering tip typesGD, LD and MD of the exten-sive 832 line are perfectlysuited for Tiffany applications.

Due to their shape and theirheavy mass combined withthe resulting heat storage ca-pacity, the gaps between theglass parts to be soldered caneasily and quickly be filledwith solder. The ERSADURtreatment guarantees a longservice life

Fig.: ERSA ANALOG 80

NEWDIMENSION

CATALOGUE

3534

ERSA - Your competent soldering partner

Just as automobiles in seriesproduction profit from Formula 1 race cars, ERSAhobby users profit from thesoft soldering technologywhich we offer professionalsin trade and industry. The basis for this is our com-plete line of soldering anddesoldering products, whichcan be found with all necces-sary technical and order datain our two catalogues, the”winning combination”:

”NEW DIMENSION” and

”PROFI-LINE”

ERSA NEW DIMENSION and ERSA PROFI-LINE products

There are people who are drivento perfection in what they do- athletes, artists and evenengineers are among them.For us at ERSA for example,everything is centered aroundsoft soldering.We want to make solderingas simple and as valuable in

quality as possible for ourusers with sophisticated andeconomical solutions. By making improvements and innovations, we want to constantly improve andpromote this effort.

ERSA Know-How seminars

More than ever, cost effectiveproduction and exceptionalquality are the basis for com-peting successfully in today’sworld. ERSA soldering tech-nology seminars are the idealforum for providing trainingand an exchange of knowledgeand experience. Leadingexperts in the field, with bothscientific and practical back-grounds, give an insight intothe current issues in theoryand practice. ERSA seminars are bothinformative and practical for small, medium and large sized operations.

Technology transfer

In order to implement tech-nology transfer, we offer free,specific process descriptionson SMD soldering and desold-ering, as well as interestingscientifically well-researchedtechnical articles on the latesttechnologies and develop-ments in the field.

These represent an ideal aid to all users and are an integral part of continuingservice.

LiteratureThese are some of our sources:

Hans G. Scheib:Werkstattbuch TiffanyWerkzeuge, Materialien, Arbeits-techniken, Anwendungsbeispiele,Augustus Verlag Augsburg 1991

B.F. Müller:WeichlötenBlaue TR-Reihe Heft 127Verlag ”Technische Rundschau”in Hallwag Verlag, Bern undStuttgart

B. F. Müller:Zinn Taschenbuch, Metall-VerlagGmbH, Berlin 33

Hans Schmidtke:Löttechnik in der ElektronikFachschriftenverlag AargauerTagblatt AG, Aarau/Schweiz,Vertrieb in Deutschland: AT-Fach-verlag GmbH, Stuttgart

Rudolf Strauss:Das Löten für den Praktiker, RPBelectronic taschenbuch Nr. 112,Franzis-Verlag, München 1984

Walter Wuich:Löten, kurz und bündig, Vogel VerlagWalter Wuich:Kleben, Löten, SchweißenLeuchturm-Fachbuch-ReiheGrundwissen der TechnikLeuchtturm-VerlagLehrgang für berufliche BildungLöten, 10 Übungen mit Lernzielenund Kenntnisvermittlung, heraus-gegeben vom Bundesinstitut fürBerufsbildungsforschung 1975,Beuth Verlag GmbH, Berlin, Köln,Frankfurt/M

Ein starkes Doppel:ERSA NEW DIMENSION und ERSA PROFI-LINE Katalog

CATALOGUE

20153 • subject to changes • © by ERSA, Wertheim, Germany

ERSA GmbHLeonhard-Karl-Str. 24

97877 Wertheim/GermanyTel. +49 (0)9342/800-0

Fax. +49 (0)9342/800-127e-mail: info@ersa.de

http://www.ersa.de