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Innovation at the Core of our existence – The World’s Greatest Solder Station

Innovation at the Core of our existence – The World’s Greatest Solder Station. Lead Free Hand Soldering Challenges. Guaranteeing quality in a Lead Free environment will put the greatest demands on hand soldering applications. ?. ?. ?. ?. ?. ?. ?. ?.

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Innovation at the Core of our existence – The World’s Greatest Solder Station

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  1. Innovation at the Core of our existence – The World’s Greatest Solder Station

  2. Lead Free Hand Soldering Challenges Guaranteeing quality in a Lead Free environment will put the greatest demands on hand soldering applications. ? ? ? ? ? ? ? ?

  3. Soldering Iron Design Requirements for Lead Free From a repeatability standpoint, all solder joints should be made with the same temperature, e.g. the tip temperature must remain constant. Due to the fact that typically irons do not recover lost heat fast enough, operators use high set temperatures. These high temperatures will be even higher for lead free. The problem lies in the fact that the iron tip is heated by a heating element and as heat is transferred to each consecutive joint, the tip temperature decreases. Where the sensor is located is critical – the further to the end of the tip, the better! How well the iron recovers or puts back the heat lost at the tip, ultimately determines the actual joint temperature.

  4. Conventional Soldering Iron Heat Recovery Problems 390° C Temperature control at heating element! Iron Tip Temp (60 W PTC Heating zone) Heat shield Lead Free Process Window Air Copper tip Cold Solder Heat transfer fromtip to solder joint Every solder joint is colder than the one before!

  5. Soldering Iron Heat Recovery Failure Poor placement of sensor leads to recovery problem! The tip is cooled during soldering, but the station does not react! No Temperature Control means No Quality Control!

  6. Revolutionary ERSA i-Tool and i-Con To meet the Lead Free challenge, ERSA is introducing its newest technology (patent pending) for a state of the art solder station – the ERSA i-Con and i-Tool! i-Tool 150W 24V Available April 2006

  7. Today at ERSA, “i ” stands for intelligent, innovative, intuitive, ingenious, interactive, informative – simply ideal!

  8. Revolutionary ERSA i-Tool vs Competition Hakko FM-2021 – 70W Metcal SP-HC1 – 35W JBC 2245 – 75W (*150W) i-Tool – 150W (*150W) • ERSA i-Tool: the smallest and most powerful iron in the world! *150W maximum power drawn at peak

  9. Revolutionary ERSA i-Tool vs Competition Heating Cartridge Tip Heating Cartridge Tip Heating Cartridge Tip Low Cost Tip ERSA i-Tips: long life, low cost lead free tips!

  10. Revolutionary ERSA i-Tool The World’s Most intelligent Soldering Iron!

  11. Revolutionary ERSA i-Tool ERSA i-Tool: The World’s Most Comfortable Soldering Iron!

  12. Revolutionary ERSA i-Tool i-Tip Fastener i-Tip i-Tool 150W Heating Element i-Tool 150W 24V i-Tool Antistatic Grip with Soft Pad i-Tool 150W 24V ERSA i-Tool: The World’s Greatest Performing Soldering Iron with the Lowest Running Costs!

  13. Soldering Iron Heat Recovery Requirements ERSA i-Tool guarantees repeatable results. 380° C Solder Tip Temp Process Window Iron Tip Temp Sensor actually measures tip temperature near solder joint! (150 W Heating element) Lead Free Process Window Solder Joint New i-Tip for better heat transfer & longer life! Every solder joint is made with nearly the same temperature!

  14. Soldering Iron Heat Recovery Success Precise placement of sensor leads to rapid recovery! • Power bar graph displays actual use of the 150W • Internal sensor reflects actual tip temp and is very reactive • Actual tip temp remains stabile during soldering The soldering tip immediately reacts to soldering conditions! Every solder joint is made with nearly the same temperature!

  15. Soldering Iron Heat Recovery Power Maximum Power for Ultrafast Heatup & Recovery! • i-Con in Standby when i-Tool in Holder –Standby temp 200 to 280°C • 3 sec required to reach set 350°C at High. Power Level with overshoot Only 3 seconds Required to Set Temperature from Standby!

  16. Revolutionary ERSA i-Tool Technical Specifications & Advantages:

  17. ERSA i-Tool Technical Specifications & Advantages: • 150W Micro Heating Element (Patent Pending) • Ultra Short Tip-to-Grip: 45 mm • Ultra small: 155 mm • Ultra Light: 30 gr. • Thinnest & Lightest Cable for Maximum Comfort

  18. ERSA i-Tool Technical Specifications & Advantages: • Ultra Fast Heat up: from 30°C to 350°C in approx. 9 sec. • Ultra Fast Heat up: from Standby to 350°C in approx. 3 sec.* • Ultra Fast Heat Recovery Time * Standby Temp 280°C, Power Level High

  19. ERSA i-Tool Technical Specifications & Advantages: • ASM – Automatic Standby Motion Sensor • Dual Material Grip with “Soft Pad” • RTC - Room Temperature Compensation

  20. Revolutionary ERSA i-Con Digital Solder Station Available April 2006

  21. ERSA i-Con Digital Solder Station • “One Touch” Operation with new i-Op Control • Ultra Large Multifunctional Display • Automatic Tool Detection of 6 Different Tools • ESD meets MIL Spec requirements • Small footprint - W:150mm x L:175mm x H:100mm

  22. Revolutionary ERSA i-Con Digital Solder Station • User Friendly Menu: • Actual Tip Temp & Set Temp • One Touch Temp Set • Actual Tool in use • Power Bar Display • System Lock display

  23. Revolutionary ERSA i-Con Digital Solder Station • Standby display • Individual Tool settings without Tool plugged in • Easy to use menu • On line Help Text

  24. Revolutionary ERSA i-Con Digital Solder Station • Menu Level 1: • Temp set • Calibration • Tip offset temp • Power Level: Low, Med, High (controls temp. overshoot) • Standby time & temp

  25. Revolutionary ERSA i-Con Digital Solder Station • Menu Level 2: • Temp Process Window setting • Process window alarm buzzer: on/off • Temp unit: °C/°F • Menu language: GER or EN • Password

  26. Revolutionary Process Alarm Window Innovation Highlight! Operator is visually and acoustically alarmed if the solder iron tip temperature goes outside of the specified process window!

  27. Revolutionary Process Alarm Window ERSA i-Tool guarantees repeatable results. Solder Tip Temp Process Window Iron Tip Temp Lead Free Process Window Solder Joint Operator is visually and acoustically alarmed if the tip temperature goes outside of the specified process window! The Ultimate Innovation in Hand Soldering Process Control!

  28. Revolutionary Energy Power Levels for Maximum Safety Innovation Highlight! Operator has maximum power available when required, or maximum safety with no tip temperature overshoot!

  29. Power Level Settings Controls Overshoot Power Level: Low, Med, High (controls temp. overshoot) Max power is available when power is required for heavy mass soldering – Power Level High Safe control is possible when temp sensitive components require NO OVERSHOOT! - Power Level Low *The 80W transformer in the station can deliver 150W to the i-Tool heating element non-stop for approx. 60 minutes before the safety switch turns on to protect from over-heating. The i-Tool heating element, however, can only draw its maximum 150W for a much shorter period of time. In this manner, the maximum power is available to the iron by using an optimal size transformer for safe continual use.

  30. Solder Tip Temperature Overshoot – a Physical Effect Large Overshoot! Maximum Power of 150W flows to tip when energy is drawn into joint. When tip is removed from the mass, the energy still flows. This leads to a large overshoot which can kill a sensitive component! Too Hot!!! 150W 150W 150W Low Mass High Mass High Mass

  31. Solder Tip Temperature Overshoot Control via Power Levels The 150W max power available is held back via this revolutionary control feature. The actual tip temperature CANNOT overshoot above the set temp in order to protect low mass, sensitive components! No Overshoot! 75W 75W 75W Low Mass High Mass High Mass

  32. Solder Tip Temperature Overshoot by Competitive Irons A cup of water and a temp measuring unit (DTM 100) can reveal the actual tip overshoot: 1. Set unit to 350°C and confirm with DTM. Make sure a small ball of solder remains on tip. 2. Place hot tip in cup of water for approx. 5 seconds in order to cause the iron to heat up at full power. 3. Remove tip from water and place tip on DTM sensor with ball of solder on the cross wires. Read temp overshoot! 65°C (150°F) Overshoot!! 55°C (150°F) Overshoot!! *Absolutley No Overshoot!! *Power Level Low

  33. Solder Tip Temperature Overshoot by Competitive Irons 1. Set unit to 350°C and confirm with DTM. Make sure a small ball of solder remains on tip. 2. Place hot tip in cup of water for approx. 5 seconds in order to cause the iron to heat up at full power. 3. Remove tip from water and place tip on DTM sensor with ball of solder on the cross wires. Read temp overshoot! 65°C (150°F) Overshoot!!!!!

  34. Solder Tip Temperature Overshoot by Competitive Irons 1. Set unit to 350°C and confirm with DTM. Make sure a small ball of solder remains on tip. 2. Place hot tip in cup of water for approx. 5 seconds in order to cause the iron to heat up at full power. 3. Remove tip from water and place tip on DTM sensor with ball of solder on the cross wires. Read temp overshoot! 55°C (130°F) Overshoot!!!!!

  35. Solder Tip Temperature Overshoot by Competitive Irons 1. Set unit to 350°C and confirm with DTM. Make sure a small ball of solder remains on tip. 2. Place hot tip in cup of water for approx. 5 seconds in order to cause the iron to heat up at full power. 3. Remove tip from water and place tip on DTM sensor with ball of solder on the cross wires. Read temp overshoot! *Absolutely No Overshoot!!!!! *Power Level Low

  36. Revolutionary ERSA i-Set Tool Innovation Highlight! The fastest and safest programming and locking out of solder stations for maximum quality control and documentation!

  37. Revolutionary ERSA i-Set Tool Automatic down-loading of station settings and lockout by acting as a type of USB stick. Simply upload the station settings from an i-CON into the i-Set Tool. The i-Set Tool is then plugged into any other i-CON station. i-Set Tool All set parameters are automatically downloaded in less than 5 seconds, and the station is locked out!

  38. Revolutionary ERSA i-Con Digital Solder Station Available April 2006

  39. ERSA i-Con2 Digital Dual Solder Station Available July 2006 ERSA Chip Tool for SMD de-soldering of components from 0201 chips up to PLCC 44

  40. ERSA heat Recovery Performance Tester FACT: the best performing solder iron will recover the fastest!

  41. Don’t let hand soldering & touch up be the “Achilles Heel” of your Lead Free operations!

  42. ERSA–Win – Win – Win ! Increase quality Win Low temperature LF hand soldering with rapid heat recovery & Process Alarm! Increase productivity Win Fastest heat up & recovery for rapid touch up and hand soldering Decrease costs Win Lowest tip cost by the high powered micro soldering irons

  43. Lead Free Soldering Improved Tip Life

  44. Lead Free Soldering Decreases Solder Tip Lifetime! Lead free soldering will require higher working temperatures. In addition, the higher tin (Sn) content in the solder will greatly increase the stress to the solder tip, thereby decreasing the life of the tip. In order to increase the tip life, soldering tip manufacturers must increase the amount of iron (Fe) plating on the tips. The increased iron, however, reduces the thermal performance and recovery of the tip. For this reason, it is essential to have a very efficient heating system! Soldering irons which use a heating element cartridge are very efficient, but are VERY EXPENSIVE! ERSA‘s new i-Tool heating technology (patent pending) guarantees: The best heat recovery & inexpensive, exchangeable tips for lead free. The new ERSADUR LF tips and i-Tipsalso guarantee a much longer tip life!

  45. New ERSADUR LF Galvanic Plating Process • New galvanic plating process for the new i-Tip series soldering tips. • Improved tip precision: +/- 0.1 mm, more iron plating: 300 – 600 microns • Improved tip life*: 60,000 to 120,000 joints *Expected tip life depends on factors such as tip temperature, flux, and mechanical pressure. The new ERSADUR LF tips should last two to three times longer!

  46. ERSA i-Tip Series Long life, low cost tips for the i-Tool • 1. Pencil point: ø : 0.2 mm, 0.4mm, 0.7mm, • 1.0 mm • 2. Chisel: W : 1.2 mm, 1.6mm, 2.0mm, • 2.4mm,3.2mm, 5.0mm • 3. Angled face: L : 2.0 mm, 4.0mm • 4. Solder Well: L : 2.0 mm, 4.0mm • 5. Knife tip: • 6. PLCC Blade: • 7. Curved tip: i-Tips are available in 7 different shape types with 17 standard tips sizes to handle most soldering applications. i-Tip Tip Fastener

  47. Thank you for your attention!

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