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METCAL SP200 SYSTEM USER GUIDE

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1. METCAL SP200 SYSTEM USER GUIDE METAL www okinternational com Copyright 1998 Metcal Inc All Rights Reserved 7022 0251 Rev D METCAL SP200 SYSTEM USER GUIDE TABLE OF CONTENTS SYSTEM ASSEMBLY unan TIP CARTRIDGES SmartHeat werner Selecting Tip Cartridges sin Changing Tip Cartridges La Extending Tip Life isciisvisscsstissseccesccsdecesescvses svszevseddavsarsosstsciassedccedistees Detinned TIPS uu TROUBLESHOOTING GUIDE Llana SYSTEM SPECIFICATIONS La WARRANTY una ASSEMBLY The Metcal SP200 Soldering System consists of a power supply workstand with wiping sponge and a solder handle that uses replaceable tip cartridges Tip cartridges are sold separately from the system a jf fi SP HC1 Solder Handle SP PW1 Power Supply SP WSK1 Workstand with Tip Cartridge The power supply features a green Power On indicator light power cord and a connecting port for the solder handle cord With the power off attach the solder handle cord to the power supply by inserting the cord connector into the power supply connecting port and turn the nut 1 4 turn clockwise until it locks ON OFF Switch Power ON Light KONG Connecting Port Connecting Port Insert a tip cartridge into the solder handle by aligning the flat end of the cartridge shaft with the openingin thehandle Push the cartridge all the way until it seats You should feel a slight click as it locks in
2. and rags Always use a clean wet industrial grade sulfur free sponge e Impurities in the solder iron plating or on the surfaces to be soldered To restore a detinned tip cartridge 1 Remove the tip cartridge from the solder handle and allow the tip to cool down 2 Remove scale and oxides from the tinned area of the tip with 80 grit abrasive polyurethane foam stock Plato AB 3 Polishing Bar or Multicore Tip Tinner Cleaner or equivalent or a 100 grit emery cloth 3 Wrap rosin core solder 0 031 diameter or larger around the newly exposed iron surface insert the tip cartridge into the handle and turn on the system Note Detinned tips are preventable with proper daily care Copyright 1998 Metcal Inc All Rights Reserved 7022 0251 Rev D 3 TROUBLESHOOTING GUIDE TIP CARTRIDGE WON T HEAT 1 Be sure the tip cartridge is pushed all the way into the handle 2 Check that the handle cord connector is tightened securely to the power supply output connector 3 Check the power supply On Off indicator light If itis not lit make sure the 3 wire power supply cord is properly connected into the wall outlet and the power supply 4 If the cartridge still wont heat try a different cartridge If the new cartridge heats discard or return if in warranty the bad cartridge If the above steps do not result in proper performance call M etcal Customer Care SYSTEM SPECIFICATIONS Powe
3. and shorten tip life 2 Use the right tip The plating on fine precision tips is less ta EAS o mana durable than the plating on blunter tips Lower temperatures decrease tip oxidation 3 Do not use the tip as a prying tool Bending the tip can cause the plating to crack shortening tip life 4 Use the minimum activation flux necessary to do the job Higher activation flux is more corrosive to the tip plating 5 When making a solder connection apply fresh solder to the members being joined not to the hot soldering tip 6 Dont apply pressure to the tip More pressure does not equal more heat To improve heat transfer use solder to form a thermal bridge between the tip and the solder joint 7 Clean tips on a clean wet sponge not on arag or dirty dry sponge 8 After you turn on the system and each time you return the tip to the holder apply rosin core solder to the tinned surfaces of the tip The solder protects the tip from oxidation and prolongs the life of the tip 9 Switch the system off when not in use DETINNED TIP CARTRIDGES Ait GG A detinned tip is one not wetted with solder This exposes the plating to oxidation and degrades the heat transfer efficiency of the tip Detinning is caused by a Failure to keep the tip covered with fresh solder during idling periods b High tip temperatures c Lack of sufficient flux in soldering operations d Wiping the tip on dirty or dry sponges
4. nt upon the user s application and practices tip cartridges are not warranted for plating wear Tip cartridges are warranted against any defects in materials or workmanship Misused abused altered or damaged tip cartridges are not warranted All tip cartridges that fail to heat will be repaired or replaced at M etcal s option For returns follow the steps outlined below Repairs replacements will be shipped freight prepaid to the original purchaser This warranty gives you specific legal rights and you may also have other rights which vary from state to state or country to country RETURN PROCEDURE 1 In Europe call OK International at 44 0 23 8048 9100 Elsewhere call your local OK International representative or OK International at 1 714 799 9910 for a return 2 Proof and date of purchase must be on file for the returned product s Copyright 1998 Metcal Inc All Rights Reserved 7022 0251 Rev D 5
5. r Supply Tip to Ground Potential Tip to Ground Resistance Idle Temperature Stability Ambient Operating Temp Maximum Enclosure Temp Input Line Voltage Input Line Frequency Output Power Output Frequency Length x Width x Height Weight total unit Power Cord 3 wire ESD Materials Handpiece Weight handle Handle Cord Assembly ESD Materials Standards Compliance lt 2mV True RMS 50 500 Hz lt 2ohms DC unit on 42 F 4 1 1 C Still air 50 104 F 10 40 C 150 F 65 C 200 260 VAC 45 70 Hz 35 Watts maximum 72 F 22 C ambient temperature 470 KHz 4 25 x 3 5 x 6 7 10 8 x 8 9 x 17 0 cm 5 Ibs 2 3 kg 6 ft 183 cm 18 3 SJT 105 109 ohm square as per ASTM D257 2 ounces 57 grams 4 ft 122 cm carbon loaded silicone 105 109 ohm square as per ASTM D257 MIL STD 2000 MIL STD 1686 MIL STD 45743E WS 6536D and E Agency Approvals FCC Approval ETL Listed CSA Approved Copyright 1998 Metcal Inc All Rights Reserved 7022 0251 Rev D METCAL WARRANTY If you need any technical assistance please call us or access our web page at www metcal com Metcal has information on systems tips accessories technical notes and more Contact your local Metcal representative for pricing and availability Metcal Inc warrants Power Supplies against any defects in materials or workmanship for four 4 years from the date of purchase by the original owner All Handle Cord Assemblies are warran
6. ted against any defects in materials or workmanship for one 1 year from the date of purchase by the original owner Metcal warrants all other products except consumables against any defects in materials or workmanship for ninety 90 days from the date of purchase by the original owner This Warranty excludes normal maintenance and shall not apply to any opened misused abused altered or damaged items If the product should become defective within the warranty period Metcal Inc will repair or replace it free of charge at its sole option The replacement item s will be shipped freight prepaid to the original purchaser The warranty period will start from the date of purchase If the date of purchase cannot be substantiated the date of manufacture will be used as the start of the warranty period SERVICE AFTER WARRANTY Metcal will repair or replace at M etcal s sole option an SP200 Power Supply that fails in normal use within three 3 years after the expiration of the four year warranty at the then current repair or exchange rate To return a failed Power Supply for repair or replacement follow the steps outlined below This offer does not apply to any previously opened modified repaired altered misused or damaged Power Supply REPLACEABLE TIP CARTRIDGE WARRANTY Metcal warrants that the heater in its tip cartridges will operate according to specifications for the lifetime of the tip plating Because tip plating is mainly depende
7. to place bia Edge maigi PA Ge Wet the sponge with deionized water until it is moist but not soaked Then place it in the workstand tray Plug the power cord into a grounded wall socket of the appropriately rated input line voltage To turn the unit on push the switch on the top of the power supply The green indicator light should light up If it does not see the Troubleshooting Guide in this manual CAUTION To provide continued protection against the risk of electric shock connect only to properly grounded outlets Copyright 1998 Metcal Inc All Rights Reserved 7022 0251 Rev D METCAL SMARTHEAT NO DIALS TO SET Each tip cartridge contains a self regulating heater that senses and maintains a set idle temperature The temperature is determined by the inherent metallurgical properties of the heater no external adjustment or equipment is required The power delivered to the tip automatically varies in direct response to the thermal load This eliminates spikes and transients associated with electrically switched elements found in conventional soldering irons SELECTING TIP CARTRIDGES Metcal tip cartridges come in a variety of tip geometries and two standard temperature ranges 600 Series and 700 Series Some tips are available in low temperature 500 Series These tips cover a broad range of tasks from delicate precision work to heavy ground plane soldering Correct Kan 1 Pick atip that maximi
8. zes contact area between the tip and solder joint Maximizing contact area gives the most efficient heat transfer producing high quality solder joints quickly 2 Pick atip that allows good access to the solder joint Shorter tip lengths allow more precise control Longer or angled tips may be needed for soldering densely populated boards 3 Pick the lowest temperature tip cartridge that will accomplish the task This minimizes the potential for thermal damage Start with a 600 Series cartridge and switch to a 700 Series only if you need more heat The temperature series is marked on the shaft CHANGING TIP CARTRIDGES 1 Push thePower Switch Off 2 Pull out the cartridge using the CP1 Cartridge Pad DO NOT USE METAL TOOLS SUCH AS PLIERS TO REMOVE TIP CARTRIDGES AS THIS CAN DAMAGE THE HEATER CAUTION THE TIP CARTRIDGE MAY BE HOT 3 Push a new cartridge into the solder handle with the CP1 Cartridge Pad as shown on previous page 4 Push the Power Switch On The new tip cartridge will heat up to temperature in less than 20 seconds 2 Copyright 1998 Metcal Inc All Rights Reserved 7022 0251 Rev D EXTENDING TIP LIFE 1 Each day remove inspect and clean the cartridge shaft and handle using denatured alcohol and a clean cloth Stubborn flux deposits on the shaft can be removed using a brass Solder brush Do not use a brass brush on the tip itself as it will damage the plating

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