Weller EC 2002 antistatic Power Unit 220 V electronics Soldering station Instruction Manual

EC 2002 antistatic
Operating Instruction

Description

1. Electronic temperature adjustment, continuously variable from 50°C – 450°C or with encoder models, fixed temperatures are obtained using encoder plugs.
2. Antistatic soldering iron LR-21 (24V/50W).
3.  High performance heating element. Insulation 500V.
4. Selection of 22 WELLER “Longlife” Soldering tips.
5.  Temperature resistant silicon cord.
6. Digital temperature display. Setting accuracy ±1 digit. Visible regulation control.
7. Switching between set/actual temperature display.
8. Socket for potential equalisation.
9. Potentiometer locking
10. Mains switch
11. Mains fuse T 0.315A (5×20)
12. 5 channel plug, interlocking
13. Safety support rack, can be free-standing or connected either to the left or right side of the control unit
14. Cleaning sponge
15.  Holder for additional tips.

The soldering Station EC 2002 is best suited for soldering electrically or thermally sensitive electronic components. A large variety of soldering tools can be connected via the 6 channel connection socket. The available soldering tools are given in the accessories list. All solderingtools are electrically isolated from mains and operate with a protective low voltage of 24V Analogue temperature regulation is carried out using a potentiometer which can be used to set the temperature continuously in the range of 50°C to 450°C. The set and actual temperatures are displayed digitally. The digital temperature display can be switched between the set and actual temperature using a slide switch. An LED illuminates in the display to indicathe status of the temperature regulation.
The mains fuse is easy to change. It can be removed by lightly pushing in the fuse holder and turning it to the left. Potential equalisation of the soldering tip can be achieved using the corresponding connection socket on the front side of the unit. Through the antistatic design of the control unit and iron, the Soldering Station fulfils all requirements of the EGB safety regulations.
The Soldering Station EC 2002 is also available in encoder versions and can be converted to a COD (encoder) version with a conversion kit.
The soldering iron LR 21 comes standard with a temperature resistant silicon cord and a “WELLER Longlife” soldering tip type ET-B. The lifetime of the “WELLER Longlife” soldering tip is lengthened substantially by the electroplated finish on the copper core.
There are 22 different soldering tip forms to choose from. You can choose the optimal tip from one of these.
Information contained in the Operation Manuals of any other connected WELLER tools should be observed in addition to the information contained in this Operation Manual.

Technical Data

Picture: Soldering tip choices, see page 47+48

Commissioning

Fasten the holder spring with funnel to the foot plate of the soldering iron holder (see exploded view) and soak the cleaning sponge with water (14). Place the soldering iron into the safety holder (13). Insert the soldering iron plug (12) into the 6-channel connection socket of the control unit and lock it. Connect the control unit to mains. Be sure to check for the correct voltage. Set the switch for SET/ACTUAL temperature (7) to “SET”. Switch on the unit at the mains switch (10) and set the desired temperature using the potentiometer (1). With COD versions, use the corresponding encoder plug to set the temperature. A red LED (6) illuminates to the right next to the numbers. This LED indicates the status of the temperature regulation. Continuous illumination”: indicates that the actual temperature lies below the set temperature. The system is heating.
“Blinking” indicates that the actual temperature corresponds to the set temperature. The system is in regulation range. “Indicator does not illuminate” indicates that the actual temperature lies above the set temperature (overshoot). Set the SET/ACTUAL temperature switch (7) to “ACTUAL”. The digital display (6) indicates the actual temperature of the soldering tip. Temperature fluctuations (overshoot when heating or temperature decrease when soldering) are also readable. When using a tip for the first time, once the tip has heated up, tin the end of the soldering tip with solder. This removes any layers of oxidation and contaminants from the soldering tip.
Available COD version temperature sockets

Maintenance
The temperature sensor (52641099 Exploded view) is encased in stainless steel. Thishas a cone-shaped tip for optimal heat contact and has been exactly adjusted for the soldering tip. This arrangement ensures the best possible temperature transfer. Please be  sure that this opening is not impaired by dirt, foreign bodies or deformation since these will affect the temperature regulation.

Potential equalisation

Potential equalisation of the soldering tip can be achieved using the 4mm metal socket on the front side of the unit. Building up of a potential-free work place including a good earthing is recommended, e.g. when soldering highly integrated MOS components.
Potential equalisation is factory set with 0 Ohm impedance. R/C filter 120 KOhm/22nF is possible by disconnecting a wire jumper on the regulator circuit board (circuit diagram point 7). As a practical supplement for building up an ESD work place, we recommend the push button adapter 52609699.
Picture: Push button adapter, see page 52

Working recommendations

Never use the soldering iron without a tip. Doing so will damage the heating element and temperature sensor.
Always be sure that the soldering tip is properly tinned during pauses in soldering and when replacing the soldering iron into the holder. Don’t use aggressive fluxing agents. Any mechanical treatment of the soldering tip destroys the electro-plated protective  coating of the soldering tip and decreases its lifetime.
There is a possibility to attach the safety support rack to the control unit. The safety support rack can be attached to the left or the right side of the control unit and locked by sliding it back. After setting the temperature with the potentiometer, the knob can be fixed in place by tightening the screw located below the turn knob underneath the control unit with a screwdriver (Philips No. 1).
The Soldering Station has been adjusted for a medium soldering tip. Temperature deviations can occur due to tip changes and by use of other tip forms.

Safety notices

The manufacturer assumes no liability for uses other than those specified in the Operation Manual as well as any self-made changes to the unit.
This Operation Manual and the warning notices therein should be read carefully as well as kept in good view and near the soldering unit. Failure to observe these warning notices can lead to accidents, injuries or damage to health.
The WELLER Soldering Station EC 2002 complies with the EC Declaration of Conformity according to the fundamental safety standards of the directive 89/336/EWG, 73/23/EWG and 89/392/EWG.

Accessory list

Contents of delivery

Soldering Station EC 2002 antistatic:
Control unit EC 2002 antistatic
Soldering iron LR 21 antistatic
Safety support rack KH-20
Operation manual
Encoder plug 350°C| Soldering Station EC 2002 COD antistatic:
Control unit EC 2002 COD antistatic
Soldering iron LR 21 antistatic
Safety support rack KH-20
Operation manual
Encoder plug 385°C
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Picture: Wiring diagram (with error analysis), see page 50+51
Picture: Exploded view, see page 53
Picture: ESD work place, see page 45

WARNING NOTICES!

1. Keep your work area in proper order.
   Always return the soldering tool to its original holder when not in use. Do not bring combustible materials near the hot soldering tools.

2. Take care for the surroundings.
   Don’t use the soldering tool in a moist or wet environment.

3. Protect yourself against electrical shocks.
   Avoid touching grounded parts with your body, e.g. pipes, heating radiators, stoves, refrigerators.

4. Keep children at a distance.
   Don’t allow other persons to touch or disturb the soldering tool or cord. Keep other persons away from your work area.

5. Store your soldering tool in an appropriate place
   Unused soldering tools should be stored in a dry location which is out of the reach of children (some place high or in a locked cabinet). Switch off all unused soldering tools.

6. Do not overload your soldering tool.
   Use the soldering tool only with the specified voltage or specified pressure and pressure range.

7. Use the appropriate soldering tool.
   Don’t use a soldering tool whose performance is not adequate for your work. Never use the soldering tool for purposes for which is was not designed.

8. Wear suitable work cloths.
   There is a danger of burning yourself with liquid solder. Wear the corresponding protective clothing in order to protect yourself against burns.

9. Protect your eyes.
   Wear protective eyewear. When working with bonding agents, it is particularly important to observe the warning notices of the bonding agent manufacturer. Protect yourself against spattering solder. There is a danger of burning yourself with liquid solder.

10.  Use a soldering vapour suction device
    If devices for solder vapour suction are available, ensure that these are connected and correctly used.

11. Do not use the cord for purposes for which it is not designed.
    Never carry the soldering tool by the cord. Don’t use the cord to pull the power plug from the socket. Protect the cord from heat, oil, and sharp edges.

12.  Protect the work piece.
    Use clamping devices to hold the work piece in place. This is more secure than using your hands, and leaves both hands free to work with the soldering tool.

13. Avoid abnormal posture.
    Set-up your work place with proper ergonomics. Avoid bad posture when working. Always use the suitable soldering tool.

14. Take care of your soldering tool.
    Keep the soldering tool clean for better and safer work. Follow the maintenance instructions and the notices concerning changing the soldering tips. Regularly inspect all connected cords and hoses. Repairs should only be carried out by a qualified technician. Use only original WELLER replacement parts.

15. Remove the power plug from the socket before opening the unit.

16.  Remove all maintenance tools .
    Before switching on the unit, check that all maintenance tools have been removed from the unit.

17. Avoid unexpected operation.
    Make sure that the mains switch is turned off when inserting the plug into the socket or connecting to mains. Don’t hold a soldering tool which is connected to a mains supply while touching the mains switch.

18. Extension cords outside.
    Use only extension cords outside which are authorised and correspondingly labelled.

19. Pay attention.
    Be careful of what you do. Work with caution. Don’t use the soldering tool if you are not concentrated on your work.

20. Inspect the soldering tool for any damage.
    Before further use of the soldering tool, safety devices or slightly damaged parts must be carefully checked for error-free and intended operation. Inspect moving parts for error-free operation and that they don’t bind, or whether any parts are damaged. All parts must be properly mounted and all requirements fulfilled for guaranteed error-free operation of the soldering tool. Damaged safety devices and parts must be repaired or replaced by a qualified technician, so long as nothing else is indicated in the Operation Manual.

21. Attention
    Use only accessories or attachments which are listed in the accessories list of the Operation Manual. Use only WELLER accessories or attachments on original WELLER equipment. Use of other tools and other accessories can lead to a danger of injury.

22. Repairs to your soldering tool should be carried out by qualified technician This soldering tool is in accordance with the relevant safety regulations. Repairs should only be carried out by a qualified electrician using original WELLER replacement parts. Failure to do so can lead to accidents for the operator.

23. Do not work on electrically live parts. The grip of antistatic designed soldering tools is conductive.

24. Applications with other WELLER equipment If the soldering tool is to be used together with other WELLER equipment and attachments, also observe the warning notices given in the corresponding Operation Manual.

25. Observe the valid safety regulations for your work place.

1. Conducting material antistatic
2.  Electric connecting-line
3. Additional connection
4. Mains
5. Low-Ohm service ground without connection to mains-earth or SL.
6. Socket for potential balance.
7. Electric connecting-line

Description| | Width| Model| Order – No . for Regular solder| Order-No. for
HMP- solder
---|---|---|---|---|---
Screwdriver Tip| | 0.8 mm
1.6 mm
2.4 mm
3.2 mm
4.6 mm
5.6 mm| ET-H
ET-A
ET-B
ET-C
ET-D
ET-E| 5 41 000 99
5 41 001 99
5 41 002 99
5 41 003 99
5 41 004 99
5 41 005 99| 5 41 000 74
–
5 41 002 71
5 41 003 72
–
–
Longscrewdriver Tip| | 1.2 mm
2.0 mm
3.2 mm| ET-K
ET-L
ET-M| 5 41 006 99
5 41 007 99
5 41 008 99| –
5 41 007 73
–
Round Tip, blunt| | 2.4 mm
3.2 mm
5.0 mm| ET-BS
ET-CS
ET-DS| 5 41 009 99
5 41 010 99
5 41 011 99| –
–
–
Sloped round Tip| | 1.2 mm
2.4 mm
3.2 mm| ET-F
ET-BB
ET-CC| 5 41 012 99
5 41 055 99
5 41 013 99| –
–
–
Conical long tip| | 0.8 mm
0.4 mm| ET-O
ET-S| 5 41 014 99
5 41 017 99| –
–
Flat Tip, slightly bent, one side wettable only | 3.2 mm| ET-MX| 5 41 016 99| –
Chip soldering-
desoldering tip| | 2,5 x
1,5 mm
3,8 x
1,5 mm| ET-SMD
ET-SMD| 5 41 039 99
5 41 040 99| –
Soldering tip for Gull wings and J-Leads| | ET-JL| 5 41 043 99| –
–
ET Measuring tip| | –|   –| 5 24 750 00| –

1. Screwdriver tip
2.  Longscrewdriver tip
3.  Round tip, blunt
4.  Sloped round tip
5.  Conical long tip
6. Screwdriver tip
7. Flat tip, slightly bent, one side wettable only
8. Chip soldering-desoldering tip
9. Soldering tip for Gull wings and J-Leads

Fault-Analysis

a) Soldering iron

1.  Balance of potential Zero-Ohm versus tip
2. Sensor 22 Ohm
3.  Heating 12 Ohm

b) Power unit
Check according to instruction:
Measuring points against mass M

1. Transformer-output 24 V
   When missing line voltage check fuse, main cable, transformer.

2. Supply voltage 6,4 V
   When supply-voltage missing or too high, replace controller 5 26 702 00.

3. Rated value (potentiometer) 3-6 V

4. If actual value on cold iron > 3 V, the sensorline or the OP-amplifier 5 26 700 00 is defective.

5. Ignition puls 1 ms – 5 V
   Condition for ignition pulse is: Actual value < rated  value. When impulse missing, replace zero-voltage switch 5 26 701 00.

6. Ignitionpuls 1 ms – 1,4 V
   If impulse 5 V, replace triac no.

7. Potential balance: for using rc-filter remove the shortering bridge or Zero-Ohm resistor.

Wiring scheme with testing instruction

Cooper Tools GmbH
Carl-Benz-Straße 2, D-74354 Besigheim
Postfach 1351, D-74351 Besigheim,
Tel.: 07143/580-0
Fax: 07143/580-108| CooperTools S.A.
ZA des Petits Carreaux; B.P. 63
4, avenue des Coquelicots
F-94382 Bonneuil-sur-Marne CEDEX
Tél.: (1) 45.13.16.80; Fax: (1) 43.77.94.24| Cooper Industries Italia S.p.A.
CooperTools Division
Via Lazio 65, I-20094 Buccinasco (MI)
Tel.: (02)45700053
Fax: (02)48843706
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