EDSYN ZD500DX SOLDAPULLT Deluxe Hot Tip Desoldering Station Instruction Manual

ZD500DX Deluxe Hot Tip
Desoldering Station
(self-contained)

ZD500DX SOLDAPULLT Deluxe Hot Tip Desoldering Station

• COMPLIES WITH MIL-S-45743E, MIL-STD-2000-1B, WS6536E AND ESD SPEC, DOD-STD-1686, DOD-HDBK-263
• UL listed

Instruction manual

FEATURES

POWER SUPPLY

A) Tool Pod, equipped with micro-switch to activate pump.
B) Power Switch, to activate WorkStation.
C) Temp. Control Knob
D) Pump LED
E) Heater LED
F) SH232 Sponge Holder, with cleaning sponge.
G) Power output, 24V, controlled
H) AF110 Filter, (note flow direction)
I) External Calibration
J) Pump
K) WT623 Tip Wrench
L) WT619 Tip Wrench

SPECIFICATIONS

• 115V, 60 Hz, 150W Power Supply

• 24V, 50/60 Hz, 70W Hand Tool

• Weight; Power Supply: 5 lbs. 12 ozs. (2.6 kg)
  Hand Tool: 11 ozs. (312 g)

• Temperature range of 400°F to 800°F (205°C-425°C)

• Voltage leakage from tip to ground, less than 2 MV

• Tip to ground resistance, less than 2 ohms

• COMPLIES WITH MIL-S-45743E, DOD-STD-2000-1B, WS-6536E and ESD SPEC, DOD-STD-1686, DOD-HDBK-263

HT500/-1/-2
Hot Tip Desoldering Tool

A) Head Assembly- Includes the primary filtering system and solder debri chamber.
B) Hot Tip Desoldering Tip- Wide range of desoldering Tips applicable.
C) Head Shaft- Allows 4-point rotation of Head Assembly.
D) Trigger- Activates vacuum suction.
E) Vacuum Hose- Low Static silicone hose. Connects to vacuum source.
F) Connector- To 24 V controlled output. G) Cleaning Shaft- For cleaning Desoldering Tip orifice: .05 (1.3 mm) and .025 (0.6 mm)

OPTIONS
FC641 Large Filter Cartridge Assembly Replaces FC640. For use in applications that require heavy use, or where No-Clean solder/flux is used at high temperature.

PA233 Dovetail Extension Bracket allows you to install additional Tool Pods.

1. Insert nut into the slot of adapter plate on both sides.
2. Screw PA233 on the adapter plate.

OPERATION

1. Connect HT500 to 24V power supply and vacuum source.
2. Press trigger to activate vacuum.
3. Always clean the Tip with wet sponge and always re-tin (add fresh solder) during and after each operation.

NOTE: When Tip orifice is blocked, use a correct size Cleaning Shaft while pressing the Trigger to clear the obstruction. CS468 is .05 in. dia.
CS468-1 is .025 in. dia.

ADJUSTMENTS

The HT500 Head assembly can be adjusted into varying positions to suit the operator. While Tool is in the Pod, push handle down and twist handle until it locks into 1 of it’s 4 positions. Twisting counter-clockwise will permit a 180° turn. Twisting clockwise will permit a 90° turn.
Note: Head Assembly does not make a full 360 0 turn

To tilt the Head assembly, loosen (2)
Adjustment Screws. Tilt the Head assembly to desired position. Retighten Screws.

AIR FLOW DIRECTION
Hoses must be clean and not kinked or cracked

For Factory repair:
Specify the problem and ship the unit to EDSYN INC.
Customer Service 15958 Arminta Street Van Nuys, CA 91406-1896

DESOLDERING POINTERS

1. When desoldering small holes on flat areas, tilt Tool to allow adequate air flow to lift solder into chamber.

2. When using SMD Tips, heat up the connections by positioning the Tool perpendicularly.
   When solder melts tilt the Tool and depress trigger. (SMD Tips are recomended for HT500 using external vacuum).

3. Extra-heavy duty desoldering on a multi-layeredboard is done by using a Heavy Duty Desoldering Tip and a Hi-Heat Soldering Tip simultaneously. Although pre-heating of the circuit board will speed up the process, it is not always necessary.

REPLACING DESOLDERING TIPS

1. Remove RS383. Use WT619.

2. Replace Tip and install new Tip.

3. Apply AN112 (in tube) or AN122 (in syringe) Anti-Seize Compound before assembling.
   INSPECT DAILY

4. Install RS383.

Hot Tip Desoldering Tips
Fractional dimensions are approx.

Extra-heavy duty desoldering on a multi-layered board is done by using a Medium Life Desoldering Tip.

To reach deep, dense and compact areas, use a Long Funnel tip When using a Replacement Desoldering Tip to desolder small holes on flat areas, tilt Tool to allow adequate air flow to lift solder into chamber. When using SMD Tips, heat up the connections by positioning the Tool perpendicularly. When solder melts, tilt the Tool and depress trigger.

Standard Tip
(High Heat Transfer)
| ZD12| .03| 1/32| 0.8| .50| 1/2| 12.7
ZD13| .04| 3/64| 1.0
ZD14| .06| 1/16| 1.5
ZD18| .07| 5/64| 1.8
ZD19| .12| 1/8| 3.2
Funnel
| ZD107| .02| 1/64| 0.5| .48| 31/64| 12.2
ZD112| .03| 1/32| 0.8
ZD113| .04| 3/64| 1.0
ZD118| .07| 5/64| 1.8
Long Funnel| ZD111| .03| 1/32| .08| 1.22| 17/32| 31
ZD115| .07| 5/64| 1.8
*Replacement
| ZD25| .03| 1/32| 0.8| .39| 32/64| 9.9
ZD26| .04| 3/64| 1.0
ZD27| .07| 5/64| 1.7
SMD
(FOR ZD505/905 series)
| ZD57| .10| 7/64| 2.5| .55| 9/16| 13.9
ZD58| .13| 1/8| 3.2
ZD60| .15| 5/32| 3.8
ZD61| .25| 1/4| 4.5

Hot Tip Desoldering Tip

Surface Sweep Tips
removes excess solder on pads for flatter surface, prior to SMD remounting.

Side Sweep Tips allows removal of solder from the component side of the board.

Economy
| ZD28| 0.03| Jan-32| 0.08| 0.3| 16-May| 7.6
ZD29| 0.04| Mar-64| 1
ZD30| 0.06| 16-Jan| 1.5
Surface Sweep Hole Dia. = .06 in.| ZD70| W
in.| in.| mm
0.08| Mar-32| 2
Side Sweep**
Hole Dia. = .06 in.| ZD71

*Tin New Iron Tips at Low Temperaturebefore using.
**Non-Plated Alloy

DAILY MAINTENANCE

• Remove and inspect Tip and Heater Assy.
• Inspect all Filters
• Remove solder debri from Desoldering Head Housing

TO REPLACE FILTER & O-RING INSIDE **DESOLDERING HEAD ASSY.**

1. Pull out FC639 from Housing.
2. Unscrew SC525 from FC639 to remove AF625.
3. Insert new AF625 inside SC525 and screw back on.
4. Clean and apply OL111 on OS731 & OS132 O-Ring.

WEEKLY MAINTENANCE

• Inspect Valve Assy.
• Inspect all O-Rings and Seals

OPTIONAL FC641
Large Filter Cartridge Assembly

1. Pull out FC641 from Housing.
2. Unscrew FC641 remove old AF041.
3. Insert new AF641 inside FC641 and screw back together.
4. Clean and apply OL111 on OS731 & OS132 O-Ring.

TO REPLACE O-RINGS INSIDE VALVE ASSEMBLY
a) Unscrew Lock Nut at the end of the HT500 Handle.
b) Remove Handle Cover.
c) Slide out Valve Assembly while placing your finger over the Spring Seat. BE CAREFUL NOT TO LET THE SPRING AND THE SPRING SEAT SHOOT OUT FROM THE HOUSING
d) Clean all parts with alcohol only.
e) Replace OS730 O-Ring Set (set of 3).

When installing OS133, the HT01 should go thru the OS133.

CAUTION: Make sure the wires are not pinched by Valve Assembly.

TROUBLE SHOOT-
Problems that occur aside from those listed below should be handled by our factory technicians.

switch.
b) Squeeze trigger to release vacuum.
Pump running but weak or no vacuum generated.| a) Loose connections between joints or connectors.
b) Dirty filters.
c) Leaky or sticky valve.
d) Wrong hose connection.
e) Broken pump diaphram.| a) Make sure all connections are tight
b) Inspect and clean all filters. Replace elements if needed.
c) Clean parts and replace O-Rings if needed.
d) HT500 Hose should be connected to AF110.
e) Ship back to factory
No power| Blown fuse| Replace fuse. See spare parts list

FUSE REPLACEMENT

SPONGE MAINTENANCE
Replace RS199 Cleaning Sponge
Pour water on RS199 to moisten it completely.
DO NOT OVERFILL.

FILTER MAINTENANCE

CALIBRATION

AIR MOVEMENT WILL AFFECT THE TEMPERATURE READING.
WORK IN AN AREA WHERE THIS IS MINIMAL.

1. Using a clean Tip, turn on power and set Temperature Control Knob to approx. 500°F (260°C). Allow Tip to warm up.
2. Tin the tip properly and place center of the thermo-couple wire on tip.
3. Apply a small amount of solder on the center of the thermo-couple wire, to form a good contact between the tip and the thermocouple wire.
4. Set Temperature Control Knob to 400°F (205°C).
5. Adjust LO-Temp. Calibration Pot so the Meter will read 400°F (205°C).
6. Set Temperature Control Knob to 800°F (427°C). 7. Adjust HI-Temp. Calibration Pot so the Meter will read 800°F (427°C).

ZD500DX Spare Parts List

HT500/-1 HOT TIP
DESOLDERING TOOL SPARE PARTS LIST

ZD500DX instruction manual

ALL RIGHTS RESERVED.
NO PART OF THIS PUBLICATION INCLUDING THE INDIVIDUAL ICONS MAY BE REPRODUCED OR UTILIZED IN ANY FORM OR BY ANY MEANS WITHOUT THE PERMISSION OF EDSYN, INC.

THE NAMES LONER, SOLDAPULLT, SOLDAVAC, ATMOSCOPE AUTO-VAC, IDLE-REST, OCTAVAC AND KLATCH ARE REGISTERED TRADEMARKS OF EDSYN, INC.
MOST PRODUCTS ARE COVERED BY U.S. AND FOREIGN PATENTS AND PENDING APPLICATIONS.

DESIGN, COLOR AND MATERIALS
SUBJECT TO CHANGE WITHOUT NOTICE.

TIP STYLE ON SOLDERING, DESOLDERING AND HOT AIR TOOLS MAY VARY.
PRINTED IN U.S.A.

15958 Arminta Street • Van Nuys • CA 91 406-1 896
Web Site www.edsyn.com •eMail [email protected]
©Copyright EDSYN, Inc. 2002
ZD500DXi .pdf
FORM.937 Rev C

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