intelligent and Performing Power for the Ultimate innovation in Hand Soldering: The Revolutionary ERSA i-Con and

i-Tool Mark Cannon President & COO ERSA GmbH

Guaranteeing quality in a Lead Free environment will put the greatest demands on hand soldering applications. From a repeatability standpoint, all solder joints should be made with the same temperature, eg. the tip temperature must remain constant! Hand soldering quality is completely determined by the skills of the operator and the efficiency of the soldering iron. Due to the fact, however, that irons generally do not recover lost heat fast enough, operators use high set temperatures (380 440C). These already high temperatures will need to be even higher for lead free as the process temperature increases by 40C. How well the iron recovers or puts back the heat lost at the tip and how long the tip remains on the joint, ultimately determines the actual joint temperature. Slow recovering irons will lead to inconsistent joint temperatures as seen in figure 1 below.
Soldering Iron Heat Recovery Challenges

390 C 390 C
Temperature control at heating element!
(60 W PTC Heating zone) Heat shield
Process Window Iron Tip Temp

Air Copper tip

Every solder joint is colder than the one before!

Figure 1: Old technology, standard soldering irons where the sensor is located far away from the tip will lead to inconsistent solder joint quality. The tip looses temperature into the joints but does not recover fast enough before the next joint is made.

Today, soldering iron manufacturers are developing better performing irons, but they are all based on the tip being attached to the heating element cartridge which means the tip temperature will overshoot and the tip price is very high (see figure 2). Such irons force companies to throw away perfectly good and expensive heating elements only because the small copper tip at the end is worn out! The tip consumption for lead free will be even higher, so it is much more important to be concerned about solder tip price and longevity!

Figure 2: Micro power soldering irons offer performance and ergonomic advantages, but have the two major drawbacks of tip temperature overshoot and expensive heating cartridge tips.

To meet the lead free hand soldering challenge, ERSA is introducing its newest and patent(s) pending technology for a state of the art solder station the ERSA i-Con and i-Tool! Today at ERSA, i stands for intelligent, innovative, intuitive, ingenious, interactive, informative simply ideal! As process windows become smaller, the soldering task becomes more difficult. True innovation demands more than just a nice slogan, a catchy word. Todays soldering stations must be intelligent themselves but intuitive for the user. The interactivity between operator and station must be greater, and the interactivity between stations must be greater. Truly ingenious solutions are engineered to optimize process quality and productivity while at the same time reducing operating costs. These are the elements that make up todays ideal soldering station, and these are precisely the elements that make up the worlds most intelligent soldering iron ever designed the ERSA i-Tool (see figure 3).

Figure 3: The intelligent i-Tool has a highly advanced PCB integrated into the handle for a level of innovation never before seen in a solder iron.

As the inventor of the first electric soldering iron for production use in 1921, ERSA is very proud to introduce one of the smallest, lightest, most powerful and most intelligent soldering irons in the world specifically developed for lead free. The 150W micro heating element technology allows for similar performance as compared to soldering irons with expensive heating cartridge tips, but offers standard low cost, exchangeable tips. The revolutionary Process Window Alarm notifies operators when the iron tip temperature is outside a specified process window. Three Power Levels offer maximum power and control (no overshoot) for all soldering applications. The ERSA i-Con (figure 4) offers One Touch easy to use operation with large, multifunctional display, automatic tool detection, as well as the optional i-Set tool for automatic downloading of settings to all stations in factory.

Figure 4: The ERSA i-Con Digital Solder Station with 150W revolutionary i-Tool solder iron and i-Op Control. The ERSA i-Con will also be available in a dual iron digital station, i-Con2, as well as a low cost, lockable analog version.

Innovative features of this technology: 1. The 150W micro heating element (patents pending) technology allows for standard, low costs tips to be removed without replacing the expensive heating element each time (see figures 5 and 10). This can only be achieved via the innovative, multiple sensor heating element control technology which is a part of the patent application.
i-Tip i-Tip Fastener

i-Tool 150W Heating Element

i-Tool

150W 24V

i-Tool Antistatic Grip with Soft Pad

Figure 5: the i-Tool is broken down into all re-usable, long lasting parts. The only consumable item is the low cost tip.

2. The 150W micro heating element technology allows for rapid heat up: room temp to 350C in approx. 9 seconds; from standby to 350C in approx. 3 seconds. The new technology offers one of the fastest heat up and recoveries of all soldering irons that have exchangeable, low cost tips (see figures 6 and 7). 3. Automatic Standby Motion Sensor: the i-Tool has an Electronic Motion Senor Chip (see figure 3) that recognizes and monitors when the iron is being used. The iron automatically goes into a lower standby temperature when the iron is put into its stationary holder or is no longer moving. Stations that use a micro switch in the holder have problems when the iron is not placed exactly into the right position. Additionally, this sensor allows for documentation of when the iron is actually soldering if using the optional Process Control Software. 4. Process Window Alarm: this revolutionary feature (patent pending) documents and alarms the operator with a visual and acoustic signal if the soldering iron tip gets too hot or too cold. QC can specify a Process Window in which the iron is allowed to work (see figure 7). In this manner and for the first time ever in the history of hand soldering, it is possible to guarantee that every solder joint is made with the proper temperature!
380 C 380 C
Sensor actually measures tip temperature near solder joint!
(150 W Heating element)
Lead Free Solder Joint Process Window Solder Tip Temp Process Window

Iron Tip Temp

Operator is visually and acoustically alarmed if the tip temperature goes outside of the specified process window!

New i-Tip for better heat transfer & longer life!

The Ultimate Innovation in Hand Soldering Process Control!

Figures 6 and 7: the i-Tool recovers so fast that all solder joints can be made with nearly the same temperature. The sensor measures the actual tip temperature very close to the tip extremity. The Process Window Alarm assists the operators in guaranteeing repeatable quality.

5. i-Tool Calibration: unlike other systems, the microprocessor which stores the temperature calibration of the iron is actually located in the PCB handle (see figure 3). This now allows for each individual i-Tool to be calibrated independent of the solder station meaning great time and cost savings. Only the irons need to be taken for calibration which is much easier and much faster! Additionally, operators can have and use their own calibrated i-Tool, thus guaranteeing quality regardless of where a calibrated i-Tool is used in the factory. 6. i-Set Tool: this revolutionary feature (optional item) allows for automatic downloading of station settings and lockout. For process control reasons, todays high end solder stations offer a password or lockout function. In this manner, the QC manager can set all proper station settings and then lock the system out. The operator turns on the station and can only work with those locked settings. The problem is however, that each station must be individually programmed and locked. By multiple stations, this is a very time intensive procedure for an expensive QC manager to be doing! The revolutionary i-Set Tool acts as a type of USB stick allowing for rapid uploading of settings into the i-Set tool and rapid downloading from the Tool into multiple stations as seen in figure 8 below. Simply upload the station settings from an i-Con into the i-Set Tool, which looks similar to the i-Tool and plugs right into the same connector. The i-Set Tool is then plugged into any other i-Con station and all set parameters are automatically downloaded in less than 5 seconds and the station is locked out! It is that fast and that easy!

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!
Figure 8: the fastest, safest programming and locking out of solder stations for maximum quality control and documentation!

7. Power Level Settings: this revolutionary feature allows for the use of three different power settings which control the 150W heating element depending on the heat required for the soldering job. With state-of-the-art, sensor controlled heating elements; there is always a balance between heating power and temperature control or overshoot. In other words, when the tip touches the joint, heat is lost and the heating element must power up to put heat back. When the tip is removed from the joint, heat energy continues to flow in an instant as if the mass was still present. This will lead to a tip temperature overshoot that can be as high as 80100C! See figure 9 below. For many sensitive components and for Mil Spec and Medical applications, this is unacceptable as components could be damaged by the overheating! Conversely, a solder application on a heavy mass TH component on a multilayer board or the soldering of heat shields or metal parts requires all the power available from the heating element to transfer the necessary heat. All other technologies available today must find a balance between power and control in the form of a compromise between these two extremes, and as such, are not optimized for either. The heating cartridge tip type irons have a rapid recovery on heavy mass joints (copper penny test), but can have a very large overshoot which can damage sensitive components! The figure below graphically depicts tip the overshoot which occurs in most high powered irons, and which will also occur with the i-Tool at Power Level High.

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

High Mass

High Mass

Low Mass

Figure 9: *When maximum energy is allowed to flow to the tip under heavy thermal stress situations, then the tip temperature will overshoot significantly!

Note: *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 in order to protect from the system overheating. The i-Tool heating element, however, will only draw its maximum 150W for a maximum of 20 seconds. In this manner, the maximum power is available to the iron by using an optimal size transformer for safe continual use.

A simple but effective Stress Test can reveal how an iron overshoots by using a cup of water. Figure 10 below describes the method and shows the results of how the i-Tool out performs competitive technologies.
A cup of water and a temp measuring unit (DTM 100) can reveal the actual tip overshoot: 1. Set unit to 350C 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!
*Power Level Low

65C (150F) Overshoot!!

55C (150F) Overshoot!!

Absolutley No Overshoot!!

Figure 10: The Overshoot Stress test reveals how the i-Tool out performs competitive technologies.

The i-Con Power Level setting feature allows for the use of three different power settings which control the heating element overshoot. At Power Level High, the system uses 100% of its 150Watts, delivers maximum heat where required and can overshoot as much as 90C. Rapid soldering on heavy mass applications is easy. Power Level Low holds back the heat delivery in order that there is absolutely no overshoot possible for the safest hand soldering applications! (see figure 11 below) Power Level Medium is a balance between the two. Thus, the operator can choose the right setting for the right job either more power or more control!
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

High Mass

High Mass

Low Mass

Figure 11: Overshoot is not possible when using Power Level Low with the i-CON station!

8. Lead Free, long life i-Tips: Lead free soldering will require higher working process temperatures as much as 40C higher. 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 proven ERSADUR plating process will be replaced by the new ERSADUR LF process (see figure 12 below) for longer life in a lead free working environment.

Figure 12: details the new ERSADUR LF galvanic plating process which has been re-designed to achieve a longer tip life when working with lead free alloys.

ERSADUR LF - new galvanic plating process for the new Lead Free series soldering tips: Improved tip precision: +/- 0.1 mm Improved 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 as much as two times longer than the old ERSADUR tips. The increased iron required for longer life, 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 tip are efficient, but are VERY EXPENSIVE to use when tip life is short and tip price is high! ERSAs new i-Tool heating technology guarantees the best heat recovery with inexpensive, exchangeable tips for lead free. The new ERSADUR LF i-Tips guarantee the best performance and a much longer tip life when working in a lead free environment! The figure below shows the seven different tip type shapes and sizes currently available.

1.

Pencil point:

: 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 L : 2.0 mm, 4.0mm

3.

Angled face:

4.

Solder Well:

L : 2.0 mm, 4.0mm

5.

Knife tip:
i-Tip Tip Fastener

i-Tips are available in 7 different shape types with 17 standard tips sizes to handle most soldering applications.

6.

PLCC Blade:

7.

Curved tip:

Figure 13: details the dimensions of the 7 tip types of the 17 standard i-Tips currently available. All i-Tip series tips are ERSADUR LF tips, thereby guaranteeing the best life time in a lead free working environment.

The innovative features noted above, differ to existing technologies by offering process controlled, repeatable results via the Process Window Alarm function, that are traceable for the first time. Additionally, this new technology differs from competitive technologies in that it offers adaptable power control for both heavy mass and temperature sensitive components. This is the first iron in the world that can control the different levels of overshoot, thereby offering maximum safety and maximum flexibility! The intelligent i-Tool is the first soldering iron which is calibrated independently from the station, thereby saving calibration costs and guaranteeing quality anywhere in the factory. Finally, this new technology offers the longest tip life and the lowest tip costs when compared to the expensive heating element cartridge tips.

Industry problems addressed or solved by this technology: 1. Problems associated with quality and repeatability: this technology offers the worlds first Process Window Alarm which notifies operator if they are working outside a specified process window. Each solder joint can be now made with the proper temperature. Overshoot is not possible, thereby reducing lifted pads and damaged components! All systems can be locked out, thereby guaranteeing repeatability. Individually calibrated i-Tools can follow an operator in order to deliver best results anywhere in the factory. 2. Problems associated with productivity: this technology offers ultra fast heat up and recovery. Additionally, QC managers can use the i-Set Tool for the fastest station setting and lockout available on the market less than 5 seconds! Finally, individual i-Tool calibration will greatly increase calibration productivity.

3. Problems associated with high running costs: this technology offers the longest tip life with the lowest tip price compared to all high powered solder irons using expensive heating cartridge tips. Station setting, maintenance and calibration costs will be dramatically reduced. 4. Problems associated with documentation and traceability: this technology offers a software package option that keeps a continual process log similar to production soldering machines.

Technology Highlights:

High Power & Top Performance: 150W Micro Heating Element (Patents Pending) Ultra Fast Heat up: from 30C to 350C in ca. 9 sec., Standby to 350C in ca. 3 sec. Ultra Fast Heat Recovery Time

Ultimate Innovations: Process Window Alarm Function alerts operator if tip temp is out of window Three Power Levels settings to control overshoot i-Set Tool for quick & easy downloading of parameter settings to all stations ASM Automatic Standby Motion Sensor Calibration of i-Tool itself, independent from station

Optimal Ergonomics & Ease of Use: Ultra Short Tip-to-Grip: 45 mm, Ultra small: 155 mm, Ultra Light: 30 gr. Thinnest & Lightest Cable for Maximum Comfort Dual Material Grip with Soft Pad stays cool during use One Touch Easy to Use Operation with new i-Op Control Ultra Large, Multi-functional Display Small footprint - W:150mm x L:175mm x H:100mm Automatic Tool Detection of 6 Different Soldering & De-soldering Tools

Low Running Costs: Low Cost, Long life, Quick Change i-Tips specially designed for lead free Lowest maintenance, station programming and calibration costs Highest productivity in hand soldering

Conclusion: Guaranteeing quality in a lead free hand soldering environment will be the biggest challenge in the future. The new and patent(s) pending technology offered in the revolutionary ERSA iCon and i-Tool bring hand soldering process control to a completely new and higher level never before imagined possible! This unique system was designed with the foremost goal of being able to offer a powerful and performing iron, which is the most comfortable in the hands of an operator, but one which saves running costs by using low cost, long life tips! It has been long overdue and over three years in the R&D, but its time has come. The ultimate innovation in hand soldering has arrived, the ERSA i-Con and i-Tool, now offering intelligent and performing power with the lowest running costs! The ERSA i-Con will be available in a dual iron digital station, i-Con2, with the Chip Tool for SMD removal.

Available July 2006

ERSA Chip Tool for SMD de-soldering of components from 0201 chips up to PLCC 44

Copyright by ERSA GmbH; Wertheim/Germany; 01/2006

For further questions to this article please contact: ERSA GmbH Mark Cannon Phone ++49 9342/800 214, Mobile ++49 171/24 18 452 e-mail: mark.cannon@ersa.de

ERSA GmbH Leonhard-Karl-Str. 24 D-97877 Wertheim / Germany Phone ++49 9342 800-0 Fax: ++49 9342 800-100 e-mail: info@ersa.de