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TERRA

Operation Manual

Thank you for purchasing the TERRA selective solder controller. This unit has the ability to
program up to 300 solder profiles (recipes) to accommodate virtually all selective solder
applications.
Please read these instructions thoroughly for proper use of this machine.
Make sure to read all "Safety Notes" before you use machine. This information protects you
from possible dangers during use.

Apollo Seiko Ltd.

Page 2 of 25
Rev. 1.01E

Safety Notes

This manual includes important information to use this machine safely. This
also includes useful information to prevent injury or damaging property. Please read
this manual carefully prior to connecting or operating the TERRA.
Keep this manual nearby the machine all the time.

Supply only specified voltage

Do not connect to a power supply greater than the specified voltage. If not,
electrical shock and /or damage to the unit may occur.
Make sure that the electrical outlet is properly grounded. If the outlet is not
properly grounded, electrical shock and/or damage to the unit may occur.

Working ambient temperature and relative humidity

This machine has been designed to use between 0401090.


Do not use this machine in an environment outside of these conditions.

Handle with care

This machine is designed to use an automatic solder feeder and heating iron for soldering.
If you touch a heated soldering iron, you will burn yourself. So, make sure the
iron has cooled down before you touch or replace the iron cartridge.
Please handle this machine with care. If the unit is dropped or mis-handled, it can cause
damage beyond repair and will not be considered a warranty item.

If you do not use the machine for extended periods

Please turn off the power, remove the power cable and keep it in a dry and cool place.

If you note malfunction on machine

If the machine malfunctions, turn off the power immediately and


contact the dealer you purchased the machine from.

Immunity from responsibility


We do take NO responsibility on damage caused by misuse, mistake,
accident, uses in abnormal conditions or natural disasters such as earthquake, fire etc.
We do take NO responsibility on contingency loss Business lossBusiness stopcaused by
machine malfunction.
We do take NO responsibility on any loss caused by the operation not
mentioned in this manual.
We do take NO responsibility on any loss caused by incorrect wiring or connection with
other equipment.
If for any reason the internal circuitry is tampered with altered or repaired
without written consent of Apollo Seiko, the warranty is null and void. The
customer is allowed to make necessary tooling adjustment, replace solder iron
tips and make any necessary adjustments to the temperature controller.

Page 3 of 25

CONTENTS
Page No.
Safety notes .......................................................................................................... 2
Contents ................................................................................................................ 3
1Summary of TERRA Components ..................................................................... 4
2Description of TERRA Components .................................................................. 5
3WK parameter setting (solder profiles) ..........................................................5 - 6
4How to change the TERRA system parameters ........................................... 7 - 9
5Operation

................................................................................................1011

6Input and output wiring diagrams ...............................................................12 - 13


7Maintenance .............................................................................................14 - 15
8Handling of Iron Tip ..................................................................................16 - 17
9Trouble shooting .............................................................................................. 18
10Care of iron tip ........................................................................................ 19 - 20
11How to change iron cartridge .......................................................................... 21
12. Iron tip selection chart ............................................................................. 22 24
13. Solder feed tube selection chart ...................................................................... 25

Page 4 of 25

A) TERRA Controller Face


01) Temperature trend graph display
The temperature trend is displayed on the screen in
real-time.
02) Temperature display
The iron temperature is displayed. To change the setting
temperature, press the Set Temp button and enter desired
temperature using keypad, then press
key.
03) WK number display (solder profile number)
Current operating WK number is displayed.
04) Heat On /Off
To turn the iron heater on/off, press this button.
05) System Parameter
Press this button to change the system parameters.
06) Iron down button
This button lowers & raises the iron unit and can be used
as a teaching aid to fine tune the iron tip in relation to the
solder joint (robot, linear slide, dial etc.)
07) Solder feed forward button
Solder wire is fed forward or reverse while this button
is pressed.
08) Power switch
Turn it on to provide power to the Terra controller

B)

TERRA Back Panel

Air inlet dia. 6

Iron cable connector


Feeder cable connector

Iron unit air outlets


I/O connector

IRS232C connector

Fuse
Power plug inlet

Page 5 of 25

1.

WK Parameter Setting

1-1. Turn ON the robot/TERRA and program the soldering conditions (WK parameter) and the
X, Y positions.
Refer to the Operation Manual of the specific robot and teach the soldering position and
cleaning position.
Soldering condition number for point soldering
101-199
(Third soldering- cannot be set.)
Soldering condition number for line soldering
201-299
Soldering condition number for special point soldering
301-399
1)
2)

Turn on the power.


The screen changes to green color after the temperature stabilizes and there are no error
conditions. The operation screen is then displayed. If not check the air supply and the
iron cartridge to ensure proper connection & power.

Power on

1-2.

Orange

Operation Screen (Green)

Commonly Used Teaching Pendant / Keypad Functions.

Teaching screen (if using a Janome robot provided by Apollo Seiko):


Key
Action
0
The solder iron will go down while this key is pressed.
1
The solder iron will go down if this key is pressed once.
To raise, press 0 key again.
3
The solder wire feed forward while this key is pressed.
4
The machine blow an air while this key is pressed.
6
The solder wire feed reverse while this key is pressed.
Setting display screen :
Key
Action
Go
The machine move to the displayed position.
F4
The machine move to the displayed position and do the soldering with
the entered condition.
Soldering condition screen :
VEIW(F4)
Entering the soldering condition setting screen (WK parameter).

Page 6 of 25

1-3 The following soldering parameters can be entered.


Point soldering (WK101-199)
WK101-199
Point Solder

Command
SV2 Time (ramp-up Temp.)
1st Amount / Speed
1st Rev. Amount / Speed
Pre-Heat Time
2nd Amount / Speed
2nd Rev Amount / Speed
Heating Time

Adjustable Range
0-99.9mm
0-99.9mm
0-99.9mm
0-99.9mm

0-99.9sec
SP0.1-99.9
SP0.1-99.9
0-99.9sec
SP0.1-99.9
SP0.1-99.9
0-99.9sec

Line soldering (WK201-299)


WK201-299
Line / Slide Soldering

Command
SV2 Time
1st Amount / Speed
1st Rev. Amount / Speed
Pre-Heat Time
2nd Amount / Speed
2nd Rev Amount / Speed
Heating Time
3rd Amount / Speed
3rd Rev Amount / Speed

Adjustable Range
0-99.9sec
0-99.9mm
SP0.1-99.9
0-99.9mm
SP0.1-99.9
0-99.9sec
0-99.9mm
SP0.1-99.9
0-99.9mm
SP0.1-99.9
0-99.9sec
0-99.9mm
SP0.1-99.9
0-99.9mm
SP0.1-99.9

Special Soldering (WK 301-399)


The following three type can be selected. Press Enter on the top of soldering mode. Then
select from the following choices:
With the 3rd (third) soldering (feed after reflow)
With the solder pool wait (delay to allow solder feeding prior
to movement)
Point soldering (Tip Down) Iron tip will stay down after one cycle of point soldering (this is
used for special cases only)
Point soldering
Line soldering

WK301-399
Point soldering
Line soldering
Point soldering
(No up)

Adjustable Range

Command
SV2 Time

0-99.9sec

st

0-99.9mm

SP0.1-99.9

st

0-99.9mm

SP0.1-99.9

1 Amount / Speed
1 Rev. Amount / Speed
Pre-Heat Time

0-99.9sec

nd

0-99.9mm

SP0.1-99.9

nd

0-99.9mm

SP0.1-99.9

2 Amount / Speed
2 Rev Amount / Speed
Heating Time

0-99.9sec

rd

0-99.9mm

SP0.1-99.9

rd

0-99.9mm

SP0.1-99.9

3 Amount / Speed
3 Rev Amount / Speed
Pool Wait Time

0-99.9sec

Page 7 of 25

1-4

TERRA soldering WK Commands :


SV2 time (sec)
Rising time to the second setting temperature
Use for setting a higher temperature for high heat-sink or grounded applications.
1st Amount, The first soldering feed amount (Pre-soldering) (mm)
Pre-soldering for tip or pattern.
Transfer the heat of the tip to the pattern / joint.
1st Speed, The first solder feed speed (mm/sec)
Set the feed speed of the solder pre-feed.
1st Rev. Amount, The first soldering return amount (mm)
Set the soldering return amount (if required).
This is used in applications where you would like to tin the tip but the lead may be
tall and require the solder to be pulled back to avoid contact with the lead on the iron
down-stroke. Most applications do not require this to be utilized.
1st Rev. Amount, The first reverse speed (mm/sec)
Set the first reverse soldering speed (if applicable, see note in 4 above).
Pre-heat Time
Pre-heat time is the time for the iron tip to contact with the lead/pad and to pre-heat
the joint area to allow for the second wire feed in the sequence.
2nd Amount, Second solder feed amount (mm)
Set the solder feed amount for the pattern/joint.
the electrical / mechanical connection.

This is the wire length that creates

2nd Speed, Second solder feed speed (mm/sec)


Set the second solder speed. This ranges between 5 & 40 mm/sec. depending upon
the application requirement
2nd Rev. Amount, Second reverse amount (mm)
Set the solder reverse amount after feeding. This removes the solder wire from the
localized heat of the joint to prevent the solder end from balling up and guarantees
consistent feed lengths.
2nd Rev. Speed, Second reverse speed (mm/sec)
Set the second reverse speed.
Heating Time (sec)
Heating time is the reflow time after the 2nd solder has been fed.
3rd Amount, Third solder feed amount (mm)
The third soldering is added if additional solder is required & to prevent icicle (Pb free)
3rd Speed, Third solder feed speed (mm/sec)
Set the third solder feed speed.
Rev. Amount, Third reverse amount (mm)
Set the third solder reverse amount.
Rev. Speed, Third reverse speed (mm/sec)
Set the third reverse speed.
Pool Wait Time
Solder pool time for slide soldering. The slide soldering starts delay time for solder
pooling to allow solder to build up on the tip and prevent open joints

Page 8 of 25

2.
1)
2)
3)
4)
5
6
7)

How to Change TERRA System Parameters


Press the Parameter key on the operation screen. The System Parameter selection
screen appears.
Press the System Parameter key to change. Eg. Alarm Hi
The setting value appears in the subsequent parameter setting screen.
To change the values, press the setting value box. Then, ten key pad appears.
Enter desired value and press
key;
Press the ESC key.
Press WRITE key. The message Writing appears and the entered value is stored.

Note

Once the TYPE has been changed, turn off the TERRA power and turn on again in
order for the change to take effect.

Parameter Selecting Screen

Parameter Setting Screen

Parameter Setting Screen

Page 9 of 25

Initial Setting (Factory Setting) System Parameter


Command
Alarm Hi
Alarm Lo
TEMP
SV2 Temp
Wait Temp
Feed
Heat

Initial Setting
50
50
300
OFF
250
ON
ON
ON

Iron U/D
U/D Time

Adjustable Range
0 - 200
0 - 200
1- 500
1 - 500
ON/OFF
1 - 300
ON/OFF
ON/OFF

ON

ON/OFF
0 - 99

ON

Heat Auto

ON/OFF

Tem Lim
Ms-Speed

500
250

100 - 500
1 - 250

Feed Cal

100

1 - 200

TIP

1/2

TCL1

-30

100

TCL2

-30

100

70
0
80
20
1

ON

1- 200
0 - 99
1 - 200
0 - 99
1- 60

STA

STA/ROB

T1PG
T1IG
T2PG
T2IG
Wait time*
Type
Stand-Alone
or Robot
Use for
E-Stop

ON/OFF

ON/OFF

Detail
Temp. alarm range High
Temp. alarm range Low
Setting temperature
SV2 temperature setting
Stand by temperature setting
Solder feed :
Enable/Void
Heater :
Enable/Void
Iron
up/down
sensor:
Enable/Void
Iron up/down sensor error limit
Heater auto start when power
on.
Maximum temperature
Manual solder feeding speed
Auto solder feeding quantity
adjust
Tip select 1 or 2 (DCS/DCN=1)
Tip type 1
temperature
calibration
Tip type 2
temperature
calibration
Tip type 1 Proportion Gain
Tip type 2 Proportion Gain
Tip type 1 Integral Gain
Tip type 2 Integral Gain
Wait time min. Enable/Void
Required emergency signal
STA Break contact
ROB Normal contact

If the Wait time is ON, enter adequate Wait Temp to operate according to your
requirements

Page 10 of 25

3.
3-1

Operation
Preparation

Make sure the following items are checked prior to initial operation.
1. Check the power supply, the connections of the power supply, the line voltage
and air pressure (The pressure range is from 4 to 7 kg/cm2).
2. The diameter of the solder wire is correct and the solder wire is sufficient.
3-2 Order of Operation
1. Turn ON the TERRA power supply. (Make sure the lamp for Power ON is on.)
2. Attach the solder wire in the following order.
3-3 Solder Wire Loading
1)

Remove the tube and pull solder wire through


first. Then attach the solder tube.

2)

Set the solder wire as per the diaggram. Make


sure to set solder wire on top of the shortage
sensor arm.

3)

If the release lever is upper position, the cutting


blade/pinch roller will not feed the solder wire.
Engage the white feed lever when solder is to be
fed. Disengage for testing or removing solder
wire.

(2)
(3)

(1)

3-4 Turn on the Robot Power (if applicable Janome Robot Instructions)
1. Turn ON the Robot power supply and press the Start button.
2. The screen changes to green color after a while and shows the operation screen.
If not check the air supply and the iron cartridge.
3. Press the start button and one cycle operation will start.

Page 11 of 25

3-5 How to Adjust RS-P Iron Unit


1) Solder wire feeding position can be adjusted.
Upper adjusting screw : Up down direction
Lower adjusting screw : Side way direction

2) Iron up down speed can be adjusted by turning


screws after undoing nut.
(2)

Upper black screw : Tip Retract Speed


Lower white screw : Tip Extend Speed
3) The second solder feeding position can be altered
by moving this screw. In the lowest position, the
2nd solder feed height will be lower, in the upper
position, the 2nd solder feed height will be higher.
The set height should match the requirements of
the application. Normally the set screw is set to
its lowest position.
When the set screw is set to its lowest position,
the pre-feed height and 2nd feed height are the
same. Normally the initial solder feed height
(with micro adjustment) should be set just under
the solder tip for pre-tinning).

Page 12 of 25

4. Input and Output Wiring Diagram

Page 13 of 25

Input
Pin No.
A1

A2
A3
A4
A5
A6
A7
A8
A9
A10
A11
A12
A13
A14
A15
A16
A17
A18
A19
A20

Signal
EMERGENCY

Description

No voltage break contact


STA mode : Emergency stop If A1 and B1 opens.
ROB mode : Emergency stop If A1 and B1 contacts.

Prog SEL 1

Solder condition select 1.

Read when Start button is pressed (BCD).

Prog SEL 2
Prog SEL 4

Solder condition select 2.


Solder condition select 4.

Read when Start button is pressed.


Read when Start button is pressed.

Prog SEL 8
Prog SEL 16

Solder condition select 8. Read when Start button is pressed.


Solder condition select 16. Read when Start button is pressed.

Prog SEL 32

Solder condition select 32.

Read when Start button is pressed.

Prog SEL 64

Solder condition select 64.

Read when Start button is pressed.

START
STOP

Automatic start
Partial stop

RESET

Error reset

S+
S-

Manual solder feeding forward


Manual solder feeding reverse

Iron U/D
Air blow

Manual Iron up and down


Manual air blow

Prog SEL 100

Solder condition select 100.

Prog SEL 200


Slide ACK

Solder condition select 100. Read when Start button is pressed.


Slide soldering end (required for slide solder applications).

Read when Start button is pressed.

OUTPUT
B1

EMERGENCY

B2
B3
B4
B5
B6
B7
B8
B9
B10
B11
B12
B13
B14
B15
B16
B17
B18
B19
B20

READY

Solder Error
Temp Error

Emergency stop if
STA mode :A1B1 opens
Ready for automatic operation
Terra is running
One cycle end
Slider start signal
Solder shortage or clogging error
Iron temperature error

AUX OUT1

Out signal for iron up/down. Use for soldering tip life count

OUT P24V

DC24V(500mA) supply
DC24V(500mA) supply
DC24V(500mA) can be entered

RUNNING
CYCLE END
ACK

OUT P24V
EXT.P24V
0V
0V

ROB mode : :A1B1 contact

Page 14 of 25

5.
5-1

Maintenance
Daily inspection requirement items are as follows:

Note: When inspecting the unit, turn off the power and cool down the iron tip (3~5 minutes).
1)

Solder Wire Presence


Ensure that the solder spool is loaded with solder

2)

Iron Tip Wear


Tip life varies depending upon flux type, substrate, tip temperature and solder set-up
(height, angle etc.). Check the tip for wear and replace on a scheduled, proactive
interval. Tip life will be between 30K & 60K cycles depending upon tin / lead or lead
free and the factors mentioned herein.

3)

Cartridge Heater Damage


If the Terra unit displays a temperature error, the internal DC heater may be damaged
or a cable issue etc.
(1) If the heater is broken, change the iron cartridge
(2) Check the relay / heater cord (CC-2F) and change if damaged
(3)The iron tip is worn. Change the iron cartridge to achieve optimal solder quality

4)

Air Pressure
Make sure the air pressure is correct. (4-5kg/cm2)

5)

Solder Clog Feed Tube


If the top (exit side) of the tube set is clogged by flux or solder wire, remove the solder
from the feed tube or feed rollers and clean with alcohol or flux remover

6)

Up/down Movement
Make sure if the up/down movement of iron unit of iron unit is smooth. Also, make
sure there is no flux sticking in moving parts. Use the silicone rings to prevent fumes
from building up on the iron cartridge unit. If the iron up/down speed is too fast,
solder balls can be created from excessive force & splatter.

7)

ZSB Feeding System (cutting gear and follower)


Make sure flux or solder does not stick to the feeder parts. If so, clean it with a soft
(brass) wire brush and alcohol.

8)

5,000 Solder Point Interval


Check the solder tip temperature with a thermometer/thermocouple. Refer to page 7
for thermo-controller temperature display calibration.

9)

Monthly
Check the solder feed delivery tube. Make sure that there is no flux build-up on the
tube end (Teflon / Stainless). The Teflon inner tube should protrude through the
stainless end by approx. 0.5 ~ 1.5 mm (0.020 ~ 0.060)

10)

Annually
Calibrate the temperature controller by using an external Thermo-couple. Set the
Terra parameters accordingly per the results. Contact Apollo Seiko for details.

Page 15 of 25

5-2 ZSB Feeder Adjustment and Alignment


If the ZSB (Zero solder ball) feeder is used, the cutting depth and the alignment needs
to be adjusted properly as follows :

1)

Remove the cover after loosing


three setting screws.

2) loosen the setting nut.


3) Adjust the screw to make the
cutting blade center of the lower
roller V grove.
1) Three set screws for
ZSB feeder cover

4) Adjust the depth screw of the


cutting blade to penetrate into flux
core.
5) Tighten the setting nut 2).
6) Put back the cover and
three screws .

3) Adjusting screw
for alignment

2) Setting nut for


the adjusting screw

4) Adjusting screw for


the cutting depth.

The cutting blade is to be at the


center of the lower roller V grove
and the depth should the center of
the solder wire as indicated.

tighten

Page 16 of 25

6.

Handling of the Iron Tip


Insert the iron tip, then the vinyl resin coating on
the iron tip is cracked and peel off during the
temperature rising (if applicable). Tin the tip prior
to use and clean with a wet sponge or other
cleaning device.

The iron tip should always have a solder coating


even when powered off to prevent oxidation..

Please remove oxidation of flux lightly by using a


wet sponge with water. If using the dry sponge or
wiping too much, tip will not be wetted by solder
easily.

Do not file the iron tip because the iron plating


under the tip is the very important. Filing the tip
profile will drastically reduce tip life and reduce
thermal transfer characteristics.

If a tip is not wetting with solder (oxidation)


Remove pre-solder on tip completely.

Remove oxidation by sand paper after


cooling down the iron tip to room temperature.
Turn on the power and apply solder on the iron tip
during rising the temperature (manually).
The tip will wet with solder by the above process.

Page 17 of 25

7.

Troubleshooting

This table is designed to help trouble shoot common problems that may occur with the Terra
unit and related components (feeder, iron etc.). If you have tried the recommended solution
and the problem persists, please contact Apollo Seiko directly for technical support.
Problem

Terra unit is not


receiving power

Failure Reason
The power cable is disconnected

Check the power cord and


electrical supply

The power cable is not working

Replace the power cord

Fuse is blown
The Control PCB is not working
(incorrect system function)
The internal heating element is
broken
Heater/Iron controller is damaged

The iron tip does


not heat up or is
not functioning
properly

TM-14A controller is damaged


The tip is at end of life
Control PCB is damaged
The solder feed engage lever is
opened (up)

The solder wire is


not being properly
fed

The solder feeding gear is racing

The stepper motor is damaged

The temperature
controller does
not allow for
adjustment or is
not functioning
properly

Recommended Solution

Replace with a standard 3 Amp


fuse
Contact Apollo Seiko for
evaluation & repair
Change the iron tip / cartridge, tip
& cartridge all 1 piece
Replace the iron unit cable and
check internal connections
Replace the iron cable & contact
Apollo Seiko for repair
Replace the iron tip, tips are to be
replaced on a standard schedule
to ensure optimal quality
Contact Apollo Seiko for repair &
replacement
Lower (close) the white plastic
feed engage lever on the feeding
unit
Align the feed gear to be
centered on the solder wire
(steps included this manual)
Check the connector to the motor
on the feeder and contact Apollo
Seiko for repair

The control PCB is damaged

Contact Apollo Seiko for repair

Heater connection is damaged

Check / replace the cable and


replace the iron tip with a new tip

Iron tip is dead

TM 14 A is damaged
An error code is being displayed
on the robot panel or Heater LED is
ON

Replace with a new tip, tips can


be checked for continuity,
contact Apollo for details
Replace with a new TM 14A
temperature controller, contact
Apollo for details
E06 is the heater error. Press
the reset button to reset the error
after correcting the problem

Page 18 of 25

Problem

Failure Reason

There is no air supplied to the unit

The Terra unit does


not display a
Stand-By signal
(LED illuminated)

All seems correct but still no


Stand-By LED or signal output
TM 14A temperature controller is
not working

An error condition exists (LED


illuminated)

Temperature
abnormality
(unstable) or the
error condition
persists

Recommended Solution

Check that the air pressure is set


to 80 PSI and connected to the
unit, the Terra requires air to
achieve stand-by to check iron unit
up/down sensors
Check the iron unit sensors to
ensure proper operation and
adjustment (LED on sensor)
Check iron tip and replace TM 14 A
temperature controller
Check related components and
remedy the problem (solder
shortage, solder clog, heater
error), once complete, press the
RESET button or send a reset
signal (I/O) to clear the error

The temperature controller is not


working

Check the cable to the iron and


replace the TM 14A temperature
controller

The values of Low/High


temperature are incorrect

Check the values in the system


parameter screen and change
according to the desired setting

The temperature fluctuates and will


not remain constant in a stand-by
mode (not soldering)

Check the calibration settings in


the system parameters and set
according to the manufacturers
recommended settings

Page 19 of 25

8.

Care of Iron Tip

Introduction
Soldering is a technique which connects a metal to another metal by an alloy reaction.
Solder material melts, but the base material (metal pieces on the work-piece) never melt
during soldering.
There are three important factors (Three great factors of soldering) that contribute to the
alloy reaction:
Cleaning the metal surface (normally with flux core solder or additional liquid flux)
Formation of an alloy layer done by melting solder and creating a metallurgical bond
Heat source which should be maintained at a suitable temperature in order to form
An alloy layer by soldering
The solder iron tip design and plating are very important to the formation of the alloy &
metallurgical bonding of the solder to the component & PCB plating. Therefore it is very
important to ensure that the solder tip is kept clean and maintains its shape. Iron tips will
wear during use and need to be replaced on a scheduled basis to ensure optimal quality and
provide the correct thermal transfer.
Care of Iron Unit
The Apollo soldering tip, HI-TIP (AS, HQ, TM and TB & DC models) achieve high
performance and long life by using 99.9% oxygen-free copper as a base material with
special iron plating and a proprietary plating over the iron plating.
Usually, the life of the tip is about 50,000 points. However, if it is used at more than
400 or with a highly aggressive flux or the solder feeding position is incorrect, the life
can be shortened up to 25%. Lead free alloys also are highly abrasive due to the high
Tin content and can cause reduced wear. Apollo Seiko recommends using pre-heated
N2 gas to help lower the overall soldering temperature and provide a local, inert
environment to help reduce oxidation to the tips plated surface.
The correct solder feeding position, minimum allowable temperature and proper
positional programming can help extend tip life by as much as 50% in many cases.
A) Check the iron tip visually first to ensure that the tip is on good condition and clean.
If the tip shows evidence of wear, change the tip immediately for best results
B) Ensure that proper tip cleaning methods are utilized which may include a rotating
sponge cleaner, compressed air and occasionally manual cleaning of the tip with a
brass cleaning pad, wooden or metal scraper or even tip tinning paste.
C) Program the SLEEP MODE (WAIT TEMP) on the Terra parameter list to ensure that
the temperature drops to a moderate temperature (100 Deg. C) during periods of
inactivity.
D) Solder at the lowest possible temperature to help extend tip life
E)

Follow the solder feed set-up instructions in order to help extend tip life as long as
possible. Proper solder feed set-up may be the most important factor to extend
useful tip life.

Page 20 of 25

1) Visually Inspect Iron Tip for Wear


An oxide layer is left on the
iron tip

Air blow cleaning or sponge cleaning may be increased


or decreased (intervals) in order to minimize oxide
build-up on the tip

The Tin electroplate of the tip


has solder built up above the
normal plating height

Corrosive chlorides reside in flux and may have caused


the undercoating to wear. Repalce the iron tip.

Solder is not flowing as normal

Excessive wear on the tip

Check the iron tip and clean to remove oxides or burnt


flux residue. Remove the Tin plating on the tip
completely by a very fine file or sandpaper at an
ambient temperature level. Re-tin the tip by turnign the
temperature up to 240 degrees Celsius and allowing the
solder to cover the base copper. Power off again, let
cool and power on to normal soldering temperature.
The tip will have a new tin coating on the desired area.
Each tip has a specific angle cut and shape inherent to
the application. If the plating wears off or the shape
has changed due to the tip wearing it is necessary to
change the tip immediately to obtain good reults.

2. Check the Substrate or Assembly for Solder Quality Defects


Solder joint imperfection due
to excessive flux residue

Rough soldering surface

Solder does not adhere to the


pad, wire, substrate

Solder flow is poor or not


correct

Iron tip shape has changed

Clean the surface to remove the flux. Increase the iron


tip temperature to ensure that the flux evaporates totally
and / or exend the heating time (dwell) after solder
feeding is complete
This occurs if the temperature is not set properly for the
applcation. Increase or decrease in 10 degree C
increments until the desired result appears. Also,
ensure that the solder feed is set up correctly
The solder temperature or heating time is too low.
Incerase as necessary to ensure a good mechanical,
electrical connection. The application may requrie
pre-heating to help achieve quality & cycle time
The soldering temperature may need to be adjusted as
well as the volume (length) of solder being fed. Pre &
post heating times may need to be increased in order
for the solder to wett to the joint area properly
Replace the iron tip on a scheduled basis. The tip is at
the end of its useful life due to flux corrosion and
normal wear of the tip by external factors.

There are many solder defects not mentioned above which include:

Insufficient Solder
Icicling or Solder Spikes
Excess Solder
Melting of Substrate (Kapton or flex material)
Solder Pad Lifting

Please contact an Apollo Seiko engineer for assistance with eliminating solder defects. It is
always a good idea to insert a new iron tip and test again for quality prior to making any
changes to the program or solder profiles.

Page 21 of 25

9.

How to Change the Iron Cartridge (tip)


Pull tip out
to remove,
keeping the
same angle
that the tip
is mounted

1) Make sure to turn the power off and cool down the iron
cartridge to room temperature and pull down on the iron
cartridge to remove and replace with a new one. If it does
not come out, using the silicone tube pull it down strongly.
In case flux is jammed, remove it carefully with an
alcohol. You can also increase the temperature to
approx. 450 Degrees C to break the flux barrier.
Power off & remove with a silicone tube. The tip will be
very hot.

2) Make sure that the power to the iron unit is off. To


insert a new tip, push gently UP until the tip stops.
Then turn it until you feel the Keyway locate into
position.
When you feel the keyway locate, push up firmly.
Insert gently to fit
until it stops, rotate
the tip to allow the
plastic keyway to
locate. Once located,
push firmly up until
seated

Note:

Do not turn the iron cartridge while the key is


not in the position or the key is damaged.

Page 22 of 25

Iron Tip List (Model DCM and DCS for point soldering)
DCM iron cartridge

DCS iron cartridge

DCM-**D-2, DCS-**D-2

DCM-**D, DCS-**D

Type
DCM DCS-08D
DCM DCS-10D
DCM DCS-13D
DCM DCS-16D
DCM DCS-20D
DCM DCS-24D
DCM DCS-30D
DCM DCS-40D
DCM DCS-50D
DCM DCS-60D
DCM DCS-80D

a
(mm)
3
4
4
4
4
4
5
5
5
6
8

0.8
1.0
1.3
1.6
2.0
2.4
3.0
4.0
5.0
6.0
8.0

0.3
0.4
0.5
0.6
0.6
0.8
1.0
1.0
1.3
1.3
1.6

d
3s
1.0
1.0
2.0
2.0
2.0
2.0
3.0
3.0
4.0
4.0
3.0

Type

a
(mm)

d
2s

DCM/DCS-16D-2
DCM/DCS-20D-2
DCM/DCS-24D-2
DCM/DCS-30D-2
DCM/DCS-40D-2

4
4
4
5
5

1.6
2.0
2.4
3.0
4.0

0.6
0.6
0.8
1.0
1.0

2.0
2.0
2.0
3.0
2.5

Page 23 of 25

Iron Tip List (Model DCM and DCS for point soldering)
DCM-** DV1, DCS-** DV1

Type

a
(mm)

DCM/DCS-08DV1
DCM/DCS-10DV1
DCM/DCS-13DV1
DCM/DCS-16DV1
DCM/DCS-20DV1
DCM/DCS-24DV1
DCM/DCS-30DV1
DCM/DCS-40DV1
DCM/DCS-50DV1

3
4
4
4
4
4
5
5
5
DCM-** PC, DCS-** PC

DCM-** DV1-2, DCS-** DV1-2

d
3s

0.8
1.0
1.3
1.6
2.0
2.4
3.0
4.0
5.0

0.3
0.4
0.5
0.6
0.6
0.8
1.0
1.0
1.3

1.0
1.5
2.0
2.0
2.0
2.0
3.0
3.0
4.0

d
2s

Type

a
(mm)

DCM/DCS-10PC
DCM/DCS-13PC
DCM/DCS-16PC
DCM/DCS-20PC
DCM/DCS-24PC
DCM/DCS-30PC
DCM/DCS-40PC
DCM/DCS-50PC

3
4
4
4
4
5
5
5

1.0
1.3
1.6
2.0
2.4
3.0
4.0
5.0

Type

a
(mm)

DCM/DCS-10DV1-2
DCM/DCS-13DV1-2
DCM/DCS-16DV1-2
DCM/DCS-20DV1-2
DCM/DCS-24DV1-2
DCM/DCS-30DV1-2
DCM/DCS-40DV1-2
DCM/DCS-50DV1-2

4
4
4
4
4
5
5
5
DCM-** DV2, DCS-** DV2

d
2s

1.0
1.3
1.6
2.0
2.4
3.0
4.0
5.0

0.4
0.5
0.6
0.6
0.8
1.0
1.0
1.3

1.5
2.0
2.0
2.0
2.0
3.0
3.0
4.0

Type

a
(mm)

d
3s

DCM/DCS-13DV2
DCM/DCS-16DV2
DCM/DCS-20DV2
DCM/DCS-24DV2
DCM/DCS-30DV2
DCM/DCS-40DV2
DCM/DCS-50DV2

4
4
4
4
5
5
5

1.3
1.6
2.0
2.4
3.0
4.0
5.0

0.5
0.6
0.6
0.8
1.0
1.0
1.3

2.0
2.0
2.0
2.0
3.0
3.0
4.0

Page 24 of 25

Iron Tip List (Model DCM and DCS for slide soldering)
DCM-** R, DCS-** R

Type

a
(mm)

DCM-** FPR, DCS-** FPR

DCM/DCS-20R

2.0

0.6

DCM/DCS-30R
DCM/DCS-40R
DCM/DCS-50R

3
4
5

3.0
4.0
5.0

0.6
0.9
1.3

Type

DCM/DCS-16FPR
6.0 DCM/DCS-20FPR
DCM/DCS-24FPR
6.4 DCM/DCS-30FPR
7.0
8.0

a
(mm)
6.0
6.0
6.0
6.0

3.4
3.4
4.0
4.5

1.6
2.0
2.4
3.0

Page 25 of 25

Robotic Solder Feed Tube Part Numbering

Example :

TAL-0.8-650S60
TAL is the tube model
(0.8 is solder diameter in mm)
(650 is total length in mm)
(S60 is stainless steel end length in mm)

Model Number

Point*

Terra, Luna, L-CAT EVO

Slide*

TAL0.3-450S60
TAL0.4-450S60
TAL0.5-650S60
TAL0.65-1000S60
TAL0.8-1500S60
TAL 1.0-450S60

TAL0.3-450S90
TAL0.4-450S90
TAL0.5-650S90
TAL 0.65-1000S90
TAL0.8-1500S90
TAL 1.0650S90

* The length of feed tube listed above is for example only. Any of the specified lengths can be ordered with
any wire diameter. It is recommended to use shorter tube lengths with smaller wire diameters

TAL (nylon end)

S60 (60 mm stainless)

Point Solder Head


Model:
Stainless End:

RS-P
S60 (60 mm)

S90 (90 mm stainless)

Slide / Line Solder Head


Model:
Stainless End:

RS-L
S90 (90 mm)