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ERSA GmbH

Innovation at the Core of our existence – The World’s Greatest Solder Station

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ERSA GmbH

Lead Free Hand Soldering Challenges

Guaranteeing quality in a Lead Free environment will put the greatest demands on hand soldering

applications.

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ERSA GmbH

Soldering Iron Design Requirements for Lead Free

From a repeatability standpoint, all solder joints should be made with the same temperature, e.g. the tip temperature must remain constant.

Due to the fact that typically irons do not recover lost heat fast enough, operators use high set temperatures. These high temperatures will be even higher for lead free. The problem lies in the fact that the iron tip is heated by a heating element and as heat is transferred to each consecutive joint, the tip temperature decreases. Where the sensor is located is critical – the further to the end of the tip, the better!

How well the iron recovers or puts back the heat lost at the tip, ultimately determines the actual joint temperature.

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ERSA GmbH

Temperature control at heating element!

(60 W PTC Heating zone)

Heat transfer fromtip to solder joint

Copper tip

Heat shield

Air

390° C390° C

Every solder joint is colder than the one before!

Conventional Soldering Iron Heat Recovery Problems

Lead FreeProcess Window

Iron Tip Temp

Cold Solder

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ERSA GmbH

Soldering Iron Heat Recovery Failure

Poor placement of sensor leads to recovery problem!

The tip is cooled during soldering, but the station does not react!

No Temperature Control means No Quality Control!

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ERSA GmbH

Revolutionary ERSA i-Tool and i-Con

To meet the Lead Free challenge, ERSA is introducing its newest technology (patent pending)

for a state of the art solder station – the ERSA i-Con and i-Tool!

i-Tool 150W 24V

Available April 2006

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ERSA GmbH

Today at ERSA, “i ” stands for

intelligent, innovative, intuitive,

ingenious, interactive, informative –

simply ideal!

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ERSA GmbH

Revolutionary ERSA i-Tool vs Competition

ERSA i-Tool: the smallest and most powerful iron in the world!

Hakko FM-2021 – 70W

Metcal SP-HC1 – 35W

JBC 2245 – 75W (*150W)

i-Tool – 150W (*150W)

*150W maximum power drawn at peak

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ERSA GmbH

Revolutionary ERSA i-Tool vs Competition

ERSA i-Tips: long life, low cost lead free tips!

Heating Cartridge Tip

Heating Cartridge Tip

Heating Cartridge Tip

Low Cost Tip

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ERSA GmbH

Revolutionary ERSA i-Tool

The World’s Most intelligent Soldering Iron!

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ERSA GmbH

Revolutionary ERSA i-Tool

ERSA i-Tool:

The World’s Most Comfortable Soldering Iron!

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ERSA GmbH

Revolutionary ERSA i-Tool

ERSA i-Tool:

The World’s Greatest Performing Soldering Iron with the Lowest Running Costs!

i-Tip

i-Tip Fastener

i-Tool 150W Heating Element

i-Tool Antistatic Grip with Soft Pad

i-Tool 150W 24V

i-Tool 150W 24V

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ERSA GmbH

Sensor actually measures tip temperature near solder joint!

(150 W Heating element)

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

380° C380° C

Soldering Iron Heat Recovery Requirements

ERSA i-Tool guarantees repeatable results.

Every solder joint is made with nearly the same temperature!

Iron Tip Temp

Lead FreeProcess Window Solder Joint

Solder Tip TempProcess Window

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ERSA GmbH

Soldering Iron Heat Recovery Success

Precise placement of sensor leads to rapid recovery!

• Power bar graph displays actual use of the 150W

• Internal sensor reflects actual tip temp and is very reactive

• Actual tip temp remains stabile during soldering

Every solder joint is made with nearly the same temperature!

The soldering tip immediately reacts to soldering conditions!

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ERSA GmbH

Soldering Iron Heat Recovery Power

Maximum Power for Ultrafast Heatup & Recovery!

• i-Con in Standby when i-Tool in Holder –Standby temp 200 to 280°C

• 3 sec required to reach set 350°C at High. Power Level with overshoot

Only 3 seconds Required to Set Temperature from Standby!

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ERSA GmbH

Revolutionary ERSA i-Tool

Technical Specifications & Advantages:

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ERSA GmbH

ERSA i-Tool Technical Specifications & Advantages:

150W Micro Heating Element (Patent Pending)

Ultra Short Tip-to-Grip: 45 mm

Ultra small: 155 mm

Ultra Light: 30 gr.

Thinnest & Lightest Cable for Maximum Comfort

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ERSA GmbH

Ultra Fast Heat up:from 30°C to 350°C in approx. 9 sec.

Ultra Fast Heat up: from Standby to 350°C in approx. 3 sec.*

Ultra Fast Heat Recovery Time

* Standby Temp 280°C, Power Level High

ERSA i-Tool Technical Specifications & Advantages:

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ERSA GmbH

ASM – Automatic Standby Motion Sensor

Dual Material Grip with “Soft Pad”

RTC - Room Temperature Compensation

ERSA i-Tool Technical Specifications & Advantages:

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ERSA GmbH

Revolutionary ERSA i-Con Digital Solder Station

Available April 2006

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ERSA GmbH

“One Touch” Operation with new i-Op Control

Ultra Large Multifunctional Display

Automatic Tool Detection of 6 Different Tools

ESD meets MIL Spec requirements

Small footprint - W:150mm x L:175mm x H:100mm

ERSA i-Con Digital Solder Station

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ERSA GmbH

User Friendly Menu:

Actual Tip Temp & Set Temp

One Touch Temp Set

Actual Tool in use

Power Bar Display

System Lock display

Revolutionary ERSA i-Con Digital Solder Station

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ERSA GmbH

Standby display

Individual Tool settings without Tool plugged in

Easy to use menu

On line Help Text

Revolutionary ERSA i-Con Digital Solder Station

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ERSA GmbH

Menu Level 1:

Temp set

Calibration

Tip offset temp

Power Level: Low, Med, High (controls temp. overshoot)

Standby time & temp

Revolutionary ERSA i-Con Digital Solder Station

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ERSA GmbH

Menu Level 2:

Temp Process Window setting

Process window alarm buzzer: on/off

Temp unit: °C/°F

Menu language: GER or EN

Password

Revolutionary ERSA i-Con Digital Solder Station

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ERSA GmbH

Operator is visually and acoustically alarmed if the solder iron tip temperature

goes outside of the specified process window!

Revolutionary Process Alarm Window

Innovation Highlight!

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ERSA GmbH

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

Revolutionary Process Alarm Window

ERSA i-Tool guarantees repeatable results.

Iron Tip Temp

Lead FreeProcess Window Solder Joint

The Ultimate Innovation in Hand Soldering Process Control!

Solder Tip TempProcess Window

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ERSA GmbH

Operator has maximum power available when required, or maximum safety with no tip

temperature overshoot!

Revolutionary Energy Power Levels for Maximum Safety

Innovation Highlight!

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ERSA GmbH

Power Level Settings Controls Overshoot

*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 to protect from over-heating. The i-Tool heating element, however, can only draw its maximum 150W for a much shorter period of time.

In this manner, the maximum power is available to the iron by using an optimal size transformer for safe continual use.

Power Level: Low, Med, High (controls temp. overshoot)

Max power is available whenpower is required for heavymass soldering – Power Level High

Safe control is possible when temp sensitive components require NO OVERSHOOT! - Power Level Low

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ERSA GmbH

Solder Tip Temperature Overshoot – a Physical Effect

High Mass

High Mass

Low Mass

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!

150W 150W

Too Hot!!!

150W

Large Overshoot!

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ERSA GmbH

Solder Tip Temperature Overshoot Control via Power Levels

High Mass

High Mass

Low Mass

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!

75W 75W75W

No Overshoot!

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ERSA GmbH

A cup of water and a temp measuring unit (DTM 100) can reveal the actual tip overshoot:

1. Set unit to 350°C 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!

Solder Tip Temperature Overshoot by Competitive Irons

65°C (150°F) Overshoot!!

55°C (150°F) Overshoot!!

*Absolutley No Overshoot!!

*Power Level Low

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ERSA GmbH

1. Set unit to 350°C 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!

Solder Tip Temperature Overshoot by Competitive Irons

65°C (150°F) Overshoot!!!!!

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ERSA GmbH

1. Set unit to 350°C 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!

Solder Tip Temperature Overshoot by Competitive Irons

55°C (130°F) Overshoot!!!!!

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ERSA GmbH

1. Set unit to 350°C 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!

Solder Tip Temperature Overshoot by Competitive Irons

*Absolutely No Overshoot!!!!!*Power Level Low

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ERSA GmbH

The fastest and safest programming and locking out

of solder stations for maximum quality control and

documentation!

Revolutionary ERSA i-Set Tool

Innovation Highlight!

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ERSA GmbH

Revolutionary ERSA i-Set Tool

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!

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ERSA GmbH

Revolutionary ERSA i-Con Digital Solder Station

Available April 2006

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ERSA GmbH

ERSA i-Con2 Digital Dual Solder Station

Available July 2006

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

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ERSA GmbH

ERSA heat Recovery Performance Tester

FACT: the best performing solder iron will recover the fastest!

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ERSA GmbH

Don’t let hand soldering & touch up be the

“Achilles Heel” of your Lead Free operations!

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ERSA GmbH

ERSA – Win – Win – Win !

Increase qualityLow temperature LF hand soldering with rapid heat recovery & Process Alarm!

Increase productivityFastest heat up & recovery for rapid touch up and hand soldering

Decrease costsLowest tip cost by the high powered micro soldering irons

Win

Win

Win

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ERSA GmbH

Lead Free Soldering

Improved Tip Life

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ERSA GmbH

Lead Free Soldering Decreases Solder Tip Lifetime!

Lead free soldering will require higher working temperatures. 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 increased iron, 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 are very efficient, but are VERY EXPENSIVE!

ERSA‘s new i-Tool heating technology (patent pending) guarantees:The best heat recovery & inexpensive, exchangeable tips for lead free.

The new ERSADUR LF tips and i-Tips also guarantee a much longer tip life!

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ERSA GmbH

New ERSADUR LF Galvanic Plating Process

New galvanic plating process for the new i-Tip series soldering tips.• Improved tip precision: +/- 0.1 mm, more 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 two to three times longer!

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ERSA GmbH

1. Pencil point: ø : 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

3. Angled face: L : 2.0 mm, 4.0mm

4. Solder Well: L : 2.0 mm, 4.0mm

5. Knife tip:

6. PLCC Blade:

7. Curved tip:

ERSA i-Tip Series Long life, low cost tips for the i-Tool

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

i-Tip Tip Fastener

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ERSA GmbH

Thank you for your attention!