Edsyn ZD905 User manual

instruction manual
•COMPLIES WITH MIL-S-45743E, MIL-STD-2000, DOD-STD-2000-1B,
WS6536E AND ESD SPEC, DOD-STD-1686, DOD-HDBK-263
•UL listed
MADE IN THE
U.S.A.
Soldering
Hot Tip
Desoldering
Vacuum
Generator
HOT TIP
DESOLDERING STATION
ZD905
V & HP series

FEATURES
Static Safe
A) Illuminated Power Switch.
B) Temperature Control Knob, indication: 400°F - 800°F.
C) Temperature Regulation Lamps for each Tool.
D) SH230 includes RS199 Cleaning Sponge, LN230 Liner and RS243
Leveling Pad.
E) AC receptacle.
F) 24V controlled output. Desoldering (right)
G)24V controlled output. Soldering (left)
DO NOT INTERCHANGE TOOL CONNECTION.
H) PM100 Vacuum Generator.
I) PD528 holds Tool when not in use.
J) AF110 Vacuum Filter (for ZD905V & ZD905V-11 only), connect to
Vacuum Hose of HT500.
K) Air Pressure input, 60 - 90 psi. (4.1 - 6.2 bar).
L) Set Pots.
SR043
Front Housing
SC581
SR042
Thermal Housing
RS199
RS243
LN230
SH230-1
I
Tool Pod for HT500
PD528 Replace SC581 Solder Collector
1. Hold the Housing firm and turn Cap counter-clockwise
and pull it away from the Housing.
2. Remove used SC581 and replace with a new one.
3. Reassemble Pod with TOP of the Cap in proper position.
CAUTION:
Over-fillingcancausethermal
shock to the tip or heating el-
ement during tip cleaning.
Cleaning sponge
1. Keep sponge moist by adding
clean water.
2. Replace dirty sponge to prevent
tip contamination during tip
cleaning.
MAINTENANCE
H (For ZD905V series only)
AB
C
D
F
E
G
L
K
J

TROUBLE SHOOTING
Symptoms Cause Remedy
Weak or
no vacuum.
Weak or no
vacuum on the
HT500.
Solder does not
adhere to Tip.
Soldering Tip to
Ground resistance
is high
No power
a) Vacuum source not working
properly.
b) Loose fittings or leak along the
line.
a) Dirty or clogged filter.
b) Dirty or leaky valve.
a) Temperature too high,
causing Tip to oxidize.
Poor contact between Tip and
Heater.
Blown Fuse.
a) refer to respective instruction
manuals.
b) All connections are properly in-
stalledandreplacecrackedhoses.
a) Replace filter.
b) Clean parts and replace O-rings.
a) Lower the temperature to 500°F.
CleantheTipandre-tin.Ifproblem
still exists, replace Tip.
Do the Tip Cleaning Procedure
Replace fuse.
SPECIFICATION
• 120V, 60 Hz, 38W-310W
• 24V Controlled Output
• PS902 Power Supply: 4 lbs (1.8 kg)
• PM100 Vacuum Generator: 12 oz. (341 g)
• HT500 Hot Tip Desoldering Tool: 11 oz. (312 g)
• LST10 Soldering Tool: 3 oz. (85 g)
• LST11 Soldering Tool: 3 oz. (85 g)
• Temperature range: 4000F - 8000F (2050C - 4250C)
• Temperature regulation: ±60F (±30C)
• Voltage leakage from tip to ground less than 2 MV
• Tip to ground resistance less than 2 ohm
• Complies with MIL-S-45743E, DOD-STD-2000-1B, MIL-STD-2000,
WS6536E and ESD SPEC, DOD-STD-1686, DOD-HDBK-263.
OPTIONS PA233 Dovetail Extension Bracket allows you to
install additional Tool Pods.
1. Insert Nut into slot on both sides of
existing Dovetail. Use this size Nut.
2. Screw PA233 on top on Dovetail after
inserting Nut into slot.
Problems other than those listed should be corrected at the factory.
Ship both Tool and Power Supply together to:
EDSYN, Inc.
Customer Service
15958 Arminta Street.
Van Nuys, CA 91406-1896

LST10 LST11
Hollow Threaded
Heater Hollow
Heater
LST10 / LST11 LONER ®
24V, 50W Soldering Instrument
3 oz (85 g) made
in
U S A
LST11
1. MAKE SURE YOUR TOOL IS COOL!
2. Turn RS372 counter-clockwise to remove.
3. Remove old Soldering Tip.
4. Insert new Tip.
5. Install RS372.
soldering tip RS372
Soldering Tip
ESD Safe
CHANGING TIP
LST10
1. MAKE SURE YOUR TOOL IS COOL!
2. Using a TW318 or WT620
(optional)Tip Wrench, turn HC273
counter-clockwise to remove.
3. For Threaded Tips, just screw the
Tip to the heater.
WT620
TIP CARE
1. Plugged-in Tool to 24V temperature controlled Power
Supply & set to desired temperature.
2. TIN the Tip (apply solder) before soldering.
3. Do not rub, bend or file Tip.
4. Always clean the Tip by wiping it against the saturated
sponge.
5. Always RE-TIN the Tip before and after using.
BASIC SOLDERING
1. Allow Tool to heat up.
2. Pre-heat the area to be soldered. Approximately 2
sec. for component leads.
3. With the Tip still in contact with the working area,
apply solder on the working area.
(for solder, ask for SS652 or SS653)
4. Always clean the Tip by wiping it against the edge of
the moist sponge and re-tin.
DESOLDERING
1. Melt solder in the area you want to
desolder.
2. While keeping the solder in a molten state,
use a Desoldering Tool , EDSYN®
SOLDAPULLT® to extract the molten solder.
for "-1"
for "-2"
Connector
TW318
soldering tip HC273
install
remove

SOLDERING TIPS
Iron Plated for long life•Nickel and
Chrome Plated for optimum heat transfer
CONTACT EDSYN FOR MORE SELECTIONS b
a
ab
Large and heavy tip for
heavy duty soldering.
Fine point tip for SMD
soldering.
.03 (0.8 mm) .48 (12.2 mm)
.06 (1.5 mm) .48 (12.2 mm)
.02 (0.5 mm) 1.13 (28.8 mm)
.07 (2.0 mm) .93 (23.6 mm)
.03 (0.8 mm) .48 (12.2 mm)
.10 (2.5 mm) .74 (18.8 mm)
.06 (1.5 mm) 1.21 (30.7 mm)
.04 (1.0 mm) 1.21 (30.7 mm)
.20 (4.9 mm) .93 (23.6 mm)
.32 (8.3 mm) .97 (21.1 mm)
LT374 Standard Probe
LT375 Standard Spade
LT392 Extra-Long Needle Point
LT394 Extra-Long Spade
LT446 SMD Probe
LT337BC Heavy Duty Terminal Spade
LT223BC Heavy Duty Fine Spade
LT222BC Extra long Needle Point
LT153BH Jumbo Spade
LT155BH Jumbo Angle Spade
SET-UP & REQUIRED ACCESSORIES FOR HEAVY DUTY AND JUMBO TIPS
Apply AN112 or
AN122* Anti-Seize
CompoundtoHeater
and area of Tip con-
tact.
"BC" HEAVY DUTY TIP
AC735 TA350 JUMBO TIP RS351
RS271
*AN122 Anti-Seize Compound comes in
syringe dispenser.
SDS100
METER
FX635
1. Turn on power and set Temperature Control
Knob to 400°F.
2. Using a clean and well tinned Tip, apply a small
amountofsolderontheTip,justenoughtoform
a bead on top of the Tip.
3. Place the center of the thermocouple wire of
the SDS100 on top of the bead.
4. Again, apply a small amount of solder on the
center of the thermo-couple wire, just enough
to embed the center.
5. Adjust LO-Temp. Calibration Pot so the Meter
will read 400°F.
6. Set Temperature Control Knob to 800°F.
7. AdjustHI-Temp.CalibrationPotsotheMeterwill
read 800°F.
AIR MOVEMENT WILL AFFECT THE TEMPERATURE
READING. WORK IN AN AREA WHERE THIS IS
TEMPERATURE CALIBRATION

A
G
F
B
I
D
E
M
H
J
ASR057 Handle for Tool 1
BSR058 Cord Strain Relief 1
CSR778 Tool Cord Assy. (for LST10) 1
C1 SR250 Tool Cord Assy. (for LST10-1) 1
C2 SR777 Tool Cord Assy. (for LST10-2) 1
DSR103 Heater Element Assembly Kit; O-Ring (e) & Collar (g) Included 1
ESR062 O-Ring 1
FSR063 Vinyl Sleeve 1
GSR064 Collar 1
HLT375 LONER® Standard Spade Tip 1
IHC273 Retaining Collar for tip 1
JRB386 Retaining Bushing 1
KSR525 Hose, Low Static, 1/4 I.D. (sold per foot) 5-1/4"
MSR371 Shrink Tube, 1/4" dia. Clear, (sold per foot) 1/2"
ITEM
NO. PART NO. DESCRIPTION QTY
REQ'D
LST10
SPARE PARTS LIST
K
C
C1
C2
ASR057 Handle for Tool 1
BSR058 Cord Strain Relief 1
CSR778 Tool Cord Assy. (for LST11) 1
C1 SR250 Tool Cord Assy. (for LST11-1) 1
C2 SR777 Tool Cord Assy. (for LST11-2) 1
DSR104 Heater Element Assembly Kit; O-Ring (e) & Collar (g) Included 1
ESR062 O-Ring 1
FSR063 Vinyl Sleeve 1
GSR064 Collar 1
HLT375 LONER®Standard Spade Tip 1
IRS382 Retaining Sleeve 1
JRB386 Retaining Bushing 1
KSR525 Hose, Low Static, 1/4 I.D. (sold per foot) 5-1/4"
ITEM
NO. DESCRIPTION QTY
REQ'D
PART NO.
LST11
SPARE PARTS LIST

A) Head Assembly- Includes the primary
filtering system and solder debri cham-
ber.
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) VacuumHose-LowStaticsiliconehose.
Connects to vacuum source.
F) Connector- To 24 V controlled output.
(for HT500) (for HT500-2)
G) Cleaning Shaft- For cleaning
DesolderingTiporifice:.05(1.3mm)and
.025 (0.6 mm)
HT500 ®
Hot Tip Desoldering Tool
D
A
F(for HT500-1)
E
B
C
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 locksinto1ofit's4positions.
Twisting counter-clockwise will
permit a 1800turn. Twisting clock-
wise will permit a 900turn.
Note: Head Assembly does not make a full 3600turn
To tilt the Head assembly, loosen (2)
Adjustment Screws. Tilt the Head as-
sembly to desired position. Retighten
Screws.
adjustment
screws
POWER REQUIREMENTS:
•24V
•VACUUM SOURCE
SPECIFICATIONS
• 24V, 50/60 Hz, 70W
• Weight: 11 ozs. (312 g)
• Temperature range of 4000F to 8000F (2050C-4250C)
• 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
• UL Listed
ESD Safe

3. Apply AN112 (in tube) or AN122 (in syringe) Anti-
Seize Compound before assembling.
INSPECT DAILY
4. Install RS383.
WT619
Tip Wrench
1. Remove RS383. Use WT619.
2. Replace Tip and install new Tip.
1. Whendesolderingsmall
holes on flat areas, tilt
Tool to allow adequate
air flow to lift solder into
chamber.
3. Extra-heavy duty desoldering on a multi-
layeredboard is done by using a Heavy Duty
DesolderingTipandaHi-HeatSolderingTipsimulta-
neously. Although pre-heating of the circuit board
willspeeduptheprocess,itisnotalwaysnecessary.
NOTE: When Tip orifice is blocked,
use a correct size Cleaning Shaft
whilepressingtheTriggertoclearthe
obstruction.
CS468 is .05 in. dia.
CS468-1 is .025 in. dia.
2. When using SMD Tips, heat
uptheconnectionsbyposi-
tioning the Tool perpen-
dicularly. When solder
melts tilt the Tool and de-
press trigger. (SMD Tips are
recomended for HT500 us-
ing external vacuum).
DESOLDERING POINTERS
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.
REPLACING DESOLDERING TIPS
install
remove
Multi-Layered
Board
Heavy Duty
Desoldering Tip

Hot Tip Desoldering Tips
When using a Replace-
ment Desoldering Tip to
desolder small holes on flat
areas,tiltTooltoallowade-
quate 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.
ZD12 .03 1/32 0.8
ZD13 .04 3/64 1.0
ZD14 .06 1/16 1.5 .50 1/2 12.7
ZD18 .07 5/16 1.8
ZD19 .12 1/8 3.2
ZD08 .03 1/32 0.8
ZD10 .04 3/64 1.0 .44 7/16 11.8
ZD11 .06 1/16 1.5
ZD107 .02 1/64 0.5
ZD112 .03 1/32 0.8 .48 31/64 12.2
ZD113 .04 3/64 1.0
ZD111 .03 1/32 .08 1.22 17/32 31
ZD25 .03 1/32 0.8
ZD26 .04 3/64 1.0 .39 32/64 9.9
ZD27 .07 5/16 1.7
ZD57 .10 7/64 2.5
ZD58 .13 1/8 3.2
ZD60 .15 5/32 3.8 .55 9/16 13.9
ZD61 .25 1/4 4.5
mmin.
in. B
HOLE DIAMETER in. in.
PART
NO. mm
Fractional dimensions are approx.
DESCRIPTION
HOLE
DIA.
HOLE
DIA.
Medium Life
(High Heat Transfer)
HOLE
DIA.
SMD**
(FOR ZD505/905 series)
Replacement*
Funnel
Long
Funnel
To reach deep, dense and
compact areas, use a Long
Funnel tip
Extra-heavy duty desolder-
ingonamulti-layeredboard
is done by using a Medium
Life Desoldering Tip.
HOLE
DIA.
Long Life
(Low Heat Transfer)

in. in. mm in. in mm
ZD28 .03 1/32 .08
ZD29 .04 3/64 1.0
ZD30 .06 1/16 1.5
in. in. mm .30 5/16 7.6
ZD70
.08 3/32 2.0
ZD71
B
PART
NO.
HOLE DIAMETER
DESCRIPTION
HOLE
DIA.
Economy**
Surface
Sweep** W
Hot Tip Desoldering Tip
Replacement
Desoldering Tip
SMD Desoldering Tip
Medium & Long Life
Desoldering Tip
Hole Dia. = .06 in.
Side Sweep**
Hole Dia. = .06 in.
*Tin New Iron Tips at Low Temperaturebefore using.
**Non-Plated Alloy
Hot Tip set-up
Heater Set-up
Side Sweep Tips al-
lows removal of sol-
derfromthecompo-
nent side of the
board.
Surface Sweep Tips re-
movesexcesssolderon
pads for flatter surface,
prior to SMD remount-
ing.
RS383
Retaining
Sleeve
AC736
Tip Adapter
HT01
AC737
Accumulator
Bushing
Side Sweep
Desoldering Tip HC273
Threaded
Retaining
Collar

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).
f) Lube new O-rings with OL111 O-Ring Lube.
Valve Assembly
Handle
Cover
Lock Nut
DAILY MAINTENANCE WEEKLY MAINTENANCE
SC525 MS229 OS133
©®®©
AF625
©
OS731
FC639
©OS132
When installing OS133, the HT01
should go thru the OS133.
®Desoldering
Head Housing
• Remove and inspect Tip and Heater Assy.
• Inspect all Filters
• Remove solder debri from Desoldering Head
Housing
• Inspect Valve Assy.
• Inspect all O-Rings and Seals
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.
CAUTION: Make
sure the wires are
not pinched by
Valve Assembly.
Spring Seat
OS730 O-ring set
HT01
OS133
© -Clean
® -Replace

32
3
19
26
24
11
28
37
41
27
20
12
13
16
17
18
14
50
29
2
1
30
10
42
22
21
25
47
25
46
49
47 9
45
6
5
7
8
33
30
43
36
38
15
4
31
39
40
35
34
44
48
HT500/-1 HOT TIP
DESOLDERING TOOL
SPARE PARTS LIST
1RS383 Retaining Sleeve 1
2ZD13 Hot Tip Desoldering Tip 1
3HT01 Hot Tube 1
4AC737 Accumulator Bushing 1
5MS229 Mica Sheet 1
6OS133 Silicone Washer 1
7SC525 Solder Cone 1
ITEM
NO.QTY
REQ'D
DESCRIPTION
PART NO.

8AF625 Felt Filter 1
9SR148 Housing for End Cap 1
10 OS731 O-Ring for End Cap 1
11 OS132 O-Ring for End Cap Elbow Connector 1
12 SR147 Connector for End Cap 1
13 FC639 End Cap 1
14 SR008 Flat Head Slotted Screw for Index Flange 1
15 SR168 Pan Head Phillip Screw for adjusting Desoldering Head Assy. 1
16 HT500H Desoldering Head Assembly- Repairable by EDSYN Customer Service Dept.1
17 SR136 Desoldering Head Housing 1
18 SR120 Heater Element 1
19 SR117 Heater Element Bushing (O-Ring included) 1
20 SR118 Retaining Key for Heater Element Bushing 1
21 SR119 Teflon Spacer for Heater Element 1
22 OS731 O-Ring for Heater Bushing 1
24 SR121 Grounding Wire 1
25 SR122 Screw, 2-56 x 1/8 Pan Head Slotted 3
26 SR145 Sleeving, Braided Fiberglass 2
27 SR004 Handle Cover 1
28 SR124 Head Shaft 1
29 SR125 Spring for Head Shaft 1
30 SR126 Washer, Nylon 2
31 SR127 Retaining Nut for Head Shaft 1
32 SR128 Trigger 1
33 HL603 Hose, Low Static Silicone, 3/16" I.D. 5"
34 SR335 Valve Assy. 1
35 SR393 Nut, Retaining, for Handle 1
36 OS730 O-Ring Set (Three O-Rings) 1 set
37 SR129 Valve Housing 1
38 SR130 Poppet (O-Ring Included) 1
39 SR131 Return Spring for Poppet 1
40 SR132 Seat for Return Spring 1
41 SR133 Wire Nuts 3
42 SR134 Hose and Wiring Assembly for HT500 1
SR565 for HT500-1 SR635 for HT500-2
43 SR123 Handle Base 1
44 SR143 Wire Guide, Nylon, 3/8" Length 2
45 SR005 Index Flange (Screw Side) 1
46 SR006 Index Flange (Nut Side) 1
47 SR007 Nut, Hex, 2-56 thread 3
48 SR135 Connector for HT500 1
SR353 for HT500-1 SR633 for HT500-2
49 SR170 Cap Nut, Hex #8-32 x 5/16" 1
50 SR169 Washer, Flat, 1/16" thick 1
PART NO. QTY
REQ'D
DESCRIPTION
ITEM
NO.

Form.558
Rev B
© Copyright EDSYN, Inc. 1997
ZD905/V/HP instruction manual
THE NAMES LONER, SOLDAPULLT, 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.
Intellectual
Property
15958 ARMINTA ST. VAN NUYS, CA 91406-1896
PHONE: [phone] FAX (sales): 818-997-0895
Email: [email protected] Internet: www.edsyn.com
AIR MOVEMENT WILL AFFECT THE TEMPERATURE READING.
WORK IN AN AREA WHERE THIS IS MINIMAL.
CALIBRATION
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-
couplewire,toformagoodcon-
tact between the tip and the
thermo-couple 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). 1. Set knob at 400°F.
2. Adjust LO to 400°F.
3. Set knob at 800°F.
4. Adjust HI to 800°F.
HI LO
Temperature
Control Knob Calibration Pot