Kurtz Ersa HR 100 A User manual

Ersa Rework System
HR 100 A
Operating Instructions

3BA00174 • 2014-02-06 • Rev. 5 HR 100 1 / 2
Contents
1. Introduction 4
2. Technical data 5
3. Concerning your safety 8
3.1 Explanations on pictograms and symbols 8
3.2 Intended use 9
3.3 Target group of readers 9
3.4 Safety notes 10
4. Transport, storage and waste disposal 13
5. Start-up 14
5.1 Scope of delivery 14
5.1.1 Hybrid Rework System HR100A (0IRHR100A) 14
5.1.2 Hybrid Rework System HR100A with heating plate (0IRHR100A-HP) 14
5.2 Control elements, displays and connections 15
5.2.1 Front view of base station 15
5.2.2 Rear view of base station 16
5.2.3 The Hybrid Tool 17
5.3 Placing and connecting the device 17
5.4 Switching on 18
5.5 Firmware 18
6. Description of function 19
6.1 Notes on operation 19
6.1.1 Base station 19
6.1.2 Hybrid tool 20
6.1.3 The three programs AD1, AD2, AD3 21
6.1.3.1 Heating time Hybrid Tool and heating plate 22
6.1.3.2 Heating plate energy level 23

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Contents
6.1.4 The expert program AD0 24
6.1.4.1 Heating time Hybrid Tool and heating plate 24
6.1.4.2 Heating plate energy level 25
6.1.4.3 Energy level Hybrid Tool 27
6.1.4.4 Blower speed Hybrid Tool 27
6.1.4.5 Selecting the temperature sensor 28
6.1.4.6 Heating power rise speed 29
6.1.4.7 Temperature monitoring Hybrid Tool 32
6.2 Changing a Hybrid adaptor 33
6.3 Working with the Hybrid Tool 35
6.3.1 Soldering and desoldering 35
6.3.2 Using the vacuum pipette 37
6.4 Working with tool holder 38
6.4.1 Soldering and desoldering 38
6.5 Connecting a PC 39
6.6 Sensitive components 40
6.7 Brief instructions 41
7. Treatment of faults 42
7.1 General faults 42
7.2 Other faults 42
7.3 Table of error codes 43
7.4 Factory settings [Default] 44
8. Maintenance, repair 45
8.1 Important service tasks 45
9. Spare parts and Accessories 46
10. Warranty 47

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1. Introduction
We would like to thank you for purchasing this high quality Rework System. With the HR 100A
Ersa offers a microprocessor controlled cutting edge handheld rework system for standard and
lead-free rework applications. It is intended for use in industrial manufacturing, repairs and
laboratory applications.
The combination of radiant and convection heat with contactless transfer to the components,
is characteristic for the hybrid technology. Due to its optimal heat transfer this technology is
most suitable for all SMT-Rework processes.
Three modes of operation enable optimal adaptation to the required purpose of use:
• Time base
• Time base with temperature measurement
• Programmable temperature control (control either through base station or with IRSoft via
PC.
An integrated laser pointer facilitates exact positioning of the heat source. With the
straightforward menu guidance settings can be comfortably edited and saved.
A rotary encoder with momentary contact function serves the purpose of programming and
operation.
The extensive range of accessories enables you to set up a flexible and modern Rework-System
for highest quality demands.

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2. Technical data
Hybrid Rework-System HR 100A, base station
Designation Value Unit
Mains voltage 220-240 VAC
Mains frequency 50-60 Hz
Fuse (slow blow) 2 A
Mains voltage 110-120 VAC
Mains frequency 50-60 Hz
Fuse (slow blow) 4 A
Secondary voltage 13 VAC
Maximum heating power 200 W
Safety class I -
Permissible ambient temperature 0-40 °C
Temperature range at outlet 30-550 °C
Air volume
With hybrid adaptor AD1 15...35 l/min
With hybrid adaptor AD2 6...11 l/min
With hybrid adaptor AD3 3...9 l/min
Miscellaneous
Function display LED display
PC interface Mini USB
Supply cable 2m, PVC, with appliance connector
Operation via rotary encoder with momentary contact function
Antistatic surface, suitable for use in ESD-environment, EMC-tested*.
Vacuum -0,2...-0,4 bar
Conformity
Dimensions WxHxD 211 x 220 x 188
mm
Weight 4,5 kg

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2. Technical data
Hybrid Tool
Length of supply cable 1,35 m
Dimensions WxHxD 230x25x25 mm
Weight approx.
300 g
Laser
Class II -
Wavelength 660-680 nm
Output max. 1 mW

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2. Technical data
Heating plate IRHP100A
Designation Value Unit
Mains voltage 220-240 VAC
Mains frequency 50-60 Hz
Fuse (slow blow) 4 A
Mains voltage 110-120 VAC
Mains frequency 50-60 Hz
Fuse (slow blow) 8 A
Control voltage 5 Vss
Maximum heating power 800 W
Safety class I -
Miscellaneous
Supply cable 2m, PVC, with appliance connector, control cable with RCA (Cinch) connector.
Antistatic surface, suitable for use in ESD-environment, EMC-tested.
Conformity
Dimensions WxHxD 200 x 260 x 53,5
mm
Height of tool suspension 214,5 mm
Dimension of holder for printed circuit board W x D 330 x 250 mm
Weight 2,5 kg
* Strong signals in the frequency range of 80...230 MHz can cause interferences in the base station display!

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3. Concerning your safety
Ersa products are developed, manufactured and tested in compliance with general
requirements concerning health and safety.
However, residual risk do remain!
You should therefore read this instruction manual before you start to operate the device for
the first time. It will help you to learn the functions of the device and to use it in the most
optimal way. Keep this instruction manual at a place that can be accessed by all users at any
time!
3.1 Explanations on pictograms and symbols
In this instruction manual pictograms are used to highlight dangers.
Special information or mandatory instructions and prohibitions with the aim
of preventing personal injury or extensive damage to property are identified
by a pictogram, followed by hierarchically structured text with words written
in bold:
Warning! Is used for warnings of immediate danger. Consequences may be
death or personal injuries.
Attention! Is used for warnings of possibly dangerous situations.
Consequences may be personal injury, damage to property or environment.
Caution! Used for application related recommendations. Negligence may
result in material damage.

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3. Concerning your safety
In addition to the hierarchically structured warning notes described above, we
use the following symbols:
Used to highlight any texts containing explanations, information or hints.
■ This symbol identifies
- action that is strictly required, or
- instructions that must be strictly complied with.
3.2 Intended use
Thermal tools from Ersa must only be used for the processing of soft solder. However, if
explicitly described in the operating instructions of the respective thermal tool, some thermal
tools may, in exceptional cases, be used for the processing of plastic materials.
In case of unintended use and tampering with the device, any warranty and liability claims of
the buyer against the manufacturer will become null and void.
3.3 Target group of readers
This instruction manual addresses persons with knowledge in the field of reflow soldering.

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3. Concerning your safety
3.4 Safety notes
Attention! Check all components before each use. Have damaged parts
only repaired by a specialist or the manufacturer. Unprofessional repairs
cause a risk of accident. Always use original Ersa spare parts for possible
repairs.
Attention! Thermal tools get very hot. Before heating up the device check
whether the tool insert (e.g. soldering tip, modelling insert, etc.) is correctly
connected with the thermal tool. The hot tool insert should never come in
contact with skin, hair or any heat-sensitive and combustible materials. Make
sure you use a sufficiently heat proof work base.
Attention! Keep unauthorized persons at a safe distance. Make sure that
unauthorized persons, especially children, have no access to the thermal
tools.
Attention! Fire hazard. Before heating up the thermal tool remove any
combustible objects, fluids and gases from the working range of the thermal
tool. Always place the thermal tool into the storage stand provided for this
purpose. Disconnect the thermal tool from the mains supply after use. Do
not leave your hot thermal tool unattended. Please remember that it will take
quite same time for the tool insert to cool down to a harmless temperature,
after the device has been switched off.

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3. Concerning your safety
Attention! Lead containing solders are toxic. Lead containing solders
entering into the organism will have a toxic effect. Eating, drinking and
smoking is therefore strictly prohibited. For the reasons mentioned above
you should always wash your hands thoroughly after having worked with lead
containing solder.
Attention! Ventilation and extraction. Working and auxiliary materials may
put your health at risk. Ensure sufficient ventilation or extraction. Follow the
relevant safety data sheets.
Warning! Protect the supply cables. Do not use the power supply cable to
pull out the plug or to carry the device. Keep power supply cables clear of
heat, oil or sharp edges. Damaged power supply cables may cause fire, short
circuit or electric shock and must therefore be replaced.
Attention! Consider environmental influences. Protect your device against
any type of fluid and moisture. Otherwise there is a danger of fire or electric
shock.
Caution! Take care of your thermal tool. Always keep your Ersa product in
a safe and dry place, out of the reach of children. Follow the maintenance
instructions. Check your device in regular intervals. Use only original
accessories and spare parts from Ersa.

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3. Concerning your safety
Attention! Laser beam! The device contains a class II laser radiation source.
Do not look into the direct laser beam and do not direct the laser beam
towards the eyes of other people!
Attention! Physically and/or mentally handicapped persons must only use
the device under the supervision of trained expert personnel! Children are not
allowed to play with the device!
National and international health and safety regulations as well as occupational health and
accident prevention regulations must be complied with.

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4. Transport, storage and waste disposal
The device is delivered in a sturdy cardboard box. Please use only the original packaging for
transportation and intermediate storage. Strictly avoid jerky movements, impacts or putting
down. The device must be adequately protected against weather influences like rain, fog or
sea air, etc. For longer storage in high humidity environments the device must be packed up
air tight, together with a dehumidifying agent. Damage caused by unprofessional transport or
storage are not covered under warranty.
Notes on waste disposal acc. to the directive 2002/96/EG of the European
Parliament and the Committee from 27th of January 2003 for for used
electric and electronic appliances:
Products marked with a crossed out waste bin must not be disposed of
together with unsorted domestic waste. The municipalities established
special collecting points for this type of waste. Please consult your council
and ask for available possibilities for the separated collection of old
appliances. You thereby contribute to the reuse or other forms of use of old
appliances, with the aim of protecting the environment and human health.

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5. Start-up
Before start-up: Please check the contents in the package for completeness. Should any of
the listed components be damaged or incomplete, you should immediately consult the supplier.
5.1 Scope of delivery
5.1.1 Hybrid Rework System HR100A (0IRHR100A)
• HR 100A digital control unit with power supply cable, vacuum pipette with suction ele-
ments, these operating instructions
• Hybrid Tool with connecting cable, Hybrid adaptor AD1, AD2, AD3 and adaptor changer.
• Optional accessory: Option: Stand 0IRHR-ST050, please read paragraph [Spare Parts and
Accessories].
5.1.2 Hybrid Rework System HR100A with heating plate
(0IRHR100A-HP)
• HR 100A digital control unit with power supply cable, vacuum pipette with suction ele-
ments, these operating instructions.
• Hybrid Tool with connecting cable, Hybrid adaptor AD1, AD2, AD3 and Adaptor changer.
• 800 W IR-heating plate complete with tool suspension for Hybrid Tool and holder for prin-
ted circuit boards, Flexpoint TE-holder and AccuTC thermocouple.
• Software package IRSoft on CDRom, USB cable.
For further accessories please refer to chapter 9.

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HYBRID TECHNOLOGY
VACRAMP
2x PUSH
5. Start-up
5.2 Control elements, displays and connections
5.2.1 Front view of base station
The base station contains the following control and display elements:
a Mains switch
b Display
c Connection for vacuum pipette
d Rotary encoder with momentary contact function
e Vacuum pipette
f Switch for vacuum pump
g Hybrid Tool

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Fuse
Mains
IRHP
100A
TC
IRS
TOOL
5. Start-up
5.2.2 Rear view of base station
The following connections and the mains fuse are arranged on the back of the device:
h Connection for Hybrid Tool
i Connection for Accu TC thermocouple
j Connection for Rework heating plate
k Fuse holder with mains fuse
l Mains supply connection
m Connection for IR-sensor
n GrounStart-up connection for ESD-protection

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5. Start-up
5.2.3 The Hybrid Tool
The Hybrid Tool is equipped with a control and display element:
r Start / Stop button
s LED as operation indicator (orange)
The following Hybrid adapters are included in the scope of delivery:
o Hybrid adaptor AD1
p Hybrid adaptor AD2
q Hybrid adaptor AD3
5.3 Placing and connecting the device
■ Place the base station on a level surface, possibly on a heat resistant base.
■ Connect the Hybrid Tool with the station (socket h) and place it into the storage stand.
■ Connect the vacuum pipette with connection c. Place the vacuum pipette into the sto-
rage stand.
■ Connect the AccuTC thermocouple or the IR-temperature sensor (both options) with the
socket i or m.
■ Stand the Rework heating plate (option) next to the base station and connect it with
socket j. Switch off the mains switch on the Rework heating plate. Connect the mains
supply cable with Rework heating plate and mains supply socket.

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5. Start-up
5.4 Switching on
■ Before switching on, make sure that the mains voltage complies with the value specified
on the type plate.
■ Switch off the base station by the mains switch a.
■ Connect the power supply cable with the base station and the mains supply socket.
■ Switch on the base station by the mains switch a.
5.5 Firmware
After the base station has been switched on the firmware version, e.g. will first be
displayed, followed by an approx. 2 second switch on dialog . After this the program
selected last, e.g. will be displayed and the station is ready for operation.
These operating instructions refer to firmware 1.3.0. For service purposes
the number of the firmware may be of help, you should therefore make a
note of it and keep it ready, as you may need it when asked by our Service
Department.

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HYBRID TECHNOLOGY
VACRAMP VA CRAMP
2x PUSH
6. Description of function
6.1 Notes on operation
6.1.1 Base station
The base station is operated by a rotary encoder with momentary contact function:
■ In order to select a program after switching on, turn the rotary encoder clockwise or anti-
clockwise, until the desired program , , or is displayed by flashing.
■ Press the rotary encoder to open the setting level of the selected program.
• The programs , and have two setting levels each.
• The program has up to seven setting levels.
■ If no input is made within a period of 8 seconds, the display will automatically change to
the previously selected program, , , or is displayed.
Your input will be durably saved in the station, even after switching off.
Settings within the programs are not possible during the heating phase.

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6. Description of function
6.1.2 Hybrid tool
The Hybrid Tool is operated by the Start / Stop button in the handle.
■ Press the Start / Stop button to start the heating process - during the heating phase the
LED in the handle lights or flashes orange.
■ Press the Start / Stop button again to stop the heating process and to start the cooling
phase - the LED goes out.
■ During the heating phase, the LED a in the display is lit or flashes.
During the cooling phase, the blower always runs at top speed. If the cooling
phase is not interrupted by re-heating, it is automatically stopped after 5
minutes. This time is set permanently and cannot be changed.
VAC RAMP