Kurtz ERSA IR 550 A User manual

ERSA GmbH
Soldering Tools & Inspection Systems Division
Operating Instructions
ERSA IR 550 A
Microprocessor controlled Rework System
12682-01

ERSA IR 550 A
Operating instructions
ERSA GmbH
31.07.03.we.no 12682_01 IR 550 A_e.doc -2/32 -
Pictures
1external keypad 6display (LED)
2bottom radiator(glass cover) 7infrared sensor
3top radiator (aperture system) 8cooling fan and laser positioning device
4component tray 9DIGITAL 2000 A soldering station
5vacuum pipette 10 Tech tool soldering iron and holder
Backside of the unit with connections
3
1
2
8
9
4
5
7
10
6
Sensor 1
Sensor 2 Serial Port
Keypad
Fuse
-
2
Fuse
-
1
Vacuum
Laser / Fan

ERSA IR 550 A
Operating instructions
ERSA GmbH
31.07.03.we.no 12682_01 IR 550 A_e.doc -3/32 -
We appreciate your decision to purchase our high-quality ERSA IR 550 A Rework System.
This device has been manufactured according to highest quality standards and was tested
thoroughly before shipment. It is very easy in operation, nevertheless we suggest to read this
manual before operating the system. If you have any additional questions to your equipment,
please do not hesitate to contact us at:
ERSA GmbH
Leonhard-Karl-Str. 24
97877 Wertheim
Germany
Tel.: [phone]
Fax: [phone]
Email: [email protected]
Web: www.ersa.com

ERSA IR 550 A
Operating instructions
ERSA GmbH
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TABLE OF CONTENTS Page
1Introduction .............................................................................................................................5
2Technical Data ........................................................................................................................6
3Safety instructions...................................................................................................................7
4Commissioning........................................................................................................................8
4.1 Before commissioning .....................................................................................................8
4.2 First start-up ....................................................................................................................9
4.2.1 Setting up.................................................................................................................9
4.2.2 Electrical connections ............................................................................................11
4.2.3 Switching on ..........................................................................................................11
4.3 Tips for the SMT Rework Process .................................................................................12
5Functional description............................................................................................................13
5.1 Functional elements of IR 550 A....................................................................................13
5.1.1 Infrared radiators....................................................................................................13
5.1.2 Temperature sensors.............................................................................................13
5.1.3 Cooling fan and laser positioning device...............................................................14
5.1.4 Vacuum pipette and vacuum pump........................................................................14
5.1.5 DIGITAL 2000 A soldering station..........................................................................14
5.1.6 Serial port, documentation software IRSoft ............................................................14
5.2 Operation and program parameters...............................................................................15
5.2.1 Menus and programs.............................................................................................15
5.2.2 Parameter setting and description..........................................................................17
5.2.3 Operating process „soldering“................................................................................21
5.2.4 Operating process „desoldering“............................................................................22
5.2.5 Factory settings......................................................................................................22
6Error diagnosis and repair .....................................................................................................23
7Maintenance..........................................................................................................................25
8Spare parts and options ........................................................................................................26
9Appendix...............................................................................................................................28
10 Index.....................................................................................................................................31
11 Warranty................................................................................................................................32

ERSA IR 550 A
Operating instructions
ERSA GmbH
31.07.03.we.no 12682_01 IR 550 A_e.doc -5/32 -
1Introduction
We appreciate your decision to purchase an ERSA IR 550 A Rework System. With this
microprocessor unit which is also equipped with powerful infrared-an sensor technique ERSA
provides a rework soldering system to meet the highest requirements of modern industrial
electronic production. Selective soldering processes during rework of surface mounted devices are
the main fields of application of this valuable soldering system.
The unique IR-radiator technique by ERSA has been optimised within the IR 550 A. The
programmable temperature control allows reproducible soldering results for nearly every
application. At any time, the soldering process is monitored by a non contacting infrared sensor
and grants for optimal process control.
Additionally, the IR 550 A provides an active cooling of the PCB. The integrated soldering station
DIGITAL 2000 A completes the IR 550 A to a modern and flexible tool for any professional user.
The combination of IR 550 A with the Reflow Process Camera RPC 550 A or the Precision-
Placement System PL 550 A creates a high-end workplace for modern rework in electronic
production.

ERSA IR 550 A
Operating instructions
ERSA GmbH
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2Technical Data
IR 550 A main unit:
Rating IR-top radiator 4 x 200 W (size 60 x 60 mm)
Rating IR-bottom radiator 2 x 400 W (size 135 x 250 mm)
max. power consumption 1600 W
Wavelength of IR radiators 2 -5 µm
Voltage 230 V ~, 50 Hz or 115 V, 60 Hz
Fuse 10 A (slow blow)
Design Safety category 1
Operation external Keypad
Display integrated LED display
Power cord approx. 2 m
Weight approx. 9.75 kg
Warm-up time bottom radiator 90 s
Heat up rate during process 0.3 to 2 K/s
Dimensions 300 x 380 mm (B x T)
Height 315 mm
max. travel (z-axis) 50 mm
Distance to top radiator
(non-contacting sensor) 40 mm
max. working depth approx. 170 mm
Airflow cooling fan 72 m3/h
For technical data of DIGITAL 2000 A soldering station, please refer to the included operating
instructions „ERSA DIGITAL 2000 A“. (3BA00044-00)

ERSA IR 550 A
Operating instructions
ERSA GmbH
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3Safety instructions
Note:
Before commissioning, please refer to the included safety instructions.
Please note that this product has been designed for the soldering and desoldering of electronic
components only!
Note:
The top and bottom radiators of the unit get very hot during the operation. Remove any
combustible objects or liquids from the working area. Do not touch hot housing parts. Keep any
flammable objects away from hot housing parts!
Note:
The Laser Positioning device includes a laser product class II. Do not look directly into the laser
beam!
Note:
Repairs should only be carried out by qualified staff. The unit contains alive parts! Inexperienced
work is extremely dangerous.

ERSA IR 550 A
Operating instructions
ERSA GmbH
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4Commissioning
4.1 Before commissioning
Please check that all components listed below are complete and undamaged:
•IR 550 A basic unit with integrated DIGITAL 2000 A soldering station
•External keypad with connection cord
•Power cord
•Spare silicone cup ∅5 mm, Spare silicone cup ∅8 mm
•Tech tool soldering iron
•Holder for soldering tool A29
•Serial modem cable for connection to a PC
•PC-Software IRSoft* (CD-Rom)
•IR 550 A operating instructions (12682-01)
•DIGITAL 2000 A operating instructions (3BA00044-00)
•Safety instructions
* Current updated software is available at ERSA GmbH.
Should the above components be damaged or incomplete, please contact your supplier.
Attention:
The top and bottom radiators of the unit get very hot during operating the system. Remove any
combustible objects or liquids from the working area. Keep any flammable objects away from hot
housing parts!

ERSA IR 550 A
Operating instructions
ERSA GmbH
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4.2 First start-up
Please read through the operating instructions completely before commissioning.
Procedure for commissioning:
4.2.1 Setting up
•Unpack the IR 550 A unit.
•Put the unit onto a plane, solid workbench.
•Swing both arms into their rear end position. They will snap in there.
•Vertical adjustment of top radiator and infrared sensor
The arm of the top radiator is vertically adjustable together with the infrared sensor. Thus
you can adjust the optimal working distance for each application.
Open the clamping lever laterally installed at the top radiator fixture. Adjust the radiator so
that the metal pin touches the PCB. Close the clamping lever again.
•Vertical adjustment of the component tray
Unscrew the clamping screw of the component tray and dismount the component tray. Turn
the tray by 180° and reinstall it so that the desktop is protected from heat radiation of the
top radiator and that desoldered parts can be deposited on the component tray with the
vacuum pipette. Adjust the component tray vertically according to the height of the top
radiator and fix it.
pin

ERSA IR 550 A
Operating instructions
ERSA GmbH
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•Aperture adjustment
The aperture system of the top radiator can be adjusted continuously with four set screws
from 20 x 20 to 60 x 60 mm. To adjust it, open all four screws. Then choose the size of the
window and tighten the screws again.
Attention:
The integrated slot apertures are reducing the irradiation in the border area. Sensitive components
are not completely protected against irradiation! Sensitive components must be protected with
reflective foil (0IR4500-40) or with standard aluminium foil.
Note:
During continuous operation the top radiator can become very hot, when the aperture window is
very small. Increase window size to avoid safety switch off of the top radiator.
•Usage of X-Y PCB Table (0IR5500-01)
If you do not use the IR 550 A together with the Reflow Process Camera RPC 550 A or the
Placing System PL 550 A, we recommend the usage of the X-Y PCB Table.
Its height adjustment scale corresponds with the adjustment of the top radiator. When the
PCB table and the top radiator are adjusted to the same level on their scales, the correct
working distance (40 mm) is always given.
For small components (up to 170 x
170 mm) we recommend the PCB
Holder PH 100.
(See chap. 8 „Spare parts and
options“)

ERSA IR 550 A
Operating instructions
ERSA GmbH
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4.2.2 Electrical connections
•Check whether the supply voltage corresponds with the voltage stated on the type plate.
•Make sure that both main switches (basic unit IR 550 A and DIGITAL 2000 A) are set to 0.
•Connect the power cord to the power socket on the backside of the unit.
•Connect the external keypad to the jack for the keypad at the backside of the unit.
•Connect the serial modem cable with the corresponding jack (serial or USB port) on the
backside of the unit and plug the cable to a serial port of a PC.
•To connect the DIGITAL 2000 A soldering station, please refer to chapter 4.2 of the
DIGITAL 2000 A operating instructions (3BA00044)
•If required, connect the optional thermocouple with the jack (Sensor 2) on the back of the
unit. For mounting please refer to chapter 8 “Spare parts and options”.
4.2.3 Switching on
•Then switch on the IR 550 A basic unit.
•After an automatic display check and the warm-up of the bottom radiator
( 90 seconds) the unit is ready for operation.
Temperature display during and after warm-up of the bottom radiator.
Note:
The bottom radiator is not preheated if the parameter Energy is set to 0 within the chosen program.
This parameter can also be used to save energy and to avoid unnecessary heat ups of the unit
during working breaks.
During working breaks the bottom radiator can also be switched off via the IRSoft PC-
Software.
(flashing display) (temperature display )

ERSA IR 550 A
Operating instructions
ERSA GmbH
31.07.03.we.no 12682_01 IR 550 A_e.doc -12/32 -
4.3 Tips for the SMT Rework Process
The IR 550 A is especially designed for soldering processes on surface mount technology (SMT)
PCBs. Here, above all, components with hidden solder connections like ball grid arrays (BGA) and
chip scale packages (CSP) can easily be desoldered and soldered with the IR 550 A.
Other components like SMT-connectors and components in PTH-technology can be processed
without any problems.
Before starting work with the IR 550 please check the following:
•PCB size and thickness
•Packaging density on the PCB
•Component type
•Component size
•Surface of package
The IR 550 A can easily be adapted to these demands by setting the following parameters:
•Working distance of component and PCB towards top-and bottom radiator
•Aperture adjustment of top radiator (adjustable from 60 x 60 mm to 20 x 20 mm)
•Selection of a program with a suitable set of process parameters
In general, the Rework Process includes the following steps:
•Desoldering of a component
•Cleaning of the pads
•Preparing pads and component for the soldering process
•Placement of the new component
•Soldering of the new component
Note: -Solder Fume -
As a lot of flux and solder fume is emerged during the
Reflow Process, we recommend the use of IR 550 A
together with a solder fume extraction unit.
In order to protect of the employees’ health, ERSA
recommends the use of EA 110 plus filter system to clean
process air.
Solder fume filtration with ERSA EA 110 plus

ERSA IR 550 A
Operating instructions
ERSA GmbH
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5Functional description
For the Functional description of the DIGITAL 2000 A soldering station, please refer to chapter 5 of
the DIGITAL 2000 A operating instructions (3BA00044-00).
5.1 Functional elements of IR 550 A
5.1.1 Infrared radiators
The IR 550 A Rework System is equipped with infrared radiators providing the necessary energy
for soldering. The wavelength of the radiators is adapted to the needs of the soldering process.
Especially components with hidden solder joints can be soldered in highest quality. The soldering
system does not need any component specific nozzles or stencils but can nevertheless be adapted
to any soldering application.
The infrared radiation heats the component pins equally and prevents small components from
being blown away.
The bottom radiator is a large-surface heating element and ensures an even PCB warm-up. It is
either covered with the included glass pane or with an optional stainless steel grid for soldering
applications where extreme bottom heating is required. The bottom radiator is operated with a
preset energy ranging from 0 to 10, depending of the chosen program (Pr1 –Pr4).
The top radiator is swung into operating position and supplies the main heat. By means of the
patented aperture system the heat is directed right into the required working area. The shielded
areas are heated with reduced radiation.
During soldering and desoldering, both radiators are controlled by the microprocessor according to
the set temperature profile.
Note:
Radiation sources are subjected to an aging process. According to load and duration of use, the
heating elements must be changed after the end of lifetime.
5.1.2 Temperature sensors
The IR 550 A contains a non-contacting infrared sensor (Se1). Optionally, a K-type thermocouple
(Se2) can also be connected to the unit.
The non-contacting infrared sensor measures surface temperatures in a certain area. A K-type
thermocouple detects temperatures at a measuring point.
Whether the non-contacting infrared sensor or the K-type thermocouple is used depends on the
soldering application. For most rework applications measurements with the non-contacting infrared
sensor are more reliable, as errors due to unequal contact cannot occur.
By calibrating the system to a given melting temperature, temperature differences between the
component surface and the solder joint can be compensated.

ERSA IR 550 A
Operating instructions
ERSA GmbH
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5.1.3 Cooling fan and laser positioning device
The cooling fan and the laser positioning device are mounted on the second arm.
When the arm is swung into working position, the laser positioning device is switched on
automatically.
Attention:
The laser positioning device includes a laser product class II. Do not look directly into
the laser beam.
The cooling fan is switched on and off via the key. It is used to cool down the PCB after
soldering and desoldering processes. While the fan is operating, the actual temperature and “Fan”
are shown alternately.
An additional external cooling fan (0IR4500-06, Ø 80 mm or 0IR5500-13, Ø 120 mm) should be
placed beside the unit; it is used for cooling the PCB after the soldering process.
5.1.4 Vacuum pipette and vacuum pump
The IR 550 A is equipped with a vacuum pipette which is integrated into the top radiator. This tool
allows an automated desoldering process: First the pipette’s silicone cup is pressed on the
component. As soon as the solder is liquid the spring-loaded pipette lifts off the component
automatically. At the same time the display is set to the melting temperature that is reached in this
moment.
The built-in vacuum pump is switched on automatically when the pipette is pressed down. When a
desoldered component is set down on the component tray, the pump switches off again. By
pressing the key, the pump can be switched manually.
5.1.5 DIGITAL 2000 A soldering station
The high-class integrated soldering station DIGITAL 2000 A completes the IR 550 A System. The
operation of this soldering station and its connectable tools is described in the enclosed ERSA
DIGITAL 2000 A operating instructions (3BA00044-00).
5.1.6 Serial port, documentation software IRSoft
The IR 550 A contains a serial port so that it can be connected to a PC. In this way process data
can be documented at any time.
Connect the system with the included serial modem cable to a PC (COM Port, serial or USB*) on
which you run the documentation software IRSoft. You will find this software on the included CD-
Rom. Please also refer to the online manual of the software. IRSoft updates are available at ERSA
or contact one of ERSA’s distributors.
* For USB, an adapter is necessary.

ERSA IR 550 A
Operating instructions
ERSA GmbH
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5.2 Operation and program parameters
The IR 550 A Rework System enables repair soldering based on parameters which are set and
can be stored by the user. In total, four programs (Pr1 to Pr4) can be saved and modified at any
time. (For more storage options use the documentation software IRSoft, see 5.1.6)
The active program, all parameters and the actual temperature value are visualized over a four
digit LED display.
Display of IR 550 A:
Digits 1 to 3 display actual temperature values and the settings of all parameters.
Digit 4 displays the units or symbols for each parameter.
The LED dots are correlated to the parameters T1, T2, TLund T3. They light up during the setting of
the correlated parameter and as soon as the measured value reaches one of these parameters
during the process is running.
The unit is operated via an external keypad with six function keys:
Key Function
change program; increase
parameter value 1)
choose program; change parameter,
store values 2)
change program; decrease
parameter value
Key Function
Adjust display to melting
temperature 3)
Switching of vacuum pump
Switching of cooling fan
1) Special function: Keep pressing at switch-on shows Firmware Version
2) Special function: Keep pressing at switch-on load factory settings
3) Special function: Reset calibration factor when top radiator is in neutral position
digit 1 2 3 4
LED dots

ERSA IR 550 A
Operating instructions
ERSA GmbH
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5.2.1 Menus and programs
The operation concept of the IR 550 A allows, similar to the integrated DIGITAL 2000 A soldering
station, to run the system by using only three keys for parameter settings. The parameters are
modified for all four programs in the same manner. By just changing the program, the user has
access to four different sets of parameters for different soldering applications.
The menu is operated with the three keys , , .
By pressing the or key the display is switched from the actual temperature to the program
display. Now, the desired program (Pr1 –Pr4) can be chosen with the same keys.
With the key the system returns to the actual temperature display, and the parameters of the
selected program are activated immediately. Alternatively, the processor returns to the actual
temperature automatically after eight seconds without any inputs.
Display during program choice
Storage scheme of IR 550 A:
(e. g.)
T
1
T
1
T
1
T
1
T
2
T
2
T
2
T
2
time time time time
T
3
T
3
T
3
T
3
T
L
T
L
T
L
T
L
Energy Energy Energy Energy
Unit Unit Unit Unit
Password
Alt. Sensor
Alt. Sensor Alt. Sensor Alt. Sensor

ERSA IR 550 A
Operating instructions
ERSA GmbH
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5.2.2 Parameter setting and description
Within the IR 550 A each of the four programs contains one set of nine parameters. For an
overview of all parameters please refer to the appendix at Table 4”.
The parameters can be modified and stored separately for every program. Only the parameter
Password is the same for all programs and saves the unit from unwanted or unauthorized
changes.
Starting from the temperature display, the next parameter of the menu will be shown by pressing
the key. The order of parameters is listed below. The values for each program are set with the
keys and .
With a double-click (pressing the key two times) on the key the display returns from each
parameter to the temperature display. Changed values will be stored and activated at once.
While setting a parameter value, the fourth digit flashes. If there are no inputs for 8 seconds, the
processor switches back to the temperature display automatically. The value is activated
immediately.
Note:
For an easier setting of values the last active parameter can be recalled to the display by using the
double-click function (pressing the key two times) of the key. A second double-click switches
back to the temperature display.
The parameters T1, time, T2and T3define the soldering process. They describe the temperature-
time profile the system is running during operation. TL marks the melting temperature of the used
solder and ranges in between T2and T3.
T1T2
T3
°C
s
time
TL

ERSA IR 550 A
Operating instructions
ERSA GmbH
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T1
The preheating temperature T1is the first temperature value reached during the soldering process.
The warm-up to T1occurs the within the permitted heat up rates defined for electronic components.
The value for T1is set with the keys and .
Display during setting of T1
time
During the period defined by time the heating process proceeds or T1is kept nearly constant.
The value for time is set with the keys and .
Display during setting of time
T2
At the end of time the preheating temperature T2is reached. Preheating of PCB and component is
finished at this time. Fluxes have been activated.
The value for T2is set with the keys and .
Display during setting of T2
T3
When T2 is reached, the unit continues to heat up with the maximum permitted heat-up rate
towards peak temperature T3. At peak temperature the soldering process ends. Component and
PCB can be cooled down using the built-in cooling fan.
The value for T3is set with the keys and .
Display during setting of T3
(e.g.)
(e. g.)
(e g.)
(e. g.)

ERSA IR 550 A
Operating instructions
ERSA GmbH
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TL
The liquidus temperature TLdefines the temperature when the used solder (-paste) begins to melt
and gets liquid. The liquidus temperature is used to calibrate the actual temperature to the
temperature at the solder joint and adjust the display to this value.
There are two possibilities to achieve this:
•Automatic adaptation during desoldering
The adaptation of the display to the stored value of TLis automatically activated during
desoldering, when the spring loaded pipette lifts the component and thereby indicates that
the solder has molten at this time.
•Manual adaptation
By viewing the soldering process (i.e. by camera support) the user can press the key
as soon as the solder becomes liquid and by this action set the actual display to the stored
value of TL.
The value for TLis set with the keys and .
Display during setting of TL
See Table 3„Melting temperatures of solder alloys”.
Energy
This parameter is used to predefine the power of the bottom radiator for each program. Energy
defines the heating power of the bottom radiator in levels from 0 to 10.
When the top radiator is in its rear position, the bottom radiator is powered according to this value
and can be used as a heating plate . Is the top radiator swung into the working position, the bottom
radiator will be controlled with this predefined power during the soldering process.
The value for Energy is set with the keys and .
Display during setting of Energy
See chart in the appendix for relationship of energy and temperature on the glass plate.
(e.g.)
(e.g. Energy 7)

ERSA IR 550 A
Operating instructions
ERSA GmbH
31.07.03.we.no 12682_01 IR 550 A_e.doc -20/32 -
Unit
The parameter Unit is used to change the temperature displayed in °C or °F within one program.
The value for Unit is set with the keys and .
Display during setting of Unit
Alternative Sensor
In addition to the built-in non-contacting infrared sensor (Se1) the user can connect a K-type
thermocouple (Se2) for temperature measurement. The parameter Alternative Sensor is used to
select the sensor. The signal of the selected sensor will be displayed and used for process control.
The value for Alternative Sensor is set with the keys and .
Display during setting of Alternative Sensor
Password
To save the unit from unwanted or unauthorized changes the parameter Password is used. When
its value is set to 0 (Display 000) password protection is inactive. After setting a numeric
combination with and and storage by pressing the key, three lines (Display ---)
indicate the active password protection of the unit. All parameters can still be displayed, changes
are only possible by input of the correct numeric combination using and to set the value
and the key to confirm. The programs can be changed when the password protection is active.
Display during setting of Password
The parameter Password stays the same for all programs and can be activated or inactivated
within each program. The system requests the input of the right password (Display ---) before any
changes are possible. The password can also be activated and be deactivated the IRSoft software.
For reset of the password please see chapter 5.2.5 Factory settings.
(e.g. „C“ for Celsius)
(e.g. „Se1“ for non contacting sensor)
(e.g.)