Metcal Metcal MX-5200 User manual

7000-2500_4
Metcal MX-5200
Power. Precision. Performance.
Soldering, Desoldering and Rework System
User Guide

MX-5200 Series User Guide 1
MX-5200 Serie Betriebsanleitung 13
Série MX-5200 Manuel d’utilisation 26
Serie MX-5200 Manuale dell'utente 39
Serie MX-5200 Guía del usuario 51
MX-5200 系列 用户指南 64
MX-5200 系列 使用者指南 76
MX-5200 シリーズ ユーザーガイド 89
MX-5200 시리즈 사용설명서 102

1
CONTENTS
1. SYSTEM SPECIFICATIONS 2
2. SYSTEM DESIGN AND TECHNOLOGY OVERVIEW
a. SmartHeat®Technology, No Calibration Required 2
b. Systems, Upgrade Kits & Accessories Guide 3
3. POWER SUPPLY OVERVIEW
a. Power Supply Features 4
b. Power Supply Mode Overview 5
4. HAND-PIECE OVERVIEW 6
a. Hand-piece Selection Guide 6
5. CARTRIDGE OVERVIEW
a. About Metcal Cartridges 7
b. Choosing the Correct Tip Geometry 7
c. Choosing the Correct Temperature Series 8
d. Temperature Series Chart 8
6. TIPSAVER WORKSTAND OVERVIEW
a. TipSaver Workstand Features 9
b.CradleGuide 9
c. TipSaver Workstand Configurations 9
d. Cradle Positioning 9
7.OPERATION
a. Initial Setup 10
b. Replacing all Tip Cartridges 10
c. MX-PTZ and TALON Operation 10
d. MX-PTZ Tip Alignment 10
e. User Programmable PowerSave Mode Adjustment 10
f. User Selectable Power Graph 10
8. APPLICATION NOTES
a. Extending Tip Life 11
b. Detinned Tips 11
9. BASIC TROUBLESHOOTING GUIDE 12
10. SAFETY 12
Warranty
OK International warrants the MX-5200 System against any defects in materials or workmanship for five
(5) years from the date of purchase by the original owner. This Warranty excludes normal maintenance
and shall not apply to any opened, misused, abused, altered or damaged items. If the product should
become defective within the warranty period, OK International will repair or replace it free of charge at its
sole option. The repaired or replacement item will be shipped, freight prepaid, to the original purchaser.
The warranty period will start from the date of purchase. If the date of purchase cannot be substantiated
the date of manufacture will be used as the start of the warranty period.
Please visit OK International’s web page (www.okinternational.com) or contact your local Metcal
representative where you will find available information on systems, accessories, technical notes,
and more.

2
1. SYSTEM SPECIFICATIONS
Ambient Operating Temperature 10 - 40°C
Maximum Enclosure Temperature 55°C
Input Line Voltage 100 - 240 VAC, grounded circuit
Input Line Frequency 50/60 Hz
Power Consumption 125W
Output Power (Max.) 80 Watts max. Per channel at 22°C ambient temperature
Output Frequency 13.56 MHz
Power Cord 3-Wire 183cm (18/3”) SJT
Dimensions w x d x h 12.1 cm (4.8”) x 13.0cm (5.1”) x 23.5cm (9.3”)
Certification / Marking cTUVus, CE
Surface Resistivity 105- 109Ω/in
Tip-to-Ground Potential <2mV
Tip-to-Ground Resistance <2 ohms
Idle Temperature Stability ± 1.1°C in still air
Hand-piece Cable Length L=122cm (48”), burn proof, ESD safe
Hand-piece Connector F connector
Workstand Dimensions w x d x h 8.6 cm (3.4”) x 19.1 cm (7.5”) x 8.3 cm (3.3”)
2. SYSTEM DESIGN AND TECHNOLOGY OVERVIEW
The MX-5200 Series is a precision, high-power soldering system with dual switchable ports. It is the
newest design of the market leading Metcal soldering systems. It adds ergonomic hand-pieces, a built
in power meter, 80 watts of power per channel or 40 watts simultaneous, and includes SmartHeat®
Technology for quick response and precise control.
a.SMARTHEAT®TECHNOLOGY
No Calibration Required
Each cartridge is equipped with a self-regulating heater which ‘senses’ its own temperature and
closely maintains its pre-set idle temperature for the life of the heater-tip; all controlled by OK
International’s proprietary SmartHeat®Technology. The tip temperature is determined by the inherent
metallurgical properties of the heater; no external adjustment or equipment is required. This
eliminates spikes and transients associated with electrically switched elements found in conventional
soldering irons. The integrated power indication meter actively monitors power delivered to the tip as
it varies in direct response to the thermal load. The power indication meter requires no calibration,
because it is monitoring an active feedback loop. Please feel free to contact your OK International
representative with any questions.
Those companies or individuals requiring periodic verification of system performance may do so in
the following ways:
Measure the performance of the system in ‘time required to solder a defined number of loads’, or
Observe start up and idle power with the integrated Power Indication Meter, or
Measure tip idle temperature as it equates to this performance.

3
b. SYSTEMS, UPGRADE KITS & ACCESSORIES GUIDE
The MX-5200 Series offers users a choice of systems, upgrade kits and accessories.
Systems Description
MX-H1-AV MX-H2-UF
MX-PTZ
MX-DS1
MX-5210 MX-PS5200 Power Supply, Metcal Advanced™Soldering
hand-piece (MX-H1-AV), TipSaver™ workstand (MX-W1AV) 


MX-5220 MX-PS5200 Power Supply, UltraFine soldering hand-piece
(MX-H2-UF), TipSaver workstand (MX-W1AV) 


MX-5250 MX-PS5200 Power Supply, MX-DS1 desoldering hand-piece,
workstand (MX-WS5DS) 

MX-5241
MX-PS5200 Power Supply, MX-PTZ tweezers hand-piece,
Metcal Advanced Soldering hand-piece (MX-H1-AV),
TipSaver workstand (MX-W4PT), TipSaver workstand (MX-
W1AV)





MX-5251
MX-PS5200 Power Supply, MX-DS1 desoldering hand-piece
Metcal Advanced Soldering hand-piece (MX-H1-AV),
workstand (MX-WS5DS), workstand (MX-W1AV)




Upgrades

MX-UK1 Metcal Advanced Hand-piece & TipSaver workstand 


MX-UK2 UltraFine hand-piece & TipSaver workstand 


MX-UK4 Precision Tweezers hand-piece & TipSaver workstand 


MX-UK5 MX-DS1 hand-piece & TipSaver workstand 

Accessories 
MX-H1GR Grip, Metcal Advanced hand-piece, Ring pattern 


MX-H1GKG Grip, Metcal Advanced hand-piece, Knob pattern, Green 


MX-H1GS Grip, Metcal Advanced hand-piece, Scallop pattern 


MX-H2GR Grip, UltraFine hand-piece, Ring pattern 


MX-H2GKG Grip, UltraFine hand-piece, Knob pattern,Green 


MX-H2GS Grip, UltraFine hand-piece, Scallop pattern 


MX-CP1 Cartridge removal pad, Metcal Logo 







AC-BP Brass Pad, package of 10 







AC-Y10 Yellow Sponge, package of 10 








4
Fron
t
LCD Display
Output Selector/
Command Button
Power Switch
Left Output
Right Output
Power Connector
Back
Integrated Carry Handle
3. POWER SUPPLY OVERVIEW
a. POWER SUPPLY FEATURES
LCD Display
The MX-5200 Series utilizes a built in LCD which displays system information including:
Integrated Power Indication Meter
The MX-5200 Series has a built in power indication meter which will display a graphical and
numerical representation of the power.
User Programmable PowerSave Mode
The MX-5200 Series has a user programmable PowerSave Mode. The time to enter
PowerSave Mode is adjustable from 10 to 120 minutes.
Universal Power Supply
The MX-5200 Series automatically senses the input line voltage and adjusts accordingly, which
allows for worldwide operation without adaptors or a change in performance.

5
POWER SUPPLY MODE OVERVIEW
READY MODE
1. Hand-piece removed from workstand.
2. System is ready for use.
SLEEP MODE
1. Hand-piece in workstand.
2. Power to the hand-piece is reduced.
POWER MODE
1. Hand-piece removed from stand.
2. System is in use. Power Meter displays power at tip.
POWERSAVE MODE
1. Hand-piece in workstand.
2. Power to the hand-piece is off.
3. LCD Display flashes.
4. Press Command Button to reset.

6
4. HAND-PIECE OVERVIEW
The MX-5200 Series offers users a choice of hand-pieces to meet the customer’s application needs.
Each hand-piece has its own range of cartridges with many choices available for tip geometry and
temperature.
a.Hand-piece Selection Guide
NOTE: This is only a small sample of tip styles available for each of the hand-pieces. Please consult your
catalog or visit Metcal’s website (www.okinternational.com) for a complete listing.

7
5. CARTRIDGE OVERVIEW
a.About Metcal Cartridges
The soldering and rework cartridges are constructed with a tip, heater, coil, connector and shaft. This
assembly is designed for precision and long life provided that the proper tip care procedures are
followed. (See Section 8)
Selecting a cartridge depends on the following variables
Need for access
Type of solder
Size and mass of load
Componenet type
The correct choice of cartridge will result in an optimized soldering process. Here are some of the
considerations for selecting the soldering or rework cartridge.
b.Choosing the Correct Tip Geometry
Metcal cartridges come in a wide variety of tip geometries and temperature ranges (for a complete up
to date listing, visit our website (www.okinternational.com) for more information). These tip
geometries cover a broad range of tasks from delicate precision work to heavy ground plane
soldering.
1. Pick a tip that maximizes contact area between the solder joint and tip. Maximizing contact
area gives the most efficient heat transfer, producing high quality solder joints quickly.
2. Pick a tip that allows good access to the solder joint. Shorter tip lengths allowquicker response.
Longer or angled tips may be needed for soldering densely populated boards.
3. Pick the lowest temperature tip cartridge that will accomplish the task. This minimizes the
potential for thermal damage. The temperature series is marked on the shaft of the Heater Tip.
(See page 8 for more Information)
Too Large
Solder/Rework Thru-hole
Desolder Thru-hole
Correct
Correct Too Small Too Large
Too Small

8
c.Choosing the Correct Temperature Series
Each cartridge is specially designed for high power delivery, which means that you can often solder
with a Metcal cartridge at a temperature 100°F (40°C) or more lower than with a conventional
soldering iron. Since Metcal tip cartridges sense thermal loads and respond to them, you need only
approximate the size of the loads you will be working with. Start with a lower temperature, going to a
higher temperature only when necessary.
d.Temperature Series Chart
Application X=Series STTC SMTC UFTC PTTC TATC STDC
High Thermal Sensitivity 500 Series 5 5 5
Moderate Thermal Sensitivity 600 Series 0 0 6 6 0
Moderate Thermal Mass 700 Series 1 1 7 7 1
High Thermal Mass 800 Series 8 8 8 8
Note: Not all temperature series available for some styles. Please consult Metcal’s webpage
(www.okinternational.com) or catalog for a complete listing.
Connector
Coil Assembly
Tip
Shaft
H
eate
r
SMTC-X60
LOT 1212
Consult Temperature
Series Chart
Lot Code
Style
Magnetic Shield Series
CARTRIDGE CONSTRUCTION AND IDENTIFICATION

9
6. TIPSAVER WORKSTAND OVERVIEW
a.TipSaver Workstand Features
b.Adjustable Angle Cradle Guide*
Workstand Cradle Description
MX-W1AV MX-W1CR TipSaver cradle, Advanced hand-piece, includes knobs
MX-W1AV MX-W1CR TipSaver cradle, UltraFine hand-piece, includes knobs
MX-W4PT MX-W4CR TipSaver cradle, MX-PTZ hand-piece, includes knobs
MX-W5DS MX-W5CR TipSaver cradle, MX-DS1, includes knobs
c.TipSaver Workstand Configurations
The TipSaver Workstand is designed to accommodate different configurations in a minimal
footprint. To change the configuration;
1. Remove the two screws from the underside of the workstand base (MX-WB).
2. Move the Workstand Sponge Holder (MX-WSH) into the desired position.
3. Replace the two screws into the underside of the workstand base.
d.Cradle Positioning
The TipSaver Workstand incorporates an adjustable angle cradle allowing the insertion angle for
the hand-piece to be adjusted for the comfort of the operator. To adjust the angle of the cradle;
1. Loosen the knobs counterclockwise.
2. Adjust the cradle to the desired angle.
3. Tighten the knobs clockwise.
Workstand Sponge Holder
(MX-WSH)
Workstand Base (MX-WB)
Adjustable Angle Cradle*
Adjustment Knobs
Coiled Brass Cleane
r
or Coiled Brass Cleane
r
with Sponge

10
7. OPERATION
a. INITIAL SETUP
1. Connect hand-piece(s) to power unit output connector(s).
2. Insert your selected cartridge into the hand-piece.
3. Push the cartridge all the way until it seats.
For TATC cartridges, align the flat side of the cartridge shaft with the opening in the
handle. Push in the cartridge until it seats. The cartridge is fully seated when the insertion
mark is flush with the handle. Do not push past this mark. Repeat for second cartridge.
4. Place hand-piece(s) into associated workstand(s).
5. Add distilled water to workstand sponge (sulfur free) if equipped.
6. Plug the power cord into a grounded wall socket of the rated input line voltage.
7. To turn the unit “ON”, push the power switch. NOTE: Unit must be grounded, otherwise it will
not work. Unit will not work in an electrical network where an isolation transformer has been
used.
8. Select the desired output left, right, or simultaneous, using the output selector/command button.
The active output will display an animated box cursor () to the left or right of the screen,
respectively, to indicate the active output.
b. REPLACING ALL TIP CARTRIDGES
1. Make sure the system is turned off.
2. Pull out the cartridge using the Cartridge Removal Pad (MX-CP1). NOTE: THE TIP
CARTRIDGE MAY BE HOT. DO NOT USE METAL TOOLS (PLIERS, ETC) TO REMOVE
CARTRIDGES!
3. Push a new cartridge into the handle.
4. Place hand-piece(s) into associated work stand(s).
5. Push the power switch “ON”. The new cartridge will heat up to temperature quickly.
c. MX-PTZ AND TALON OPERATION
1. Clean, and then tin tips well once heated.
2. Ensure tips contact all leads on device, either the bevel or straight
portion of the tip can be used. Use solder across the leads to create a
Thermal Bridge.
3. Squeeze tool. Wait for all leads to reflow.
4. Maintaining pressure, lift component.
d. MX-PTZ TIP ALIGNMENT
e. USER PROGRAMMABLE POWERSAVE MODE ADJUSTMENT
1. With the system in the Ready or Power Modes, press and hold the Output Selector/Command
Button for 3 seconds until the time flashes.
2. Release the Output Selector/Command Button.
3. Press the Output Selector/Command Button until the desired time is achieved. The time will
increment by 10 minutes with each press of the button.
4. Press and hold the Output Selector/Command button for 3 seconds to return to operation.
f. USER SELECTABLE POWER GRAPH
1. With the system in the Ready or Power Modes, press and hold the Output Selector/Command
Button for 3 seconds until the time flashes
Thermal Bridge

11
2. Release the Output Selector/Command Button.
3. Press and hold the Output Selector/Command button for 3 seconds.
4. Release the Output Selector/Command Button.
5. Press the Output Selector/Command Button until the desired bar graph is displayed; Standard
or UltraFine.
6. Press and hold the Output Selector/Command button for 3 seconds to return to operation.
8. APPLICATION NOTES:
a.EXTENDING TIP LIFE
1. Each day, remove, inspect, and clean the cartridge shaft and handle using denatured alcohol and
a clean cloth. Stubborn flux deposits on the shaft (and on the entire SMTC, PTTC & TATC tip)
can be removed using a brass brush.
2. After you turn on the system, and each time you return the tip to the holder, apply solder to the
tinned surfaces of the tip. The solder protects the tip from oxidation and prolongs the life of the
tip.
3. Select the lowest temperature series tip cartridge that will do the job. Lower temperatures
decrease tip oxidation and are easier on the components being joined.
4. Use fine point tips only when necessary. The plating on fine precision tips is less durable than the
plating on larger tips.
5. Do not use the tip as a prying tool. Bending the tip can cause the plating to crack, shortening tip
life.
6. Use the minimum activation flux, appropriate to solder type, as necessary to do the job. Higher
activation flux is more corrosive to the tip plating.
7. When making a solder connection, apply fresh solder to the items being joined, not to the hot
soldering tip.
8. Switch the system off when not in use.
9. Do not apply pressure to the tip. More pressure does not equal more heat. To improve heat
transfer, use solder to form a thermal bridge between the tip and the solder joint.
10. Clean the tip on a clean, damp sponge or a coiled brass cleaner -- not on a rag or dirty, dry
sponge.
b.DETINNED TIPS
If a tip is not wetting with solder then it is detinned. This exposes the plating to oxidation and
substantially degrades the heat transfer efficiency of the tip. Detinning is caused by:
Failure to keep the tip covered with fresh solder during idling periods.
High tip temperatures.
Lack of sufficient flux in soldering operations.
Wiping the tip on dirty or dry sponges and rags. (Always use a clean, damp, industrial grade,
sulfur-free sponge or brass sponge)
Impurities in the solder or on the surfaces to be soldered.
NOTE: Detinned tips are preventable with proper daily care!
c.CHOOSING THE CORRECT TIP CARTRIDGE AND GEOMETRY
MULTI-LEAD PACKAGES
Multi-lead components can be drag soldered using Metcal hoof-tip cartridges. Tin the working face
of the tip with solder and gently drag it across the array of leads.
SMT REMOVAL
First, measure the dimensions of your component, then, use the SMTC charts that are available
from Metcal’s web page (www.okinternational.com) to match component and tip dimension.

12
9. BASIC TROUBLESHOOTING GUIDE
Problem: LCD displays ‘Open Source’.
1. Ensure cartridge is properly seated.
2. Ensure animated box cursor () is on desired output connector.
3. Tighten hand-piece connector to output connector.
Problem: Solder hand-piece tip cartridge does not heat up.
1.Replace tip cartridge.
2.If problem persists, replace hand-piece with known good hand-piece and insert new cartridge.
3.If cartridge heats up, replace non-functioning hand-piece.
Problem: Low power operation of the unit.
Check input power to the unit. The unit can draw up to 10A of current at 110V.
Do not plug into power sources such as power strips that are rated less than 10A.
Multiple high current devices plugged into the same electrical circuit can cause low power operation,
distribute high current devices among multiple circuits or increase the electrical circuit capacity.
Problem: Power indication meter displays maximum power without variance when both channels are
operated simultaneously and one tip cartridge does not heat.
1.Ensure cartridges are properly seated.
2.Tighten hand-piece connector to output connector.
3.Replace tip cartridge in left hand-piece with known good tip cartridge.
4.If problem persists, Replace tip cartridge in right hand-piece with known good tip cartridge.
10. Safety
With power applied, the tip temperature can be > 300°C. Failure to observe the following
precautions may lead to injury to users or damage the equipment:
Do not touch any metallic parts of the hand-piece
Do not use near flammable items
Do not use unit for any function other than described in this manual
Use only genuine Metcal replacement parts
Use in a well ventilated area or with fume extraction
Do not use the equipment with wet hands
Connect only to properly grounded outlets to prevent risk of electric shock.
Always place hand-piece back into the work stand to prevent accidental burning of oneself or
surrounding objects.
This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless they have been given
supervision or instruction concerning use of the appliance by a person responsible for their
safety.
Children should be supervised to ensure that they do not play with the appliance.
Although the systems offer superior EOS (Electrical Overstress) protection, periodic checks of the
instrument cord should be incorporated into standard operator maintenance procedures.
Waste Electrical and Electronic Equipment Directive - WEEE (2002/96/EC).
When this product is no longer required, if it cannot be re-used, we ask our customers not to
dispose of it as unsorted municipal waste but to appropriately recycle the product. In Europe, please
contact your OK International distributor who can advise the recycling options available
(www.okinternational.com).
WARNING
!