Spike xg classic SGS-2000 series User manual

Thank you for purchasing one of the XG Classic Soldering Systems. This temperature controlled soldering
system is an electronic device developed to meet the present and future needs of the production of electronic
industry. Please read this manual before operating the unit. Store the manual in a safe, easily accessible place
for future reference.
This publication may not include some last minute technical changes and/or revisions to the unit. Changes are periodically made to the information
described here. Future editions of this manual will incorporate these changes.
This manual is provided for information purposes only. All information included herein is subject to change without notice. Spike is not responsible for any
damages, direct or indirect, arising from or related to the use of this manual.
Patent No: 013171461, 01217422X, 012179477
Spike (Changzhou) Electronics Co., Ltd.
4FT13-1300-034
Made in China
Normal use of this product could expose the
user to solders containing lead which is known
to the State of California to cause cancer and
birth defects, or other reproductive harm, or
other Proposition 65 listed chemicals.
WARNING
!
XG Classic SGS-2000 Series
Standard / ESD Model
Temperature Controlled Soldering System
Operation Manual
XG SGS-2000 Series
Temperature Controlled Soldering System
Operation Manual
Table of Contents
Packing List............................................................
Precautions............................................................
Features.................................................................
Name of Parts.........................................................
Operating the Classic Series Soldering System..........
1. Control Base
2. Iron Holder
3. Soldering Iron
4. Turn on the Power Switch
Care and Maintenance of Soldering Iron.............. ......
1. Working Temperature
2. Use and Care of Tips
Calibrating Iron Temperature....................................
1. Tools Required
2. Steps of Calibrating Iron Temperature
Checking for Breakage of the Heating
Element & Cord Assembly ..................
1. Broken Heating Element
2. Broken Soldering Iron Cord
Replacing Fuse........................................................
Troubleshooting Guide......... ............... .
Specifications ............................ ........
Control Base
Soldering Iron
Soldering Iron Temperature Curve ...... .
Schematic Diagram ........................... .
Parts and Accessories .................... .
Soldering Tips ........................... .
.......... ..................
....... .............. .....
........................ ....
.................. .. ........
........ ........... .........
........... .................. ...
....................... ........... ....
1.
2
2
4
6
7
11
13
14
16
17
18
19
19
20
24

Please Check the contents of the XG Classic package
and confirm that all the items listed below are included.
Packing List
Control Base
Iron Holder
Soldering Iron
Cleaning Sponge
Hex Wrench
Documentation Package
(Figure 1)
When seeking Tip replacements, select Spike
genuine Soldering Iron Tips. Please refer to the
instruction on how to use, and care of Tips. If an
incompatible Tip made by another manufacturer is
used, the original performance of the Soldering
System may not be obtained. We take no
responsibility for any problem caused by using
products or parts made by another manufacturer.
!CAUTION
Precautions
In this operation manual, “Warning” and “Caution” are
defined as follows:
!WARNING: Misuse may potentially cause death of,
or serious injury to, the user.
!CAUTION: Misuse may potentially cause injury to
the user or physical damage to the objects involved. For
your own safety, be sure to comply with these precautions.
2.
1
1
1
1
1
1
When the power is on, the Tip temperature is
between ( ). Since mishandl-
ing may lead to burns or fire, be sure to comply with
the following precautions.
392 F-896 F 200 C-480 C
!CAUTION
Do not
Do not
touch the metal parts near the Tip.
use the product near inflammable items
and/or explosives.
Advise other people in the work area that the unit
can reach a very high temperature and should be
consid ered potentially dangerous.
Turn the power off while taking breaks and when
fin ished using the unit.
Before replacing parts or storing the unit, turn
the power off and allow the unit to cool to room
temperature.
To prevent damage to the unit and ensure a safe
working environment, be sure to comply with the
following precautions.
Do not
Do not
Do not
Do not
Do not
use the unit for applications other than
soldering.
turn on the power when the Soldering
Iron is not connected to the Control Base to
prevent any damage to the unit.
rap the Soldering Iron against any hard
surface to shake off soldering residual, or
otherwise subject the iron to severe shock.
modify the unit. Use only genuine
Spike replacement parts.
wet the unit or use the unit when your
hands are wet.
The soldering process will produce smoke, so
make sure the work area is well ventilated.
3.
XG Classic is one of a series of high quality soldering
systems featuring:
Features
High Efficiency and Low Interference

 

Switching technology designed circuit, allowing maxi-
mumefficiency reaching at least 80%
High power factor: Q 90%
Minimal interference, effectively restraining EMI and
RFI with zero voltage switching
Applying high open loop gain to improve the
temperature adjusting accuracy
This system allows the closest possible monitoring of
extremely small temperature variation of the Tip, thus
result ing the Soldering Iron to be in a state of constant
temperature for working purposes
Rapid heat up and recovery



High Temperature-Fidelity, Rapid Heat up and Recovery
Safe and Reliable






Sensitive protection against short circuit
Variable input voltage does not affect working
temperature
The sealed Iron Receptacle is convenient and safe for
operation. The Iron Holder Cover is designed to prevent
the Soldering Iron being accidentally touched
The power unit and the control system is isolated from
each other, only about 24V is used to drive the Heating
Element
The Soldering Iron is attached to the Base using a
heatresistant Cord Assembly and a five-pin, heavy
duty Plug
The Tip is grounded to ensure working voltage to
ground less than 2 milivolts
Original Design with Comfortable and Unique Style
 This compact unit of modern style takes up little space
on the workbench. Stackable as shown so that two or
more Control Bases and/or an Iron Holder can be put
onto each other for more convenience. Combinatory so
that the Control Base and the Iron Holder can be used
together or separately at ease (See Figure 2)
4.

Products of a Series for Your Selection
Several models to meet different working requirement:
Classic and Digital Control with ESD safe style
More Tips are available
Melt Solder flows into Iron rack and will not spray or
overflow onto the workbench, and the Iron Holder can
be easily cleaned
The metal Control Base housing is molded that it can
stand high impact and it has an excellent heat
dissipation ability and serves as a shield against
radiation of EMI and/or RFI
A unique electronic control circuit is employed enabling
the user to adjust Tip temperature from through
( - ) without changing Tip or Heating
Element
This system is equipped with a locking feature to allow
the operator the ability to set and lock the system at a
specific temperature
Thinner grip makes the Soldering Iron easier and more
comfortable to use
Convenient to use and easy to clean
392
896 200 480

  
Convenience and Ease
(Figure 2)
a b
c d
5.
Name of Parts
(Figure 3)
Cleaning Sponge
Hex Wrench
Iron Cord
Assembly & Plug
Temperature
Control Knob
Front Panel
Control Base
Iron Holder
Heating Indicator
CAL
Receptacle
ESD
Socket
Back Panel
Power Switch
Fuse & Fuse Box
Power Plug
& Cord Assembly
Soldering Iron Iron Holder Cover
Cleaning
Sponge Pool
6.
Operating the XG Classic Soldering System
1. Control Base
1) Front Panel (See Figure 4)



Five-pin Receptacle: For connection with the
Soldering Iron.
Temperature Control Konb: To allow the operator to
adjust temperature. The temperature scale on the
Front Panel in white is the Celsius, while in gold, the
Fahrenheit.
LED Indicator: Indicating the working condition of
the Soldering System.

CAL Pot Plug: For calibrating Iron temperature.
2) Back Panel (See Figure 5)
Power Switch: Switch to O” to turn off the Soldering
System, while “I” to turn on the Power Supply.
Fuse Box: Refer to “Replacing Fuse”.
ESD Grounding Socket: For connecting with
protective device against ESD designed for ESD
Safe models (Such as ESD Wrist Ring).
“



(Figure 4)
(Figure 5)
Front Panel Name Plate Temperature
Scale
Temperature
Control Knob LED Indicator CAL Pot Plug Five Pin Plug
Receptacle
Back Panel Fuse Box Power Switch
Power Cord
Assembly
ESD Grounding
Socket
7.

3) Lock Temperature
Set the Temperature control Knob to the desired
temperature. (Please refer to “
” and
“Calibrating Iron Temperature”).
Lock the Knob: XG Classic Series are equipped with
a Temperature Control Konb Lock. After setting
desired temperature, tighten the Hex Nut on the
underside of the Potentiometer Mount using the
supplied Hex Wrench. Turn the Nut clockwise to
tighten the Knob Lock. (See Figure 6)
Care and Maintenance
of Soldering Iron-Working Temperature

!CAUTION: Do not overtighten the knob Lock. Do
not attempt to turn the Knob when the Konb Lock is set.
!
2. Iron Holder
CAUTION: Before using the unit, dampen the
Sponge with water and squeeze it dry. Failure to do so
may result in damage to the Soldering Tip.
The Iron Holder can be used together with the Control
Base or separately as wished. To stack up with the
Control Base, just slide the Iron Holder slot
(See Figure 7a) from the back of the Control Base. See
Figure 2 and Figure 7. The locking device will lock its
position to maintain the firm hold with the Control Base.
1)

Temperature
Contorl Knob
Potentiometer
Mount
Front Panel
Locking Hex Nut
Counterclockwise
Clockwise
(Figure 6)
8.
(Figure 7)
2) With a little push, the Iron Holder can be easily pulled
off the Control Base. (See Figure 7)
3) To clean the Holder, simply take the Holder off the
Control Base, open the Cover, and pour out the residual
& wipe the Holder clean with a soft dry cloth.
(See Figure 8)
Dampen the small Cleaning Sponge with water and
then squeeze it dry. Place it in one of the openings
of the IronHolder. (See Figure 9)
Add water daily to approximately the level as shown
in Figure 9. The small Sponge will absorb water to
keep the large Sponge above wet at all times.
Dampen the large Cleaning Sponge and place it in the
Cleaning Sponge Pool of the Iron Holder. The large
Sponge may be used alone (without small Sponge
& water).
For your convenience, 4 verticle holes are designed
on the Iron Holder for lron Tips. (See Figure 10)
4)
5)
6)
7)
(Figure 7a)
(Figure 8)
(Figure 9) (Figure 10)
9.
Iron Holder Slot
Back Panel
3. Soldering Iron
Be sure to turn off the Power Switch
before disconnecting the Soldering Iron. Failure to do so
may damage the PWB.
CAUTION:
Connect the Cord Assembly to the Receptacle as shown
in Fig. 11.
Place the Soldering Iron in the Iron Holder. See Fig.12.
Please refer to Care and Maintenance of Soldering Iron
for more details.
!
1)
2)
(Figure 11)
CAUTION: The Soldering Iron must always be
placed in the Iron Holder when not in use.
(See Figure 12).
!
4. Turn on the Power Switch
WARNING: Be sure to ground the unit.
!
Plug the Power Cord into the power supply. Make sure
the Power Switch is at the “O” (Off) position.
(See Figure 5)
Turn on the power switch. The Heating Indicator
lights orange when power is on.
The Indicator blinks green and
orange, when the temperature
of Heating Element of the
Soldering Iron reaches the
set temperature. (See Figure 13)
Wait for about half a minute and
the unit is now ready to perform
soldering work.
1)
2)
(Figure 12) (Figure 13)
Front Panel Heating Indicator
10.

Care and Maintenance of Soldering Iron
1. Working Temperature
A low temperature will slow the rate of flow of solder.
A high temperature will burn the flux in the solder, which
in turn will emit a heavy white smoke resulting in a dry
joint, or damage to the soldered components or parts.
When the Tip working temperature is set within the
correct parameters suited to the particular solder
being used, a good joint is assured. The most common
solder alloy used in the electronic industry is 60% tin,
40% lead. The typical working temperature of the solder
is detailed below but it can vary from manufacturer to
manufacturer.
Melting Point
Normal operation
Production line operation
Desoldering operation for small joint
Desoldering operation for large joint
The temperature above ( ) should not be used
for normal soldering functions, but can be used for short
period of time when excessive heat is required.
770 F 410 C
2.Use and Care of Tips
Tip Temperature
When Not in Use
Before Use and After Use
High soldering temperature can degrade the Tip.
Use the lowest possible soldering temperature.
The excellent thermal recovery characteristics of
this system ensures efficient and effective
soldering even at low temperature. This also
protects the soldered items from thermal damage.
Clean the Tip regularly with the supplied Cleaning
Sponge, as oxides and carbides from the solder
and flux can form impurities on the Tip. These
impurities can reduce the Tip’s heat conductivity
or result in defective joints.
Wipe the Tip clean and coat the Tip with fresh solder.
This helps prevent Tip oxidation. Always keep the
11.
419 F (215 C)
608 F (320 C)
716 F (380 C)
608 F (320 C)
752 F (400 C)
Tip tinned before returning to Holder, switching off or storing
for any period of time,wipe only before using.
When using the Soldering lron continuously, be sure to
loosen the Tip and remove all oxides at least once a week.
This helps prevent seizure and reduction of the Tip
temperature.
Set the temperature to ( ).
When the temperature stabilizes, clean the Tip with the
Cleaning Sponge and check the condition of the Tip.
If black oxides appear on the solder-plated portion of the
Tip, apply new solder (containing flux). Wipe the Tip on the
Cleaning Sponge. Repeat until the oxides are completely
removed. Coat with new solder.
If the Tip is deformed or heavily eroded, replace with a new
one.
If any oxide film does form, this can be cleaned by carefully
rubbing with a 600-800 frit fine emery cloth, isopropyl
alcohol or the equivalent, then wrap rosin-core solder
around the newly exposed surface and reheat, flood the
482 F 250 C
Maintenance
tinned area with rosin-core solder after wrapped rosin-
core solder melted.
1.
2.
3.
5.
6.
!CAUTION
Do not
Do not
Do not
Never
keep lron set at high temperature for long period
of time as this will break down the surface of the Tip.
give any excessive pressure on a Tip or rubbing a
Tip on a joint during making a joint, it does not improve
heat transfer but only damages the Tip.
use fluxes containing chloride or acid, use only
rosin or resin activated fluxes.
remove Tip oxides with files.
12.
Calibrating lron Temperature
CAUTION: The Soldering System should be
recalibrated after changing the lron, or replacing the
Heating Element or Tip.
!
The initial temperature calibration of this Soldering
System has been set at the factory in accordance with
various industrial standards. No further calibration is
necessary by the user within about 6 months after first
use if no part change is needed.
1. Tools Required
1) Digital thermometer with leads and alligator clips
or digital thermometer equipped with surface
contact sensor specifically for Soldering lron
temperature measurement.
2) Test Tip fitted with thermocouple or SGT-710B
standard Tip for ceramic Heater.
3) 2.3-3mm (3/32” ) small flat screwdriver.
4) Multimeter
2. Steps of Calibrating lron Temperature
1) Connect the Cord Assembly Plug to the
Receptacle on the Control Base. (See Figure 11)
Set the Temperature Control Knob to
().
Remove the CAL Pot Plug on the Front Panel
(See Figure
and turn on the Power Switch.
Wait until the temperature stabilizes. Use a
small flat (-) or philips (+) screwdriver to adjust
the screw (through the CAL hole behind the
Front Panel at the Base) until the Tip
thermometer indicates the temperature to be
( ). Turn the CAL Screw slightly
clockwise to raise the temperature or
counterclockwise to lower the temperature.
Reposition the CAL Pot Plug.
750 400
750 400
 
 
2)
3)
4)
5)
!CAUTION: The
Soldering System
should be recalibrated
at the factory or service
agent if the 200
temperature scale
needs to be set.

(Figure 14)
Front Panel
CAL
Clockwise
Counterclockwise
CAL Pot Plug
13.

Checking for Breakage of the Heating Element & Cord Assembly
Disconnect the Plug and measure the resistance value
between the connecting Plug Pins as follows.
(See Figure 15)
a
b
c
Between Pin 4 & 5 (Heating Element)
Between Pin 1 & 2 (Sensor)
Between Pin 3 & Tip
2.5-3.5 (Normal)
43-58 (Normal)
About 2
W
W
W
(Figure 15) (Figure 16)
If the values of ‘a’ and ‘b’ are outside the above value,
replace the Heating Element (sensor) and/or Cord
Assembly. If the value of ‘c’ is over the above value,
remove the oxidization film by lightly rubbing with fine
sand-paper or steel wool the points as shown in Figure 16.
1. Broken Heating Element
Measure when the Heating Element is at room
temperature (See Figure 17)
After replacing the Heating Element:
(Please see Figure 24 for details.)
1) Turn Nut (2) counterclockwise and remove the Tip
Enclosure(3), the Tip (4).
2) Turn Nipple (5) counterclockwise, remove it from the
lron.
3) Pull both the Heating Element (7),Terminal Board (8)
and the Cord Assembly (12) out of the Handle (9)
(toward the Tip of the lron).
1) Resistance value of Heating Element 2.5-3.5 W
2) Resistance value of Sensor 43-58 W. If the resistance
value is not normal, replace the Heating Element.
1) Measure the resistance value between
Pin 4 & 1 or 2
Pin 5 & 1 or 2





Disassembling the Iron unit
If it is not , the Heating Element and Sensor are
touching. This will result in damage of PWB.

1
2
3
4
5
14.
Measure the resistance value a, b, and c to confirm
tha tthe leads are not twisted and that the Grounding
Spring is properly connected.
2)
(Figure 17)
2. Broken Soldering lron Cord
There are two methods of testing the Soldering lron
Cord.
Turn the unit ON and set the Temperature Control Knob
to its maximum on the dial ( ). Then wiggle
and kink the lron Cord at various locations along its
length, including the strain relief area.(See Figure 18).
If the LED Heater Indicator flickers, the Cord needs to
be replaced.
896 480  
1)
CAUTION: The LED Indicator will flicker even
with a normal lron Cord if the temperature reaches
().896 480  
!
Check the resistance value between the Pin of the
Plug and the Wire on the Terminal.
2)
(Figure 18)
Pin 1: Black Pin 2: White Pin 3: Green
Pin 4: Red Pin 5: Blue
The value should be 0. If it is greater than 0 or is , the
Cord should be replaced.

Heating
Element Sensor
15.
Replacing Fuse
Turn loose the Fuse Cover counterclockwise and remove
the blown Fuse, change a new one with the same rated
Fuse. (See Figure 19). Check the Specifications on page
18 for Fuse rating.
(Figure 19)
Fuse Box Cover Counterclockwise
Fuse
Back Panel
16.

Troubleshooting Guide
!WARNING: Disconnect the Power Plug before
servicing. Failure to do so may result in electric
shock. If Power Cord Assembly is damaged, it must
be replaced by the manufacturer, or its service agent
to avoid personal injury or damage to the unit.
Problem Check Cause & Action
The Heater Indicator is
not lit up
The Heater Indicator is
lit up but the Tip does
not heat up
The Tip heats up
intermittently
1) Is the Power Cord and/or
connecting plug disconnected?
2) Is the Fuse blown?
3) Is the Soldering lron Cord
broken?
4) Is the Heating Element
broken?
Check 3)
Connect it
Determine why the Fuse was
blown and eliminate the cause,
then replace the Fuse
Is the inside of the Soldering
Iron short-circuited?
Is the Grounding Spring touch-
ing the Heating Element?
Is the Heating Element Lead
Wire twisted and short-
circuited?
Is the PWB already damaged?
Refer to “Checking for Breakage
of the Heating Element & Cord
Assembly”
1
2
3
The Tip is not wet

5) Is the Tip temperature too
high?( [ ])770 410  
Set an appropriate
temperature
4
6) Is the Tip clean?
A. Refer to “Use and Care of
Tips”
B. Working surfaces not well
tinned during idling periods
C. Lack of flux in soldering,
wicking, repairing and touch-
up operations
D. Wiping Tip on high sulphur
content Sponges, dirty or dry
Sponges and rags
E. Contacting with organics,
such as plastic resins,
silicone grease, and other
chemicals
F. Impurities in solder and low
tin
7) Is the Tip coated with
oxides?
Refer to “are and Maintenance
of Soldering lron.”
8) Is Iron temperature
calibrated correctly?
Refer to “Calibrating the Iron
Temperature.”
9) Is the Tip seized?
Is the Tip swollen because
of deterioration?
Replace the Tip and the
Heating Element.
Check 8)
Check 8)
10) The indicator is not lit at all or
it stays orange for long period
of time
PWB is damaged
5The Tip temperature is
too low
6The Tip cannot be
pulled off
7
8
The Tip does not hold to
the desired temperature
The Tip temperature is
too high
17.
A.
B.
C.
D.
Specifications Control Base
Model #
Description
Power Consumption
Output Voltage
Temperature
Dimension of Control Base
Dimension of Iron Holder
Weight (Ele. Cord not included)
Fuse
SGS-2000 SGS-2005 SGS-2010 SGS-2015
Standard ESD Safe
AC 200-240V ~ 50Hz 6W AC 90-125V ~ 60Hz 60W
24V
392-896 F (200-480 C)
L x W x H = 5.7 x 4.3 x 1.8” (145 x 110 x 45mm)
Standard ESD Safe
L x W x H = 5.7 x 3.6 x 2.8” (145 x 91 x 70mm)
2 lb (< 1kg)
250V-T-1A ( 250V-T-2A (F5 x 20) F5 x 20)
Soldering Iron
Model #
Input Voltage
Tip to Ground Resistance
Tip to Ground Potential
Heating Element
ESD Safe
SGI-900 SGI-901
24V
< 2
< 2mV
Ceramic Heater
No Yes
W
The above specifications and design are subject to change without notice.
18.
Soldering lrom Temperature Curve Schematic Diagram
(Figure 20) (Figure 21)

500
450
400
350
300
250
200
150
100
50
H: 65sec
O: 180sec
D: 60 
D: 18 
T: Room Temperature 25
H: Heat-Up Time
O: Operating Time
R: Thermal Recovery Time
D: Temperature Drop

Test Criteria
1. Soldering Tip: SGT-716D
2. Epoxy Resin Board
3. Solder: 1.6 5mm
4. Cycle: Every 3 Seconds
F 
1234567
Minute
AC Input EMC
Filter
Rectified Phase
Correction Filter
Zero
Voltage
High Frequency
Switch
Transformer
Circuit
High Frequency
Rectified Circuit
Low-pass
Circuit
Heating
Element
Temperature
Sensor
COMP
Setting
Grounding
Starting
Circui
19.

Parts & Accessories
Control Base
M3 X 10
Philips Tapping Screw (8)
M3 X 10
Philips Tapping Screw (2)
M3 X 5
Philips Tapping Screw (1)
(Figure 22)
20.
Part List
No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Art. Number
SGX-101
SGX-117
SGX-119A
SGX-126
SGX-126A
SGX-126P
SGX-126PS
SGX-141
SGX-143
SGX-146
SGX-149
SGX-151
SGX-163
SGX-163A
SGX-170
SGX-180
SGX-185
SGX-190
SGX-192
SGX-195
SGX-380
Name
Control Base
Control Base Housing
PWB Insulator
Transistor Fastening Plate
Front Panel Assembly
Front Panel
Front Panel Plate
Front Panel Plate
Potentiometer Mount
Temperature Control Knob
Five-Pin Socket
CAL Pot Plug
Water Resistant O Ring
Back Panel Assembly
Back Panel
Power Cord Assembly
Cord Stopper
Power Switch
Fuse Box
Fuse
ESD Grounding Socket
ESD Plug & Clip
Remark
ESD Safe
Optional
SGX-201
SGX-222
TME-01
TME-02
SGX-281
PWB
Basic PWB
Module P
Module C
Potentiometer
PWB (Printed Wire Board)
1
2
3
4
5
21.
Parts & Accessories
Iron Holder and others
(Figure 23)
M3 X 8 Tapping Screw(2)
2
1
4
5
3
2
1
3
4
5
6
11
10
9
8
7
12
(Figure 24)
22.

Parts & Accessories
SGX-301
SGX-326
SGX-351
SGX-360
SGX-391
Iron Holder
Iron Holder Lower Cap
Cleaning Sponge
Hex Wrench
Operation Manual
Iron Holder
1
2
3
4
5
1
2
3
4
5
6
7
8
9
10
11
12
SGI-905
SGI-906
SGI-930
SGI-935
SGI-941
SGI-941S
SGI-945
SGI-950
SGI-955
SGI-960
SGI-960S
SGI-971
SGI-971S
SGI-975
SGI-980
SGI-980S
Soldering Iron
Soldering Iron
Nut
Tip Enclosure
Soldering Iron Tip
Nipple
Nipple
Spring
Heating Element
Terminal Board
Handle
Handle
Handle Cover
Handle Cover
Iron Cord Bushing
Soldering Iron Cord Assembly
Soldering Iron Cord Assembly
Soldering Iron
ESD Safe
ESD Safe Model
See Soldering Iron Tips
ESD Safe
ESD Safe
ESD Safe
23.
Soldering Tips
For normal joint soldering, please use SGT-700 series.
If you need special types of tips, please contact us. SGT-700 Tip outside diameter 6.5O
24.