Weller EC1002S User manual

Weller®Tech Sheet EC1002S
Model EC1002S
Electronic Soldering Station
TECH MANUAL

Operating Instructions
Unpack unit carefully. Place sp rin g and funnel in slot in top of tool stand. Attach
tool stand
to either s ide of power unit, ifdesired. Fill reservoir with water and wet
sponge, distilled water
is preferred. Insert tool in holder and connect tool plug to
receptacle on power unit; rotate plug hou sing to lock plug into receptacle. In sert
line cord plug into properly gro
und ed AC receptacle a nd turn station on. Se t
tempe
ra ture control knob to desi re d ti p t em pera tu re (appro ac h de si red temperature
by turning CCW). Wait 30 seconds. Remove tool from ho lde r and tin tip with
so
lde r. Un it is now ready for u se.
Always use the lowest temperature that will handle the load you are soldering.
The
Weller~} electronic control provides maximum power to the heated lo ad even
when set to the lowest temperature; therefore, there is no need to use high
temperature to hand le heavy soldering loads. By using lower temperatures and
properly selecting tip styles, sensitive components will
be protected from heat
damage.
WARNING: Do not remove ground prong from line cord plug. Removal
may cause tip temperature control to be erratic.
AvailableModels and HandPieces
Product
EC1002S-0
EC1002S-OD
EC1002S-l
EC1002S-l
D
.EC1002S-2
ECl 002S -2D
EC1002S-3
ECI002S-3D
ECI20tA
ECl302A
EC1503A
Page 2
~tinllim
Power unit only. 120V 60Hz. "F dial markings
Power unit only.
230V 50 /60Hz. ac dial markings
Power unit, l20V 60Ht.. °F dial markings, EC1201A t oo l with ETA tip, and tool ~ rand
Power unit, 230\' 50/6011z. ocdial markings. ECI201A tool with ETA tip. and t oo l stand
P ow er unit. 120Y 60Hz. "F dial markings, EC1302A t oo l with EPJ-!101 tip . and tool stand
Power unit. 230V 50 /60 Hz, "C dial markings. EC 1 302A t oo l wilh E PH 1 OJ tip. and tool stand
Power unit. l20V 60Hz. "F dial markings, EC 1503/\ t oo l with EM/\ tip, and tool sta nd
Power unit. 230V 50/60Hz. "C dial markings. EC !503A t ool with EMA tip. and t ool stand
40 watt soldering tool w/ ET A tip
20 \\ atc soldering tool w/EPH l0 I tip
42 watt high ca pacity ~oldc ring tool w/EM1\ tip
EC1002S

Sp ec ifications
I. Power input: 12 0VAC +!- 10%, 60 1l7. , (230VAC t/ - 10 %, 50!60 Hl .). 60 wa lls
2. Power unit output vo!tJgc: isolated 24 VAC @ 2.1 amp cn.: s.
3. Si~e : 4.5" x 5.9" x 3.6"
4. L in e C<> rd · 3 wire. U 1.. recogni~.:d
5. Tip tc mpcr:.turc control r:.ngc: 3SO "F to 850°1' (1 75 "C to -<55 °C).
6. Control selli ng rc $o lution· I O"F (5"C).
7. Stabilit y.+/- J O" F (+I- 6"C) per Mii-Std-2000.
!!. Absolute accuracy: Average tip temperatur<.: is calibratablc to+ /- <J°F (+/- S°C) at idle with no load.
9. Ambi cmtem peraturc range: 60''Fto 1!0° 1' (1 6"C to 44°C}
I0. Housing made with Electrostatic Protective Material as required in 1\ lil-B-81705.
II. H ou, in g pass.:s Static Decay te st per FederalTest Method Std. No. I0I, method 4046.
12. Weller' ESD tools co mpl y wi th DOD·I IDG K-263
13. EC1 002S units arc UL li sted ami meet DOD-STD-2000, Mii-Stu-2000, 1\lii -S -4 5743, W-S -6536,
W-S-570, DOD-STD-1686.
Materials Needed For Calibration Ch eck
The EC1 20 IA, EC1302A and EC J503A soldering t oo ls u se high precision
platinum RTD temperature sensors and therefore require
no calibration and are
i
nt erchangeable. The po wer unit is fac tor y calibrated; but can easily be checked
usi
ng a WC I 000 Calibration Reference Unit and re-calibrated if required.
Cl
D
CJ
oQ Cl
ju2j
CJ
CJ CJ
~~~
Cl
CJ
Cl
D
CJ
[)
Cl
R25 CJ R24
D G
Cl
D
CJ
D
01
Cl
Dl CJ CJ CJ
CJ
D CJ
Cl D
Cl
01
CJ
P1
CJ
8455
R10
Ci rcuit B oa rd Layo ut
EC1002S Page 3

ECJ002S Calibration Check
I. Disconnect soldering tool from the tool receptacle on the power unit and connect
to the receptacle on th e WC 1000 Calibration Reference Unit. Connect the
WC I000 to the tool receptacle on the power unit aod select resistor "8" .
CAUTION: The power unit should not be turned above 350°F (175 c- C) for more
than l m
inut\! with the tool connected to the WCI000 to prevent damage to the
tool heating element.
2. Rotate temperature set knob fully CCW and turn power unit on. Indicator lamps
on
we I000 should be out. Allow 30 minute warm-up before continuing.
3. Rotate temperature
se t knob fully ew , indicator lamps should be full on.
4. Rotate temperature set knob cew until indicator lamps start fl as hing, note
temperature se tting. Continue rotating temperature set knob cew until lamps ju st
stop flashing. Temperature set should equal 745°F ± 10 (395°C :!- 6) a nd the
indicator lamps shou
ld have started flashing approximately 35°F ( 19 c- C) higher.
5. Select resistor "A" on
th e We I 000 Calibration Reference Uni t.
6. Rotate temperature set knob ecw until indicator la mp s just stop fl as hin g.
Temperature set should equal 395°F ±l0 (200"C ±6).
7. Ifcalib ra tion is out of tolerance, perfonn there-calibration procedure.
ECJ002S Tip Temperature Calibration Procedure
1. Monitor the t ip temperature with a 30 gauge thermocouple resistance welded to
the center of the wetted area, tinning should be removed before welding. K-Ill ,
K-121, and
K-131 temperature test kits are recommended: see Replacement parts
and Accessories section.
2. Se t the temperature set knob to t he desired temperature and allow the tip
temperature to stabilize.
3. Adjust RI 0, accessible through the hole in the station bottom directly be l ow the
temperature set knob. until the indicated tip temperature matches the
se t
temperature.
ECJ002S Re-calibration Procedure
Because the power unit must be dis-assembled to gain access to the calibration
adjustments, this procedure is not recommended unless the Calibration Check
is
performed and re-calibration is indicated.
CAUTION: Disconnect power cord before di s-assembling power unit.
I. Remove 4 rubber feet and sc rews under feet; remo ve top cover from station.
Page 4 ECI002S

2. Set temperature set knob fully CW and then CCW to 745°F (395°C). Carefully
remove knob by sliding off of pot. shaft without rotating shaft.
3. Remove retaining nut
and washer from temperature set pot.
4. Note how front panel is engaged with base and then lift front panel free of base.
5. Lift control board
clear of front panel to gain access to the calibration pots. Check
that RIO (see figure) is centered.
6. Connect the WC I000 Calibration Reference Unit
to the tool receptacle on the
power unit and select resistor "B". Do not connect tool to the WC!OOO at this
time!
7. Connect power cord and turn power unit on . Allow 30 minute warm-up before
continuing.
CAUTION: The power unit should not be turned above 350°F (l75 °C) for more
than I minute with the tool connected to the WC!OOO to prevent damage to the
tool heat:ng element.
8. Connect tool
to the WCIOOO receptacle as a load. Adjust R25 (see figure) until
indicator lamps
just stop flashing.
9. Hold the board in position
on the front panel, slide the knob on temporarily and set
CCW to 395 °F (200"C). Remove knob without rotating pot shaft.
l0. Select resistor "A" on the WCI000
and adjust R24 (see figure) until indicator
lamps
just stop flashing.
II. Turn power unit off and dis-connect power cord and WCI000.
12. Position board on front panel such that alignment pins are engaged. Place washer
and nut
on temperature set pot., tighten nut
I3. Install temperature set knob on temperature set pot. shaft.
14. Position front panel
on base as noted above.
15. Perform Calibration Check
to verify calibration.
16. Install top
cover on station and replace 4 screws and rubber feet.
Troubleshooting Guide
WARNING: AC line voltage is present inside power unit even when
power switch is off. Refer service to qualified personneL
NOTE: Access to internal parts may be gained by removing four
rubber feet, four screws under feet and top case.
~DoestVot}{ea(
With line cord unplugged and power switch on, check for about 21 ohms at line
cord blades (55
ohms for 230V unit).
•Check fuse, located on bottom of case -replace if required. Use slow
blow fuse- 0.6A for 120V, 0.3A for 230V.
•Check power switch -replace if defective.
•Check line cord- repair or replace if defective.
•Check transformer primary- replace transformer if defective.
EC1002S Page 5

With line cord plugged in and pow~r switch on, check for 24 VAC ±I0% between pin s If I
and #4 of tool receptacle.
•Check transformer secondary for 24 V AC ± l 0% - replace transformer if
defective.
•Check wiring to printed circuit board assembly -repair or replace if
defective.
•Replace printed circu it board assembly.
Check wiring from tool receptacle to primed circuit board
•Repair or replace ifdefective.
Replace soldering tool with known good tool and recheck.
•Troubleshoot soldering tool usi ng guide in tool tech sheet.
Replace printed circuit board assembly.
Tool Overheati ng
Replace soldering tool with known good tool and recheck.
•Troubleshoot soldering tool using guide in tool tech sheet.
Replace printed circuit board assembly in station.
Tip Temperature Testing Error.~
Note: Tip temperature testing mu st be done using 30 gauge them10couple wire
resistance welded to the center of the wened area on the tip. tinning should
be removed before welding. Other method s, or heavia thermocouple wire.
will cause _error s. K-111, K-121, and K-13 I temperature test kits are
available; see Replacement Pans and Accessories section.
Replace soldering tool with known good tool and recheck tip temperature.
•Troubleshoot soldering tool using guide in tool tech sheet.
Calibra te station according to Tip Temperature Calibration Procedure.
Hh:h Tin Voltaf:e
Replace so ld ering tool with known good tool and recheck tip temperature.
•Troubleshoot solderi ng tool using guide in tool tech s he et.
Check for continuity from pin #5 of tool rec<!ptacle to line cord ground pin .
•Check wiring from tool receptacle to line cord gro und pin -repair if
defective.
Customer Service
Should your ECJ002S requi re service, it ma y be se nt to the following address:
COOPER TOOLS-CHERAW PLANT
81 S State Road
Cheraw, SC 29520
ATTN: Repair Department
[phone]
Page 6 EC1002S

ReplacementParts and Accessories
Key No.
I
2
3
4
Not Shown
5
Not Sh own
Not Shown
Not Shown
Not Shown
Not Shown
Not Shown
No t Shown
Not Shown
Not Shown
Not Shown
No t Shown
No t Shown
No t Shown
Not Sho"n
Not Shown
Nllt Shown
Not Shtnvn
Nnt Shown
P:
trr No.
SWIIO
EC270
E
C271
TR234
TR235
FP3
FP30
TC205
DS200K
TC204
IH F225EC
EC254
EC120
1AP
EC I302/\P
EC 1503/\P
SF60
SMT t\
Sl\ iTA -F.M
\\' CI000
\'< /\2000
WPBI
K-Ill
K-121
K-1 31
o~scription
Power Switch
Receptac
le ond wire harness
Circuit boa
rd <JSscmbly
Po'-er transformer. 12 0V/\C. EC I002S-0
Power transformer. 230VAC.
F.C 1 00 2 S-OD
Fuse .. 6 AM P Slo Blo
Fu se. 315m/\ (for 230V 1\ C model$)
Sponge
Dc: so ldc:rin g odaptcr kit
Spring and funnel for EC I20I!\ tool
Spring
;1nd funnel for E CI302/\ tool
Spring and funnel tor EC1503/\ to ol
EC120 1A tool with Fume ElCtraction att:~chm cnt and stand
EC 1302/\ tool with Fu me E lCtr ac ti on attachme nt o ml stand
ECI503A tool with
Fu me ElCt r:~ ct i on ;'lttachmcnt :~nd sta nd
Tool funnel for SMT tips
Surface mo unt t ip adaprcr for EC I 201 /\ tool
Surface mo unt tip adapter for ((1503/\ roo(
Calibr:nion Unit
Sol dering Tool Analyzer
WELLER'
Po lishing B :~ r
Tempcratun: te st kit for EC 120 I i\ tool
Tcmpcr:tturc
tc st kit for EC1302,\ tool
Tcmpcraturc
tc st kit for EC1 5031 \ tool
ECI002S
Page 7

c-1995 Cooper Industries
Cooper Hand Tools Division
Weller Products
Apex, NC 27502
""
CDDP~ER=-=----------=-------=------
CooperTools S849
Rev. 1126/95