Zhongdi ZD-985 User manual

ZD-985 Desoldering Station

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Unpacking and Setting Up Your ZD-985
Desoldering Station
Carefully unpack the ZD-985 from the shipping box. The box should contain the
following items:
ZD985 Base unit with attached gun holder base
Handpiece Gun with attached vacuum hose and control cable
Handpiece Gun holder
Accessories and Consumables
Figure 1

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Refer to Figure 1 on page 4
Ref. A) (3) Solder Tip Cleaning Tools (Labeled on handle A –B –C)
A 0.75 mm B 0.94 mm C 1.25 mm
Ref. B) Black Filter Housing and Rubber Gasket (Mates to vacuum inlet on ZD-985
Base)
Ref. C) (1) Additional Base Vacuum Filter (One is already in the front of the
vacuum inlet)
Ref. C) (3) Additional Gun Vacuum Filters (One is already in the Solder Capture
Chamber)
Ref. D) (3) Tips (Note: One is already installed on the gun)
Note: All Consumable supplies, and replacement parts are available from:
Memotronics
Phone: [phone]
E-Mail: [e-mail]
See the “Parts and Accessories” listing on page 18 of the manual for more details.
Setting Up the Unit
Step 1: Put the black rubber seal into the filter housing. Check to make sure
there is a white felt filter inserted in the front of the black vacuum outlet on the
base unit. Screw the filter housing onto the vacuum outlet. Snug the housing
down but be careful not to over tighten.

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Step 2: Insert the Handpiece Gun Holder into the slot on the top of the Gun
Holder Base. Note that the Gun Holder Base is able to be detached from the main
unit by sliding it towards the back. This allows you to use the Gun Holder either in
an attached arrangement or in a remote position if that is more convenient.
Step 3: Remove the strap on the Gun Cords and straighten them out. Place the
Gun into the Holder and attach the control cord with the notch towards the top
into the jack and then slide the black vacuum hose over the barb on the vacuum
outlet of the filter housing.
Step 4: Attach the power cord to the receptacle in the back of the ZD-985 unit
and plug the other end into a mains AC outlet.

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Step 5: Turn on the ZD-985. The display will light all the LCD segments briefly
followed by a version number and finally the main screen readout. The screen will
appear similar to Figure 2.
Figure 2
The “TEMP.” gives us the current temperature of the Tip in degrees centigrade.
The “SET” gives us the target temperature that we have selected for the tip. Note
that the left button marked C/F will allow you to switch between Centigrade and
Fahrenheit Units. The HEAT ON is telling us that the ZD-985 is actively heating the
tip and the WAIT is telling us that the system has not stabilized within 10 degrees
of the target temperature yet. We can easily adjust the SET Temperature by
pushing the UP or DOWN buttons below the display. Each push of a button will
move the SET by one degree. To more rapidly adjust the SET temperature, push
and hold either the UP or DOWN button. To help choose a proper setting for your
application a solder temperature chart is included under the “Tips and
Techniques” section of this manual.

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Step 6. It is now necessary to clear the solder plug that came with your new
Desoldering tip. The manufacturer dips each tip in solder to seal and protect the
tip from oxidation until it is put in service. Turn the SET to the Maximum setting,
480 degrees C. When the unit stabilizes push the trigger on the gun and the solder
plug should be vacuumed into the Solder Capture Container. If for some reason
the plug doesn’t clear, use the appropriate cleaning rod (A, B or C) from the
accessory kit that was supplied with the unit to gently push the solder plug free.
After the solder plug is cleared return the unit to an appropriate temperature
using the DOWN button. It is important to select a SET Temperature for the unit
that is high enough to do the job but not so high that the tip is put under
excessive corrosion risk or that the parts that you are desoldering are damaged.
Auto Tip Saver Function
As an additional protection against tip corrosion due to excessive heat the ZD-985
has a timed Auto Tip Saver function that drops the SET to 200 degrees C every 15
minutes. When this occurs it is only necessary to push the “UP”, “DOWN”, or
“C/F” button to reset the machine to your selected SET point.

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Tips and Techniques
The following is a list of the common solder alloys and their respective melt
points. This can be used as a guide to choosing the appropriate SET point for your
application. Keep in mind that many variables factor into the optimal set point
and you may have to experiment to get the best results. One of the important
considerations, if you are salvaging usable parts, is to have the temperature of the
tip high enough so that you can quickly heat the joint and evacuate the solder
before heat can travel up the lead and damage the component.
Alloy Melt Ranges
LEAD-FREE
215 C to 245 C
TIN-LEAD
Sn60/Pb40 through Sn30/Pb70 185 C to 258 C
Sn05/Pb95 301 C to 320 C
TIN-LEAD-SILVER
180 C to 300 C
Effective Desoldering Technique
Choose a solder tip hole size that is appropriate for the size of the solder pads
that you will be cleaning. See the “Maintenance of the ZD-985” section for the
proper tip changing procedure. Use enough tip heat so that you can place the tip
over the target solder joint and within a second or two push the trigger of the
gun. Continue to hold the trigger as you pull the gun from the solder joint. This
allows air to enter the tip and sweep the residual solder into the solder capture
container. Once you are clear of the joint you can release the trigger. If the board
has traces on multiple levels or if the traces are very wide it may be necessary to
leave the Desoldering tip on the pad longer to allow complete solder melting to
occur before pulling the trigger. Sometimes it is also necessary to move the tip
laterally on the pad so as to reposition the wire slightly so all the solder can be
vacuumed from the pad.

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Maintenance of the ZD-985
Changing the Tip
Make certain that the gun is cool before attempting to change tips. When under
power all the metal parts associated with the tip of the gun become dangerously
hot and can create serious injury. Once the gun has cooled to room temperature
unscrew the knurled finger nut near the base of the heater element. If it is too
tight for manual removal gently use a plier. This retaining nut has standard right
hand threads. Once the nut is loose, pull the tip retention Outer Sheath forward
to uncover the Tip and Heater Element. Be aware that there is a secondary sheath
that covers the heater element and may also come off with the Outer Sheath and
the Tip. See Figure 3. The Inner Sheath must be placed back on the Heater
Element before the Tip is re-installed. If the Tip is still on the front of the heater
the inner sheath is still in place as it will not slide over the Tip. Pull the Tip off the
Heater Element and vacuum tube. Use your fingers or a soft tool to do this. The
Tip is precision and the use of pliers or other hard tools may damage its surface or
its seal with the heater element. Push the new Tip onto the vacuum tube and seat
it securely against the heater element. Slide the Outer Sheath and Knurled Nut
over the Tip and Heater Element and finger tighten the nut. You can tighten this
as much as you can with your fingers. It is not uncommon for this nut to loosen
with time due to the heating and cooling of the gun from one use to another. It is
recommended that the tightness be checked before each use and prior to turning
the unit on. Do Not use a pliers to over tighten the nut.
Figure 3

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ERROR Message
The ERROR message on the display indicates that something is wrong with the
system. Most simply the handpiece gun may not be plugged into the front jack or
it may be loose. Make certain the plug is tight and turn the unit off and on again
once more to see if the problem has cleared. If the ERROR persists contact
Memotronics at [phone] or email us at [e-mail]
Cleaning the Solder Capture Container
The first step in cleaning the Solder Capture Container is to remove it from the
gun. Check out Figure 4 for a picture of the release button on the back of the gun.
Figure 4
Apply some pressure with your thumb to the breach to relieve tension on the
release latch. Slide the black button #2 down and this will release the breach.
Next, take a hold of the Clear Glass Solder Capture Chamber and push it back
against the open breach far enough so that you can lift the front of the chamber
up and out of the front recess. See Figure 5:

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Figure 5
Please note that there is a thin black vacuum seal washer that sits ahead of the
black plastic cap of the Solder Capture Chamber. It is possible for this washer to
be pulled out along with the chamber. When the washer sticks to the Capture
Chamber it makes the removal of the chamber more difficult. A thin coating of
talcum powder on the washer can minimize this problem. Be careful not to lose
this washer. If it comes out with the chamber it is best to put it back in place in
the front housing immediately. The Glass Chamber is breakable if dropped so use
due caution. The Solder Capture Chamber itself and associated seals are shown in
Figure 6. Note the Breach Plunger Silicone Seal is not removed during the routine
cleaning procedure. These parts are available as The Glass-Spare Kit. See the Parts
and Accessories List on page 18.

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Figure 6
From left to right these parts are the Vacuum Seal, Black Plastic Cap, Spring,
Splash Plate, Felt Debris Filter, Chamber, and Silicone Breach Seal. It is important
that these parts are assembled in the proper order to provide the best service
from the ZD-985. The Spring slips over the small shoulder of the cap. The Splash
Shield sits on top of the Spring and the Felt Filter sits on top of the Splash Shield.
The Chamber slides over the other parts and on to the larger shoulder of the Cap.
When solder enters the Capture Chamber it will impact with the splash shield at
the back of the chamber. Most of the solder will accumulate in this area. The Felt
Filter keeps small particles of solder from getting into the vacuum hose. The
spring serves the purpose of holding the Splash Plate to the back of the Chamber
against the Filter and also helps to keep the molten solder off the Chamber wall.
To clean the solder from the chamber, disassemble and remove the impacted
solder from the Splash Plate and then carefully from the spring. It is important not
to bend or stretch the spring in this process. If you wish to clean the splatter from
inside the clear Chamber, use a wooden or plastic stick or a brush. When the
gross splatter is removed a soft cloth can be twisted into the chamber to
complete the job.
Note: The solder, depending on the alloys involved, can be hazardous to the
environment and should be collected and recycled in the proper manner.

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Reassemble the Chamber and place the Felt Filter against the spring loaded
plunger of the breach. Be careful to ensure the filter is centered on the breach
plunger as it is easy for the fibers of the felt to break the seal that the Silicone Seal
must make with the Chamber Housing. Once properly positioned, push back on
the chamber and tip it into the front housing. Finally push the Breach forward
until it clicks and locks into place. The ZD-985 is now once again ready to return to
service. Figure 4 identifies the Plunger and Silicone Seal.
Be sure to keep adequate consumables and spare parts on hand to eliminate
down time and to protect the function of the Desoldering Station.
Routine Tip Cleaning
It is important to routinely clear the residual oxidized solder and scale from the
Desoldering tip. This is easily accomplished by pushing the, appropriate, cleaning
rod (A, B, or C) through the tip and into the solder capture chamber, at the end of
each use, before turning the machine off. Use the vacuum trigger to apply
vacuum during and after the cleaning rod is push through and removed. This
routine procedure should eliminate the need to fight with a clogged tip. Caution
as cleaning rods become very hot when inserted into the tip.
Cleaning a Clogged Tip
Note: This is the only maintenance procedure where it is necessary to have the
unit at high temperature. Extra caution should be exercised to prevent burns and
injury. If proper techniques are followed a clogged tip should be a rare
occurrence. Select the correct cleaning rod from your accessory kit. SET the target
temperature to the maximum 480 degrees C. Try once again to clear the clog with
the vacuum alone. If the clog is still present, activate the vacuum trigger again and
push the cleaning rod (A, B, or C) gently into the tip orifice. Alternately push and
remove the cleaning rod to allow the vacuum to clear any debris to the Collection
Chamber. It is important to approach the surface of the tips surfaces, internally
and externally, with care as scratches and abrasions will shorten the life of the tip.
Do not Drill or use cutters to clean a tip. If your tip is scratched or corroded,
contact Memotronics for replacement parts.

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Fuse Replacement
Note: A blown fuse may indicate an internal problem with the circuitry of the unit.
Never use a fuse larger than the one specified. (3.15A for 120 Volt unit). Repeated
replacement of a fuse can push the problem with the unit deeper into the
circuitry and exacerbate the problem.
Figure 7
Remove the power cord from the back of the unit and slide the fuse holder out of
the lower section of the power cord jack. See Figure 7. The fuse holder comes
with one stored replacement fuse. Insert the replacement fuse into the holder in
place of the failed fuse and slide the holder back into the AC cord jack. Replace
the power cord and turn on the unit. Get a replacement fuse to put back in the
storage position of the fuse holder for future needs.

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Poor Vacuum
Begin the trouble shooting process by removing the Solder Capture Chamber
from the gun. Make sure there is no debris around the large hole in the Breach
Plunger. Briefly turn on the unit and trigger the vacuum. Place your finger tip over
the hole in the center of the Plunger and test the strength of the vacuum. Turn off
the unit. If you have no vacuum at the plunger, go to paragraph “A”. If there is a
vacuum at the Plunger, go to paragraph “B”.
“A” If there is no vacuum at the plunger, pull the black hose off the Black Filter
Housing on the front of the unit. Once again briefly turn on the unit and trigger
the vacuum. This time check the vacuum at the inlet to the Black Filter Housing.
Turn off the unit. If there was no vacuum at the vacuum inlet then there is an
internal problem with the vacuum pump. If you had vacuum at the vacuum inlet
you will have to check the hose that goes up to the Breach of the gun for an
obstruction or kink.
“B” Since we have vacuum at the Breach we will check the path from the tip to
the Solder Capture Chamber. Choose the proper Cleaning Rod for your tip and
insert it into the tip. If the Tip and vacuum pipe are clear you should be able to
push the rod all the way through to the area of the Solder Capture Area.
If the rod will not go through, this is the source of your poor vacuum. Remove the
tip and look down the vacuum tube towards the Solder Capture Chamber. You
should be able to see a clear, unobstructed, path. If not you may have to
reassemble the chamber and heat up the gun and try to clear the pipe with the
cleaning rod. If the tip and the vacuum pipe are both clear then it is likely that you
have a poor seal on the housing of the Solder Capture Chamber. Make certain
that the flat Black Vacuum Seal washer that sits ahead of the Chamber Cap is in its
proper position. Check to make certain that the felt filter is not frayed with pieces
hanging to the sides as this can prevent a good vacuum seal. Inspect the clear
Silicone Seal on the Breach for cuts or tears. Reinstall the Solder Capture Chamber
paying attention to the position of the felt filter and making certain that the
Breach seal seats properly into the Chamber Housing.
Turn on the unit and run it up to temperature and test it on a solder pad.

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Specifications
Supply Power: AC 110-130 V or AC 220-240 V 140 Watts
Gun Rated Voltage and Power: 24 Volts 80 Watts
Dimensions: W: 18 cm H: 16 cm D: 16 cm (Not including Gun profile or AC Cord)
Weight: 2.2 Kg
Temperature Range: 160 C to 480 C or 320 F to 896 F
Tip Orifice: 0.8 mm, 1.0 mm, 1.3 mm
Static Vacuum Level: 23 cm of Hg
Sound Level: 75db @ 1 Meter
Warranty
Available from Memotronics
Phone: [phone]
E-Mail: [e-mail]
Web Site: www.memotronics.com
Thank you for purchasing the ZD985 Desoldering Station. Your product is
guaranteed against defects in material and workmanship for a period of 6 months
from the date of receipt. It is vital that you keep your receipt if you need to make
a claim under this warranty. For all warranty related inquiries, please contact our
customer service department by e-mail at [email protected] or by
phone: [phone]

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Parts and Accessories
The following Parts and Consumables are available on the Memotronics Web Site:
www.memotronics.com
Note: Please inquire for the availability of any non-listed parts.
Description Reference Part Number
Desoldering Tip, Large Fig. 1 (D) Pg. 4 SOLTIPLG
Desoldering Tip, Medium Fig. 1 (D) Pg. 4 SOLTIPMD
Desoldering Tip, Small Fig. 1(D) Pg. 4 SOLTIPSM
Cleaning Rod Large Tips Fig. 1 (A) Pg. 4 SOLRDLG
Cleaning Rod Medium Tips Fig. 1 (A) Pg. 4 SOLRDMD
Cleaning Rod Small Tips Fig. 1 (A) Pg. 4 SOLRDSM
Gun Reservoir (17mm)
Capture Chamber Filter(10) Fig. 6 Pg. 13 SOLLFLTRSM
Filter for Station (21mm) (10) Fig. 1 (C) Pg. 4 SOLFLTRLG
Yellow Tip Cleaning Sponge SOLSPG-A
Complete Gun Assembly (Medium Tip Included) SOLGUN-A
Heating Element (Includes Temperature Sensor) SOLHTR-A
Spares Kit ( 3 Tips, 10 Small + 10 Large Filters, 1 Sponge and
1 Heater Element) SOLACC552
Capture Chamber (Reservoir) Kit:
(Glass Chamber, Spring, Splash Plate, Cap, Disk, Silicone Seal) SOLGLASS-552

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!!! Words of Caution !!!
The manufacturer and distributor assume no responsibility for uses of this device
other than those described in the operating instructions. The manufacturer and
distributor assume no liability for any alteration of the device mechanically or
electrically.
HIGH TEMPERATURES, The unit can reach temperatures that are over 400 C ( 752
F) which can cause serious burns and can cause materials to combust. Be certain
to comply with the following precautions:
Do not touch any of the metal surfaces near the tip/nozzle.
Do not use the unit near flammable items.
Advise other people in your work area about the temperatures and dangers
related to the unit.
Turn off the switch on the unit when it is not in use or being monitored by
qualified personnel.
Except for Tip Cleaning always turn off the unit, unplug it and allow it to
cool to room temperature prior to performing any maintenance.
Tip temperature may exceed the flash point of some materials so be aware
of adjacent materials in your work area.
Place the gun in its stand when not in use. Do not lay it on the bench or
place it near items that may melt or combust.
Do not place the tip on any spot for an extended period of time.
Do not use in an explosive atmosphere.
Be aware heat can be transferred along adjacent metal and to combustible
material that may be out of sight.
OTHER RECOMMENDATIONS:
Do not use this device for purposes for which it was not designed or
intended.
Do not try to dislodge debris or clogs by striking the gun or tapping it on a
hard surface.
Do not file the soldering tip to remove scale. Use the wet sponge to clean
the tip.

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Use only accessories and replacement parts that are designed for the ZD-
985 and are listed in the operation manual.
Turn off the power before disconnecting the Handpiece Gun from the main
unit.
This unit is not intended for the use of unsupervised children. Proper
training in the use of the unit is important for all ages.
Protect yourself from electrical shocks. Avoid touching grounded parts with
your body while working on equipment. The grips, of antistatic designed
soldering tools, are conductive.
Observe the safety regulations that are specific to your work place.
This Manual Designed and Co-Authored by
John C. Wiltrout