Int968

DELUXEREPAIRINGSYSTEM

ThankyouforpurchasingAoyueInt968RepairingSystem. Itisimportanttoreadthemanualbeforeusingtheunit. Pleasekeepmanualinaccessibleplaceforfuturereference.

Manufacturer: AOYUETONGYIELECTRONICEQUIPMENTFACTORY JishuiIndustrialZone,Nantou,ZhongshanCity, GuangdongProvince,P.R.China http://www.aoyue.com

o o Thetemperatureofthesolderingiron,hotairgunandthenozzlerangesfrom200 ~480 C o o (400 ~850 F)whentheunitisswitchedON.Injurytopersonnelordamagetoitemsinthe workplace may result if not carefully used. Please read the contents on how to use the equipmentandobservethefollowinginordertomaximizeusage: Afteropeningthepackage,checkifeach componentisin goodworking condition.If thereareanysuspecteddamages,donotusetheitemandreportthistothedealer. Turn OFF the power switch and unplug the unit from the main power source when movingtheequipmenttoanotherlocation. Donotstrikeorsubjectthemainunittoanyphysicalshock,includingthehotairgun, solderingironoranypartsofthesystem.Usecarefullytoavoiddamageinanyparts. Makesuretheunitisgrounded.Alwaysconnectpowertoagroundedreceptacle.

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LAUNAM NOITCURTSNI

CAUTION

BASICTROUBLESHOOTINGGUIDE
PROBLEM 4: BANNER OR PRODUCT NAME IS ALWAYS SCROLLINGTHEUNITISNOTUSABLE Description:Theproductnameisjustalwaysscrollingfromthedigital panel,renderingthedeviceunusable. SOLUTION: Try to press Reset from the panel. Note that resetting the device will also reset all previously defined configurations. If the problempersists,contactthevendor. PROBLEM5:AIRPRESSURELEVELISSIGNIFICANTLYLOWNO MATTERHOWHIGHTHEAIRFLOWLEVELISADJUSTED Case 1: Check the mains voltage (AC power source). If the voltage level falls significantly low, about 1520% lower than the standard, therewillalsobeanoticeabledropintheairpressurelevel. SOLUTION:Pleaserefertoyourlocalpowerserviceprovider. Case 2: The microcontroller might have detected the operating frequencyincorrectly.Theairflowlevelisnoticeablyweaker. SOLUTION: TrytopresstheResetbuttononthepanelandletthe deviceredetecttheproperoperatingfrequency.Notethatresettingthe devicewillalsoresetallpreviouslydefinedconfigurations. PROBLEM6:THEUNITISVIBRATINGTOOMUCH Check if the 4 screws that hold the pump in place are properly and tightly connected. Unplug the system from the main power source beforeopeningthecasetochecktheinternalsettings. PROBLEM7:DISPLAY&OTHERDEVICEOPERATIONISSUES SOLUTION: TrytopresstheResetbuttononthe device.Notethat resettingthedevicewillalsoresetallpreviouslydefinedconfigurations.

OTHERPROBLEMSNOTMENTIONED:

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BASICTROUBLESHOOTINGGUIDE
PROBLEM1:THEUNITHASNOPOWER 1. CheckiftheunitisswitchedON. 2. Checkthefuse.Replacewiththesametypeiffuseisblown. 3. Checkthepowercordandmakesuretherearenodisconnections. 4. Verifythattheunitisproperlyconnectedtothepowersource. PROBLEM2:TEMPERATUREDISPLAYISALWAYSABOVE500 C o Description: Constant display of above 500C temperature from the panel C3 then displays a blinking OFF on display panels C2 and C3 afterafewminutes.
o

TABLEOFCONTENTS
Package Inclusion ..... 4 Functions and Features ............ 4 Product Specifications ...... 5 Care and Safety Precautions ... 6 Panel Controls .............. 7 Preparation 8 Operating Guidelines ..... 910 Care and Use of the Tip .... 11 Maintenance ..... 1213 Basic Troubleshooting Guide 1415

SOLUTION: Thethermalsensormaybebrokenandneedstobereplaced. PROBLEM3:ACTUALAIRTEMPERATUREISNOTINCREASING Description: Actual temperature reading is not increasing or decreasingbasedondesiredlevel.Thepanelwillthendisplayablinking OFFondisplaypanelsC2andC3afterwards. SOLUTION: Theheatingelementmaybebrokenandneedstobereplaced.

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PACKAGEINCLUSION
AoyueInt968MainStationwithHotAirGun AirNozzles (1124113011971313 B003SolderingIronwithTip 2630SolderingIronHolderwithSolderWireStand Z003HotAirGunHolder G001ICPopper 2pcs.FilterPads PowerCord

MAINTENANCE
SPAREPARTSLIST
NUMBER 10094 30105S S005 20962 P003 NAME&SPECIFICATION Hotairgunheatingelement Plastichandleofhotairgun Hotairguncompletehandle Hotairgunmetalpipe Diaphragmpump Solderingironheatingelement Plastichandleofsolderingiron Solderingironcompletehandle Tipenclosure Filterpads

FUNCTIONSandFEATURES

C001 3098S B003 201701 30181X

Microprocessorcontrolledelectrostaticdischarge(ESD)safeunit. Easytousetouchtypepanelcontrolswithdigitaldisplay. Environmentfriendly repairing system that integrates hot air gun, solderingiron,andsmokeabsorberinonepackage.

Builtinsmokeextractorthatabsorbsfumescreatedatthesource. Knobtypesolderingirontemperaturecontrolforsimpleyetefficient workingtemperatureselection.

NOTE: Toensuresafetyandquality,useonlygenuinepartsforreplacement.

Intelligent errorreporting mechanism. Detects and informs the personnelforproblemswiththesensorandheatingelement.

Autocoolingfunctionality.Blowsairtocooldownthesystemtoasafe temperaturebeforeturningOFF.

Compatibilitywithvarioustypesofairnozzles. Compatibilitywithdifferentkindsofsolderingtips.

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MAINTENANCE
IMPORTANT: Unless otherwise directed, carry out these procedures withthepowerswitchedOFFandthepowercordUNPLUGGED.

PRODUCTSPECIFICATION
Power Input : Main Station Dimensions: available in 110V & 220V 188(w) x 126(h) x 250(d) mm 5.25Kg SOLDERING IRON Power Consumption: Temperature Range: Heating Element with Tip: Output Voltage: Tip to Ground Resistance: 35W 200C 480C Ceramic Heater 24V Below 2 Below 2mV HOT AIR Power Consumption: Temperature Range: Heating Element Nozzle to Ground Resistance: Pump/Motor Type: 550W 100C 480C Metal Heating Core Below 2 Diaphragm Pump 23 l /min (max) SMOKE ABSORBER Vacuum Pressure: 600mm Hg

CARBONFILTER
Weight:

K1 filter drawer K2 active carbon filter pads (30181X) K3 smoke absorption nozzle

An active carbon filter device is installed at the outlet of the smokeabsorbingsystem.Theactivecarbonfilterpadshouldbe cleaned and replaced regularly, depending on the frequency of use.

REPLACINGTHEHEATINGELEMENT 1. Loosen the 3 screws that secure the hot air gun handle. The heatingelementislocatedinthemiddlepartofthehotairgun. 2. Slideofftheplastictube. 3. Disconnectthegroundwiresleeve. 4. TheQuartzglassandheatinsulationareinstalledinsidethepipe. Loosenthecableandremovetheheatingelement. 5. Insert the new heating element and reconnect the terminal.Be carefulnottorubheatingelementwire. 6. Reconnectthegroundwireafterreplacingtheheatingelement. 7. Reassemblethehandle. NOTE: The life expectancy of a heating element is 1 year under normaloperatingconditions.

Tip to Ground Potential:

Air Capacity:

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CAREandSAFETYPRECAUTIONS
CAUTION:Misusecancauseinjuryandotherphysicaldamage.
Foryourownsafety,besuretoobservethefollowingprecautions.

CAREANDUSEOFTHETIP
1.TipTemperatureHightemperatureshortenstiplifeandmaycause thermal shock to other components. Always use the most appropriate temperaturewhensoldering. 2. Cleaning Always clean the soldering tip before using. Remove any residualsolderorfluxthatarestilladhering.Useacleanandmoistcleaning spongetoremoveunwantedresidues.Contaminantsonthetiphavemany detrimentaleffects whichmay impact soldering performance one being reducedheatconductivity. 3. After Use Alwayscleanthetip.Coatit with fresh solderafter use. Thisprotectsthetipagainstoxidation. 4. Never allow the unit to stay idle at high temperature for long periods. Thismakesthe tip proneto oxidation. Turn OFFthe power switch if it will notbeusedforseveralhours.Unplugthemainunitfromthepowersource ifpossible. CLEANINGTHETIP IMPORTANT:Performingthisprocedureextendslifeofthesolderingtip.
o 1. Setthetemperatureto250C.

Temperaturemayreachashighas480CwhenunitisswitchedON. Donotusenearpaper,plastic,andflammablegasesandmaterials. Donottouchheatedparts. Donottouchmetallicpartsnearthetip.

ThermalProtector The unit is equipped with auto shutoff ability when temperature gets too high. This will automatically switch ON when the temperaturehasdroppedtoasafelevel.

HandlewithCare Neverdroporsharplyjolttheunit. Containsdelicatepartsthatmaybreakifunitisdropped.

Unplugtheunitfromthemainpowersourceifitwillnotbeusedfor alongperiod. Turnoffpowerduringbreaks,ifpossible.

Useonlygenuinereplacementparts. Turnoffpowerandletunitcooldownbeforereplacinganyparts.

Soldering process produces smoke use the equipment on well ventilatedplace.

Do not modify or alter the unit in any manner, particularly the internalcircuitry.

2. When the temperature has stabilized, clean the tip and check its condition.Replacethetipifitisbadlywornorappearstobedeformed. 3. If the solder plated part of the tip is covered with black oxide, apply freshsoldercontainingfluxandcleanthetipagain.Repeatuntilallthe oxideisremoved.Coatthetipwithfreshsolderafterwards. 4. TurnOFFthe power andremovethe tip using heat resistant pad. Set thetipasidetocool. 5. Remainingoxides such as the yellow discolorationon the tip shaft can beremovedwithisopropylalcohol.

CAUTION:Neverusefiletoremoveresiduefromthetip.

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OPERATINGGUIDELINES
5. SetthedesiredairtemperatureusingbuttonsA3andA5. 6. You may start reworking as soon as the desired temperature is reached.RefertodisplaypanelC3toverify. 7. Whenreworkingiscompleted,turnofftheSMDReworkpower switch.Theautocoolingfunctionalitywillcommenceifthesystem detectsatemperaturehigherthan95C.Airatroomtemperature willblowatfullspeedtoacceleratethecoolingdownofthehotair gun.Theautocoolingfunctionalitywillstopwhenthetemperature of the hot air gun reaches about 95C or below, asshown from the actual temperature display panel, C3. The system will then switch off and display an OFF message from userdefined temperaturedisplaypanel,C2. NOTE: MakesurethesmokeabsorptionfunctionalityisswitchedOFF whenusingtheequipmentforSMDRework.

PANELCONTROLS

A1

Airpressureregulator Solderingirontemperatureregulator Increasehotairguntemperature Resethotairguntemperature Decreasehotairguntemperature Solderingironpowerswitch Smokeabsorberpowerswitch SMDreworkpowerswitch Airpressureindicator Settemperaturedisplay(Hotairgun) Actualtemperaturedisplay(Hotairgun) Solderingironterminal Vacuumoutlet Hotairgunoutput

SOLDERING 1. With the unit plugged to the main power source, turn ON the Solderingpowerswitch,B1. 2. Useregulatingknob,A2,tosetthedesiredsoldertemperature. 3. Start soldering when the indicator light above the Soldering power switch starts blinking. This means the temperature of the solderironhasreachedthedesiredtemperature. 4. Switch the Smoke Absorber power, B2, ON to activate the smokeabsorptionfunctionality. NOTE: Turn the Smoke Absorber ON after the soldering iron reached the desired temperature. This is to avoid affecting the temperatureincreaseofthesolderingironintermsofheatingtime.

A2 A3 A4 A5 B1 B2 B3 C1 C2 C3 D1 D2 D3

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PREPARATION
A.SolderingIron 1.Installsolderwiretothesolderironholder(seeFigure1).

OPERATINGGUIDELINES
SMDREWORKING 1. With the unit plugged to the main power source and all unit switchesOFF,thepanelshouldinitiallydisplaytheproductname inascrollingmanneranddisplayoffonpanelC2after.

Figure 1. Soldering Iron stand with solder wire holder

2.Attachthesolderingirontothemainunitviathe5pinoutput terminal,D1,foundattheleftsideofthecontrolpanel. 3.Placethesolderingirontothesolderingironstandasshown inFigure1. B.SmokeAbsorber Attach the smoke absorbing pen to the smoke absorber output terminal, D2, on the control panel. Make sure that the cord connectionsarefreefromanytangles. C.HotAirGun Placethehotairguninthestandtoprepareforusage.

NOTE: The product name may scroll more than once upon pluggingthesystemtothepowersource.Thesystemistryingto determinetheappropriateoperatingfrequencybasedontheuser location. This is normal and should not have any impact to the device. If the product name keeps on displaying for more than thrice, please refer to the Basic Troubleshooting Guide at the backofthismanualforresolution(seepage1415). 2. TurnONtheSMDReworkpowerswitch,B3. 3. Thesystemwillstarttoblowhotairandincreasethetemperature to 90C, by default. Display panel, C2, shows the userdefined (set) temperature while display panel, C3, shows the actual temperatureofthesystem. 4. Adjust air pressure by turning knob A1. It is recommended to keep the knob setting at3 or above.Itis also advised to adjust the airflow level first before increasing the air temperature to avoidthermalshockonthecomponents. NOTE:Ifairpressureknobissettominimumuponswitchingthe SMD Rework ON, the system will automatically run at average airflow to protect the device from excessive heat. The user will gainfullcontroloncetheknobhasbeenadjustedtothedesired

airflowlevel.