- American Beauty Tools
Contents
1. If you have purchased a specific product it s product data sheet will be inserted in the centerfold of this manual www americanbeautytools com reesisteance soledereing a method of soldering where the heat to melt solder is instantaneously ponens by passing an electrical current through a resistive material Power Unit amp Footswitch The foundation of a resistance soldering system produces and controls an ample supply of safe high amperage low voltage current Handpiece Completes an electrical circuit carrying the current from the source through the pieces being soldered and back Electrodes Power Unit Generates an_ instant Footswitch ADU Handpiece and intense leve iii of thermal output as current is forced through its highly resistive material Advantages Smash Operational Bottlenecks Concentrated heat reduces solder many times over Flameless process Improve Solder Joint Quality Poor solder joints are often the result of insufficient heat throughout the joint creating weak spots Eliminate Thermal Damage Traditional soldering methods introduce too much heat into surrounding areas damaging critical components or desoldering of previously soldered joints Reduce Liability Hon weignt handpieces cool within seconds greatly reducing the likelihood of repetitive strain injury and virtually eliminating the burn risk for the user Solder in Tight Spots Versatile syste2. testing Note Please keep in mind that while cleanliness of materials has always been paramount to a quality solder joint it takes on an even greater importance with resistance soldering Oxidation contaminants and any coatings can impede the flow of electricity and render resistance soldering ineffectual e Begin with a mid range power setting e Ensure a good fit between the components to be soldered Establish contact between the electrode s of your handpiece and the components Electrodes should be as close to the solder joint as practically possible e Depress the footswitch You can often feel and hear that the system has activated by a slight vibration in the handpiece and buzz in the power unit If you do not it s most likely that an electrical circuit has not been established Check connections and cleanliness of components and electrodes Hold solder at the joint so that it will begin to reflow as soon as the temperature at the joint permits If solder has not flowed after 20 seconds STOP Allow components to cool turn the power setting higher and repeat e Once you are satisfied with the amount of solder added to the joint release the footswitch and let cool Warning Components will take much longer to cool than they took to heat e Evaluate solder joint and surrounding materials e Did the solder flow too quickly resulting in an unreliable solder joint or uncontrollable application of heat If so turn the
3. com The goal of your process is to establish the shortest controllable cycle time to achieve a quality solder joint without causing thermal damage to the components being soldered To develop this process you will need a basic understanding of how resistance soldering generates heat and some scrap pieces for testing Resistance soldering systems require an electrical circuit running from the power unit down the handpiece and through the solder joint itself which is why our systems cannot be used to heat non conductive components Handpiece Current returning to power source Joint to be apeo soldered ST Direction 5 of current flow through 51141 materials ae Electrode Current flow from power source In the graphic above the electrodes holding the soldered components have a much higher degree of electrical resistivity than the rest of the circuit When electricity is forced through a resistive material the result is heat Since the components being soldered have their own unique resistive qualities heat is also being generated within the joint itself The result is virtually instantaneous intense heat that stays largely localized to the point s of contact Therefore heat and speed at the solder joint is going to be unique to each application based upon system used and materials components soldered Hence the need for a trial and error approach to process development that will require scrap components and a few rounds of
4. e Electrodes can be bent to allow for even better access to difficult locations Tip from our Soldering Guru Insert the electrodes into a vise amp bend to approx 25 degrees reinsert rotate and align so that tips are at appropriate distance to match your application e Tweezer functionality and lighter handpieces lends itself to hold in place functionality during soldering operation and electrodes last considerably longer than soldering tips e Available systems run from 100 to 1 800 watts maximum working opening between electrodes ranging from 375 to 625 and electrode diameters from 04 to 1 8 12 PLIER STYLE SYSTEMS e The carbon electrodes used in these systems have a higher intrinsic resistivity to electricity and permit more surface contact than the steel electrodes used in tweezer systems The result is more intense heat and better thermal saturation lending these systems to tackle more demanding applications such as semi rigid coax brazing operations and production work e Electrodes can be easily shaped or notched with a jewelers file or similar tool Tip from our Soldering Guru Modify the electrode to match the contour of the intended components surface A little extra time in prep results in easier soldering later e Available systems run from 250 to 3 000 watts working opening between electrodes ranging from 25 to 3 and electrode widths from 25 to 5 Resistan
5. read this manual carefully It contains all the information required to understand how to properly set up operate amp maintain this American Beauty equipment Additionally please feel free to visit our full service website www americanbeautytools com for links to instructional videos product specifications a technical blog an on line shopping cart and much more For those new to Resistance Soldering Brazing and it s many uses rest assured it is a tried and true product that offers many benefits American Beauty has been manufacturing testing and refining their entire line up of Resistance Soldering Brazing and Thermal Wirestripping equipment for over fifty years As the manufacturer of the world s largest assortment of power units handpieces and related accessories we pride ourselves in being the leader in the design and development of resistance based soldering equipment All American Beauty products are manufactured using the highest quality materials available and are assembled with great care so they will consistently conform to our quality specifications This manual will provide an overview of the principles behind Resistance Soldering Brazing and Thermal Wirestripping and other applications requiring intense localized heat General operating procedures as well as guidelines for model system selection will be covered to help make your Resistance Soldering Brazing or Thermal Wirestripping experience a positive one
6. setting lower and repeat as necessary until satisfied e Was the cycle time too slow resulting in thermal damage to the components and or surrounding materials Turn the setting higher and repeat as necessary until satisfied e Ideal cycle times are typically between to 8 seconds Larger joints or brazing will require longer cycle times Please pay close attention to Risk of Thermal Damage Caused by Overuse pg 10 Watch our Soldering Guru tackle all sorts of challenging jobs using our Resistance Soldering Systems Scan here or follow this link www youtube com user SolderingGuru www americanbeautytools com ever present concern wit any resistance based system is the buildup of heat within the system s handpiece and power unit Left unchecked this buildup can cause permanent non warrantied damage to your system Here are some steps that should be taken to reduce this occurrence Follow a 50 50 Duty Cycle as a general rule your system should idle cool for an equal period of time that its active with cycle time not exceeding 20 seconds Monitor the Heat Operator MUST monitor the heat that builds up within their handpiece s cables and handle Warm is normal Hot is a clear sign that the system is being overtaxed and should be allowed to rest and dissipate the heat Reduce cycle time You always want to be soldering as fast as controllably possible The longer you are active on a solder join
7. C and high voltage 220 240VAC version Please consult your cord label to determine what version you have purchased and ensure your system is properly plugged in to the appropriate outlet Always wear Personal Protective Equipment PPE when operating your system This includes safety glasses protective gloves and sleeves if necessary to cover your body The temperature of your electrodes and parts of your handpiece can reach in excess of 900 F Mishandling can result in a serious burn or fire Do not touch any metal parts of the handpiece while in operation Do not use the unit for any application other than its intended use Do not leave unit unattended Soldering will produce smoke Make sure the soldering location selected is well ventilated Let the handpiece cool to room temperature prior to storage or before changing electrodes Always make sure the unit has been properly turned OFF and unplugged when finished using or prior to moving unit Never attempt to perform repair replacement diagnostics or routine maintenance while unit is plugged in Repairs should only be performed by a qualified technician familiar with the product Do not modify the system or use it with damaged parts www americanbeautytools com TWEEZER STYLE SYSTEMS e Family of systems ranging from those appropriate for micro connectors and PC Board work to those with enough power to tackle large military connector and 4G antennas
8. Sao neice Soldering Solutions User Manual for Resistance Based Soldering Brazing amp Thermal Wirestripping Systems MADE IN USA TABLE OF CONTENTS 2 INTRODUCTION 3 INTRODUCTION TO RESISTANCE SOLDERING 4 5 Definition 4 Core Requirements 4 Advantages 5 QUICK START GUIDE 6 7 Basic Set Up 7 DEVELOPING YOUR PROCESS 8 10 Risk of Thermal Damage Caused by Overuse 10 Refining Your Process 10 SAFETY 11 TWEEZER STYLE SYSTEMS 12 PLIER STYLE SYSTEMS 13 PROBE STYLE SYSTEMS 14 WIRESTRIPPING amp REFLOW SYSTEMS 15 WARRANTY AND SERVICE DETAILS 16 Company Information American Beauty Tools are made just outside of Detroit Michigan USA Ph 1 248 280 2810 1 800 550 2510 Fax 1 248 280 2878 Email into americanbeautytools com Website www americanbeautytools com American Beauty has been a fixture the soldering tool marketplace since 1894 Our tools are a throw back to a time when people took pride in the tools they used and companies took pride in the tools they manufactured Today American Beauty tools are routinely chosen to tackle the most challenging soldering brazing and thermal management applications with a diverse line of soldering irons and stations solder pots resistance soldering systems and accessories With these types of tools the operator plays an essential role in achieving quality end results avoiding injury and ensuring a long product lifespan Please ensure that you take the time to
9. ce Brazing System Resistance Brazing System High Capacity 13 www americanbeautytools com PROBE STYLE SYSTEMS Probe systems require the use of a return lead to close the electrical circuit required for resistance systems to function When this is feasible single probe systems are highly desirable as they offer instant localized heat combined with pin point control Ideal for multi pin connectors multiple joints along a bus bar and many other challenging joints Try using a conductive plate or mounting fixture for added repeatability Tip from our Soldering Guru Depending upon materials being soldered the return lead does not always have to be clamped directly on or even near the joint being soldered Available systems run from 100 to 3 000 watts with electrodes diameters ranging from 1 16 to V Ultra Light Capacity Probe Style 10508 Light Capacity Probe Style 10519 14 WIRESTRIPPING amp REFLOW SYSTEMS Wirestripping and Reflow systems Thermal Wirestripping System Micro Capacity Thermal Wirestripping System Std Capacity Thermal Wirestripping System High Capacity differ from the other styles of resistance soldering systems as these systems pass a controlled current through a closed loop resistive material creating a hot formed wire that can be used to strip insulating jackets off wires including Teflon and other PTFE type materials used as a hot knife to melt and tri
10. ight will not come on at this point 5 Depress the Footswitch The indicator light for power should come On when the Footswitch is depressed and Off when it is released 6 With the Power Unit Off install the Handpiece to the Power Unit by inserting the taper pins into the receptacle or by threading the ring terminals onto the threaded posts Image 3 amp 4 next page In the case of a Single Probe Handpiece the Lead for Return Current will need to be used amp wie Noe and wine You are ready to start using your system Systems can be operated without a footswitch but it is not recommended All of the American Beauty Handpieces use either a Ring Terminal or Taper Pin to connect to the power unit Always connect the handpiece to the power unit with the power OFF or unit unplugged LA eS Ring Terminal Taper Pin It is essential that the connection between the handpiece and power unit is flush and secure at both points to avoid intermittent heating at the solder joint It is a good habit to double check these connections at the beginning of each shift or after extended down time The output receptacles on your power unit that the handpiece plugs into should be treated like a plug outlet in the wall DO NOT apply a metal piece or strip across these receptacles as it will result in live current being released and could lead to electrical shock www americanbeautytools
11. m plastics and waxes reflow solder balls and even perform some wood burning Wirestripping handpieces are either tweezer style for smaller gauge or V notch style for stripping the insulation on large wires and cables Stripping with heat versus a blade guarantees not fo nick any conductors Available systems run from 100 to 1100 watts with a wide variety of handpiece styles Model Name Reflow System Micro Capacity 5 5 5 1OSRFH 15 Reflow System Standard Capacity Reflow System High Capacity www americanbeautytools com American Beauty tools are warrantied to be free from defects in material and workmanship as outlined below No warranty is made with respect fo products which have been altered subjected to abuse or improperly used Consumable Parts NOT COVERED Items include such parts as Soldering Iron Tips Desoldering Braid Resistance Soldering Elements and Electrodes etc Serviceable Parts 90 DAY PERIOD Items include such parts as are Heating Elements Thermostats Voltage Controllers Cord sets etc It is the customer s responsibility to make themselves aware of proper operating parameters that when not followed can greatly reduce the life span of this type of part Standard American Beauty Products 3 YR PERIOD These items include all American Beauty soldering tools that don t fall into the two categories highlighted above Complete warranty details can be loca
12. ms allow easy access to restricted areas Cut Down on Energy Consumption Instant heat means yov re not paying to heat a soldering station all day long Save on Maintenance and Consumables Electrodes last twice as long as soldering tips and don t require constant re wetting tinning American Beauty When it comes to Resistance Soldering no other company the world combines the depth of knowledge with the breadth of product offerings as American Beauty Tools We offer the widest selection o andpieces electrodes and power units and bac our equipment with the industry s best warranty 5 www americanbeautytools com System set up for Resistance Soldering is fairly simple and requires relatively few steps Care should be taken during each step by keeping in mind the Safety Guidelines outlined later in this manual Most of our Resistance Soldering Systems come with 3 basic components Power Unit Footswitch Handpiece additional components may be included depending on the system you have purchased 1 Insert the plug from the Power Unit into piggy back receptacle on the Footswitch Image 1 Note Our high voltage versions feature hardwired footswitches eliminating this step 2 Plug the Footswitch Power Unit plug combination into an appropriately rated outlet Image 2 3 Adjust the power setting on the Power Unit to the lowest setting if applicable 4 Turn the Power Unit On Note the power l
13. t the more time for heat to buildup within the handpiece and power unit Turning up the power shortens the active cycle time and thereby reduces the opportunity for thermal build up If you are already operating at the top power setting you may wish to investigate moving to a high wattage power unit Handpiece Stacking If your application simply requires prolonged active cycle times investigate running two handpieces off of one power unit This is called handpiece stacking and can assist heavy users in production style environments For those desiring further control and refinement once their process has been developed a Precision Timer Module can be added to the system to more accurately control your cycle time making it more repeatable and reliable The Precision Timer Module can be set to your cycle time requirement and used to power up your system for a defined period of time accurate to a hundredth of a second American Beauty offers the 105PTM for systems 1 100 watts and less or the 105HCPTM for systems of 1 200 watts or more As with any soldering process the presence of electrical current and high temperatures are required to make the system work Each application should be evaluated for unique safety needs beyond the general guidelines listed below and the appropriate training developed Most American Beauty Resistance Brazing and Thermal Wirestripping Systems are available in both a low voltage 110 120VA
14. ted on our company website at www americanbeautytools com warranty Eventually even the toughest soldering tools require minor repair work We have expanded our internal repair department and reassigned our most experienced technicians to work on repairs We implemented customized software fo ensure accurate and timely processing of all returned products Save yourself unnecessary downtime and aggravation by taking advantage of American Beauty s world class repair and refurbishment service Contact us today to make arrangements or visit www americanbeautytools com repair
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