Hakko 936 ESD temperature controlled soldering station
A soldering station is a multipurpose power soldering device designed for electronic components soldering. This type of equipment is mostly used in electronics and electrical engineering. Soldering station consists of one or more soldering tools connected to the main unit, which includes the controls (temperature adjustment), means of indication, and may be equipped with an electric transformer. Soldering stations may include some accessories – holders and stands, soldering tip cleaners, etc.
Soldering stations are widely used in electronics repair workshops, electronic laboratories, in industry. Sometimes simple soldering stations are used for household applications and for hobbies.
Soldering Station Components
The main soldering station elements which determine its compatibilities are soldering tools. Different tools are used for different applications and soldering stations may be equipped with more than one of them at a time. The main tools for soldering are:
Soldering iron is the most common working tool of a soldering station. Some stations may use simultaneously several soldering irons to make the process quicker and more convenient, as there is no need to change the soldering tips or readjust the station or the soldering temperature. Some stations may use some specialized soldering irons, such as ultrasonic soldering irons or induction soldering irons.
Soldering Irons
Soldering iron as a part of soldering station has a number of advantages.
Increased operability
The operator may set the temperature according to the solder alloy in use
Stability of the preset temperature.
Operation mode indication, including temperature display.
Better heating element quality
Main unit with power supply
Galvanic isolation of the heating element from the electricity network. This increases the safety of the operator and protects the components that are being soldered.
Heating element operates under low voltage (10-30 V), increasing safety. It also prolongs the lifetime of the heating element.
Grounding of the whole unit.
The station has a fuse.
Increased user comfort
The working part has smaller size and weight.
Station design integrates soldering aid accessories: soldering iron stands, soldering tip cleaners, etc.
Some stations have auto switch-off function.
However, most soldering stations can only be used on a desk and they usually cost more than a standalone soldering iron.
Desoldering Tools
Desoldering is a very important stage in PCB repair. It is often needed to disassemble some components just to make sure they work or check their condition. That is why it is important to detach the elements without any possible damage to them.
The means that may be integrated in soldering stations are:
SMD hot tweezers heat up and may not only melt the solder alloy but grab the needed component as well. They may have different types of tips for different applications.
Desoldering iron is usually made in a shape of a gun. It is capable of taking in the air (vacuum pickup) and solder alloy.
Non-contact heating tools include hot air and infrared heaters. They are used for SMT disassembling.
Hot Air Guns
Accta 301 soldering station with hot air gun and soldering iron
They use a hot air stream for heating up the components. Hot air is focused on the certain area using special hot air nozzles. Usually soldering hot air guns are capable of providing temperatures from 100 to 480 °C.
Infrared Heaters
Soldering stations with infrared (IR) heaters are a separate type of soldering stations and differ a lot. Such stations provide high-precision soldering and the process is more like that in electronics industry. The temperature profile may be set based on the components being soldered. This minimizes the risk of components deformation or damage due to the temperature difference.
Soldering Station Classification
Contact Soldering Stations
This type requires a soldering iron equipped with an electronic temperature adjustment unit. The main technical parameter of the contact soldering station is the power. The power determines the operation convenience and soldering effectiveness. The modern stations have power from 10 to 200 W and more. The most common are the models with 50-80 W power. The higher is the power the more amount of heat you may transmit for the same time. It allows reducing the temperature on the heating element to the minimal possible value for melting the solder alloy. And vice versa – the lower is the power the higher temperature you need to melt the solder. High temperature means a risk of a component overheating. Especially it concerns semiconductor components or electrolytic conductors.
According to the solder alloy used these soldering stations may be divided into two subtypes:
Tin/lead soldering stations
Lead-free soldering stations
This type of stations is characterized by heating element with a power up to 160 W. Lead-free solder alloys need higher temperatures to be melted, so the station needs more power. If the station is equipped with a temperature regulator, it may be used for operation with a traditional lead-containing solder.
Digital and analogue soldering stations
The stations may be divided into digital and analogue according to the control unit operation method.
Analogue stations have a temperature stabilization that operates as follows:
The heating element is working till the soldering tip reaches certain temperature, then the power switches off.
When the temperature becomes lower than a certain level the heating element is on again and the soldering tip is being heated.
The operation is ensured by the magnetoelectric relay. It is controlled by electronics and a temperature sensor. Analogue control system has an advantage – it is the cost. The disadvantage is a low operation precision that results in soldering tip overheating. This leads to problems like: electronic components overheating, often tip change.
Digital soldering station is operating using a PID regulator that is controlled by a microprocessor. Digital control method is more precise.
Induction soldering stations
Induction soldering stations are characterized by high power and excellent thermal stability. They use the technology of heating and thermal stabilization based on Curie temperature.
American manufacturer Metcal is a leader in this market segment, however there are other brands.
Non-contact soldering stations
Infrared soldering stations
Hot air soldering stations
Stations with hot air guns are used in cases when just a soldering iron is not enough. Disassembling microchips requires a hot air gun. SMD components soldering with hot air is much more convenient. Hot air guns usually come with special nozzles for hot air stream regulation. Popular manufacturers: Hakko, Quick, Accta, Goot, etc.
Rework systems
For professional laptop, game console and other electronics repair, special repair systems are used. These repair systems usually combine several components: hot air gun, soldering iron, desoldering gun, etc. This equipment allows effective desoldering and soldering large BGAs. These operations require special approach and certain amount of process automation. The most popular manufacturers: Ersa, Martin, Jovy Systems, Quick, Scotle.
A soldering iron is a hand tool used in soldering. It supplies heat to melt solder so that it can flow into the joint between two workpieces.
Surface-mount technology (SMT), originally called planar mounting, is a method in which the electrical components are mounted directly onto the surface of a printed circuit board (PCB). An electrical component mounted in this manner is referred to as a surface-mount device (SMD). In industry, this approach has largely replaced the through-hole technology construction method of fitting components, in large part because SMT allows for increased manufacturing automation which reduces cost and improves quality. It also allows for more components to fit on a given area of substrate. Both technologies can be used on the same board, with the through-hole technology often used for components not suitable for surface mounting such as large transformers and heat-sinked power semiconductors.
In metallurgy, a flux is a chemical cleaning agent, flowing agent, or purifying agent. Fluxes may have more than one function at a time. They are used in both extractive metallurgy and metal joining.
Tweezers are small hand tools used for grasping objects too small to be easily handled with the human fingers. Tweezers are thumb-driven forceps most likely derived from tongs used to grab or hold hot objects since the dawn of recorded history. In a scientific or medical context, they are normally referred to as just "forceps", a name that is used together with other grasping surgical instruments that resemble pliers, pincers and scissors-like clamps.
A reflow oven is a machine used primarily for reflow soldering of surface mount electronic components to printed circuit boards (PCBs).
In electronics, desoldering is the removal of solder and components from a circuit board for troubleshooting, repair, replacement, and salvage.
A hot plate or hotplate is a portable self-contained tabletop small appliance cooktop that features one or more electric heating elements or gas burners. A hot plate can be used as a stand-alone appliance, but is often used as a substitute for one of the burners from an oven range or a kitchen stove. Hot plates are often used for food preparation, generally in locations where a full kitchen stove would not be convenient or practical. A hot plate can have a flat surface or round surface. Hot plates can be used for traveling or in areas without electricity.
A heating element is a device used for conversion of electric energy into heat, consisting of a heating resistor and accessories. Heat is generated by the passage of electric current through a resistor through a process known as Joule Heating. Heating elements are used in household appliances, industrial equipment, and scientific instruments enabling them to perform tasks such as cooking, warming, or maintaining specific temperatures higher than the ambient.
Reflow soldering is a process in which a solder paste is used to temporarily attach anywhere from one to thousands of tiny electrical components to their contact pads, after which the entire assembly is subjected to controlled heat. The solder paste reflows in a molten state, creating permanent solder joints. Heating may be accomplished by passing the assembly through a reflow oven, under an infrared lamp, or by soldering individual joints with a hot air pencil.
In electronics, rework is the repair or refinish of a printed circuit board (PCB) assembly, usually involving desoldering and re-soldering of surface-mounted electronic components (SMD). Mass processing techniques are not applicable to single device repair or replacement, and specialized manual techniques by expert personnel using appropriate equipment are required to replace defective components; area array packages such as ball grid array (BGA) devices particularly require expertise and appropriate tools. A hot air gun or hot air station is used to heat devices and melt solder, and specialised tools are used to pick up and position often tiny components. A rework station is a place to do this work—the tools and supplies for this work, typically on a workbench. Other kinds of rework require other tools.
ColdHeat was an American company founded to develop and market products using the proprietary graphite-like compound Athalite. The composite material is claimed by the manufacturer to have the unusual ability to conduct large amounts of heat and return to room temperature in a short amount of time.
A soldering gun is an approximately pistol-shaped, electrically powered tool for soldering metals using tin-based solder to achieve a strong mechanical bond with good electrical contact. The tool has a trigger-style switch so it can be easily operated with one hand. The body of the tool contains a transformer with a primary winding connected to mains electricity when the trigger is pressed, and a single-turn secondary winding of thick copper with very low resistance. A soldering tip, made of a loop of thinner copper wire, is secured to the end of the transformer secondary by screws, completing the secondary circuit. When the primary of the transformer is energized, several hundred amperes of current flow through the secondary and very rapidly heat the copper tip. Since the tip has a much higher resistance than the rest of the tubular copper winding, the tip gets very hot while the remainder of the secondary warms at a much slower rate. An additional secondary winding is often used to power a pilot lamp which illuminates the workpiece.
A heat gun is a device used to emit a stream of hot air, usually at temperatures between 100 and 550 °C, with some hotter models running around 760 °C, which can be held by hand. Heat guns usually have the form of an elongated body pointing at what is to be heated, with a handle fixed to it at right angles and a pistol grip trigger in the same pistol form factor as many other power tools.
Electric heating is a process in which electrical energy is converted directly to heat energy. Common applications include space heating, cooking, water heating and industrial processes. An electric heater is an electrical device that converts an electric current into heat. The heating element inside every electric heater is an electrical resistor, and works on the principle of Joule heating: an electric current passing through a resistor will convert that electrical energy into heat energy. Most modern electric heating devices use nichrome wire as the active element; the heating element, depicted on the right, uses nichrome wire supported by ceramic insulators.
A fan heater, also called a blow heater, is a heater that works by using a fan to pass air over a heat source. This heats up the air, which then leaves the heater, warming up the surrounding room. They can heat an enclosed space such as a room faster than a heater without a fan, but like any fan, create a degree of noise.
Resistance wire is wire intended for making electrical resistors. It is better if the alloy used has a high resistivity, since a shorter wire can then be used. In many situations, the stability of the resistor is of primary importance, and thus the alloy's temperature coefficient of resistivity and corrosion resistance play a large part in material selection.
Dip soldering is a small-scale soldering process by which electronic components are soldered to a printed circuit board (PCB) to form an electronic assembly. The solder wets to the exposed metallic areas of the board, creating a reliable mechanical and electrical connection.
Ultrasonic soldering is a flux-less soldering process that uses ultrasonic energy, without the need for chemicals to solder materials, such as glass, ceramics, and composites, hard to solder metals and other sensitive components which cannot be soldered using conventional means.
Soldering is a process of joining two metal surfaces together using a filler metal called solder. The soldering process involves heating the surfaces to be joined and melting the solder, which is then allowed to cool and solidify, creating a strong and durable joint.
The "Scope" soldering iron is a tool for soldering with lead-tin alloys, made in Australia since 1950, and intended for occasional or intermittent use. It has the virtue of quickly coming up to soldering temperature (~300C) and delivering considerable heat to a small area, but requires care to avoid overheating. It operates on low voltage and high current from a battery or suitable transformer, so is by design electrically safe, and as it cools down rapidly when it leaves the operator's hand, should not constitute a fire risk.
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