SOLDERING MANUAL A simple, yet easy to follow manual for your basic soldering needs. Copyright 2017 TortugaPro. All Rights Reserved

Transcription

1 A simple, yet easy to follow manual for your basic soldering needs Copyright 2017 TortugaPro. All Rights Reserved

2 Purpose Soldering is not limited to electrical and electronics work. It is a skill that can be used for various projects. Soldering is a quick way to join many types of materials, and creates a strong, electrically conductive bond. One of the primary uses is to join components resulting in a permanent connection between electronic components, this allows a reliable circuit to be formed. The reliable operation of a circuit with soldered connections depends on good soldering practices. Soldering differs from welding. In welding, the component pieces are melted together; in soldering, a softer metal with a lower melting point is used to connect them. Because soldering doesn't melt components, it's useful for more delicate applications, such as electronics work, or plumbing. Definition The joining of less fusible metals through the use of a low-melting alloy (solder). Soldering occurs at relatively low temperatures (around 400 degrees Fahrenheit). It is a process in which two or more metal items are joined together by melting and then flowing a filler metal into the joint (solder) the filler metal having a relatively low melting point. Apprehension - Those who ve never used a soldering iron are afraid of damaging equipment. But the true danger is injury to yourself. Protective gloves and safety glasses should be worn at all times. Keep loose clothing and hair out of the way. Remember that soldering is a skill that can be done well with practice. Common sense and preparation is the best practice. Be careful with your eyes and hands. Always take proper precautions and you ll be fine. Safety Precautions: Always were safety glasses or goggles, use protective gloves and work in a well ventilated area. A soldering iron can heat to around 425 C, which can cause serious burns (remember that solder itself is molten metal). USE CAUTION WHILE WORKING WITH A HOT SOLDERING IRON. Always return your soldering iron to its stand. Un-intentional damage of surrounding area or to your project will occur if not handled properly. Your soldering iron stand should be on a stable, level work surface. During soldering projects, take great care to avoid touching the tip of the soldering iron on to the electric cord. Serious risk of electric shock may occur if the power line is melted or compromised. Never leave the soldering iron unattended. Unplug the iron when it is not in use. Solder typically contains lead. Always wash your hands thoroughly after working around or handling items that may contain lead. It s important to work in a well-ventilated area as fumes from the rosin and flux can cause damage to your lungs when inhaled. Keep out of reach of children.

3 Materials and Equipment Soldering Iron A soldering iron is used to heat the connections to be soldered. Soldering irons are designed to apply focused heat to the tip of the iron. There are multiple tips in this kit, care should be given to choose the one that best fits your particular task. Solder Solder is a thin wire material, usually rolled in spools, made of various metal alloys. The following types are discussed: Rosin core solder - The term rosin core means that its core contains rosin. Rosin acts as a flux and is applied to surfaces that are to be soldered together. Flux cleans the surfaces, prevents oxidation and removes impurities, resulting in a better bond. It is best used on electronic equipment. Acid core solder - Is used to join copper pipes and has an acid core. It is appropriate for pipes, but will corrode electronic connections. Pro Tip: Historically, many solders contained lead or cadmium, but for health and environmental reasons, these are being phased out. It is critical to know your solder. The solder in this kit is 60% tin/40% lead. This is one of the most common solders used today. For most electronics work, a solder with a diameter of 0.75 millimeters (mm) to 1.0 mm is best. Thicker solder might make soldering small joints difficult and also increases the chances of creating solder bridges between copper pads that are not meant to be connected. Soldering iron stand (various types are available) A soldering iron stand is used to keep the hot soldering iron safely away from you and the work area. Sponge A damp sponge should be available and is used to clean the tip of the soldering iron. Solder braid (a.k.a. desoldering braid or wick, or solder wick) It is used to remove solder. To use the braid, you place it over the solder to be removed and heat it from above with the soldering iron. The solder will flow into the braid by capillary action. It can also be used to reduce the amount of solder on a connection.

4 Preparation The success to any project is preparation. Soldering successfully takes practice. The following steps will aid your success: Pro Tip Always clean your components! This can be done by cleaning with water or isopropyl alcohol, sand paper or flux. Metal components should always be clean and have a shine. Dirty components will not bond properly, require excessive heat, and corrode quickly. Dull, or oxidized finished are the tell signs for a poor repair. Tinning the Tip Place the soldering iron in its stand and plug it in. Wait for the soldering iron to heat up. Moisten the sponge. Wipe the tip of the iron on the damp sponge. This will clean the tip. Melt a little solder on the tip of the iron. This is called tinning and it will help the heat flow from the iron's tip to the joint. Pro Tip: A dirty tip means that you ll have to hold the soldering iron on longer and risk heat damage to the electronic component. The solder should flow onto the tip, producing a bright shiny surface. Wipe excess solder off on the wet sponge. If the solder will not flow onto the tip, clean it by wiping it on the wet sponge. You do not need to tin the tip before every joint, but you should re-tin it if it has gone dull when the soldering iron has not been used for a few minutes. The tip of the soldering iron should be a shiny silver color. If it is black and pitted, replace it with a new one. You may also check the manufacturer's instructions related to tinning a tip. Soldering (Solder will not flow over a dirty connection) To solder, heat the connection with the tip of the soldering iron for a few seconds, then apply the solder (Heat the connection, not the solder). CAUTION: Don't overheat the connection, as this might damage the electrical component you are soldering. Hold the soldering iron like a pen, near the base of the handle. Both parts that are being soldered have to be hot to form a good connection. Keep the soldering tip on the connection as the solder is applied. Solder will flow into and around well-heated connections. Use just enough solder to form a strong connection. Remove the tip from the connection as soon as the solder has flowed where you want it to be. Remove the solder, then the iron. Don't move the connection while the solder is cooling.

5 Pro Tip: Modern electronics, particularly Printed Circuit Boards (PCBs) are being manufactured using Restriction of Hazardous Substances (RoHS) compliant, Lead-free Solder. This solder has a smaller working temperature than traditional solder. A great way to aid your project is to use a hair dryer or heat gun to heat up your project (you want it warm, ~ 150deg. C.). This will help allow your subcomponents to reach optimal temperature without localized hot spots that can damage or ruin your project. Soldering a connection should take just a few seconds. Do not blow on the solder or try to help it cool. This may make your solder appear lumpy or add impurities that may deteriorate its conductivity. Inspect the joint closely. It should look shiny. If the connection looks bad, reheat it and try again. Wipe the tip of the iron on a damp sponge to clean it. The tip should now be shiny. Unplug the soldering iron when it is not in use. Desoldering When removing a connection or undoing a mistake, you can often re-solder over the original and add a touch of new solder. If you want to take the extra step and do it right, you can remove the old solder completely and start with a fresh work area. There are two tools you can use for this, a vacuum-based solder sucker, or (as previously discussed) a solder braid. A solder sucker is essentially a tiny hand-held syringe-like pump. It creates and uses vacuum pressure to suck solder away from the working area. Additional Soldering Tips: Soldering isn't especially dangerous or difficult if you take necessary precautions. To solder efficiently and effectively as possible, there are a few additional pieces of equipment you should have. Use clamps or alligator clips to hold the components in place while you solder. Use adequate lighting to ensure that you can see project as clearly as possible. Use additional ventilation and keep fresh air constantly flowing if you re going to be soldering for an extended period of time. Even without lead in the mix, there can be harmful fumes produced from soldering. Use the correct soldering iron temperature setting for your materials. Re-tin your soldering iron's tip periodically while using, and once more before you put it away. This will help to extend the life of your iron. Pro Tip: Always use the minimum heat setting required to melt the solder onto your project. A common mistake is to crank up the heat settings to maximum and throw on solder. If you are new at soldering, start at a lower temperature and work your way up. Take your time, be patient and don t rush your project. Heat damage is often worse and costlier than taking your time.

6 Common Problems and Troubleshooting Solder will not flow: The parts to be joined may be dirty. Remove the solder and clean the parts. The connection looks grainy or crystalline: Parts were moved before the solder was allowed to cool. Reheat to form a good joint. You may need a larger soldering iron to heat connections adequately. The tip is oxidized: In order to conduct heat properly, your soldering iron needs to be free of any old solder. After being exposed to air, it oxidizes and insulates against heat. Heat needs to be able to conduct so that soldering can we can be done quickly and efficiently. Clean the tip with a damp synthetic sponge while the iron is hot. To avoid oxidizing the tip, do not leave the iron plugged in when not in use. There is too much or too little solder: Using too much solder can cause a solder bridge, which means that two adjacent joints are accidentally connected. Using too little solder might result in poor electrical continuity between the board and component. The connection should be smooth, shiny, and rigid. Thank you and please visit our website for additional information: