Weller DTL1000 User Manual

MODEL DTL1000 THERMOLOCK® PRECISION ELECTROSTATIC DISSIPATIVE SOLDERING STATION

The DTL1000 Soldering Station offers the ultimate in
controlled temperature hand soldering tools for production
and repair facilities at the lowest possible cost. The
DTL1000 combines two complete and separate control
units in one housing to minimize required bench space.
The user has the choice of using EC1201A or EC1503A 40
watt tools, EC1302A 20 watt tools, EC1204AP or
EC1504AP 54 watt tools, or any two of the five. These
tools are designed to be used interchangeably without
adversely affecting the tip temperature calibration; and a
wide variety of tip styles are available for each tool. See
insert for available tip styles.

The Thermolock® tool design controls tip temperature through the use of a Thermolock® key. The key is plugged into the
front panel of the unit and is marked with the calibrated temperature. The key contains a precision resistor element that
sets the electronic circuitry of the tool to the temperature indicted on the key. The tip temperature set by the key is not
adjustable by the operator; but can be changed by replacing one key with another key marked with a different
temperature. The Thermolock® key provides the manufacturing engineer with control of the soldering tip temperature
selection. The keys are available for 600°, 650°, 700°, 750°, 800°, and 850°F in three categories to allow for different tip
styles.

Dynamic response to soldering load variation is insured by use of a rapid response platinum sensor and full proportional
heater control. The sensor is positioned deep inside the solid copper, iron plated tip to insure quick response.

The electronic circuitry features a custom integrated circuit to give precise tip temperature control. The heater power is
controlled by a zero voltage circuit in the IC, which drives a thyristor to insure that no switching transients are present on
the tip. In addition, the power unit is isolated from the AC line by a transformer and only 24 VAC is used to drive the heating
element. The soldering tip is grounded through the power units three wire line cord. These features combine with the
calibrated temperature control to give the ultimate in safety for sensitive hand soldering.

The Weller® ESD soldering stations carry the science of hand soldering one level higher. These stations also have complete
freedom from stored static charges. The blue plastic used in this product meets the requirements for ELECTROSTATIC
PROTECTIVE MATERIALS as required in MIL-B-81705. The blue plastic material passes STATIC DECAY tests per Federal
Test Method Standard Number 101, and SURFACE RESISTIVITY test per ASTM-D257. The station housing and hand piece
are grounded with a separate conductor that terminates at the third pin on the power cord. All Weller® ESD tools comply
with DOD-HDBK-263.

The Weller® DTL1000 units are UL listed and meet DOD-STD-2000, MIL-STD-2000, MIL-STD-45743, W-S-6536, W-S-570,
AND DOD-STD-1686.

DTL1000 OPERATING INSTRUCTIONS

Unpack unit carefully. Place spring and funnel in slot in top of tool stand. Attach tool stands to sides of power unit, if
desired. Fill stand reservoirs with water and wet sponge, distilled water is preferred. Insert tools in holders and connect tool
plugs to receptacles properly grounded AC receptacle and turn unit on. If the desired temperature keys are not installed,
the keys may be changed while power is on. Wait 30 seconds and tin tip with solder. Unit is now ready for use.

Always use the lowest temperature that will handle the load you are soldering. The Weller® electronic control provides
maximum power to the heated load even when set to the lowest temperature; therefore, there is no need to use high
temperature to handle heavy soldering loads. By using lower temperatures and properly selecting tip styles, sensitive
components will be protected from heat damage.

WARNING: Do not remove ground prong from line cord plug. Removal may cause tip temperature control

to be erratic.

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SPECIFICATIONS

1. Power input: 120 VAC ±10%, 60hz, 120 watts.

2. Power unit output voltage: isolated 24 VAC @ 3.4 amperes.

3. Size: 4.5" x 5.875" x 3.625".

4. Line Cord: 3 wire, U.L. recognized.

5. Tip temperature control range: 600°F to 850°F (315°C to 455°C).

6. Control Accuracy: ±10°F of setting at idling temperature. No load - 30 minute warmup.

7. Ambient temperature range: 60°F to 110°F (16°C to 44°C)

WARNING: AC line voltage is present inside power unit even when power switch is off. Refer service to

qualified personnel.

NOTE: Access to internal parts may be gained by removing four rubber feet, four bottom screws and top

case.

1. Tool does not heat.

1.1 Neither heater on indicator LED illuminates:

1.1.1 Check power line on indicator LED illuminates:

1.1.2 Check for 12-15 ohms at line cord blades.
Fuse open - replace. Fuseholder located on bottom of case. Replace fuse with 1

Amp rating.
Line cord open - replace.
Transformer defective - replace.

1.2 Either heater on indicator LED illuminates:

1.2.1 Troubleshoot soldering tool.

1.2.2 Check switch for side that is inoperative.

1.2.3 Check continuity from receptacle pins to control board.
Repair as required.

1.2.4 Replace control board.

2. Tool overheating.

2.1 Troubleshoot soldering tool.

2.2 Replace control board.

3. High tip voltage or indication of circuit component damage.

3.1 Check for 2 ohms maximum from tip to ground prong on line cord plug, repair as required.

4. Tip temperature testing errors.

4.1 Tip temperature testing must be done using 30 gauge thermocouple wire resistance welded to the
center of the wetted area on the tip, tinning should be removed before welding. Other methods or heavier
gauge thermocouple wire will cause errors. WTTK1 and WTTK2 temperature test kits are available.

4.2 Replace soldering tool with different tool and recheck tip temperature. If this corrects the readings, the sensor
in the soldering tool should be replaced.

4.3 Adjust the potentiometer on the control board.

4.4 Replace control board.

CUSTOMER SERVICES

Should your DTL1000 require repair of adjustment it may be sent to the following address:

Cooper Tools - Weller Division

1000 Lufkin Road

Apex, NC 27539

ATTN: Repair Department

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