Weller WA2000 User Manual

WA2000

SOLDERING IRON ANALYZER

INSTRUCTION MANUAL

INTRODUCTION
The WA2000 soldering iron analyzer was developed for testing soldering irons for

compliance with the DOD-STD-2000 and the new MIL-STD-2000 specifications. This
portable unit is capable of testing tip temperature, tip to ground resistance and tip to
ground noise (mVRMS). Correctly used and maintained, it is the most accurate of any
comparable tester currently available on the market. Please read this document
thoroughly, prior to using the WA2000.

TEMPERATURE

Range: 32 to 10400°F (0 – 560°C)
*Accuracy: Contact Pyrometer, ±.1% over a ten degree span (stability).
Auxiliary T/C, ±.5% of reading (Absolute) ±1 digit.
Resolution: 1°F or 1°C, user selectable

Sensor: CP-01** or CP-02** Contact Pyrometer, K-111, K-121, K-181 Type K

Thermocouple assembly.

*NOTE: Analyzer accuracy only. Tolerance of thermocouple and external fixturing

must be added.

**Patent pending

TIP OHMS TO GROUND

Range: 0 to 100 Ohms
Accuracy: 1% of reading ±.2 Ohms

Resolution: .1 Ohms
Test Current: 10 milliamperes AC Current Sou rce to RMS Conversion.
US Patent #5,073,758

TIP VOLTAGE TO GROUND

Range: 0 to 100 mV RMS, Crest Factor of 3
Accuracy: 1% of Reading ±0.2mV

Resolution: 0.1 mV
Measurement: True RMS conversion

Digital Display: 3 1/2 Digit LCD
Power: 9VDC Battery

Battery Life: 50hrs.

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TIP TEMPERATURE MEASUREMENT

The unit has the ability to check for either temperature stability (T) or absolute
temperature. To perform these tests, two methods must be used.

TEMPERATURE STABIL ITY

This test is used for compliance with the MIL-STD-2000 requirement. The detachable
contact pyrometers were designed for use in this test. The pyrometers will not give
accurate absolute measurements. Due to loading effects, the temperature measured

will be lower than the actual tip temperature (about 30°F or 17°C); however, stability can
easily be checked with the pyrometer. The T measured has an accuracy of better than
±0.1% over a ten degree span. This is more than adequate to fulfill the temperature
measurement requirements of the MIL-STD-2000 specification.

ABSOLUTE MEASUREMENT

The K-111 and K-181 thermocouple assemblies have been provided for making
absolute temperature measurements. These assemblies can also be used to monitor
active soldering and can measure temperature loading, excursions and heater
response. Although not a requirement for compliance to the MIL-STD-2000
specification, it does provide a good tool for process control and improvement.

MEASUREMENT PROCEDURE

1. Set the rotary selector switch to the TEMP position and the slide switch to °C or
°F to select the desired unit of measure.

2. Plug either a contact pyrometer or thermocouple assembly into the TEST
receptacle. If using a pyrometer, place the tinned tip of the iron to be tested onto
the contact pyrometer. Using the iron "holder" provided with the WA2000 will aid
in obtaining an accurate reading. Add additional solder to increase contact area
to each side of the pyrometer. Response time will be 5 seconds or less.

3. Record both the low and the high temperature reading and calculate T = (T

-

H

TL).

*** PLEASE NOTE ***

The ground adapter is provided for testing tip noise and resistance only. For
temperature measurements, the ground adapter must not be connected to the tester or
temperature errors can occur.

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TIP VOLTAGE POTENTIAL

Tip to ground noise is typically associated with any electrical voltage that is induced
by the iron itself and can be measured from the working area of the tip referenced to
ground. The DOD requirements are quite clear as to the maximum RMS voltage that
should not be exceeded.
To measure this low level voltage accurately, it should be tested under "ideal"
conditions, i.e., an electrically shielded screen room. This helps to eliminate spurious
noise generated from sources other than the iron itself.

MEASUREMENT PROCEDURE

1. Set the analyzer rotary selector switch to the mVAC position.

2. Plug the iron under test into the ground adapter and plug the adapter into an AC
source. Connect the ground lead from the adapter into the analyzer GND
receptacle and plug a pyrometer into the TEST receptacle (Do not use the K-111
or K-181 thermocouple assembly for this test).

3. With the iron under test off, contact the pyrometer with the iron's tip. The iron
"holder" provided with the WA2000 may be used to hold the iron steady. Record
the analyzer reading V

.

1

4. Turn iron under test on and allow to stabilize. With the iron's tip making contact to
the pyrometer, add additional solder to the tip to increase contact area. Allow to
stabilize for thirty seconds. Record the analyzer reading V2.

5. Calculate tip noise V

= V2 - V1. This procedure removes extraneous noise,

TIP

which is measured with the iron off. Remember, per the MIL-STD-2000
procedure, for adjustable temperature controlled irons, measurements are to be
taken at the maximum temperature setting. For fixed temperature irons,
measurements will be taken at its rated temperature.

TIP TO GROUND RESISTANCE

The WA2000 is capable of measuring tip to ground resistance up to 100.0 ohms. Per
the MIL-STD-2000 specification, an iron's tip to ground resistance must not exceed two
ohms. This measurement must be made with the iron hot. There is no need to be
concerned with polarity (Seebeck induced errors) since the patented circuit design
removes the error electronically which provides an accurate, corrected reading in ohms.

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MEASUREMENT PROCEDURE

1. Set the analyzer rotary selector switch to the OHMS position.

2. Insert the yellow plug from the ground adapter into the analyzer TEST receptacle
and the ground pin into the GND receptacle. Record lead resistance R

, which

L

will be subtracted later.

3. Remove yellow plug from the analyzer TEST receptacle and reinstall pyrometer.
Plug iron to be tested into the ground adapter and the adapter into an AC power
source. Turn on the iron under test and allow to stabilize. Lay the iron's tip onto
the pyrometer to complete the test circuit. Add additional solder to increase
contact area.

4. Record the reading R

and subtract lead resistance, RT - RL. The result will be the

T

iron's tip to ground resistance.

**IMPORTANT**

When making measurements, always use a clean tinned tip. A dirty oxidized tip can
cause erroneous measurements.

Always add additional solder to the tip and pyrometer, during measurement, to
ensure sufficient electrical contact. Do not add solder to the thermocouple assemblies.

RECORDER OUTPUT

A buffered output and recorder plug assembly has been provided for connection to a
chart recorder. This output can also be connected to a DVM with an IEEE 488 type
output for data acquisition and statistical analysis on a P.C.

Recorder Output Parameters
Temperature: 1mV/degree (°F or °C)

Resistance: 1mV/0.1 ohms
Tip Noise: 1mV/0.1 mVRMS

HANDS OFF OPERATION

A small stand is provided with the analyzer to enable the user to support the iron
under test when using the contact pyrometer. This helps in providing a stable method of
supporting the iron, which results in consistent measurements.

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MIL SPECIFICATION REQUIREMENTS AND FREQUENCY OF PERIODIC TEST S

REQUIREMENT MIL-STD-2000 DOD-STD-2000 WS-6536

Tip to ground, max.
resistance, hot

Tip to ground, max.
voltage, hot

Tip temperature, at
idle (stability)

Visual for damage,
oxidation, and
cleanliness

Proper operation and
performance

ESD per DOD-STD­1686

Note 1: Complete soldering within 2-5 seconds.
Note 2: Complete soldering within 5 seconds.
*Cleanliness only required
N.R. - Periodic test not required

For confirmation of specifications write to:
WD6536E-2 CODE 3681 Soldering Technology Standards

NAVAL WEAPONS SYSTEM
China Lake, CA 93555

MIL-STD-2000 CODE 9313 Soldering Technology Standards
NAVAL AIR ENGINEERING CENTER
Lakehurst, NJ 08733-5100

2.0 ohms quarterly 2.0 ohms quarterly 20.0 ohms daily

2.0 mv biannually 2.0 mv biannually 2.0 mv monthly

±10°F monthly ±10°F monthly ±10°F weekly

daily daily daily*

undefined
daily

N.R. N.R. N.R.

see note 1
daily

see note 2
daily

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CONTACT PYROMETER MAINTENANCE

The contact pyrometers have been designed for accuracy, ease
of use and low cost. As with any pyrometer, certain guidelines
should be followed in order to obtain maximum precision of
measurement.

Prior to use, it is important that the wire ends (A) be inspected
and cleaned if necessary. Use a solvent such as alcohol and a stiff
brush to clean the wires. It is sometimes necessary to use a sharp
instrument to shave the burned flux off. After about eight hours of
actual use it will be necessary to either file or clip off the wire ends.
The wire should then be bent to maintain a gap (B) of .06". This will
restore the pyrometer to like new condition. This process may be
repeated as many times as the wire length will allow.

DISPLAY CALIBRATION

1. Set the analyzer rotary selector switch to OHMS.

2. Connect a 100 ohm, ±0.1%, resistor from the TEST receptacle to the GND
receptacle.

3. Measure voltage from pin 7 (+) to pin 8 (ground) of the ribbon cable (pin 1 of the
cable is nearest to the battery leads, see figure on page 7) and adjust R3 on the
display board until display and volt meter readings match, i.e., 1.000V = 100.0
ohms.

TEMPERATURE CALIBRATION

1. Set the analyzer rotary selector switch to TEMP and the slide switch to °F.

2. Connect K-111 or K-181 thermocouple assembly to the TEST receptacle.

3. Measure room temperature with a calibrated thermometer and record
temperature T

.

A

4. Adjust R24 until display matches thermometer reading. Set the slide switch to °C
and adjust R85 until display reads the °C equivalent of room temperature, i.e., TA

= 72°F = 22°C.

5. Disconnect thermocouple assembly from the analyzer and set the slide switch to
°F.

6. Using a precision millivolt power supply, input 22.251 mVdc (type K equivalent
voltage of 1000°F) to the TEST socket.

7. Adjust R84 until display reads 1,000°F + (TA-32°F). For example, if room
temperature TA = 72°F then adjust display to read 1,000°F + (72°F - 32°F) =
1,040°F. Set slide switch to °C and adjust R81 until display reads °C equivalent

of °F input, i.e., 1,040°F = 560°C.

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mVAC RMS CALIBRATION

1. Set the analyzer rotary selector switch to mVAC.

2. Connect a signal generator to the analyzer TEST and GND receptacles. The test
cable should include an internal two ohm load from input (TEST) to ground
(GND).

3. With no signal applied (zero signal), adjust R80 for a reading of 00.0 on display.
Allow time for the reading to settle, it will take several seconds.

4. Connect a precision digital voltmeter to monitor input and adjust signal generator
output for a 100 mVAC RMS sinusoidal 60 Hz. signal.

5. Adjust R77 until the analyzer display matches the voltmeter reading.

OHMS CALIBRATION

1. Set the analyzer rotary selector switch to OHMS.

2. Connect a 100 ohm, ±0.1%, resistor to the analyzer TEST and GND receptacles.

3. Adjust R82 until the display reads 100.0 ohms, or the actual value of the
connected resistor.

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CUSTOMER SERVICE

Should your WA2000 analyzer require repair, it may be sent to the following address:

USA

CANADA

COOPERTOOLS- WELLER DIVISION COOPERTOOLS
1000 Lufkin Road 164 Innisfil Street
Apex, NC 27539 Barrie, Ontario, Canada L4N3E7
Attn: Repair Dept. Attn: Repairs
Phone: [phone] Phone: [phone] Ext. 2026
Fax. [phone] Fax. [phone]

REPLACEMENT PARTS FOR THE WA2000

(Please include model number when ordering these parts from your original supplier.)
Please allow six weeks for delivery of items marked with *.

ITEM DESCRIPTION P/N

1 Vinyl Accessory Case *C724
2 Ground Cord Adapter *7-3400
3 Contact Pyrometer, Large Gauge CP-01
4 Contact Pyrometer, Small Gauge CP-02
5 Type K Thermocouple Assembly, ETA tip K-111
6 Type K Thermocouple Assembly, EPH107 Tip K-121
7 Type K Thermocouple Assembly, LTB Tip K-181
8 Recorder Cable Assembly *P143
9 Iron Stand *S719

Weller offers a calibration and certification service for the WA2000 analyzer through the
factory. Contact above address.

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