The Revolutionary ERSA i-CON and i-Tool:
intelligent and Performing Power
For the Ultimate innovation in Hand Soldering
ERSA GmbH
Soldering & Inspection Systems
ERSA i-Tool / i-CON
Guaranteeing quality in a Lead Free
environment will put the greatest demands
on hand soldering applications. How well
the iron recovers or puts back the heat lost
at the tip and how long the tip remains on
the joint, ultimately determines the actual
joint temperature. Slow recovering irons will
lead to inconsistent joint temperatures.
Today, soldering iron manufacturers are
developing better performing irons, but
many are based on the tip being attached
to the heating element cartridge which
means the tip temperature can overshoot
and the tip price is very high! Such irons
force companies to throw away a perfectly
good and expensive heating element only
because the small copper tip is worn out!
To meet the Lead Free challenge, ERSA is
introducing its newest technology (patent
pending) for a state of the art solder station
The i-Tool has a highly advanced PCB integra-
ted into the handle for a level of intelligence
never before seen in a solder iron.
ERSA i-Tool
The World’s Most intelligent
Professional Soldering Iron!
Micro power soldering irons offer performance
and ergonomic advantages, but have the two
major drawbacks of tip temperature overshoot
and expensive heating cartridge tips.
Standard soldering irons where the sensor is located far
away from the tip will lead to inconsistent solder joint
quality. The tip looses temperature into the joints but does
not recover fast enough before the next joint is made.
As process windows become smaller, the
soldering task becomes more difficult. True
innovation demands more than just a nice
slogan, a catchy word. Today’s soldering
stations must be intelligent themselves but
intuitive for the user. The interactivity between
operator and station must be greater, and the
interactivity between stations themselves
must be greater. Truly ingenious solutions are
engineered to optimize process quality and
productivity while at the same time reducing
operating costs. These are the elements that
make up today’s ideal soldering station, and
these are precisely the elements that make
up the world’s most intelligent soldering iron
ever designed – the ERSA i-Tool!
Actual size
Expensive heating cartridge tips
Old iron technology
Highest Power & Performance:
• 150 W Micro Heating Element
(Patents Pending)
• Ultra Fast Heat up:
from 30 °C to 350 °C in approx. 9 sec.,
Standby to 350 °C in approx. 3 sec.
• Ultra Fast Heat Recovery Time
Ultimate Innovations:
• Process Window Alarm Function alerts
operator if tip temp is out of window
• Three Power Levels settings to control
overshoot
• i-Set Tool for quick & easy downloading
of parameter settings to all stations
• ASM – Automatic Standby Motion Sensor
• Calibration of i-Tool itself, independent
from station
Optimal Ergonomics & Ease of Use:
• Ultra Short Tip-to-Grip: 45 mm,
Ultra small: 155 mm, Ultra Light: 30 gr.
• Thinnest & Lightest Cable
for Maximum Comfort
• Dual Material Grip with “Soft Pad” stays
cool during use
• “One Touch” Easy to Use
Operation with new i-Op Control
• Ultra Large, Multi-functional Display
• Small footprint
W: 150 mm x L: 175 mm x H: 100 mm
• Automatic Tool Detection of 6 Different
Soldering & De-soldering Tools
Lowest Running Costs:
• Low Cost, Long life, Quick Change i-Tips
specially designed for lead free
• Lowest maintenance, station programming
and calibration costs
• Highest productivity in hand soldering
Highlights:
ERSA i-Tool and i-CON
Solder Tip Temp
Process Window Iron Tip Temp
Lead Free
Solder Joint
Process Window
– the ERSA i-CON and i-Tool! Today at
ERSA, “i ” stands for intelligent, innovative,
intuitive, ingenious, interactive, informative –
simply ideal!
The i-Tool recovers so fast that all solder joints can be
made with nearly the same temperature. The sensor
measures the actual tip temperature very close to the tip
extremity. The Process Window Alarm assists the operators
in guaranteeing repeatable quality.
Iron Tip Temperature
Solder joint temperature
380°
3
2
1
i-Tool Solder iron: Ultra light (only 30 grams),
ultra short (only 155 mm), and ultra short
tip-to-grip (only 45 mm).
ERSA i-CON:
Solving the Industries Toughest Hand Soldering Problems!
150 W micro heating element (patent
pending): allows for standard, long life, low
cost tips to be removed without replacing the
expensive heating element each time the tip
wears out.
Ultra fastest heat up and recovery of
all soldering irons that have exchangeable,
low cost tips: room temp to 350 °C in approx.
9 seconds; from standby to 350 °C in approx.
3 seconds.
“One Touch” Easy to Use operation:
user friendly station software with large,
multifunctional display has on-line Help Text
and easy menu navigator with i-Op control.
Automatic Standby Motion Sensor:
recognizes when the iron is being used
and automatically goes into a standby
temperature when the iron is put into its
holder.
i-Set Tool: this optional item allows
for automatic down-loading of station
settings and lockout by acting as a
type of USB stick. Simply upload the
station settings from an i-CON into the
i-Set Tool. The i-Set Tool is then plugged into
any other
i-CON station and all set parameters
are automatically downloaded in less than
5 seconds and the station is locked out!
Process Window Alarm: informs
operator with a visual and acoustic signal if
the soldering iron tip gets too hot or too cold.
QC can specify a Process Window in which
the iron is allowed to work, and for the first
time ever in the history of hand soldering,
it is possible to guarantee that every solder
joint is made with the proper temperature!
i-Tool Calibration: unlike other systems,
the microprocessor which stores the
temperature calibration of the iron is actually
located in the PCB handle. This now allows
for each individual i-Tool to be calibrated
independent of the solder station meaning
great time and cost savings. Only the irons
need to be taken for calibration, which is
much easier and faster!
Lead free i-Tips: The low cost i-Tips are
specially plated with the new ERSADUR-LF
galvanic process lasting 2 to 3 times longer
than standard tips!
Power Level Settings: allows for the
use of three different power settings which
control the heating element overshoot
depending on the heat required. Thus, the
operator can choose the right setting for
the right job – either more power or more
control! Power Level Low guarantees
NO OVERSHOOT for maximum component
safety!
The fastest, safest programming and locking out of solder
stations for maximum quality control and documentation!
1. Low cost i-Tip
(Consumable, long life)
2. i-Tip fastener
(Re-usable, long life)
3. Heating element
(Re-usable, long life)
Highest Quality & Repeatability:
this technology offers the world’s fi rst Process
Window Alarm which notifi es operator if they
are working outside a specifi ed process
window. Each solder joint can be now made
with the proper temperature. Overshoot is
not possible, thereby reducing lifted pads
and damaged components! All systems
can be locked out, thereby guaranteeing
repeatability. Individually calibrated i-Tools
can follow an operator in order to deliver best
results anywhere in the factory.
Highest Productivity:
this technology offers ultra fast heat up and
recovery. Additionally, QC managers can use
the optional i-Set Tool for the fastest station
setting and lockout available on the market –
less than 5 seconds! Finally, individual i-Tool
calibration will greatly increase calibration
productivity.
Operator is visually and acoustically alarmed
if the tip temperature goes outside of the
specifi ed process window
The i-Tool recovers so fast that all solder joints can be made with nearly the same temperature. The sensor measures the
actual tip temperature very close to the tip extremity. The Process Window Alarm assists the operators in guaranteeing
repeatable quality.
Lowest Running costs:
this technology offers long tip life with low tip
prices compared to all high powered solder
irons using expensive heating
cartridge tips. Station
setting, maintenance
and calibration costs
will be dramatically
reduced.
Sensor actually measures
tip temperature near
solder joint!
(150 W Heating
element)
New i-Tip for
better heat
transfer &
longer life!
Solder Tip Temp
Process Window iron Tip Temp
Lead Free
Solder Joint
Process Window
Safe control is possible when temp sensitive components
require NO OVERSHOOT! - Power Level Low!
innovative features of this technology
The Ultimate innovation
in Hand Soldering Process Control
ERSA i-Tip series for the i-Tool
with long-life ERSADUR plating
The i-Tips are available in
6 different shapes and in 17
dimensions - suiting them for
most applications.
Lead free soldering will require higher
working temperatures. In addition, the
higher tin (Sn) content in the lead free solder
will greatly increase the stress degradation
to the solder tip, thereby decreasing the life
of the tip considerably. In order to increase
the tip life, soldering tip manufacturers must
adjust the amount of iron (Fe) plating on the
tips.
New galvanic plating process for the
ERSADUR-LF long life soldering tips.
• Improved tip precision
• More iron plating
• Improved tip life*
*
Expected tip life depends on factors such as tip
temperature, fl ux, mechanical pressure etc.
The new ERSADUR-LF tips should last up
to times longer than standard tips!
1. Pencil point:
ø: 0.2 mm, 0.4 mm,
0.7 mm, 1.0 mm
2. Chisel-shaped:
W: 1.2 mm, 1.6 mm,
2.0 mm, 2.4 mm,
3.2 mm, 5.0 mm
3. Angled face:
L: 2.0 mm, 4.0 mm
4. Solder Well:
L: 1.6 mm, 2.3 mm,
3.5 mm
5. PLCC blade
6. Curved tip
Chip tool
SMT desoldering tweezers
X-Tool
High power through hole desoldering
Multiple soldering and desoldering
Tools for maximum fl exibility
X-Tool with compressor unit and i-CON
Both the i-CON and the i-CON2 allow for
the use of various soldering and desoldering
tools to be used in addition to the i-Tool.
The Chip Tool offers a wide range of SMT
desoldering tips for safe and fast removal of
the smallest chips (0201, 0402, etc.) up to
medium size PLCCs.
The X-Tool is a high powered desoldering
iron designed for the toughest through hole
desoldering applications which must be
used in combination with the CU compressor
unit. All tools are automatically detected
when connected to either the i-CON or
the i-CON2 station and can be individually
programmed.
Low temp., safe SMD soldering.
High mass SMD soldering in hard-to-reach areas.
High mass Through hole soldering.
422 Series for Chip tool
722 Series for X-Tool
Tools are automatically detected when inserted into the
station and a pre-determined program is started.
Special Chip Tool tips for 0201 rework.
i-CON2 offers all the amazing features of the revolutionary i-CON in a double iron digital station
with Chip tool for SMD removal
Nickel-plating
The base material made of highly conductive
electrolytic copper ensures unhindered heat
transfer from the heating element to the
ERSADUR-LF coating
ERSADUR-LF coating (up to 600
micron) of iron-plating (subject to
type of tip) is factory pre-tinned
with lead-free solder at working
end
Iron-plating
Chrome-plating prevents corrosion and
solder collection on undesirable spots
Nickel-plating
Cross-section of an ERSADUR soldering tip, non-scale representation
Industrial Technology Companies
3200 W
Dynamic
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1400 W
Dynamic
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Lötwerkzeuge, Rework- und Inspektionslösungen
ERSA GmbH
Rework Katalog
ERSAs DynamicIR:
Der neue Standard beim Rework
www.ersa.com
More than 70 ERSA representatives
in over 65 countries.
For additional information see ERSA website, other ERSA brochures or contact ERSA directly.
Headquarters
ERSA GmbH
Leonhard-Karl-Str. 24
97877 Wertheim / Germany
Phone: +49 (0) 9342 / 800-0
Fax: +49 (0) 9342 / 800-100
e-mail: info@ersa.de
www.ersa.de
America
ERSA North America
A Division of KURTZ North America Inc.
1779 Pilgrim Road
Plymouth, WI 53073
USA
Phone: 800 363 3772
Fax: +1 920 893 3322
e-mail: infoersa@kna.net
www.ersa.com
Asia
ERSA Asia Pacific
A Division of KURTZ Far East Ltd.
Suite 3505, 35/F.,
China Resources Building
26 Harbour Road, Wan Chai
Hong Kong
Tel.: +852 2331 2232
Fax: +852 2758 7749
e-mail: kurtz@kfe.com.hk
www.ersa.com
Room 601, 6th Fl. Beethoven Plaza
1158 Chang Ning Road
Shanghai 200051
China
Tel.: +86 (21) 5241 6000
Fax: +86 (21) 5241 9918
e-mail: kurtz@kurtz.com.cn
www.ersa.com
Ask for the latest issue of the
ERSA multimedia Demo CD!
Lead-free soldering,
inspection or rework: ERSA
solutions for a safe process.
Features, technical description
ERSA i-Tool and i-CON:
i-CON soldering station
Supply voltage; frequency: 220 – 240 VAC/50Hz; 110 – 120 VAC/60 Hz
Admissible ambient temperature: 0 °C – 40 °C / 0 - 104 °F
Secondary voltage: 24 V~
Continuous rating:80 W (120 W with i-CON 2) protection class I (double insulation)
Weight:2 kg / 4.4 lb
Control technology: i-Tool: i-TRONIC control (patent pending) with digital PID
algorithm and multiple sensors; X-Tool: SENSOTRONIC
control system with digital PID algorithm;
Chip tool: RESISTRONIC control system
Temperature range:continuous 150 °C – 450 °C / 300 °F – 842 °F
Display: blue LCD display
Operation: one-touch operation by means of a rotary type push button
Cable: 2 m / 6.5 ft PVC with connector
Antistatic: antistatic design suitable for operation in an ESD environment.
MIL-SPEC/ESA standard
Non-operative temperature fluctuation:less than +/-2 °C
Tip to ground resistance: less than 2 ohms
Tip leakage: less than 2 mVeff, VDE, EMV checked
Fuse rating:800 mA, slow-blow
Connectable soldering and desoldering tools: i-Tool, Chip tool, X-Tool
i-Tool soldering iron
Voltage: 24 V~
Rating: 150 W +/- 10 %
Heating time:approx. 9 s to 350 °C / 662 °F
Weight (without cable): approx. 30 g / 1 oz
Cable: 1.5 m / 5 ft highly flexible, heat resistant, antistatic
Model: antistatic according to MIL-SPEC/ ESA standards
with integrated ID and standby function
Total weight soldering station, tool holder, soldering iron incl. packaging: approx. 3.1 kg / 7 lb
113039 - 0406 • subject to changes • © by ERSA
