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Offline trisonicTopic starter

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Handle hack
« on: October 16, 2012, 03:07:22 pm »
Hi

Im working on my soldering station, its a Lafayette sdd-9.
It works ok but its very hard to find some compatibile tips. The inner diamater its ~6mm!

So i have decide to fit an hakko handle to my solder station.
Its very easy to find this tips...
But i have some problems with the heating element:
The original (of my lafayette) heating element has ~3 Ohm at the sensor line, the hakko has ~ 53 Ohm
I cant find an heating element with this requirements and my soldering station cant control the handle for this reason...

How can i reduce the ohm at sensor line?
Any suggestions?

Regards
« Last Edit: October 17, 2012, 11:20:43 am by trisonic »
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Offline Psi

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Re: Soldering handle hack
« Reply #1 on: October 16, 2012, 11:32:58 pm »
First you need to takes some more measurements of the lafayette sensor and the hakko sensors at a different temperatures (or fine the specs online)
You need to figure out what direction the resistance goes when heated and how much the resistance changes per degree, also are they linear?

Then you can look at a conversion circuit.
« Last Edit: October 16, 2012, 11:35:26 pm by Psi »
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Offline nukie

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Re: Soldering handle hack
« Reply #2 on: October 16, 2012, 11:46:55 pm »
The Hakko has a special PTC sensor whereas your sensor is probably thermocouple K type sensor.

For your ZD-931 stazione saldante you might want to try this type of heating element (fits hakko tips)

ORIGINAL LINK REMOVED - astronomical price!!

Item 230681537349 ~$10 for 5 pieces
http://www.ebay.com/itm/5x-24V-50W-Ceramic-Core-Heating-Element-Soldering-Iron-/230681537349?pt=LH_DefaultDomain_0&hash=item35b5b0eb45

Item 170805536465 ~$10 for 5 pieces
http://www.ebay.com/itm/5x-1322-Ceramic-Core-Heating-Element-Soldering-Iron-/170805536465?pt=LH_DefaultDomain_0&hash=item27c4cda6d1

Unfortunately this type of heating element might not last as long as your 6mm, they are Nichrome wound in ceramic sleeve instead of heating element printed on ceramic tubes. But seeing that your stazione is 48W it should be okay. I use these with my 70W station it would overheat and die every 6 months or so, with 3-4 hours of use each day.

So basically heating element with thick glass impregnented insulation sleeves are the ~53 Ohm Hakko compatible types.
And if they are only insulated with thin pieces of silicon sleeves they are the ~3 Ohm thermocouple sensors.

Please be note, when installing the thermocouple type, make sure the polarity of the sensor output is correct. Incorrect connection might cause malfunction. Check with your DMM and use a fire lighter to heat up the tips.
« Last Edit: October 17, 2012, 11:15:01 am by nukie »
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Offline trisonicTopic starter

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Re: Soldering handle hack
« Reply #3 on: October 17, 2012, 06:52:04 am »
Quote from: nukie on October 16, 2012, 11:46:55 pm
Please be note, when installing the thermocouple type, make sure the polarity of the sensor output is correct. Incorrect connection might cause malfunction. Check with your DMM and use a fire lighter to heat up the tips.

Thanks a lot for your support!  ;D

I will contact the seller for make sure that sensor line is 3ohm

best wishes!
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Offline nukie

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Re: Soldering handle hack
« Reply #4 on: October 17, 2012, 10:51:40 am »
Resistance changes according to temperature, ~1 ohm at 22C degree. You want low ohm at ambient temperature.

When you heat it up, the resistance should increase, if it decrease you got the polarity wrong. Swap the sensor pins.
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Offline trisonicTopic starter

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Re: Soldering handle hack
« Reply #5 on: October 17, 2012, 10:54:10 am »
Quote from: nukie on October 17, 2012, 10:51:40 am
When you heat it up, the resistance should increase, if it decrease you got the polarity wrong. Swap the sensor pins.

thanks so much!
when i fill find the correct element i will measure evrything.

thanks again
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Offline nukie

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Re: Soldering handle hack
« Reply #6 on: October 17, 2012, 10:56:49 am »
Correction to my post above. My 70W transformer is 27VAC when fully loaded so that's the reason it burned the ceramic sleeve Nichrome heaters. It works fine with 24VAC transformers.

I just found out the greedyanalhole (ebay link in my first post) has jack up the price to $109 !!! Usually they sell for around $1 each in China electronics market for 10 pack.

So I searched two more thermocouple type heater for you ( HAKKO USERS PLEASE AVOID THIS! )

Item 230681537349
http://www.ebay.com/itm/5x-24V-50W-Ceramic-Core-Heating-Element-Soldering-Iron-/230681537349?pt=LH_DefaultDomain_0&hash=item35b5b0eb45

Item 170805536465
http://www.ebay.com/itm/5x-1322-Ceramic-Core-Heating-Element-Soldering-Iron-/170805536465?pt=LH_DefaultDomain_0&hash=item27c4cda6d1
« Last Edit: October 17, 2012, 11:23:48 am by nukie »
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Offline Psi

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Re: Soldering handle hack
« Reply #7 on: October 17, 2012, 11:02:10 am »
Quote
Topic: Soldering handle hack
You call that a handle hack, this is a handle hack

(The plastic cracked and it wouldn't tighten up)
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Offline nukie

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Re: Soldering handle hack
« Reply #8 on: October 17, 2012, 11:08:11 am »
Hacking competition!

~45 grams mod! Maneuver like chopsticks!
« Last Edit: October 17, 2012, 11:16:14 am by nukie »
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Offline trisonicTopic starter

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Re: Soldering handle hack
« Reply #9 on: October 17, 2012, 01:12:55 pm »
Quote from: nukie on October 17, 2012, 10:56:49 am
So I searched two more thermocouple type heater for you ( HAKKO USERS PLEASE AVOID THIS! )

Item 230681537349
http://www.ebay.com/itm/5x-24V-50W-Ceramic-Core-Heating-Element-Soldering-Iron-/230681537349?pt=LH_DefaultDomain_0&hash=item35b5b0eb45

Item 170805536465
http://www.ebay.com/itm/5x-1322-Ceramic-Core-Heating-Element-Soldering-Iron-/170805536465?pt=LH_DefaultDomain_0&hash=item27c4cda6d1

Thanks dude!

Are you completely sure that this elements are 3ohm on the sensor line?
Because if i will ask to the sellers to measure it, they will reply (im sure about that) that: they cant measure it... or cant open the package... etc etc
They doesnt wants problem from a pedantic* geek like me!

*im italian, i dont know if its the rights word :)
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Offline trisonicTopic starter

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Re: Handle hack
« Reply #10 on: October 17, 2012, 02:11:41 pm »
Look at the instructions paper about the above ebay link: http://www.kcheungshop.com/supports/menu/menu_ac_heating_element_x5_01.jpg

It has 2-2.5ohm at sensor and 16-17ohm at heating element.

On my original element both values is ~3ohm!
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Offline nukie

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Re: Handle hack
« Reply #11 on: October 17, 2012, 10:11:37 pm »
You have small balls sized like peanuts. :))

Send me your address privately i'll send you a set of heater.

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Offline trisonicTopic starter

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Re: Handle hack
« Reply #12 on: October 18, 2012, 07:20:29 am »
 :'(
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Offline trisonicTopic starter

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Re: Handle hack
« Reply #13 on: November 05, 2012, 04:57:23 pm »
it works! thanks dude!
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