Students must read this important information before using the equipment
PRE-OPERATIONAL SAFETY CHECKS
- Examine the power lead & soldering iron for obvious damage.
- Ensure that the cord does not create a slip/trip hazard.
- Ensure the workspace is well ventilated to prevent fumes in the breathing zone
- Check condition of soldering tip. Replace if damaged.
- Ensure tip is ‘tinned’ & free from waste. Once the tip has warmed-up, wipe on a damp sponge to clean.
- Leave the soldering iron in the stand when warming up.
- Never leave a soldering iron unattended when turned on or still hot. Leave unplugged when not required.
- Clear area work area (i.e. cables, tools organised, cable neatly coiled on your table, hair tied back, etc).
- Make sure the power outlet is not overloaded.
OPERATIONAL SAFETY CHECK
- Do not plug in and turn on until the tip element has been checked, or replaced and tightened.
- Never touch the soldering tip. Keep your fingers clear.
- Always wear safety glasses. Smoke and hot embers can often result when soft soldering.
- Avoid positioning your head directly over the soldering process. Soldering creates fumes that are toxic.
- Avoid prolonged use. This could overheat the tip element causing it to fail or oxidise.
- Use a vice to grip components that are being soldered. Allow components to cool before touching them.
- Ensure electrical cords are well clear of the soldering process. Do NOT touch electrical cords with the tip.
- Wash your hands after using solder – many soft solders contain toxic lead products.
- Never leave the machine unattended when still switched ON or when switched OFF but still HOT.
- Turn off and wait until the tip element has completely cooled before storing the machine away correctly.
HOUSEKEEPING
- Switch off, unplug & allow to cool down before storing.
- Leave the work area in a safe, clean, & tidy condition.
POTENTIAL HAZARDS AND RISKS
Hot element, surfaces, burns, electricity, eye injury, toxic fumes, trip
& slip, fire.
HOW NOT TO SOLDER
SOLDERING PREPARATION
- Plug the soldering iron into an electrical outlet, and allow it to heat up. This can take several minutes, depending on the quality of your soldering iron.
- Securely place your audio jack into your vice or wood box. You must not touch the jack while you are soldering or immediately after,
- Push the tip into the soldering tip cleaner and wait about 15-20 seconds. Large quantities of smoke are produced, keep your face at an arms length to avoid breathing fumes.
- Dampen a sponge before using the soldering iron. After each application of solder, dip the tip into the damp sponge. This will keep the tip clean after every use.
SOLDERING 101
Each Soldering kit has the following:
Additional items if required (used only with teacher assistance);
SOLDERING PRACTICE
HOW TO SOLDER
1. Tin the tip of the iron if this has not already been done. Only a very thin amount is required.
2. Identify the cable fault (e.g. use a cable tester and/or physically check the cable and jack).
3. Before doing anything else consult your wiring chart.
4. Cut the cable.
5. Put on the heat shrink, the shell and insulator collar in this order.
6. Before stripping the cable measure how much you will need to strip (e.g. measure it with the blade).
7. Strip back the jacket - take care not to cut the strands.
2. Identify the cable fault (e.g. use a cable tester and/or physically check the cable and jack).
3. Before doing anything else consult your wiring chart.
4. Cut the cable.
5. Put on the heat shrink, the shell and insulator collar in this order.
6. Before stripping the cable measure how much you will need to strip (e.g. measure it with the blade).
7. Strip back the jacket - take care not to cut the strands.
8. Twist the shield into one conductor and tin the conductor.
9. Strip and twist the hot conductor and tin the conductor.
9. Strip and twist the hot conductor and tin the conductor.
Clean the tip
10. Tin the jack tip and sleeve with some solder for a second – avoid overheating the jack.
Clean the tip
11. In one hand hold the soldering iron and in the other apply the solder. Preheating will help to solder and DO NOT DIRECTLY APPLY THE SOLDER TO THE SOLDER IRON.
12. Allow the solder to cool (do not move your job!)
Clean the tip
13. Move onto your next conductor and follow the same process.
14. After soldering is completed clamp the cable using pliers. It must be tight - check that it cannot be pulled out.
15. Use the cable tester to check that your solder is making a proper connection.
Insert the insular collar, the back shell and the heat shrink
16. When finished clean the tip. Use the sponge to clean the tip while it is still hot and then tin the tip – not to much solder – just a thin layer.
17. Unplug the solder and carefully place it out of the way to cool down. Do not leave it near you!
14. After soldering is completed clamp the cable using pliers. It must be tight - check that it cannot be pulled out.
15. Use the cable tester to check that your solder is making a proper connection.
Insert the insular collar, the back shell and the heat shrink
16. When finished clean the tip. Use the sponge to clean the tip while it is still hot and then tin the tip – not to much solder – just a thin layer.
17. Unplug the solder and carefully place it out of the way to cool down. Do not leave it near you!
