Dip Tester

Model DS-03

-INSTRUCTION MANUAL-

MALCOMTECH INTERNATIONAL
26200 INDUSTRIAL BLVD.
HAYWARD, CA 94545 USA

TEL. (510) 293-0580 FAX. (510) 293-0940

www.malcomtech.com info@malcomtech.com
 TABLE OF CONTENTS

I. INTRODUCTION TO THE DS-03 DIP TESTER

1. Overview ...........................................................................................
2. Features..............................................................................................
3 Specifications.....................................................................................
a. Measuring Data Specifications....................................................
b. General Specifications.................................................................
4. Dimensions ........................................................................................
5. Name of Units and their functions.....................................................
a. Control Panel .............................................................................. 5
b. Sensors......................................................................................... 8

II. HANDLING
1. Normal Mode.....................................................................................
a. Cleaning Sensors .........................................................................
b. Setting Upper Limits for Solder and Flux ...................................
c. Setting Width for Mounting Plate ...............................................
d. Measuring ....................................................................................
e. Reading Data After Measuring....................................................

III. MAINTENANCE AND

1. Replacing Battery ..............................................................................
2. Altering Flux Dry Resistance ............................................................
3. Checking Accuracy............................................................................
4. Repair and Calibration.......................................................................

IV. WARRANTY
1. Warranty ............................................................................................
I. INTRODUCTION TO THE DS-03 DIP TESTER

1. Overview

Model DS-03 Dip Tester is a special purpose tester to stabilize and uniform the soldering
performance of automatic soldering systems. Formerly, soldering temperature, preheater
temperature and dip time of a soldering system to serve as the reference data were
individually measured using specially devised measuring instruments. With these measuring
instruments, it was difficult to measure individual data under constant conditions and
simultaneously. Quite often, the measurement values were different from the actual values of
printed circuit boards as they showed while running through the automatic soldering line.

This system solves the above problems by feeding printed circuit boards in the same way
as you put them on an automatic soldering line and reading various data on soldering
performance in one stroke at the end of a circuit of the automatic soldering process. Since
these data are simultaneously measured, conditions of the soldering systems are consistent
and thus reliable, and can be used as reference data for uniform and stable soldering.

The DS-03 measures dual-tank type soldering systems which cannot be measured with
the conventional models DS-01 and DS-02. The DS-03 covers Model DS-02 in terms of
function. Major features are described as follows.
2. FEATURES

The DS-03 features the same performance as that of conventional DS-01 and DS-02, and
measures soldering temperature and dip time, respectively, of dual tank type soldering
systems.

a) Soldering temperature of the 1st soldering tank.

b) Soldering temperature of the 2nd soldering tank.
c) Dip time of the 1st soldering tank.
d) Dip time of the 2nd soldering tank.
e) Total dip time for the 1st and 2nd soldering tank.
f) Temperature on the underside of the board by preheaters (preheater temperature)
g) Confirmation of flux dryness by preheater.
h) Confirmation of upper limit of flux height.
I) Confirmation of upper limit of solder height.

NOTE: In the case of a single-tank soldering system, soldering temperature and dip time are
displayed for the 1st tank, and 000 is displayed for the 2nd tank.

The control panel is flat and a microcomputer is incorporated to improve operability.

Measurement data are retained until power is shut OFF.
The battery has a longer life because of the setting of lower power consumption.
Measurement results can be printed and stored by using an optional printer adapter.
3. SPECIFICATIONS
a. Measurement Data Specifications

Item Sensor Display Method Measuring Accuracy/

Range Contents
Soldering CA Sheath 0 to 300C 2C
Temperature
Temperature on CA LCD Digital 3-Digit 50 to 300C 2C
the underside of Thermocouple
board
Dip Time Electrode 0 to 10.0 sec. 0.2 sec.

Flux Dryness Electrode Red LED lights 10k to 5m 2 electrode

(resistance) when each item is intervals of
defective 4mm
Flux Height Electrode Green LED lights With reference Scale
when all are to underside of resolution
acceptable board 0 6mm 1mm
Solder Height Electrode

b. General Specifications

Item Contents

Cold Contact Point Compensation Automatic compensation with platinum

temperature measuring resistor.
Ambient Temperature 5 minutes or less OK at ambient 120C

Battery S-006 9VDC, 1 piece

Usable Time More than 10 continuous hours

Life of Sensor Mounting Plate More than 5,000 times at soldering

temperature 250C and dip time 5 sec.
Dimensions 94mm x 230mm x 51mm

Weight 840g (without battery)

4. DIMENSIONS (Unit: mm)
5. PART NAMES AND FUNCTIONS
a. Control Panel

Figure 2
(1) POWER ON SWITCH
Power is supplied when switch is pressed. Version statement appears for about 3
seconds, and then the system is ready to start.

(2) POWER OFF SWITCH

Power is shut OFF when switch is pressed. On turning OFF the system, the internal
memory is reset to erase measurement results.

(3) HOLD SWITCH

This is not used in normal measurements. Your system will not measure temperature
of soldering tank and dip time unless the preheater temperature reaches 50C. When
the preheater temperature does not reach 50C, you may press this switch and then
feed the items to the line. With this, you can measure solder temperature and dip time
even when the preheater temperature is low. This function is released when power is
turned OFF.

(4) SELECT SWITCH

This is the switch to select the display for measurement data. Press and release the
switch after measuring, and the lamps light and the display data are switched as
shown in the table below.

For double-tank soldering systems ({: lit -: extinguished)

Order Display (9) Heater (10) Solder (11) Dip Time (12) Dip 1 (13) Dip 2
Lamp Lamp Lamp Lamp Lamp
1 Preheater {
Temperature
2 Primary Solder { {
Temperature

3 Secondary { {
Solder
Temperature
4 Primary Dip { {
Time
5 Secondary Dip { {
Time
6 Total Dip Time { { {
(5) FLUX WET LAMP
The flux coated on boards is dried by preheaters, and then enters the soldering tank.
If it is not fully dry, soldering can be unsatisfactory. Accordingly, dryness of the
flux by preheaters is shocked with the flux dryness sensor (h) immediately before it
enters the soldering tank. If the flux is not dry, the lamp lights up.

(6) FLUX LEVEL LAMP

If the flux level is too high, the flux may spill to the board. The flux level sensor (g)
is used to set the upper limit for the flux level. If the flux is applied above the preset
height, the flux level lamp lights up to indicate the flux leel is too high. The lamp is
retained until power is shut OFF.

(7) SOLDER LEVEL LAMP

Like the flux level, the upper limit for the soldering solution level is set by the
solder level sensor . The sensor monitors the level of the soldering solution.
When the level becomes too high, the solder level lamp lights up. The lamp is
retained until power is shut OFF.

(8) OK LAMP
After measurement, OK lamp goes when flux dryness, flux level and solder level
were normal to indicate that there were no abnormal measurements.

(9) HEATER LAMP

The lighting heater lamp indicates that the figures on display are preheater
temperatures. Immediately after making power, heater lamp goes on and preheater
temperatures are displayed.

(10) SOLDER LAMP

The lighting solder lamp indicates that the figures on display are the first or second
solder temperature. The primary and secondary solder temperature are identified by
(12) First Dip Lamp and (13) Second Dip Lamp. On making power, 000 will be
displayed in place of temperature even if you try to display solder temperature with
(4) Select Switch when no measurements have been made. For a single-solder tank,
the lamp goes on as if the secondary solder temperature were displayed, but
actually, the secondary solder temperature is displayed as 000.
(11) DIP TIME LAMP
The lighting dip time lamp indicates that the figures on display are dip time.
Primary dip time is displayed when (12) First Dip Lamp is lit; secondary dip time
when (13) Second Dip Lamp is lit; and total dip time when both lamps are lit.

(12) FIRST DIP LAMP

The lighting lamp indicates that the primary solder temperature or dip time is
shown.

(13) SECOND DIP LAMP

The lighting lamp indicates that the secondary solder temperature or dip time is
shown.

(14) LCD DISPLAY

The LCD display show various measurement, temperature and dip time. The LCD
display goes off and OVER mark is shown in the lower left hand corner of the LCD
when the battery is low; battery voltage dropped; and it is time to replace the
battery.
b. Sensors

Figure 3
(a) DIP TIME SENSOR
This is the electrode to detect dip time in the solder tank.

(b) FLUX WET SENSOR

This is the sensor to detect dryness of flux located between these two electrodes as
electri resistance. (Resistance varies with the flux to use. See II-3.b for details).

(c) PREHEATER TEMPERATURE SENSOR

This is the CA thermocouple to detect the temperature on the underside of boards
heated by preheaters.

(d) SOLDER TEMPERATURE SENSOR

This is the CA sheath thermocouple to detect solder temperature. It is mad of soft
material. Do not have it caught, drop, change the shape, or bend..

(e) SOLDER LEVEL SENSOR

This is the electrode to detect the highest solder level. (See II-1.b) for instructions.

(f) SOLDER LEVEL INDICATOR

This indicates the height to set the upper limit for the solder level.

(g) SOLDER LEVEL SENSOR FIXING SCREW

This screw is loosened when setting the upper limit for solder level. The sensor is
fixed when measuring.

(h) FLUX LEVEL SENSOR

This is the electrode to detect the highest flux level. (See II-1.b) for instructions.

(i) FLUX LEVEL SENSOR FIXING SCREW

This indicates the height to set the upper limit for the solder level.

(j) FLUX LEVEL SENSOR FIXING SCREW

This screw is loosened when setting the upper limit for solder level. It is tightened
to fix the sensor when measuring.
(k) F.S. DIAL
If you see indicators (f) and (I) are at the lowest position on the scale, you can
assume that the sensors for the flux and solder levels are in the same position as the
underside of the printed circuit boards. The scale is graduated in 1mm intervals.
II HANDLING
Model DS-03 measures soldering systems in the same way as conventional Models DS-01
and DS-02, and also partly confirms electrical setting conditions. The former is called
normal mode (ordinary measuring mode), and the latter user mode. Both modes are
described below.

1. Normal Mode
a. Cleaning Sensors
Before measuring, always clean sensors with alcohol (IPA). It is particularly important to
fully remove flux from sensors for flux level, solder level, dip time and flux dryness. Do
not have the solder temperature sensor caught in the cleaning cloth and deform it: the
sensor does not have enough strength.

b. Setting Upper Limit for Solder and Flux

Before starting measurement, the upper limit for solder and flux is set. This is necessary
to use the function of I-5, (6) and (7). The upper limit varies with your soldering system
and printed circuit boards fed to the production line. It must be adequately set by
individual customers. Setting method is as follows:

(1) Loosen screws g and j in Figure 3.

(2) Move sensors e and hto the position where the conditions are met [while
watching indicators f and I.
(3) Fix sensors e and h by tightening screws g and j.

c. Setting Width for Mounting Plate

This system must be installed on the conveyor carriers or conveyor claws of your
soldering system when using the system for measurement. The system is provided with
two mounting plates as mounting fixtures. Install the mounting plates to the underside of
the main unit with knurled screws (two on each side). Each plate is adjustable about
15mm sideways. Adjust them to the width of your soldering system. Be sure to fully
tighten the screws. If they are loose, they may drop in the machine and damage it.
Mounting procedures are shown in Figure 4.
 Mounting holes on the underside of dip

Figure 4

4) MEASUREMENT
1. Press POWER ON SWITCH to make power.
On making power, LCDs other than BATT go on, and V0.3 (Version No.)
appears. The display lasts about three seconds, and the system is ready to start.

2. Be sure HEATER lamp is lit, and a temperature closed to room temperature is

shown. If a temperature much higher than room temperature (by 5C or more) is
shown, turn the system OFF, and cool it OFF (to approximately 25C). Turn the
system ON.
NOTE: If you see OVER display, take necessary action by referring to III-1.

3. Be sure you have already adjusted the mounting width of the system in the steps
shown in II-1.c. Install the unit on the carrier of the conveyor. For a unit without
carriers, fix the system by hooking plates on the claws on the conveyor. Note that
if the system is loose and moves, stable data measurement is not possible.

4. When the soldering operation ends, the system is lifted and the measurement
ends. Be sure not to turn power OFF. If you turn power OFF on ending the
operation, the data are erased.
WARNING!!! BE CAREFUL OF GETTING BURNED BECAUSE THE
SYSTEM IS HOT WHEN LIFTING IT!!
5) Reading Data After Measuring
a. To protect the sensors, place the unit with the handle on the top lifted.
b. If flux dryness, flux level or solder level is abnormal, lamps (5), (6), and (7), Figure
2, lights up, respectively. If all data are normal, green lamp (8), Figure 2, light up.
c. Press Select Switch (4), Figure 2. Measurement temperature and dip time are
displayed in the order shown below.

PREHEATER TEMPERATURE
(Switch one time)

PRIMARY SOLDER TEMPERATURE

SECONDARY SOLDER TEMPERATURE

PRIMARY DIP TIME

SECONDARY DIP TIME

PRIMARY DIP TIME

The lamp indicates what measurement values the data on display are:
({: lit -: extinguished)

Order Display (9) Heater (10) Solder (11) Dip Time (12) Dip 1 (13) Dip 2
Lamp Lamp Lamp Lamp Lamp
1 Preheater {
Temperature
2 Primary Solder { {
Temperature

3 Secondary { {
Solder
Temperature
4 Primary Dip { {
Time
5 Secondary Dip { {
Time
6 Total Dip Time { { {
NOTE: When measuring in a single-tank soldering system, the secondary solder
temperature and dip time are displayed as 000 or 00.0. The total dip time is the
same value as primary dip time.

4). To print the measurement results, set the system to the optional printer before
shutting OFF power for the system after measurement.

5) After having recorded the results of measurement, press POWER OFF switch, turn
power OFF, and cool down the system to room temperature.

2. Activating User Mode

As mentioned before, the electrical setting of DS-03 main unit can be partly confirmed
in the user mode, in addition to the functions of conventional dip testers.

a) Turn power OFF.

b) Press POWER On switch while pressing HOLD switch (3), Figure 2, to turn power
ON.
c) The display read V0.3 does not appear, try again.
d) The version statement goes off in about 5 seconds. HEATER lamps are lit, and
preheater temperature are displayed.
e) The display changes each time you press SELECT switch.
 PREHEATER TEMPERATURE
(HEATER lamp lights)

SOLDER TEMPERATURE
(SOLDER lamp lights)

DS-03 INTERNAL TEMPERATURE

(No lamp lights)

FLUX DRYNESS RESISTANCE

(FLUX WET lamp lights)

NOTE: Preheater and solder temperature are not measurement values but the current
temperatures of preheater and solder temperature sensors. Touch the solder
temperature sensor with your finger, and you can confirm the temperature change.

NOTE: Flux dryness resistance is described briefly in II-3.b, you need only to confirm the
values at this stage.
3) What you should know
This section describes the items which have not been mentioned in the previous sections.
a. Function of DS-03 during measurement (in normal mode)
(1) On making power, the version statement appears for approximately 3
seconds. The system is then ready for measurement. Preheater temperature are
displayed.
(2) Install the system on your soldering system. On reaching the fluxer and
coating flux, FLUX LEVEL lamp lights up when the flux attaches to FLUX
LEVEL sensor which has been set.
(3) The sensor board is heated by the preheater and the preheater temperature
rises. If the preheater temperature is below 50C, solder temperature will not be
measured after plunging into the solder tank.
(4) Having passed through the preheaters, the maximum temperature received
from the preheaters is held and stored.
(5) On plunging into the first solder tank, the dip sensor on the sensor board is
electrically shorted, and detects that the subject has plunged into the first solder
tank. FLUX WET lamp lights up when FLUX WET sensor detects a resistance
value lower than the preset flux dryness resistance.
(6) The solder temperature sensor starts measurement when the dip sensor (4)
was electrically shorted. Note that no measurement will be made even when the
dip sensor was shorted if the preheater sensor is still below 50C at this time.
Further, when you pressed HOLD button before measurement, the system starts
measuring solder temperature as soon as the dip sensor is shorted even if the
preheater temperature is below 50C.
(7) SOLDER LEVEL lamp goes on when the solder liquid level touches the
SOLDER LEVEL sensor while passing through the solder tank.
(8) Measurement of the solder temperature of the first solder tank is completed
when the dip sensor is electrically released on leaving the first solder tank.
(9) Like the first tank, plunge into the second solder tank is detected when
electric short of the dip sensor is detected.
(10) Measurement of the solder temperature of the second tank starts with the
detection of the plunge of the second tank. Passage is confirmed on detecting
electrical release of the dip sensor. Measurement of the solder temperature of the
second tank is completed at this time.
 (11) Dip time is a time period from when the dip sensor plunged into the solder
tank and electrically shorted to when it is released.
(12) OK lamp goes on immediately after passing the first solder tank when the
preset conditions were met. When there is trouble in the second solder tank OK
lamp goes off and TROUBLE lamp goes on instead.

b. Detecting Flux Dry Resistance

Dry flux has a high resistance. When it is not dry, the resistance decreases. A guideline
on the dryness of flux can be established by comparing the resistance of flux with a
reference resistance.

Since dry resistance varies with the type of flux, a single common resistance for all types
of flux cannot be used with DS-03. Several resistance value is adjustable according to the
type of flux you use. To change the value, refer to III-2.

0.01M
0.10M
0.22M
0.50M
1.00M
2.20M
5.00M

You can check the flux dryness resistance with user mode. The unit is M. Your system
has been set to 0.22M at the factory.
III MAINTENANCE AND WARRANTY SERVICE

1. Replacing Battery
When you see OVER message in the lower left-hand corner of the LCD display, it is time to
replace the battery. Replace it in the steps below:

(1) Press POWER OFF to turn power OFF.

(2) Remove the battery cover by removing two screws at the bottom of the main body.
(3) Pull out the old battery and replace (006P, 9V, 1 piece). Be sure of polarity of the
battery. If the battery is placed wrongly and left as it is for a long time, the battery
may be damaged or system failure may result.
(4) Replace the cover as shown and fix it with the screws. A failure may result in the
cover is mounted inside out.
(5) Press POWER ON switch to run the system on. Be sure the system operates
correctly, and OVER is not shown. If BATT appears on the display, the battery is
old. Replace it with a new one. If nothing is displayed on making power, the battery
polarity is reversed. Replace the battery to the correct polarity.
NOTE: Measurement data are not affected even if OVER appears while in the
measurement (running in the line). Replace the battery as soon as possible.

Figure 5
2. Changing Flux Dry Resistance
Dry resistance of flux can be varied. The following resistance values are available for
detection with the DS-03. The steps to change the values are as described below:

0.01M 0.10M
0.22M 0.50M
1.00M 2.20M
5.00M
NOTE: Your system has been set to 0.22M at the factory.

(1) Shut OFF power with POWER OFF switch.

(2) Remove the battery cover referring to II-1 Replacing the Battery.

(3) Pull out the battery.

(4) Locate a small switch on the side of the battery case. Slide the switch knob away from
you.

(5) Replace the battery and the cover.

(6) Turn power ON. Current resistance is displayed.

(7) The resistance value changes each time you press and release SELECT switch.

(8) Continue to press and release SELECT switch until the desired value appears. With the
value on display, press HOLD switch. The value is stored.

(9) Turn power OFF. Remove the cover and the battery. Reset the switch know to original
position.

(10) Replace the battery and the cover.

(11) Turn the power ON. Check that the system operates normally. If not, re-check polarity
of the battery and the position of the switch.
3. Checking Accuracy
For correct measurement, the system must operate normally, and the performance must be
maintained in good condition. Check accuracy of the system periodically, and calibrate if the
performance shows difference.

Accuracy is maintained for a long time if the system is checked for accuracy once every 6
months by the user, in addition to the yearly calibration. Steps for accuracy confirmation are
described below.

Preparation:
- Calibration CA sensor (optional)
- Standard glass thermometer
- Boiling water
- Water of ordinary temperature

(1) Turn power OFF.

(2) Remove the terminal cover on the sensor plane by removing two screws.
(3) Remove the solder temperature sensor, and install the calibration CA sensor.
(4) Put the calibration CA sensor and the standard glass thermometer in the boiling
water.
(5) Press POWER ON SWITCH while pressing HOLD switch to activate the user mode.
Select solder temperature (See II-2.a).
(6) Check that the difference between the temperature on the LCD and the reading of the
glass thermometer is within 2C.
(7) Put the calibration CA sensor and the standard glass thermometer in the water of
ordinary temperature. Like (6) above, check that the difference between the temperature
on the LCD and the reading of the glass thermometer is within 2C.
(8) Turn power OFF.
(9) Remove the calibration CA sensor from the main unit, and replace the solder
temperature sensor.
4. Repair & Calibration
Should you experience any difficulties in operating DS-03, and/or calibration is required,
please contact your Malcom dealer or Malcom Instruments Corporation for assistance.

IMPORTANT!!
DO NOT ATTEMPT TO DISASSEMBLE OR SERVICE THE EQUIPMENT
YOURSELF!!
MALCOMTECH INTERNATIONAL
26200 Industrial Blvd.
Hayward, CA 94545 U.S.A.
Tel. (510) 293-0580 Fax. (510) 293-0940

Email. info@malcomtech.com
Web. www.malcomtech.com

IV. WARRANTY

Malcom Company Limited warrants this equipment against defects in parts and
workmanship for one full year from date of purchase. The company will, at its own
discretion, repair or replace any defective parts, which the company, upon inspection shall
determine to be defective in material and/or workmanship. This is provided that the unit is
returned, in safe proper packing, to the dealer or manufacturer.

The following will void the warranty:

- improper installation, abuse, misuse or misapplication, use beyond specifications, namely
prolonged exposure to high temperatures, improper storage, damage caused from accidents,
damages caused by improper packing.

Malcom shall not be held responsible for damage caused from: natural and man-made
disasters, pollution, improper operating environment, abnormal voltages or transient power
surges.
 MALCOMTECH INTERNATIONAL MANUFACTURERS
26200 Industrial Boulevard SPIRAL VISCOSITY MEASUREMENT DE-
Hayward, CA 94545 VICES
Tel. (510) 293-0580 Fax. (510) 293-0940 SOLDERING PROCESS CONTROL DEVICES

Email. service@malcomtech.com

SERVICE
Thank you for purchasing this Malcom product. It was manufactured using the highest quality
components and was meticulously adjusted and calibrated to factory specifications. We hope that it will
provide you with many years of trouble-free operation.

Should you encounter difficulty in using your instrument, or if its performance has become abnormal,
please consult the troubleshooting section of your operation manual. Should this not enable you to solve
the problem, do not attempt to dissemble, lubricate or repair the unit yourself, doing so will void the
warranty. Instead, contact Malcom Instruments directly at:

Tel. (510) 293-0580 Fax. (510) 293-0940

Email. service@malcomtech.com

Quite often it is possible to resolve problems over the phone. If the difficulty is such that it requires the
return of the product for repair, please secure the instrument with the supplied shipping brackets and place
it into its original packing. If this is not possible, use a strong tape or cord to secure the unit for shipping.
Pack the device in a rugged box much larger than the actual instrument. Use plenty of packing material
that is elastic, such as bubble wrap. Styrofoam, etc. Do not use material such as newspaper, popcorn or
wood shavings. Damages caused by shipping is not covered by the warranty. Send the unit, postage
prepaid and insured, to the address given below.

Warranty
The warranty for your Malcom product is six (6) months parts, and three (3) months labor. To
guarantee in-warranty service, please fill out the below sheet and return to:

Malcomtech International, 26200 Industrial Blvd., Hayward, CA 94545

Your time in this matter is greatly appreciated.

Model: _____________________ Serial Number: _________________________

cut on this line

Model: _________________________ Serial: _________________ Purchase Date: ________________

Company: _____________________________________________________

Name of Owner/Operator: ______________________________________ Tel. ( )_______________________

Company Address: ______________________________________________________________________________

City/State/Zip: _________________________________________________________________________________

NOTE: NO WARRANTY WILL BE HONORED WITHOUT THIS FORM ON FILE AT MALCOM.