General Operating Instructions
SET-UP
Plug the Power Unit into the foot switch receptacle. Plug the Footswitch into a properly
grounded 230v AC outlet. Depress and hold the Footswitch. The light on the Power Unit will
come on, indicating that the unit has power. The light will go out when the Footswitch is
released. After this test, unplug the Footswitch and continue with set-up below. Small and
medium American Beauty® Resistance Soldering Handpieces are manufactured with taper
pin quick connect terminals to connect to the taper pin receptacles on the front of American
Beauty® Resistance Soldering Power Units (push in turning clockwise until snug). The larger,
Heavy Duty Handpieces are manufactured with ring terminals, for connection to the posts on
the front of the higher output Power Units. There is no concern for polarity since the power
supply delivers alternating current. You may now connect your system through the
Footswitch to the outlet. Metal Electrodes are stainless steel, or Nickel-Chromium, with a
copper jacket. Only the core metal is to touch the work piece while soldering. If necessary,
remove some of the copper jacket with a file to insure that it does not come in contact with
the work piece. Metal electrodes can be bent, flattened, notched, milled or slotted to better
accommodate an application. Carbon electrodes can also be notched, milled or slotted,
however they are more brittle and can not be bent without breaking.
SOLDERING PROCEDURE
Determining the proper power setting will be dictated primarily by the work piece and then by
your personal preference. It is strongly recommended that you experiment on scrap pieces
until you become more familiar with the use of your resistance soldering system. In general,
very small, or delicate items will require a lower setting. Larger items require a higher setting
or longer dwell time. Trial and error, using test pieces that are the same size and material as
the work piece, is the best method for determining the proper power setting. Set the power
unit at 50% and solder, noting the time required for the solder to flow evenly in the joint.
Work up and down the dial in 5% increments until you find the high and low extremes. You
can then decide on your preferred setting between these points. Your goal is the fastest
setting at which you are comfortable. A low power setting with excessive dwell time tends to
allow heat sinking into areas adjacent to the joint. High settings can produce dwell times so
short that you have little measure of control. Dwell times of less than one second are not
recommended. Be certain the metal to be joined is bright and clean. Use steel wool, a file,
emery cloth or sandpaper to clean if necessary. The actual soldering procedure is simple.
Contact the work-piece with both electrodes of the tweezers. Make contact as close to the
solder joint as possible. Depress and hold the Footswitch. Apply solder to the joint as it heats
and release the Footswitch when the solder flows. Allow the joint to cool undisturbed until the
solder sets. Use caution when soldering. Always wear protective gear and avoid inhaling any
fumes that may be generated while using resistance soldering equipment. Do not touch parts
until they have cooled. When you are soldering pieces of greatly different sizes, you may
want to consider pre-tinning (applying solder to) each piece separately and joining them by
reflowing the solder, adding just enough new solder to complete the joint. Trial and error may
seem time consuming at first, but you will find that as you become more accustomed to the
equipment you will be able to predict dwell times and output settings, with better accuracy
and you will become more proficient with time and practice.
General Operating Instructions
OPERATING PARAMETERS
Power Units that are set higher than 50% of their available output will require utilizing a 50%
duty cycle. For example, if it takes 10 seconds (10 seconds on) for the solder to flow on an
application and the Power Unit is set higher than 50%, you must let the Power Unit rest for
10 seconds (10 seconds off) before soldering again (15 seconds on, 15 seconds off, etc.).
Never run the unit continuously on any power setting for more than 20 seconds. If you
cannot get the solder to flow in that amount of time the Power Unit setting is too low, the
work is too large for the unit or there is a problem with the set-up or approach. Check the
electrodes and connections. Always ensure that the appropriate Handpiece and Power Unit
have been selected for the application that you are performing.
MAXIMUM OPERATING PARAMETERS
The maximum wattage information shown on the front of this sheet is in accordance with the
maximum allowable heating duration of 20 seconds. A higher wattage may be used when
operating for a shorter heating duration. If you have questions regarding this information,
please contact our technical support team at the factory.
OPTIONAL SINGLE ELECTRODE HANDPIECE
Plug your Single Electrode Handpiece into one socket on the Power Unit, and ground lead
with clip into one of the other sockets. Attach the clip as close to the solder joint as possible.
Touch the intended joint area with the tip of the single electrode and depress the Footswitch
until solder flows. As with tweezers electrodes, keep the tip of the single electrode clean and
free from burnt flux and solder residue.
BASIC TROUBLE SHOOTING
If you are experiencing any problems:
1. Check your power outlet to insure supply voltage is available.
2. Check the fuse, or circuit breaker in the Power Unit and, if necessary, replace it with
the appropriate fuse, or reset the circuit breaker.
3. Check the connections. Handpiece to Power Unit and electrodes to Handpiece
4. Check to see if the electrodes are fouled with burnt flux. Clean them if necessary by
dressing them with an emery cloth, a fine file or a small wire brush.
5. Check that the work piece is clean and free of oil and that the electrodes are making
contact with the work surface.
Summary: This American Beauty® Resistance Thermal Wirestripping System has been
assembled for your convenience, in order to help eliminate confusion when ordering
equipment to be used for thermal wirestripping applications on wires 14 AWG and Finer.
Description: This System consists of a Model 105A3T (100 watt) Power Unit, a Model
10517, (Regular Tweezer) Wirestripping Handpiece and a Model 10519 Footswitch.
Power Unit Description: The Model 105A3T Power Unit has a low-voltage, high
amperage, variable output, isolated transformer. The output voltage is 0 - 2.65 VAC
General Operating Instructions
(with no load). The control knob reads 0 to 100% of output voltage. This Power Unit
has a normally closed pressure switch mounted below the Handpiece cradle
attached to the top of the Unit. When the Handpiece is nested in the cradle the
Power Unit has no output. This Power Unit may be adapted to automated and
fixtured production tooling. For more detailed information please read the
Information/Instruction sheet included with the Power Unit in this Kit.
Handpiece Description: The Model 10517 Regular Tweezer, Wirestripping
Handpiece is supplied with two, specially formed, resistance wire, nickel-chromium
elements, to create heat for stripping insulation from wire, by softening and/or melting
through the outer jacket of the wire to be striped. It has a four-foot (1.22 m), 14-2
HPN neoprene cable, with taper pin quick connect terminals for fast, easy connection
to the 105A3 Power Unit (push in turning clockwise until snug) and padded handles
for operator comfort. For more detailed information please read the
Information/Instruction sheet included with the Handpiece in this Kit.
Uses: This System can be used to cleanly strip 14 AWG and finer wires having lowtemperature PVC, (PVC will require lower heat settings – just to soften, but not burn), up to
and including high-temperature, fluorocarbon types of insulation. Because heat is being used
to soften and part the insulating material, time required to strip will vary with the type and
thickness of the jacket, as well as the conductor size. Any shielding under the jacket will slow
the softening time, but most insulation will strip cleanly without fraying, given the appropriate
amount of time. The proper stripping method is to heat, twist and pull gently to remove the
insulation. With this system the Handpiece activates immediately upon removal from its
cradle which is situated on the top of the Power Unit.
Please reference the General Operating Instructions for American Beauty® Resistance
Soldering Systems for more detailed operating instructions and guidelines.
Replacement Electrodes/Elements:
Model 10545 metal elements (round cross section, 1 notched)(Pkg. of 2)
Model 10529 metal elements (both flattened, 1 notched)(Pkg. of 2)
Model 10520 metal elements (both flattened and notched)(Pkg. of 2)
NOTE: Always keep elements clean and free from burnt flux and solder residue by
cleaning them with an emery cloth, a fine file or a small wire brush.
Duty Cycle: The Power Unit has been rated to operate at a 50% maximum duty cycle. Do not
operate beyond this rating. WARNING: THERE ARE NO USER SERVICEABLE PARTS
INSIDE OF THE POWER UNIT. DO NOT ATTEMPT TO OPEN THE POWER UNIT
HOUSING FOR ANY REASON, DUE TO THE RISK OF ELECTRICAL SHOCK. ELEMENTS
CAN GENERATE A SIGNIFICANT AMOUNT OF HEAT WHEN POWER IS APPLIED. USE
WITH CAUTION TO AVOID BURNS, FIRE OR OTHER POTENTIAL DAMAGE. NORMAL
USE OF THIS PRODUCT IS LIKELY TO EXPOSE THE USER TO SOLDERS CONTAINING
LEAD, WHICH IS KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND
BIRTH DEFECTS (OR OTHER REPRODUCTIVE HARM) OR OTHER PROPOSITION 65
LISTED CHEMICALS.