Hacking and Upgrading a ZD-985 Desoldering Station

RE: Hacking and Upgrading a ZD-985 Desoldering Station

volly — Tue, 16 Aug 2016 17:47:58 GMT

[mention:f80b53cee57c44bc9d7c577d07d7c791:e9ed411860ed4f2ba0265705b8793d05], you might not be an engineer but you are ingenious, you've got indeed a beautiful mind. I really find your touch to things very useful and thought provoking.

Thank you so much.

Yunus.

RE: Hacking and Upgrading a ZD-985 Desoldering Station

atomickidd — Wed, 06 Jul 2016 14:07:27 GMT

Very nice work. An Actual redesign using alternate components is wonderful. In my computer youth graduating and starting with a wonderful company TRW Data Point. All Bench techs and my QC shop all had "PACE"

Desoldering units on our desks. The insides used similar Graphite Veins on an armature providing vacuum. With In/Out passing thru a filter bottle to catch melted solder. Worked very well. I managed to find some of these Motors in a Toronto Junk Store now no longer. Learning of other great minds thinking of making better. This is wonderful to see such a share to all.

Well Done.

RE: Hacking and Upgrading a ZD-985 Desoldering Station

jw0752 — Tue, 21 Jun 2016 19:26:28 GMT

SIDE EFFECTS:

Anyone who has ever Hacked or modified a piece of equipment knows that there are always side effects for every change made. While there may still be more problems coming here are the side effects that have been encountered so far and my first attempts to ameliorate them.

Vacuum Pump Heat:

After using the desoldering station for an hour the other night I checked the temperature of the vacuum pump under the bench. The temperature reading was approaching 100 degrees Centigrade. (Actual 205 degrees F) While this was probably still within safe limits it was decided to investigate it further and install a fan that would provide a better atmospheric heat sink than just the normal convection currents. Here is a picture of the unit with the fan in close proximity.

[View:/resized-image/__size/620x465/__key/commentfiles/f7d226abd59f475c9d224a79e3f0ec07-daa391e4-5ac3-4278-b170-9fa35eddf085/2046.contentimage_5F00_181687.jpg:620:465]

Next I set up a graph sheet and timer and turned the unit on. Temperature in Fahrenheit was taken every 5 minutes until the temperature of the vacuum pump stabilized after 70 minutes. Here is a graph of the temperature rise for the vacuum pump. The use of the Fan brought the final temperature down to 185 degrees F or (85 degrees C). Here is the graph of the temperature rise of the vacuum pump.

[View:/resized-image/__size/620x472/__key/commentfiles/f7d226abd59f475c9d224a79e3f0ec07-daa391e4-5ac3-4278-b170-9fa35eddf085/3617.contentimage_5F00_181688.jpg:620:472]

Line Filter Damage by Higher Vacuum Level

The second side effect that was noted from the initial extended test of the modified system was that the stronger vacuum was pulling the inline filter apart and into the breach of the desoldering gun.

[View:/resized-image/__size/620x465/__key/commentfiles/f7d226abd59f475c9d224a79e3f0ec07-daa391e4-5ac3-4278-b170-9fa35eddf085/0564.contentimage_5F00_181689.jpg:620:465]

The white felt filter sandwiched between the spring and the breach of the desolder gun prevents small particles of solder and other debris from entering and clogging the vacuum supply hose. The increased vacuum level provided by the modification was pulling the felt loose and into the breach of the gun. Here is a picture of a used filter that shows the effect.

[View:/resized-image/__size/620x465/__key/commentfiles/f7d226abd59f475c9d224a79e3f0ec07-daa391e4-5ac3-4278-b170-9fa35eddf085/4606.contentimage_5F00_181690.jpg:620:465]

Here are two pictures showing the breach without the filter covering it and with the filter in place:

[View:/resized-image/__size/620x465/__key/commentfiles/f7d226abd59f475c9d224a79e3f0ec07-daa391e4-5ac3-4278-b170-9fa35eddf085/3201.contentimage_5F00_181691.jpg:620:465][View:/resized-image/__size/620x465/__key/commentfiles/f7d226abd59f475c9d224a79e3f0ec07-daa391e4-5ac3-4278-b170-9fa35eddf085/1157.contentimage_5F00_181692.jpg:620:465]

My first attempt to fix this problem will be a brass wire support inserted into the hole in the breach to help support the filter so that there will be less unsupported surface area. Here is the small brass support and a picture of it properly positioned in the hole in the breach.

[View:/resized-image/__size/620x465/__key/commentfiles/f7d226abd59f475c9d224a79e3f0ec07-daa391e4-5ac3-4278-b170-9fa35eddf085/4380.contentimage_5F00_181693.jpg:620:465][View:/resized-image/__size/620x465/__key/commentfiles/f7d226abd59f475c9d224a79e3f0ec07-daa391e4-5ac3-4278-b170-9fa35eddf085/2146.contentimage_5F00_181694.jpg:620:465]

Hopefully these fixes will solve these side effects. Most of the time modifying equipment to suit ones desires is more of a continuing process than just a quick fix. Time will tell.

John

RE: Hacking and Upgrading a ZD-985 Desoldering Station

clem57 — Tue, 21 Jun 2016 00:41:32 GMT

I would have guessed no solution, but you came up with an ingenious solution to the noise. I like it! [View:/resized-image/__size/16x16/__key/commentfiles/f7d226abd59f475c9d224a79e3f0ec07-daa391e4-5ac3-4278-b170-9fa35eddf085/contentimage_5F00_1.png:16:16]

Clem

RE: Hacking and Upgrading a ZD-985 Desoldering Station

DAB — Mon, 20 Jun 2016 22:33:55 GMT

Excellent hack John.

Great bit of problem analysis and scavenging hunt to find acceptable replacement parts.

We will make an engineer of you yet.

DAB

RE: Hacking and Upgrading a ZD-985 Desoldering Station

Jan Cumps — Mon, 20 Jun 2016 06:17:39 GMT

You may have enough umpph left in your reservoirs to also feed a hot air soldering station?

the air flow volume is more critical in that application, you might have to introduce a reduction valve so that the debit is within the regulation range of the station's regulation valve.

RE: Hacking and Upgrading a ZD-985 Desoldering Station

mcb1 — Mon, 20 Jun 2016 05:40:26 GMT

Nice work.

All the ones I've come across are the same ... loud.

The hand gun types where the pump is in the handpiece are no quieter, but the vibration acts to help move the component leg, so it's a bonus (and a noisy pain)

Well done luckily you were in the right profession.

mark