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kesleyelectric(at)chooseb
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 Posted: Mon Jan 05, 2009 10:22 am Post subject: Metcal soldering wand repair |
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A while back I purchased a Metcal soldering wand, model MX RM3E, which was damaged when it arrived. The cable had been severed about in the middle. The company sent me a replacement, but I was wondering if the cable could be repaired. The cable has a braided shield around a single stranded conductor. Any thoughts?
Regards,
Tom Barter
Kesley, IA
Avid Magnum
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nuckolls.bob(at)aeroelect
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| Posted: Mon Jan 05, 2009 1:23 pm Post subject: Metcal soldering wand repair |
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At 12:19 PM 1/5/2009, you wrote:
| Quote: | A while back I purchased a Metcal soldering wand, model MX RM3E, which was damaged when it arrived. The cable had been severed about in the middle. The company sent me a replacement, but I was wondering if the cable could be repaired. The cable has a braided shield around a single stranded conductor. Any thoughts?
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Sure. It's not "magic" wire. It's not even a true coaxial
cable suitable for transmission lines. The Metcal power
supplies are really a radio frequency transmitter with
an operating frequency about 300 Khz and a 30 watts or
so power output.
The soldering tips are the "magic" parts. At temperatures
below their rated heating value, they represent a rather
low impedance load to the "transmitter". Hence they
draw power and convert it to heat (really useful for
melting solder).
At their calibrated operating temperature, the "magic"
material in the tip (30% unobtainium alloyed with 69%
youneverheardofit and 1% pixiedust) goes into a high
impedance state thus reducing its power consumption
thereby regulating temperature AT THE TIP.
The wand wiring is special to the extent that it is
very flexible, resistant to damage from the hot iron,
and reasonably robust (but as you've observed, not
invincible!).
Ordinary craftsmanship can be used to splice your damaged
wire. Take a look at this comic book:
http://aeroelectric.com/articles/shldwire/shldwire.html
Suggest you prepare the cut ends as shown except cut
the center conductor to about 1/4" exposed insulation
and 1/2" exposed wire. Lap splice the center conductors.
Wrap with two layers electrical tap. Trim outer
conductor for 1/2" overlap and solder those too. Cover
whole thing with heat-shrink (oh yeah, the heat shrink
needs to go on before you start stripping/splicing
the conductors.
I've made similar repairs to Metcal wands like this
twice with gratifying results.
Bob . . .
----------------------------------------)
( . . . a long habit of not thinking )
( a thing wrong, gives it a superficial )
( appearance of being right . . . )
( )
( -Thomas Paine 1776- )
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