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Handpiece Stacking: Definition & How it Can Help You

The Operating Parameters of every resistance soldering system include the following set of instructions:

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.

This duty cycle recommendation must be followed to keep from damaging either the power unit, or the handpiece. This recommendation, however, is still no guarantee that the handpiece will not accumulate heat in the adapters or the cabling. If heat is not being drawn from the handpiece rapidly enough you may still have to periodically interrupt the application being performed to allow adequate cooling of the handpiece before continuing.  Damaged caused by excess heat build-up destroys tools and is not covered under the warranty program

Handpiece "STACKING" can be utilized to avoid the potentially damaging accumulation of heat in the handpiece's adapters, handles or cabling. When the 50% duty cycle requirement is being followed and you find that substantial heat is developing in the handpiece, you can get around the interruption of work by having two handpieces attached to the power unit at the same time. This suggestion (which we refer to as STACKING) is easier to implement if the power unit being used is one of our higher output models, including 105C1, 105C2 and 105D1 as they are manufactured with 3/8-16 threaded studs for hooking up the appropriate handpieces. The handpieces developed for use with the larger Power Units are manufactured with 3/8" ring terminals attached to them (you just attach both pair of handpieces to the Power Unit by placing the ring terminals over the studs and tighten the wing nuts snuggly over them). The idle handpiece will not develop heat as long as it is on a non-conductive surface and there is nothing conductive between the electrodes or elements. When the handpiece that is being used for the application begins to develop excessive heat the operator can set it aside to cool and use the back-up handpiece to avoid a loss of productivity which otherwise would be unavoidable.

When using any of the lower wattage Power Units that have the standard taper pin receptacles on them you can still use the above-mentioned suggestion. The difference being that the handpieces, which are normally suggested for use with the lower output Power Units, have taper pins attached instead of ring terminals. You will need to cut the taper pin off of the cable assembly and attach 1/4" ring terminals in their place. You will need 1/4" ring terminals because you will be using (3/4" length) 1/4-20 threaded brass hex head bolts for the handpiece to Power Unit hook-up. You will find that the taper pin receptacles on the front of the Power Unit have already been tapped to accept a 1/4-20 threaded bolt. These changes can be requested on new product orders, additional charges may apply. If you already own American Beauty Resistance Soldering Equipment you can utilize our repair service to have these changes made. For more information please feel free to contact our Technical Support or Customer Service Teams at the factory.

This suggestion of stacking is not intended as a way of utilizing two or more handpieces simultaneously. It is only recommended as a way of allowing a handpiece to cool without interrupting the work being done, in order to prevent excessive heat damage when performing applications, which demand a higher volume of heat. It may also be an interim solution for applications where you have reached the maximum available output of a Power Unit and are not yet ready to step up to a higher output Model as long as the 20 second maximum cycle time is not being violated (Please remember that the operator must still adhere to the required 50% duty cycle). Whenever an application has a cycle time of 10-20 seconds you may want to consider looking into a higher output Model. As with all applications, the faster you can achieve the proper end result, the better. That way there is less chance of thermal damage to the work, the surrounding components and the equipment being used.

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