936A/936

Temperature Controlled
Soldering Station
Instruction Manual

ThankyouforpurchasingtheAoyue936A/936
temperaturecontrolledsolderingstation.
Pleasereadthemanualbeforeusingtheunit.
Keepmanualinaccessibleplaceforfuturereference.

Manufacturer:
AOYUETONGYIELECTRONICEQUIPMENTFACTORY
JishuiIndustrialZone,Nantou,ZhongshanCity,
24
GuangdongProvince,P.R.China
http://www.aoyue.com

REPLACEMENT SOLDERING TIPS

23

PARTS LIST
Soldering Iron Stand
Part Number

TABLE OF CONTENTS

Description

20090726303 IronStand

200726302

HeatProtector

30100417

AluminumRing

20051304

M4 Nut

200726303

Plate

30090303

14x3RubberFoot

2005334*4

4x4 Screw

2005334*6

4x6Screw

30090302

14x13 RubberFoot

Packagecontent.4
Nameofparts.....4
CareandSafetyPrecautions.....5
Specification.......6
AssemblyandUsage....7
SolderingTipcareandMaintenance..8
Tiptemperature
Cleaning
Whennotinuse
Soldering Iron
#

Part Number

Description

200606

20080309 TipEnclosure

T-I

20080307 TipLock

3011936

201093601 GroundSpring

CopperNut
SolderTip
PlasticNut

Tipcalibration
Disassemblingthehandpiece.10
Testingtheheatingelement....11
Replacingtheheatingelement...12
Troubleshootingconnections....1315
Replacingsolderingironcord..16
Reassemblingthehandpiece..17
Changingoffuse...18
BasictroubleshootingGuidelines...20

#
7

Part Number

Description

C008

936AHE

C001

936 HE

#
11

Part Number

Description

30125S

936APlasticHandle

30124S

936PlasticHandle

20070203 CrossChip

12

30091001 WireHolder

10076936 SupportBoard

13

30090901 HandleProtector

10

20070204 SecuringChip

14

10110502 WireCord

15

10270205 5pinreceptacle

22

PartsList......2122
ReplacementSolderingTips.23

PARTS LIST

PACKAGE CONTENT

Main Station

Please check if the listed parts below are included in the package:

Aoyue936A
936AMainStation
.........1unit
SolderingIron
.........1pc.
SolderingIronStand
(includingSponge) .........1pc.
InstructionManual
.........1pc.
PowerCord
.........1pc.

Aoyue936
936MainStation
.........1unit
SolderingIron
.........1pc.
SolderingIronStand
(includingSponge) .........1pc.
InstructionManual
.........1pc.
PowerCord
.........1pc.

Part Number

Description

3002290005

CaseCover

2005143X8

3x8 Screw

PCB936A

936APCB

PCB936

936PCB

3004290030

FacePlate

20051009

M9 Medium

20051309

M9 Nut

3005936

Knob

30090301

RubberStop

10090405

FuseHolder
withFuse

10

2005154x60

NAME OF PARTS
MainStation

SolderingIron

Powercord

SolderingIronstand

Part Number

Description

10039.220V 936Atransformer 220V

11

10039.110V 936Atransformer 110V

10037.220V 936transformer 220V
10037.110V 936transformer 110V

4x60Screw
12

960101.1

13

3002290006 CaseBottom

14

2005154x12 4x12 Screw

15

960101

16

101020201 PowerSwitch

ReceptacleNut

ReceptacleHolder

21

BASIC TROUBLESHOOTING
GUIDE
Aoyue936

CARE and SAFETY PRECAUTIONS

PROBLEM3:SOLDERINGIRONTEMPERATUREISINTERMITTENT

CAUTION:Misusemaycauseinjuryandphysicaldamage.
Foryourownsafety,besuretocomplywiththefollowing
precaution.

Description: Main power LED lights up and so does the heater LED but
solderingirontemperaturerisesandfallsuncontrollably.

SOLUTION:

Soldering iron plug may be loose from the receptacle unplug the
solderingironandreattach.
Soldering iron cord may be damaged or loose and needs to be

Donotusenearflammablegases,paperandothermaterials.
Donottouchheatedparts,cancausesevereburns.
DonottouchmetallicpartsneartheTip.

replaced or repaired. See trouble shooting soldering iron cords

sectionofthismanual.
PROBLEM4:SOLDERWOULDNOTSTICKTOTHESOLDERINGTIP

PROBLEM5:SOLDERINGIRONDOESNOTPRODUCEENOUGHHEAT
Description: Soldering iron cannot melt solder fast enough, or actual
temperaturedoesnotreachthedesiredsettemperature.

Useonlygenuinereplacementparts.
Turnoffpowerandletunitcoolbeforereplacingparts.

Soldering process produces smoke, make sure work area is well

ventilated.

Donotmodifyunit

Nevertouchtheelementortipofthesolderingiron.Theyareveryhot
(about400C)andwillgiveyouanastyburn.
Take great care to avoid touching the mains flex with the tip of the
iron. The iron should have a heatproof flex for extra protection. An
ordinaryplasticflexwillmeltimmediatelyiftouchedbyahotironand

SOLUTION:

The system may need to be recalibrated please see steps in

thereisaseriousriskofburnsandelectricshock.
Alwaysreturnthesolderingirontoitsstandwhennotinuse.

Workinawellventilatedarea.Thesmokeformedasyoumeltsolder

calibratingthetiptemperatureonpage9ofthismanual.
Solderingirontip may alreadybetoodirty oroxidized . Please see
oursoldertipmaintenanceguideonhowtocleansolderingtips.

Disconnectplugwhennottobeusedforalongperiodoftime.
Turnoffpowerduringbreaks.

HandlewithCare
Neverdroporsharplyjolttheunit.
Containsdelicatepartsthatmaybreakifunitisdropped.

soldertoattachtothetip.

oursoldertipmaintenanceguideonhowtocleansolderingtips.
Temperature could be set too high causing solder to quickly burn
away,Pleaseadjusttoamoresuitablelowertemperaturerange.

ThermalProtector
Unit is equipped auto shutoff ability when temperature gets too
high and automatically turns on when temperature dropped to a safe
level.

Description: Solderingironisabletoquicklymeltsolderbutcannotcausethe

SOLUTION:

Solderingirontip may alreadybetoodirty oroxidized . Please see

Temperaturemayreachahighof480Cwhenturnedon.

is mostly from the flux and is quite irritating. Avoid breathing it by

keepingyourheadonthesideandnotdirectlyaboveofyourwork.

20

Washyourhandsafterusingsolder.Soldermaycontainleadwhichis
apoisonousmetal.

BASIC TROUBLESHOOTING
SPECIFICATION GUIDE

SPECIFICATION
SPECIFICATION

Model#

936A

936

Power Consumption

60W

35W

Fuse

1A

0.5A

MAIN STATION
24V

24V

Temperature Range

200480C
392896F

200480C
392896F

110(w)93(l)
168(h)mm

110(w)93(l)
168(h)mm

Tip to Ground
Resistance

24V60W

24V60W

Checkinternalcircuitryforshortsthatmaycausetheblownfuse.See
TroubleshootingConnectionsonpage1315.
Checkfortanglesofwiresintheheatingelementcausingittoshort.
SeeTroubleshootingConnectionsonpage1315.

Lessthan2Ohm Lessthan2Ohm
PROBLEM2:SOLDERINGIRONDOESNOTRISEINTEMPERATURE
Description: Main power LED lights up and so does the heater LED but

Tip to Ground Potential Lessthan2Ohm Lessthan2Ohm

Heating Element

1. CheckiftheunitisswitchedON.
2. Checkthefuse.Replacewiththesametypeoffuseifblown.
3. Checkthepowercordandmakesuretherearenodisconnections.
4. Verifythattheunitisproperlyconnectedtothepowersource.
Additionalprecautions:

SOLDERING IRON
Power Consumption

PROBLEM1:THEUNITHASNOPOWER/MAINPOWERLEDDOESNOT
LIGHTUP

Output Voltage

Dimension

WARNING: To avoid personal injury or equipment damage,

disconnect power cords before making any servicing to the
equipment, or unless instructed otherwise in the
troubleshootingprocedures.

Japanmade
CeramicHeating
CeramicHeating
Element
Element

solderingirontemperatureisrelativelowandisnotheatingup.
SOLUTION:
Soldering iron cord may be damaged and needs to be replaced or
repaired.SeeTroubleshootingConnectionsonpage1315ofthismanual.

Power Cord

1.1meters

1.1meters

HeatingelementmaybedamagedandneedstobereplacedseeTesting
theHeatingElementonpage11andReplacingtheHeatingElementonpage

Length

1.2meters

1.2meters

12onthismanual.

Weight

108grams

100grams

Design and specification might change without prior notice.

19

ASSEMBL
Y936
and
USAGE
Aoyue

CHANGING THE FUSE

Checkingthefuse:

I. SOLDERING IRON HOLDER

The Fuse can be found at the back of the unit, it is incorporated

intotheACpowerreceptacle.Iffuseisblownreplacewithsametype
fuseonly.

1. Installsolderwiretothesolderironholder.(Fig.1)
2. Dampen the cleaning sponge with water, squeeze it dry and
placeitinitsbase.(Fig.2)

FuseHolder
Fig.1

480C
Failure to dampensponge might
damagethesolderingtip.

Fig.2

II. SOLDERING IRON

Activefuse
holder

Fuseinuse
Sparefuse

1.

2.

holder.
3.

Solderingironmustbeplacedinthe
ironholderwhennotinuse.

III. MAIN UNIT

Use a screw driver to pop

openthefuseholder,slidethe
fuseholderout
Check if the fuse in use is
blown. If blown/damaged,
detach the spare fuse and
attach to the active fuse

1. Attach the soldering iron to the receptacle connector at the

bottomrightareaofthemainunit.
2. PlacesolderingirontothesolderingironstandasshowninFig.1
3. Plugthepowercordintoareceptaclewithground.

1. Turnonunitand
2. Whentheheaterlampblinksonandoffthenitmeansthatthe
tiptemperaturehasreachedthesettemperatureandisreadyfor
use.
Sparefuse
holder

Temperature
adjustmentknob

Powerindicator
Heaterlamp
Calibrationpoint

Reattachthefuseholder.

Powercord

Main power
switch

18

Handpiece
receptacle

SOLDER TIP CARE and MAINTENANCE

Tip Temperature

Ifthetiptemperatureistoohigh,itdecreasesthelifeofthe
tip. So we suggest you to use the lowest *possible* tip
temperaturewhensoldering.Thisnotonlyprolonglifeofthetip,
it also quickens heat recovery and decreases harm to sensitive
components.

Cleaning

REASSEMBLY OF HAND PIECE

After test or replacement of heating elements are done follow the
following steps to reassemble the hand piece:
1.
2.
3.
4.
5.

Thesolderingirontipshouldbecleanedafterusebywiping
iton thedampspongefoundinthesolderingironstand,thisisto

6.

getridofburntsolderorfluxesthatcausesoxidationonthetip.
Regularcleaningisalsoneededwhentipsareusedforprolonged

7.

periodoftime(removetipfromsolderingironandcleanitoncea
week). The solder tips are chrome electroplated on the surface

SlideinhandpiecePCBintothemainhandle.Besuretosecure
thePCBinthenotchatthemouthofthemainhandle.
Attachthefrontmodule5tothemainhandle.
SlideintheTipholder4.Makesurethesmallerendisinserted
firstasseenintheillustrationbelow.
Insertthesolderingirontip3asseenbelow.
Secure the tip by inserting the tip enclosure 2 and nut 1
securely.
Reattach the hand piece plug 15 to the receptacleat the main
station.
Recalibrate the soldering iron, see guide on tip care and
maintenancesectionofthismanual.

andshouldbe brightsilverwithnofluxresidueorsolderonit.
Remembertotinthetipaftercleaninginpreparationforthenext

When Not in Use

If a solderingiron does not havea thin consistentlayer or

solder over the entire surface, the tip has not been properly
tinned.Whenyouarenotusingyouriron,makesureyouleavea
largelumpofsolderonthetip.Thismaintainsthetinningonthe
tip,andthetipwilllastmuchlonger. Many technicians mistakenly
clean the tip before they put the ironinto the holder. Leave the
solderonthetiptoprotectit.

17

SOLDER TIP
CARE 936
and
MAINTENANCE

Aoyue

REPLACING SOLDERING IRON CORD

When cord is proven to be faulty follow the steps to replace the cord:
1.
2.

Followthestepsindisassemblingthehandpiece.
Write down or make a brief illustration of wire configuration in
thePCB.

Note : Different models have different configurations it is critical to

have proper wire configurations clearly noted before proceeding to
the next step. (See proper connections table for reference)
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

Unsolder the wires connecting the hand piece PCB and cord
together.
Unattached the (white wire for 936 , black wire for 936A)
connectingthecordandgroundingspringtogether.
DetachthePCBfromthecordbyreleasingthemetalgripslocated
atthebottomofthePCB.
Slideoutthemainhandle,softgrippadandtailendofthehand
piece.
Insertthetailendandsoftgrippadintothenewcord.
Insertthenewcordthoughtthemainhandle.
Solder the wires back into the PCB, using the proper
configurations.
Reattach the wires (white wire for 936 , black wire for 936A)
fromthenewcordtothegroundingspring.
Bend the metal on the bottom end of the PCB to grip the cord
firmly.
Follow Reassembly of hand piece procedure to complete the
process.

16

STEPS in Checking, Cleaning and Tinning the Tip

Neverusefileorsharproughobjectsinremovingoxidationofthetip

1. Settemperatureto250C(482F)
2. Afterrealtemperaturereachesthesettemperature,useadamp
spongetocleanthetipandcheckfordamages.
3. If the tip has oxidation, apply solder and wipe using the damp
sponge,repeatthesestepsuntiloxidationisremoved.
4. Aftercleaning,coattipwithathinlayerofsolderandsetitaside
readyforthenextusage.
5. Ifthetipshowsdisfigurationorhasrustonit.Changethetip.
Temperaturecalibrationmustbedoneeverytimeyouchangethe
soldertiporchangetheheatingelement.

STEPS in Calibrating the Tip Temperature

1. Pluginstationandturniton.
2. Settemperatureto400C(750F)
3. WaitforHeaterLEDtolightup.
4. Useanexternalsensorandplaceitonthesoldertip.
5. TakeofftherubberstopintheCALpoint.Useascrewdriver,one
thatfitstheCALhole,toadjusttheCALpoint.
Turnclockwise

Toincreasetemperature
Counterclockwise

Todecreasetemperature

6. Adjustuntiltheexternalsensorreads400C(750F).

DISASSEMBLING
THE
HAND PIECE
SPECIFICATION
Aoyue936A

TROUBLESHOOTING
CONNECTIONS
Aoyue936

The hand piece may be disassembled for trouble shooting and

repair:
1.
2.
3.
4.

5.
6.

Turnoffmainstationandunplugfrompowersource.
DetachtheSolderingIronReceptacle(15 asshowninthe
figurebelow)fromthemainunit.
Turn the Copper Nut, (1 as shown in the figure below)
counterclockwisetoloosenit.
Pull out the Tip Enclosure (2 as shown in the figure
below),theSolderTip(3asshowninthefigurebelow),
andtheTipLock(4asshowninthefigurebelow).
Turn the Plastic Nut (5 as shown in the figure below)
counterclockwisetoreleaseitfromthemainbody.
Push out the Heating Element (6 as shown in the figure
below) via the Wire Cord (14 as shown in the figure

10

Additional notes:
Properconnectionstable:

For936A:
PIN

CORDCOLOR

CORDCOLOR Heatingelement

RED

RED

RED

BLUE

BLUE

RED

BLACK

BLACK

SPRING

GREEN

GREEN

BLUE

WHITE

WHITE

BLUE

For936:
PIN

CORDCOLOR

CORDCOLOR Heatingelement

RED

RED

RED

YELLOW

YELLOW

RED

WHITE

WHITE

SPRING

BLUE

BLUE

BLUE

BLACK

BLACK

WHITE(coarse)

15

TROUBLESHOOTING
CONNECTIONS
SPECIFICATION
Follow the following direction to test for hand piece cord

TESTING THE
HEATING
Aoyue
936
ELEMENT
Totestiftheheatingelementisinworkingcondition:

faults:
Test1:Renderingphysicalstraintothecord

1. Turnontheunit.
2. Settemperatureto480C.
3. Bend and straiten the entire length of the cord bit by bit. The
heater lamp should always be lit while doing so. If the heater
lamp becomes intermittent the cord is faulty and should be
Note:replaced.
the Heater lamp will blink if the temperature of the soldering

iron tip has reached the set temperature i.e. 480C. this is not an
indication of a faulty cord.

Test2:Resistancetest

1. Followthestepsindisassemblingthehandpiece.
2. Testforcontinuitybetweenthefollowingpinsandcoloredwiresat
thehandpiecePCB,alltestsshouldregister0 to2.
3. Ifanyoftheabovementionedcombinationdoesnotregister0

Cool down assembly to room temperature before continuing the tests

below:
1.
Followdisassemblingthehandpieceguide.
2.
DothefollowingtestsonthehandpiecePCBboard:

Resistancevalueofheatingelement(RED)2.53.5

Resistancevalueofsensor(blue)4358
Aftertestingcheckresultswiththefollowing:

If the resistance value is not as stated above replace the

heatingelement.

Ifa0orinfiniteresistancesaremeasuredcheckforshorts
oropencircuits.

Itermittentreadingscanalsobecausedbycoldsolderdouble
check solder points if the heating element has recently been
replaced.
To replace the heating element follow Replacing the heating element
guideonthenextpage

thecordisfaultyandshouldbereplaced.
Heatingelement(RED)

For936A:

Sensor(BLUE)

Pin1&Redwire

Pin2&BLUEwire

Pins3&BLACKwire

Pin4&GREENwire

Pin5&WHITEwire

14

Pin1&REDwire

Pin2&YELLOWwire

Pins3&WHITEwire

Pin4&BLUEwire

Pin5&BLACKwire

Heatingelement

Note: Illustration shows diagram for 936A station, for the 936
station the sensor wire is blue and white with waxed coat.
11

REPLACING
THE HEATING
ELEMENT
SPECIFICATION

TROUBLESHOOTING
CONNECTIONS
Aoyue936

Theheatingelementcanbereplacedasfollows:

The 5 pin socket can be tested to detect faults in the

1.
2.

handpiece:

5.

Followthestepsindisassemblingthesolderingiron.
Unsolder the heating element wires (RED) and the sensor wires
(blueand/orwhite).
Theoldheatingelementcannowbedetachedfromthehandpiece
board.
Detach the metal protector located at the bottom part of the
heatingelement.(936only)
Reattach the metal protector to the bottom part of the new

6.

heatingelement.(936only)
PasstheNewheatingelementswires(RED)thrutheholeslocated

3.
4.

7.

ontopoftheboard.
Solder the heating elements wires and the sensor wires to the
boardmatchwiththesamecoloredwires(redwiretoredwireon
board,bluewirewithbluewireonboardetc.)

Pins4&2

Pins4&1

Pins5&1

Pins5&2

Beforeplugginginthehandpiececonductthefollowingtest:
If any of the above mentioned combination registers a short
review thestepsin replacing the heating element to ensure proper

Warning: Ensure none of the above mentioned conditions are

present before plugging in the hand piece. Failure to do so can
damage the internal circuitry of the unit.
Testtheresistancesofthefollowingconfigurations:

For936A:
SolderoneREDwireofheatingelementwithredwireonPCB.
SoldertheotherREDwireofheatingelementwithbluewireonPCB.

SolderoneBLUEwireofheatingelementwithwhitewireonPCB.
SoldertheotherBLUEwireofheatingelementwithgreenwireonPCB

For936:

Pins1&2

2.3to3.5

Pins4&5

43to58

Pin3&soldertip

Below2

SolderoneREDwireofheatingelementwithREDwireonPCB.

Solder the other RED wire of heating element with YELLOW wire on
PCB.
SolderBLUEwireofheatingelementwithBLUEwireonPCB.

SolderWHITEwireofheatingelementtowithBLACKwireonPCB

For936A:

12

For936:
Pins1&2

19to23

Pins4&5

1.2to1.5

Pin3&soldertip

Below2
13