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INSTRUCTION MANUAL




Thank you for purchasing Aoyue Int866 Complete Repairing system.
It is important to read the manual before using the equipment.
Please keep manual in accessible place for future reference.






INT 866
(Centigrade / Fahrenheit switchable)
Complete
Repairing System
AOYUE

2


TABLE OF CONTENTS


Product Description 3
Specifications ... 3
Package Inclusion . 4
Functions and Features ... 5
Safety Precautions . 6
Assembly and Preparation . 7
Control Panel Guide . 8
Operating Guidelines . 912
Auto-Sleep Functions .. 1314
Digital Calibration .. 1516
Care and Maintenance . 17
Basic Troubleshooting Guide .. 18
Replacement Tips 19
Air Nozzles 20


This manual is designed to familiarize and instruct the
operator with the proper usage and maintenance of the
equipment. The Care and Safety Precautions section
explains the hazards of using any type of soldering or
reworking device. Please read carefully and observe the
guidelines in order to maximize usage and minimize the
risk of injury or accidents .
19


REPLACEMENT SOLDERING TIPS

18

BASIC TROUBLESHOOTING GUIDE
PROBLEM 1: THE UNIT HAS NO POWER
1. Check if the unit is switched ON.
2. Check the fuse. Replace with the same type if fuse is blown.
3. Check the power cord and make sure there are no disconnections.
4. Verify that the unit is properly connected to the power source.

PROBLEM 2: HOT-AIR GUN TEMPERATURE DISPLAY IS ALWAYS
ABOVE 500
o
C
Description: Constant display of above 500
o
C temperature from the panel
then displays an Err1 on the panel after a few minutes.
SOLUTION:
The thermal sensor may be broken and needs to be replaced.

PROBLEM 3: HOT-AI R GUN ACTUAL AI R TEMPERATURE IS NOT
INCREASING
Description: Actual temperature reading is not increasing or decreasing
based on desired level.
SOLUTION:
The heating element may be broken or is at the end of its life and needs to
be replaced.

PROBLEM 4: SOLDERING IRON TEMPERATURE DISPLAY PANEL
SHOWS PLUG CHARACTERS
Case 1: The system shows PLUG from the soldering iron temperature
display panel .

SOLUTION : Check if the soldering iron connection assembly is properly
connected and secured to the receptacle on the control panel.

PROBLEM 5: UNIT SHOWS UNCONVENTIONAL BEHAVIOR
Description: Unit operates erratically.

SOLUTION1: Try to switch OFF the device and switch ON again. Unplug the
system from the main power source and plug in again when necessary

SOLUTION2: Restore unit to default factory setting. switch off/on the unit
while holding the hot-air temperature down button until the banner finishes
scrolling, the unit would revert to its default factory setting.

OTHER PROBLEMS NOT MENTIONED:
Contact the vendor.



3
The Aoyue INT866 Complete Repairing System is a reworking equipment
that combines the functionality of Hot Air Gun, Soldering Iron, Hot Air Gun
stand, Temperature Meter and Pre-heating in one package.
It has several safety features such as the auto-cooling process of the
Hot Air Gun. This functionality protects the device (and its components) from
excessive heat upon reaching any of the following conditions: (1) when the
soldering gun remained idle after a certain period and (2) when the
temperature of the device is above a safe threshold upon turning off. It has
several advanced features such as solder iron digital calibration, configurable
auto sleep for hot-air and soldering iron and switchable centigrade or
Fahrenheit readout.


PRODUCT DESCRIPTION
MAIN STATION
Power I nput : available in 110V / 220V
Station Dimensions: 192(w) x 100(h) x 325(d) mm
Weight: 6.58 Kg
SOLDERING IRON
Power Consumption: 60W
Temperature Range: 200C - 480C / 392F - 896F
Heating Element: Ceramic Heater
Output Voltage: 24V
HOT AIR GUN
Power Consumption: 400W
Temperature Range: 100C - 480C / 212F - 896F
Heating Element Metal Heating Core
Pump/ Motor Type: Siroccoo Fan
Power Consumption: 400W
Temperature Range: 100C - 480C / 212F - 896F
Heating Element Quartz Crystal
PRE-HEATER


SPECIFICATION
Specifications are subject to change without prior notice.
4


PACCKAGE INCLUSIONS
* Type of soldering tip included might change depending on availability. T-I
already installed on Soldering Iron.
** Kindly refer to soldering iron stand installation insert for parts and
instructions.
1 unit Int866 Main Station with Pre-heater and Hot Air Gun
1 pc. Spare Hot Air Gun Heating Element
1 pc. External Sensor
1 pc. Hot Air Gun Mast with Wire Holder
1 pc. 3-Segment Fully Articulating Arm Holder
1 pc. Holder Stopper with Securing Screw
6 pcs. PCB Holder
7 pcs. PCB Holder Securing Screw
1 pack AT-9 Air Nozzle Set (T1194, T1195, T1198, BGA-S)
1 pc. B016 Soldering Iron with Tip
1 pc. Spare Soldering Iron Heating Element
1 pack Soldering Iron Tips (10pcs) includes T-0.5C, T-0.8C, T-0.8D,
T-1C, T-1.2D, T-1.6D, T-2.4D, T-B, T-LB, T-I*
1 pc. 2663 Soldering Iron Stand**
1 pc. Soldering Iron Stand Assembly guide
1 set Vacuum Pen with 3 vacuum caps
1 pc. Tool Box
1 pc. G001 IC Popper
1 pc. Instruction Manual
1 pc. Power Cord
17

CARE and MAINTENANCE
Part No. Description
10094 Hot air gun heating element
30106S Plastic handle of hot air gun
S009 Hot air gun complete handle
20962 Hot air gun metal pipe
B012 Soldering Iron complete handle
Spare Parts Guide
Soldering Iron Tip
Always keep the solder-plated section of the tip/nozzle coated with a small
amount of solder. Oxide coating on the tip of the nozzle reduces its heat
conductivity. Coating the tip with a small amount of fresh solder ensures
maximum heat conductivity is obtained.


Soldering Iron Error Messages
1. Soldering Iron connection assembly is not connected or not properly
connected to the receptacle on the control panel.
2. Soldering iron tip is damaged and needs to be replaced. The device will
display PLUG.
3. Indicating a problem with the contacts of the soldering iron
or the tip.




16

DIGITAL CALIBRATION
NOTES:
The calibrated data is saved into the memory an shall remain effective
until it is recalibrated again or new data is entered.
Calibration will only make the newly calibrated point the most accurate.
Other temperature points may be a little off.
The soldering Iron has a lowest temperature limit such that when the
temperature has been set to 200 degrees with external actual
temperature also showing 200 degrees, further decreasing the
temperature offset would be only have minimal effect to the actual
temperature.
Solder I ron Digital Temperature Calibration Example
The external temperature sensor displays 248 to 252 degrees.
The set temperature and displayed actual temperature of the
soldering iron is 300 degrees.
300 248 = 52. An additional adjustment of 52 degrees is required.
Enter calibration mode
We increase from 0000 to 0052.
Exit calibration mode.
The external temperature sensor would now display 298 to 302
degrees.

5

FUNCTION and FEATURES
Microprocessor-controlled ESD safe equipment.
4-in-1 repairing system combining Hot Air Gun, Soldering Iron,
Pre-Heater, External Sensor, Hot Air gun stand in one
sophisticated package.
Digital control and display of hot air temperature, soldering iron
temperature, air pressure, pre-heater temperature with touch
type panel controls for precision and ease of use.
Switchable temperature readout between Fahrenheit and
centigrade.
Integrated hot air gun platform.
User configurable 1 to 30 minute idle-to-auto-stand-by mode
(with 30 minutes as default) for additional device protection and
power saving.
Built-in auto-cooling process that protects the system and its
components from excessive heat, prolonging usage life.
Built-in auto-sleep mode for soldering iron.
Compatibility with air nozzles of various types.
Compatibility with different kind of soldering tips.
6



SAFETY PRECAUTIONS
CAUTION: Improper usage can cause serious injury to personnel
and/or damage to equipment. For your own safety, please observe
the ff. precautions.
Check each component after opening the package to make sure
everything is in good condition. If there are any suspected damage, do
not use the item and report the issue to your vendor.
Turn OFF the main power switch and unplug the device when moving
the device from one location to another.
Do not strike or subject the main unit to physical shock. Use carefully to
avoid injury and damage to any part.
Handle with care.
- Never drop or sharply jolt the unit.
- Contains delicate parts that may break if the unit is dropped.
Make sure the equipment is always grounded. Always connect power to
a grounded receptacle.
Temperature may reach as high as 480C when switched ON.
- Do not use the device near flammable gases, paper and other
flammable materials.
- Do not touch heated parts, which can cause severe burns.
- Do not touch metallic parts near the tip.
Disconnect the plug from the power source if the unit will not be used
for a long period.
- Turn off power during breaks, if possible.
Use only genuine replacement parts.
- Turn off power and let the unit cool before replacing parts.
The unit may produce a small amount of smoke and unusual odor
during initial usage. This is normal and should not yield any negative
result when reworking.
Soldering process produces smoke use on well ventilated place.
Do not alter the unit, specifically the internal circuitry, in any manner.

15

DIGITAL CALIBRATION
SOLDER IRON DIGITAL TEMP CALIBRATION
By default, the system is properly calibrated but for cases when a little
adjustment of the soldering iron calibration is required the following
procedure can be done.
1. Turn on the soldering iron function switch.
2. Set to appropriate temperature you want to calibrate. Place the tip of
the soldering iron on an external temperature sensor.
3. The readings on the external temperature sensor should be more or
less equal to the displayed temperature.
4. If there are large discrepancy in the temperature reading we can re-
calibrate the temperature setting.
5. While the solder iron is operating make sure the hot air gun and
Preheating function is in off mode (0 FF is displayed on the panels
1 and 2), hold the preheater UP button for a few seconds until
four zeroes are displayed 0000 .
6. Adjust the temperature compensation using the UP and DOWN
buttons of the Soldering iron adjustment buttons.
7. A zero 0 on the first digit signifies addition to the current
temperature and a minus - on the first digit will subtract the
displayed value from the current settings.
8. Confirm the change by pressing the air pressure down button.

14


SOLDERING IRON AUTO-SLEEP MODE
The soldering irons SLEEP mode is deactivated by default. Follow the
set of procedures below to activate this feature.
CONDITION: SOLDERING IRON function is inactive.
1. While soldering iron is displaying OFF or in stand-by mode, push
both UP and DOWN buttons of the SOLDERING IRON TEMPERATURE
adjustment buttons (6 from the CONTROL PANEL GUIDE page).
2. Wait until t0FF appears from soldering iron temperature display
panel. This means sleep mode is currently turned OFF.
3. Release the two buttons after the change in display.
4. Use the same two buttons to adjust the countdown time. t001
means solder iron will go to sleep in 1 minute. Timer is adjustable from
1 to 60minutes.
5. Confirm the change by activating the SOLDERING IRON switch.
6. To DEACTIVATE this feature, simply follow the above procedures.
This time, select tOFF .
7. During sleep mode, the soldering iron temperature display panel will
show an all-dash, - - - - .
8. To wake the soldering iron from sleep mode, press the soldering iron
temperature adjustment buttons.



AUTO SLEEP FUNCTIONS
7

ASSEMBLY and PREPARATIONS
A. Main Station and Hot Air Gun Stand

















B. Soldering Iron
1. Follow instructions on Soldering Iron Stand Assembly guide.
2. Connect the soldering iron cord assembly to the soldering iron output
terminal found at the lower middle portion of the main unit.
3. Place the soldering iron to the soldering iron stand.
C. Pre-heater
1. Screw in PCB Holder using Securing Screw on desired position.
2. Adjust multipurpose PCB holder to accommodate PCB shape.

D. Hot Air Gun
To set up the Hot Air Gun stand:
1. Use the 8 mm screw to secure the holder to the station.
2. Place the hot air gun onto the stand in preparation for usage.


1. Det ach
screw from
hot air gun
mast.
2. Inset mast into base.
3. Insert screw and
lock mast into
position.
4. Slide in holder
stopper and hot air
gun arm holder.

Adjust height and
screw to lock.
8

CONTROL PANEL GUIDE
LEGEND:
1 Hot Air Gun Temperature Display
2 Pre-Heater Temperature Display
3 Soldering Iron Temperature Display
4 Hot Air Gun Temperature Adjustment Buttons
5 Pre-Heater Temperature Adjustment Buttons
6 Soldering Iron Temperature Adjustment Buttons
/ External sensor activation
7 Hot Air Gun Output Terminal
8 Soldering Iron Receptacle, External Sensor Probe Receptacle
9 Hot Air Gun Function Activation Switch
10 Pre-Heater Function Activation Switch
11 Soldering Iron Function Activation Switch
12 Hot Air Gun Airflow Adjustment
Prefixes and meanings:
A - External Sensor
H - actual temperature
h - temperature being set
C - cooling down
- - - - sleep mode display
OFF - function deactivated display

13


AUTO SLEEP FUNCTIONS
AUTO-SLEEP MODE (Hot Air Gun)
The device has a built-in auto-sleep mode feature such that if the there
has been no user input from the hot air gun temperature adjustment button
for 30 minutes (default) the Hot Air Gun d remained , the device will switch
to sleep mode. The system will blow air (at room temperature) at maximum
rate in order to bring down the temperature. Once the temperature drops to
approximately 90C, the Hot Air Gun will automatically stop and show an all-
dash - - - - display indicating that the system is now on sleep mode.

CHANGING SLEEP MODE TIMER (HOT AIR GUN)
By default, the system has 30-minute countdown time before the hot air
gun goes to sleep mode. This can be altered by the following procedure.
1. While the hot air gun is on stand-by mode (0FF is displayed on the
panel 1 ), hold both UP and DOWN buttons of the HOT AIR GUN
TEMPERATURE adjustment buttons.
2. Wait until t030 is displayed on the Hot Air Gun Temperature
display panel, 1.
3. Release the buttons when t030 appears.
4. Adjust the time using the same UP and DOWN buttons of the HOT
AIR GUN TEMPERATURE adjustment buttons.
5. Confirm the change by activating the HOT AIR GUN function switch.
6. The system will immediately switch back to operation and use the
defined countdown parameter for the entire usage.

NOTES:
The sleep mode timer is configurable between 1 and 30 minutes.
Sleep mode settings for Hot-Air gun and Soldering Iron are saved into the
memory and shall remain effective until it is res-et or new data is entered.
12

OPERATING GUIDELINES
E. PRE-HEATER
1. Follow the initial procedures (A. INITIAL PROCEDURES).
2. Place PCB to be pre-heated on top of the pre-heater.
3. Activate the Pre-Heater Activation switch (10 from control panel). This
will automatically start to increase the temperature of the soldering iron
to 100C (default).
4. Adjust the Pre-heating temperature using the PREHEATING
TEMPERATURE ADJ USTMENT buttons (5 from the control panel).
5. The top heater may be activated for reworking multilayered boards once
the PCB has been pre-heated to desired temperature.
6. The actual board temperature may be determined by placing the external
sensor on the target board.
7. After reworking deactivate the PREHEATING activation switch.

F. EXTERNAL SENSOR
1. Follow the initial procedures (A. INITIAL PROCEDURES).
2. Place PCB to be pre-heated or reworked on top of the pre-heater.
3. Attach the external sensor probe to the external sensor probe receptacle.
(8 from the control panel).
4. With the soldering iron function switch deactivated press the down button
of the solder iron temperature adjustment button to activate the external
sensor function.
5. The actual board temperature may be determined by placing the external
sensor on the target board.
6. To turn off external sensor probe function press the solder iron up switch.


9


IMPORTANT REMINDERS:
1. Make sure the equipment is placed on a flat stable surface and all
the heat-generating components placed on their respective holders
or stands.
2. Ensure all function switches are OFF prior to reworking.
3. Ensure all terminal connections are properly secured.

IMPORTANT: Please refer to the CONTROL PANEL GUIDE
page for buttons and display panel directory.

OPERATING GUIDELINES
A. INITIAL PROCEDURES
1. Plug the device to the main power source using the power cord
provided in the package.
2. With all function switches deactivated and all terminal connections
properly secured, switch ON the device by activating the main power
switch located at the back of the unit.
3. The display panels, will temporarily show the product name in a
scrolling manner and then display OFF on all rows once the scroll is
finished (see below illustration). The system will remain at this state
until the user activates a function.

B. CELCIUS TO FAHRENHEIT SWITCHING
1. Plug the device to the main power source using the power cord
provided in the package.
2. Press and hold the solder iron UP button while turning on the system
power to set system to Centigrade mode. The display will show Aoyue
866C with the last character indicating the type of temperature scale
used. C Centigrade, F Fahrenheit.
3. Press and hold the solder iron DOWN button while turning on the
system power to set system to Fahrenheit mode. The display will show
Aoyue 866F with the last character Indicating the type of temperature
scale used. C Centigrade, F Fahrenheit.

10

OPERATING GUIDELINES
C. HOT AI R GUN
1. Follow the initial procedures above, A. INITIAL PROCEDURES.
2. Adjust Hot Air Gun Airflow Adjustment to the middle position.
3. Activate Hot Air Gun switch (9 from the control panel).
4. The system will immediately start to blow air at a medium airflow while
rapidly and safely increasing the air temperature to 100C (default
system operating parameters). These values will be reflected from the
Hot Air Gun Air Temperature display panels, 1 from the control panel,
respectively.
5. Adjust to desired air flow.
6. Adjust the hot air gun temperature using the HOT AIR GUN
TEMPERATURE ADJ USTMENT BUTTONS (4 from the control panel).
The prefix of the display for Hot Air Gun Temperature will change from
H to h indicating that air temperature is being adjusted. It will return
to H (indicating actual temperature) while the temperature is
gradually increasing or decreasing until the desired temperature is
reached.
7. Reworking task can be started 1 minute after the desired hot air
temperature and airflow level are reached, as also indicated from
display panel 1.
8. When reworking is complete, return the Hot Air Gun to its holder and
DO NOT immediately turn off the main power switch.
IMPORTANT: When adjusting the air temperature, it is strongly
advised to initially increase the airflow level in order to manage
the system temperature. This is to protect the heating element
inside the handle from excessive heat and avoid the possibility of
subjecting adjacent components to thermal shock.
11

OPERATING GUIDELINES
9. Deactivate the Hot Air Gun Activation button first in order to activate
the auto-cooling process. The system will start to blow air (at room
temperature) at a fast rate to reduce heat from the hot air gun and
bring down the temperature to a reasonable safe level of 90C. During
this time, the prefix of the display for hot air gun temperature will also
change from H to C while temperature is gradually decreasing.
Likewise, the air pressure level is at its highest reading as indicated
from the display panel. Once the temperature drops to approximately
90C the system will halt and display OFF on the panel. It is now safe
to switch off the main power switch.
10. Turn OFF the main power switch.
11. Unplug the device from the main power source.

D. SOLDERING IRON
1. Connect the Soldering Iron connection assembly to the 6-pin receptacle
located at the front of the control panel (8 from the CONTROL PANEL
GUIDE).
2. Follow the initial procedures (A. INITIAL PROCEDURES).
3. Activate the SOLDER IRON Activation switch (11 from control
panel). This will automatically start to increase the temperature of the
soldering iron to 350C (default).
4. Adjust the soldering iron temperature using the SOLDERING IRON
ADJ USTMENT buttons (6 from the control panel).
5. Start using the soldering iron as soon as desired temperature is
reached.
6. Deactivate the SOLDER IRON activation switch.
7. Allow sufficient time for the soldering iron to cool down before keeping
in a safe storage.