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METCAL MX-500P-11 TECHNICAL DOCUMENTATION

This documentation was carefully reverse engineered from several actual MX-500P units, and although it has been
meticulously triple checked, it may contain errors and omissions so use it at your own risk. It is provided solely for the
purpose of helping you satisfy your personal curiosity about how a Metcal MX-500P works, and you must never use it for
any other purpose, especially not for any commercial or business purpose, and certainly not as an aide to experimenting
with or performing work on MX-500P units, as it is inadequate for such unintended use. Reproduction is strictly forbidden.

MECHANICAL DESCRIPTION:
The small plastic cover at the two RF output connectors is held in place by it's two plastic hooked clips which descend into
the aluminum housing at the top and bottom. Beneath this plastic cover are two hex nuts that bolt the RF connectors to the
aluminum housing. The RF connectors are soldered directly into the circuit board. On the rear of the MX-500P are four
deeply recessed T15 tamper proof Torx screws which hold the two halves of the aluminum casting together. Loosening the
single screw in the upper-middle back of the MX-500P by a few turns releases the internal heat sink which is attached to the
circuit board. The internal heat sink couples heat into the MX-500P aluminum case from where it can dissipate into the
ambient air. Good thermal coupling between the internal heat sink and the case is aided by a thin coating of white thermal
compound. The circuit board inside the MX-500P is fastened down by six internal screws, four of which are rather large
because they also hold down the line transformer. The tiny grub screw on the upper right hand side of the MX500 controls
the Auto Sleep feature and should not be tightened past the point where it gently activates the switch. Note that it can be
dangerous to power up an MX-500P unit that has been taken apart or that has been reassembled by anyone other than an
trained Metcal service technician.

DESCRIPTION OF FUNCTION:
The MX-500P Power Unit provides RF energy at 13.560MHz to the Soldering Tip Cartridge, which contains an induction
heater consisting of an 18 turn AWG33 wire coil wound around a 0.11" diameter by 0.5" long slug. The slug is composed of
a copper core, clad in a thin magnetic alloy having a curie point equal to the desired soldering tip temperature. The magnetic
alloy absorbs RF energy from the coil, causing the slug to heat up until the curie temperature is reached. At this point
absorption stops and heating ceases, because the RF energy is now reflected back to the power unit by the copper core.

The On/Off switch atop the power unit controls the 18V power supply U8, which runs all the supervisory circuits. When the
18V supply is off, Q6 turns off thereby causing Q7 to turn on and disable the RF generator.

Q5 and Q8 control a small DC bias voltage out to the soldering hand piece, so that U2a can sense an intermittent or
disconnected hand piece cable, in which case the yellow LED DS2 will light and U2b will latch Q7 on, thereby disabling
the RF generator until the On/Off switch is cycled.

U5a senses small changes in RF generator output power to the soldering hand piece. If no changes are detected for half an
hour then sleep mode timer U6 times out causing U7 to latch Q11 on, thereby disabling the RF generator until the On/Off
switch is cycled. This functionality can be disabled by backing out the tiny grub screw in the upper right side of the unit.

If thermal switch TS1 detects an over temperature condition inside the power unit then Q9 will turn on and disable the RF
generator until the temperature drops back down to normal.

If Forward Power at T3 and C33 exceeds reasonable limits due to a fault in the power unit circuitry, then Q19 will turn on
and disable the RF generator until Forward Power returns to acceptable levels.

U5b monitors the supervisory circuits and lights green LED DS1 if everything is OK, in which case Q12 will be on,
enabling U4 to power up the RF generator.

U1 provides a 13.560MHz square wave out to class C driver stage Q3, which in turn drives the class C final output stage
Q4, providing RF power to the soldering hand piece. Note that Q3 is unusual in that it has an input capacitance of only 55pF
and a gate threshold voltage of only 1.6V.

Diodes D8 and D9 sense the RF voltage level coming out of the RF generator, providing negative feedback to switching
power supply U4 Q1 Q2, which powers the final RF output stage Q4 of the RF generator.

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J1 provides a DC voltage which is proportional to the power being delivered to the hand piece. It can be connected to an
analog meter movement or other measuring instrument.

TRIMPOT DESCRIPTIONS:
RV2 adjusts the RF-Output-Power delivered to the hand piece; if this adjustment is incorrect then the voltage at C8 will
likely not correspond to the values given elsewhere in this document.

RV1 sets the Forward-Power-Fault safety shutdown circuit trip point; if this adjustment is incorrect then the voltage at C16
will likely not correspond to the values given elsewhere in this document.

RV3 calibrates the signal out to any Meter connected at J4; the signal at J4 is not normally used so it is hard to imagine how
this adjustment could have any impact upon the operation of the unit.

Calibration is well beyond the scope of this document and must not be attempted by anyone other than a qualified Metcal
service technician.

MEASUREMENTS FROM SOME GOOD WORKING UNITS:


Whenever unit is plugged into the AC line:
Voltage at C2 will measure approximately 26 VDC
Voltage at C6 will measure approximately 53 VDC
Whenever the power switch is on and unit is plugged in:
U8 pin 3 will measure 18 VDC
U7 pin 14 will measure 12 VDC
Whenever a hand piece is connected and the green LED is lit:
U4 pin 4 will measure 1.3 VDC
U4 pin 5 will measure 0.0 VDC
If the green LED is extinguished but the unit is plugged in:
U4 pin 5 will measure 26 VDC
Whenever the hand piece is idling hot in the stand:
Voltage at C8 will measure between 17 and 18 VDC
Voltage at C3 will measure between 14 and 15 VDC
Voltage at C16 will measure approximately minus 1.2 VDC
U1 pin 14 will measure approximately 4.8 VDC
U1 pin 4 will have a 13.56 Mhz waveform approximately 2.8 Vpp
When the soldering hand piece is heating up from a cold start:
Voltage at C8 may temporarily rise as high as 21 VDC
Voltage at C16 may temporarily rise as high as minus 0.22 VDC
When the hot hand piece is touched to something cold:
U5 Pin 1 will pulse high momentarily
Characteristics of a cold MX Soldering Tip Cartridge:
Inductance at 1kHz is somewhere around 2.8 uH
DC resistance is fairly close to 0.21 ohms

ADDITIONAL INFORMATION:
For specifications and descriptions of operator controls and lights, please consult you Metcal Users Manual and the 1999
Metcal product catalog which can be found on the Internet via Google as of this writing.

US Patent Number 4626767 c o n t a i n s a wealth of a d d i t i o n a l t e c h n i c a l i n f o r m a t i o n . US


P a t e n t s a r e a v a i l a b l e f o r f r e e on t h e I n t e r n e t from v a r i o u s sources such a s
http://www.freepatentsonline.com/

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IEC J3 Fl T4
JP1 BR1 U4
C7
RFC
C53
C6 C8

D3
L3

R26
L11
LF1 R1 C9

D4
RV2 R6
C1
C2 R11
S1 Q1 R4 R12
U8 R7
R3
C13
R5
C40 C51 L1 Q2
L2

Dl
C3
D9
CO C21
R41 R2 C4
C28
D5

C25 C30 C31


T1 D8
U1

R42 D2
C19 T2 L5 L6
D7

D6
R25 C22 R45
C26
U1

C27 C29

Q4
R24 C24
C50
Q3
U7

L4
Yl
L7
R27

L10
P28

C20 C32
C17 C18 C41
T5

C35
D18 D17
J1 R30 C33
Q5 R18 T3
J4 D19 D16

R66
C34
S2 L9
R19 RV3

R65
R29

D20
J2 C52

L8 U3
D11 R31
R10
R32 Q10
D10 R55
Q8 RV1
C36 C44 C16 D14 R46
C45
R33 R40

C43 C49
C48 U5
DS2 C37 C47
R47

R48

C42 C46
R52

R21
R53
U7

R35
R34 R49
U2

D12 Q7 R54

R36 R22
R39 R8 R9
U6
R38 R37 C39
R16
R17
JP2

R50
C14
U2 R13 R14
Q9
Q6

R43 R15 Q11


R57 R58

DS1 TS1
R51
U5
R56
R20
R54
R51
JP2

U6
R50 TS1

C47

R13
R14
Qll R52
CI8

U7
R53 R21
Q9
C46

C48
R43 C17 R20
J4
R17
D14 R49 DS1

R24
R25

R35
R55 Yl

R40
Q6.

RV3
U5
C49
R48 DS2

Ul
R41
R42
R57

CO
R22

C19
R58 R56
C39
R47 R46
C50 C37
C45 D5 D6

R66
R65
C42 U2

D2
C40

C43
C3 R36
Q7
R15

Dl
R38

R34
R8
R39
Q12 C51 R37

D20
C2

L2
R16

R2
L1

C20

L4
C4
D4

D12
C52
S1
RV2 R33
D11
R45 D7 D10
C7
U4
U8 Q4 Q3

R26 R9
R18
C53

L10
R19
R6
C21
R31
D3

R11
C8

C24

R28

R27
R12

Q2
R7

R32
C9 C22

T1
C13

R4
L3 L11

T2
R5
R3

Q1 C25

C29
D16 Q8

C30
R1 C26 D17
D18
L6
D8 D19
C14 L5
C6 D9
C31

Q10

C44
Jl
C16

T5
R10

BR1

C36
R30
RV1

U3

C41

L7
L8
L9

C32
S2

T3

C1

C33

C34
R29
J2

JP1
F1

J3

T4
MX-500P-11 CIRCUIT BOARD PARTS LIST

BR1 Bridge Rectifier 4A 100V (GBU4B) D7 Small Signal Silicon Diode ( 1 N 4 1 4 S )


D8 Small Signal Silicon Diode ( 1 N 4 1 4 S )
CO lOOnF 63V 5 % P o l y e s t e r (W1MA MKS02 PCM2.S) D9 Small Signal Silicon Diode ( 1 N 4 1 4 S )
C1 3 3 0 n F 63V 5 % P o l y e s t e r (W1MA MKS2 PCMS) D10 S c h o t t k y Rectifier 1A 60V (MBR160 or S R 1 6 0 )
C2 lOOOuF 3SV Aluminum Electrolytic D11 S c h o t t k y Rectifier 1A 60V (MBR160 or S R 1 6 0 )
C3 lOOuF 3SV Aluminum Electrolytic D12 Z e n e r Diode 6.2V 50OOmW (1NS234B)
C4 3 3 0 n F 63V S % P o l y e s t e r (W1MA MKS2 PCMS) D14 Zener Diode 12V 1W ( 1 N 4 7 4 2 A )
C6 2 2 0 0 u F SOV Aluminum Electrolytic D16 Small Signal Silicon Diode ( 1 N 4 1 4 S )
C7* 3 3 0 n F 63V S % P o l y e s t e r (W1MA MKS2 PCMS) D17 Small Signal Silicon Diode ( 1 N 4 1 4 S )
C8 2 2 0 u F 63V Aluminum Electrolytic D18 Small Signal Silicon Diode ( 1 N 4 1 4 S )
C9 InOF 200V 1 0 % C e r a m i c (CK0SBX102K 200V) D19 Small Signal Silicon Diode ( 1 N 4 1 4 S )
C13 InOF 200V 1 0 % C e r a m i c (CK0SBX102K 200V) D20 Z e n e r Diode l.8V 50OOmW ( 1 N 4 6 7 S )
C14 lOuF 3SV Aluminum Electrolytic
C16 lOOnF 63V 5 % P o l y e s t e r (W1MA MKS02 PCM2.S) DS1 Green R e c t a n g u l a r LED 2xSrnrn
C17 2 4 p F S00V S % SilverMica (CM0SED240J03) DS2 O r a n g e R e c t a n g u l a r LED 2xSrnrn
CI8 S2pF SOOV S % SilverMica (CM0SEDS20J03)
C19 lOnF 200V 1 0 % C e r a m i c (CK06BX103K 200V) Fl Time Delay F u s e 1.2SA/2S0V ( L i t t l e F u s e 2 3 9 )
C20 2 4 p F SOOV S % SilverMica (CM0SED240J03)
C21 3 3 0 n F 63V S % P o l y e s t e r (W1MA MKS2 PCMS) J1 PCB M o u n t e d C o n n e c t o r F e m a l e T y p e F
C22 3 3 0 n F 63V S % P o l y e s t e r (W1MA MKS2 PCMS) J2 PCB M o u n t e d C o n n e c t o r F e m a l e T y p e F
C24 lOOnF 63V S % P o l y e s t e r (W1MA MKS02 PCM2.S) J3 PCB M o u n t e d F e m a l e Q u i c k - C o n n e c t s
C25 3 3 0 n F 63V S % P o l y e s t e r (W1MA MKS2 PCMS) J4 U n s h r o u d e d H e a d e r Two Pin 0 . 1 I n c h Pitch
C26 4 7 p F SOOV S % SilverMica (CM0SED470J03)
C27 130pF SOOV S % SilverMica (CM0SED131J03) JP1 Line Voltage S e l e c t i o n S t r a p p i n g on PCB
C28 130pF SOOV S % SilverMica (CM0SED131J03) JP2 Miniature PCB Mount P u s h b u t t o n S w i t c h
C29 130pF SOOV S % SilverMica (CM0SED131J03)
C30 lOpF SOOV S % SilverMica (CM0SED100J03) L1 700uH Toroidal I n d u c t o r Many T u r n s
C31 lOOpF SOOV S % SilverMica (CM0SED101J03) L2 22uH RF C h o k e 6 - P o r t Bead
C32 lOOpF SOOV S % SilverMica (CM0SED101J03) L3 5OOuH Toroidal I n d u c t o r 9 4 . 7 S T u r n s
C33 2 4 p F SOOV S % SilverMica (CM0SED240J03) L4 luOH I n c u c t o r DRWW
C34 4 7 p F SOOV S % SilverMica (CM0SED470J03) L5 luOH Toroidal I n d u c t o r 1 6 . 7 S T u r n s
C35 lOOnF 63V S % P o l y e s t e r (W1MA MKS02 PCM2.S) L6 luOH Toroidal I n d u c t o r 1 6 . 7 S T u r n s
C36 lOnF 200V 1 0 % C e r a m i c (CK06BX103K 200V) L7 400nH Toroidal I n d u c t o r 1 0 . 7 S T u r n s
C37 lOOnF 63V S % P o l y e s t e r (W1MA MKS02 PCM2.S) L8 22uH I n c u c t o r DRWW
C39 lOOnF 63V S % P o l y e s t e r (W1MA MKS02 PCM2.S) L9 22uH I n c u c t o r DRWW
C40 lOOuF 3SV Aluminum Electrolytic L10 270nH I r d u c t o r DRWW
C41 S2pF SOOV S % SilverMica (CM0SEDS20J03) Lll 22uH RF C h o k e 6 - P o r t Bead
C42 4 n 7 F 63V S % P o l y e s t e r (WIMA MKS02 PCM2.S)
C43 lOOnF 63V S % P o l y e s t e r (WIMA MKS02 PCM2.S) LF1 Two S t a g e Line Filter (Delta 03SEEG3H)
C44 4 n 7 63V S % P n l y p s t e r (WTMA MKSn? PCM2 S)
C45 2u2F SOV Dipped T a n t a l u m Q1* PNP 1 W a t t T r a n s i s t o r ( Z T X 7 4 9 )
C46 luOF 63V S % P o l y e s t e r (WIMA MKS2 PCMS) Q2 NPN 1 W a t t T r a n s i s t o r ( Z T X 6 4 9 )
C47 luOF 63V S % P o l y e s t e r (WIMA MKS2 PCMS) Q3* N-Channel P o w e r MOSFET (VN0109NS)
C48 lOuF 3SV Aluminum Electrolytic Q4* N-Channel P o w e r MOSFET (IRFS30)
C49 lOnF 200V 1 0 % C e r a m i c (CK06BX103K 200V) Q5 PNP Small Signal Transistor (2N3906)
C5O 33nF 63V S % P o l y e s t e r (WIMA MKS2 PCMS) Q6 NPN Small Signal Transistor (2N3904)
C51 lOuF 3SV Aluminum Electrolytic Q7 NPN Small Signal Transistor (2N3904)
C52 4 7 u F 63V Aluminum Electrolytic Q8 NPN Small Signal Transistor (2N3904)
C53 lOnF 200V 1 0 % C e r a m i c (CK06BX103K 200V) Q9 NPN Small Signal Transistor (2N3904)
Q10 NPN Small Signal Transistor (2N3904)
Dl S c h o t t k y Rectifier 1A 60V (MBR160 or S R 1 6 0 ) Qll NPN SrriE Signal Transistor (2N3904)
D2 Z e n e r Diode 6.SV 1W (1N4736A) Q12 NPN SrriE Signal T r a n s i s t o r ( 2 N 3 9 0 4 )
D3 F a s t A v a l a n c h e Rectifier 2A 1S0V (BVV27-1S0)
D4 Z e n e r Diode S.6V 1W (1N4734A)
D5 Small Signal Silicon Diode ( 1 N 4 1 4 S )
D6 Small Signal Silicon Diode ( 1 N 4 1 4 S )
R1 100R 1/4W 5 % C a r b o n Film R65 470R 1/4W 5 % C a r b o n Film
R2 1S0R 2W 5 % C a r b o n Film or Metal Film R66 470R 1/4W 5 % C a r b o n Film
R3 470R 1/4W 5 % C a r b o n Film
R4 4K7 1/4W 5 % C a r b o n Film RV1 Linear 1 Turn T n m p o t 1K0 1/2W (Bourns 3 3 S 6 )
R5 1K0 1/4W 5 % C a r b o n Film RV2 Linear 1 Turn Trimpot 5KO 1/2W (Bourns 3 3 S 6 )
R6 13K 1/4W 5 % C a r b o n Film RV3 Linear 1 Turn Trimpot S00R 1/2W (Bourns 3 3 S 6 )
R7 1S0K 1/4W 5 % C a r b o n Film
R8 3K3 l / 4 w 5 % C a r b o n Film S1 P o w e r S w i t c h ISA 12SVAC (C&K S e r i e s CA)
R9 4K7 1/4W 5 % C a r b o n Film S2 PCB Mount DPDT Slide S w i t c h
RIO 4K7 1/4W 5 % C a r b o n Film
R11 3K3 1/4W 5 % C a r b o n Film Tl T r a n s f o r m e r Toroidal 9uH E a c h Winding
R12 1SK 1/4W 5 % C a r b o n Film ( T h r e e Windings With 1 0 . 7 5 T u r n s E a c h )
R13 4K7 1/4W 5 % C a r b o n Film T2 T r a n s f o r m e r Toroidal 9uH E a c h Winding
R14 4K7 1/4W 5 % C a r b o n Film ( T w o Windings With 1 0 . 7 5 T u r n s E a c h )
R15 10K 1/4W 5 % C a r b o n Film T3 C u r r e n t T r a n s f o r m e r Toroidal 6uH S e c o n d a r y
R16 IKS 1/4W 5 % C a r b o n Film (Primary 1.7S T u r n s , S e c o n d a r y 9 . 7 S T u r n s )
R17 10K 1/4W 5 % C a r b o n Film
R18 2K2 1/4W 5 % C a r b o n Film T4 Line T r a n s f o r m e r 3SVAC S e c o n d a r y With CT
R19 10K 1/4W 5 % C a r b o n Film ( M e t c a l P a r t No: M P 1 0 0 - 2 - S 3 6 X A S 6 0 0 - 0 0 2 S )
R20 IKS 1/2W S % C a r b o n Film T5 C u r r e n t T r a n s f o r m e r Bifilar Toroidal 12uH S e c
R21 47K 1/4W S % C a r b o n Film (Primary 1.7S T u r n s , S e c o n d a r y S 4 . 7 S T u r n s )
R22 10K 1/4W S % C a r b o n Film
R24 100K 1/4W S % C a r b o n Film TS1 O v e r t e m p e r a t u r e S w i t c h 170F Normally Closed
R25 100R 1/4W S % C a r b o n Film ( S e l c o OA-170-PCB U S - 6 0 2 S )
R26 1SK 1/4W S % C a r b o n Film
R27 100R 1W S % C a r b o n Film or Metal Film Ul Hex I n v e r t e r (SN74HC04N)
R28 100R 1W S % C a r b o n Film or Metal Film U2 Dual Voltage C o m p a r a t o r (LM393P)
R29 220R 1/4W S % C a r b o n Film U3* Array Of8 I n d e p e n d e n t Diodes (MAD110S)
R30 IKS 1/2W S % C a r b o n Film U4* 3-Amp S t e p Down S w i t c h e r (LM2S76HVT)
R31 100K 1/4W S % C a r b o n Film U5 Dual Voltage C o m p a r a t o r (LM393P)
R32 10K 1/4W S % C a r b o n Film U6 14-Bit Binary C o u n t e r & Oscillator (CD4060BE)
R33 2K2 1/4W S % C a r b o n Film U7 Q u a d 2 - l n p u t NOR G a t e (CD4001BE)
R34 22K 1/4W S % C a r b o n Film U8* V o l t a g e R e g u l a t o r +1SV 1A (MC7S1SCT)
R35 IKS 1/2W S % C a r b o n Film
R36 2K2 1/4W S % C a r b o n Film Y1 Crystal 13.S60MHZ HC49U (ECX-1S70 XX)
R37 7RS 1/4W S % C a r b o n Film or Metal Film
R38 470R 1/4W S % C a r b o n Film
R39 1K0 1/4W S % C a r b o n Film
R40 4K7 1/4W S % C a r b o n Film
R41 39K 1/4W 5 % Carbon Film
R42 39R 1/4W S % C a r b o n Film
R43 10K 1/4W S % C a r b o n Film
R45 10K 1/4W S % C a r b o n Film
R46 27K 1/4W S % C a r b o n Film
R47 S10R 1/4W S % C a r b o n Film
R48 910K 1/4W S % C a r b o n Film
R49 100K 1/4W S % C a r b o n Film
R50 2K2 1/4W S % C a r b o n Film
R51 1K0 1/4W S % C a r b o n Film
R52 S2K 1/4W S % C a r b o n Film
R53 330K 1/4W S % C a r b o n Film
R54 10K 1/4W S % C a r b o n Film
R55 620R 1/2W S % C a r b o n Film
R56 22K 1/4W S % C a r b o n Film
R57 10K 1/4W S % C a r b o n Film
R58 IKS 1/4W S % C a r b o n Film
R54
R51
JP2

U6
TS1 R50

R13
R14
C47
R52 Q11
C18

U7
R21 R53
Q9
C46 R43

C48
R20 J4 C17
R17
DS1 R49 D14

R25
R24
R35
Yl R55

R40
Q6

RV3

U5

C49
DS2 R48

U1

R41
R42
R57

CO
R22

C19
R56 R58
C39
R46 R47
C37 C50
D6 D5 C45

R66
U2

R65
C42

34C

D2
C40
R36 C3
Q7

Dl

R8
R38 R15
R34

R39
C51 Q12
R37
D20

C2

L2

R2

R16
L1
C20
L4

C4

D4
D12

C52

S1
R33 RV2
D11
D10 D7 R45
C7
Q4 U8
Q3 U4

R18 R9 R26

C53
L10
R19
C21 R6
R31

D3
R11
C24

C8
R27

R28

R12
R7
Q2
R32

C22 C9
T1

C13
L3 R4
L11

R3

R5
T2
C25
C29

Q8 Q1
D16
C30

D17 C26 R1
Q5
L6
L5 D8 C14
D9
C27

C6
C28

C31

C35
Q10

C44
Jl
C16

T5
BR1
C36
R30

RV1
U3

C41

L7
L8
L9

C32
S2

T3

C1

C33

C34
R29
J2

JP1
F1

T4
J3