Chicago Electric 96350 25W Operation Instructions Manual

The Chicago Electric 96350 is a 25W soldering iron designed for hobbyists, DIY projects, and light electrical work. It features a temperature-adjustable control, a replaceable iron-clad tip, a comfortable ergonomic handle, a safety stand, and operates on 120V AC. Below are key sections for safety, features, setup, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Safety Instructions 3. Setup & Installation 4. Specifications 5. Controls and Operation 6. Soldering Techniques 7. Maintenance & Tip Care 8. Storage 9. Regulatory Information 10. Troubleshooting

Features at a Glance

Key components: Temperature Control Dial, Soldering Iron Tip, Ergonomic Handle, Safety Stand, Power Indicator Light, Power Cord.

Feature	Description
Temperature Control Dial	Adjustable heat setting from 200°C to 450°C
Replaceable Iron-Clad Tip	Standard conical tip for general-purpose soldering
Ergonomic Handle	Heat-resistant, comfortable grip for extended use
Safety Stand	Keeps hot iron secure when not in use
Power Indicator Light	LED lights up when unit is powered on
Power Cord	6-foot cord with 3-prong plug (120V AC)
ON/OFF Switch	Integrated power switch on handle
Tip Wrench	Included for safe tip replacement

Safety Instructions

Read all instructions before use. Soldering iron becomes extremely hot during operation.

Work in a well-ventilated area to avoid inhaling fumes.
Always place the hot iron on the safety stand when not actively soldering.
Keep flammable materials away from the work area.
Allow the iron to cool completely before handling or storing.
Do not touch the metal tip or heating element.
Unplug the unit when not in use and before performing any maintenance.

WARNING! Risk of burns and fire. Never leave the iron unattended while plugged in. Keep out of reach of children.

Setup & Installation

Unpack and inspect all components. Ensure work area is clean, dry, and stable.

Insert the Tip: Using the provided wrench, screw the soldering tip into the heating element until snug (do not over-tighten).
Place Safety Stand: Position the stand on a stable, heat-resistant surface.
Power Connection: Plug the 3-prong cord into a standard 120V AC outlet.
Power On: Flip the ON/OFF switch to the "ON" position. The indicator light will illuminate.
Temperature Setting: Turn the control dial to the desired temperature. Allow 3-5 minutes to reach operating temperature.

CAUTION! The tip will be hot within minutes. Handle only by the insulated handle.

Specifications

Power Rating: 25 Watts.
Voltage: 120V AC, 60Hz.
Temperature Range: Adjustable 200°C to 450°C (392°F to 842°F).
Tip Type: Replaceable iron-clad conical tip.
Cord Length: 6 feet (1.8 meters).
Dimensions (Unit): 9.5 inches length.
Weight: 0.4 lbs (0.18 kg).
Compliance: ETL listed.

Controls and Operation

Handle Controls: ON/OFF Switch, Temperature Control Dial.

Basic Operation: After setup, turn dial to desired setting. For delicate electronics, use lower heat (250-300°C). For heavier wires, use higher heat (350-400°C). The indicator light will remain on while heating. The light may cycle on/off as the iron maintains temperature.

Tip: "Tin" the tip before first use and periodically during use by applying a small amount of solder to the hot tip to improve heat transfer and prevent oxidation.

Soldering Techniques

For successful solder joints, ensure components are clean and properly positioned.

Heat the Joint: Touch the hot tip to both the component lead and the circuit board pad simultaneously.
Apply Solder: After 1-2 seconds, touch the solder wire to the joint (not directly to the iron tip).
Feed Solder: Allow enough solder to flow and create a shiny, concave fillet around the joint.
Remove Solder: Withdraw the solder wire first.
Remove Iron: Remove the iron tip from the joint. Do not move the joint until the solder solidifies (a few seconds).

Tip: A good solder joint is smooth, shiny, and fully covers the connection without blobs or spikes.

Maintenance & Tip Care

Proper maintenance extends the life of the tip and ensures consistent performance.

Cleaning: Wipe the hot tip frequently on a damp (not wet) sponge or brass wool to remove oxidation and old solder.
Re-tinning: After cleaning, immediately apply a small amount of fresh solder to the tip to coat it.
Tip Replacement: Unplug and let iron cool completely. Use the wrench to unscrew the old tip. Screw in the new tip snugly.
Do Not File: Never file or sand the iron-clad plating on the tip, as this will destroy it.

CAUTION! Always unplug and allow to cool before any maintenance. Never immerse any part of the unit in water.

Storage

Unplug and allow the iron to cool completely. Clean and tin the tip. Store the unit in its original box or a dry place, with the cord loosely coiled. Ensure the tip is not touching anything that could be damaged by residual heat.

CAUTION! Confirm the iron is cool before storing. Do not store in a damp environment.

Regulatory Information

This product is ETL listed, conforming to relevant safety standards. Copyright © Chicago Electric Power Tools. For technical support or to order parts, contact Customer Service at 1-888-899-2256 or visit www.harborfreight.com.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Iron does not heat up	No power / faulty connection	Check outlet; ensure switch is ON; check cord for damage.
Poor heat transfer	Dirty or oxidized tip	Clean tip on damp sponge; re-tin with fresh solder.
Solder won't melt or flow	Temperature too low / dirty joint	Increase temperature setting; clean components with isopropyl alcohol.
Indicator light not on	Bulb failure / internal issue	Iron may still be heating. If no heat after 5 minutes, discontinue use.
Tip becomes black and pitted	Lack of tinning / excessive heat	Replace tip. Always keep tip tinned when hot and use appropriate temperature.

Service: This unit contains no user-serviceable parts. Do not attempt to disassemble. For service, contact Customer Service at 1-888-899-2256.