Hakko FM-202 User Manual

High-output, temperature controlled

soldering station

Instruction Manual

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Thank you for purchasing the FM-202 soldering station. This high-output, temperature controlled soldering station uses a composite tip, incorporating heater and sensor functions into one element. Several process control features, unique to the FM-202, make it applicable to a broad range of soldering applications. Please read this manual before operating the FM-202. Keep this manual readily accessible for reference.

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TABLE OF CONTENTS

1. PACKING LIST ................................................................ 1

2. SPECIFICATIONS ........................................................... 1

3. WARNINGS, CAUTIONS, NOTES AND EXAMPLES ..... 2

4. PART NAMES..................................................................3

5. INITIAL SETUP ...............................................................3

6. OPERATION ....................................................................5

7. TIP IDENTIFICATION NUMBER ..................................... 9

8. PARAMETER SETTINGS ............................................. 10

9. MAINTENANCE ............................................................ 12

10. ERROR MESSAGES .................................................... 14

11. TROUBLE SHOOTING GUIDE ..................................... 15

12. PARTS LIST .................................................................. 17

13. TIP STYLES .................................................................. 20

14. APPENDIX A .................................................................22

15. WIRING DIAGRAM ....................................................... 23

1. PACKING LIST

FM-202 soldering station ................................1

FM-2021 connector assembly ........................ 1

Sleeve .............................................................1

Sleeve stopper ................................................1

Power cord ...................................................... 1

Control card, with chain ..................................1

Control card

Cleaning sponge

Card chain

Iron holder

FM-202 Soldering station

Tip (not included)

Heat resistant pad ........................................... 1

Tip tray ............................................................1

Iron holder ....................................................... 1

Cleaning sponge ............................................. 1

Instruction manual .......................................... 1

Tips (not included)

OFF

FM-2021 connector assembly

Sleeve

Sleeve stopper

Tip tray

Heat resistant pad

2. SPECIFICATIONS

● FM-202 soldering station

Power consumption

Temperature range

Temperature accuracy

Temperature stability

● Station

Output

Dimensions (l x w x h)

Weight

● Soldering iron

Power consumption

Tip to ground resistance

Tip to ground potential

Length, less cord

Weight, less cord

Length of cord

75 W (Max. 130 W)

200 – 450

±10 See Figure 1.

±5

24 V

178 x 119 x 117 mm (7.0 x 4.7 x 4.2 in)

2,700 g (5.9 lb.)

70 W (24 V)

< 2

< 2 mV

188 mm (7.4 in.) with 2.4D tip

30 g (0.067 lb./1.07 oz.)with 2.4D tip

1.2 m (4 ft)

C (400 – 840°F)

C (±18°F) of set temperature.

C (±9°F) at idle temperature

Power cord

Accuracy: ±10°C (±18°F)

Set temperature

Stability: ±5°C (±9°F)

Temperature

Time

Figure 1. Temperature accuracy and stability.

NOTE:

This product is protected against electrostatic discharge. Specifications and design are subject to change without notice.

WARNINGS, CAUTIONS, NOTES AND EXAMPLES

Warnings, cautions and notes are placed at critical points in this manual to direct the operator’s attention to significant items. They are defined as follows:

WARNING: Failure to comply with a WARNING may result in serious injury or

death.

CAUTION: Failure to comply with a CAUTION may result in injury to the

operator, or damage to the items involved. (Two examples are given below.)

NOTE: A NOTE indicates a procedure or point that is important to the process being

described.

EXAMPLE: An EXAMPLE is given to demonstrate a particular procedure, point or

process.

CAUTION

When power is ON, tip temperatures will be between 200 and 450°C (400 to 840°F). To avoid injury or damage to personnel and items in the work area, observe the following:

● Do not insert any foreign substance or incompatible tip into the process gate.

● Do not insert the tip end of the cartridge into the process gate.

● Do not touch the tip or the metal parts near the tip.

● Do not allow the tip to come close to, or touch, flammable materials.

● Inform others in the area that the unit is hot and should not be touched.

● Turn the power off when not in use, or left unattended.

● Turn the power off when connecting the FM-2021 or storing the FM-202.

● Do not remove or damage the bar code sticker.

CAUTION

To prevent accidents or damage to the FM-202, be sure to observe the following:

● Do not use the FM-202 for applications other than soldering.

● Do not allow the FM-202 to become wet, or use it with wet hands.

● Do not modify the FM-202.

● Use only genuine Hakko replacement parts.

● Do not bend or damage the control card. If the card does become damaged, do not force the

card into the station slot.

● Do not strike the iron against hard objects to remove excess solder. This will damage the iron.

● Remove power and iron cords by holding the plug – not the wires.

● Be sure the work area is well ventilated. Soldering produces smoke.

4. PART NAMES

OFF

Power switch

Control card

Cleaning sponge

Iron holder

Tip tray

Card chain

Receptacle

Heat resistant pad

FM-202 Soldering station

Process gate

Tip (not included)

Power receptacle

Fuse

FM-2021 connector assembly

Sleeve

Sleeve stopper

Power cord

5. INITIAL SETUP

A. Iron holder

1. Adjust the height of the iron holder to suit, as follows: i. Loosen the adjusting screws. ii. Set the iron holder to the desired height. iii. Tighten the screws.

2. Put the small cleaning sponge in one of the

four holes in the iron holder base.

3. Add water to the level shown in the accompanying illustration. The small sponge will keep the large sponge moist through capillary action.

4. Wet the large cleaning sponge, squeeze it dry, and put it on the iron holder base.

Procedure 2-4 -ORWet the large cleaning sponge, squeeze it dry, and put it on the iron holder base.

5. Place the spare tips in the tip tray.

B. Connector cord

Pass the connector cord through the hole in the heat resistant pad.

NOTE:

Be sure the cleaning sponge is kept CLEAN and DAMP. A dirty sponge will transfer contaminants to the soldering tip, reducing thermal efficiency and possibly causing defective solder joints. A dry sponge will abrade the soldering tip, reducing its life.

C. Soldering station

CAUTION:

Be sure the power switch is OFF before connecting or disconnecting the soldering iron cord. Failure to do so may result in damage to the circuit board.

1. Insert the power cord into the receptacle at the back of the station.

2. Insert the connector cord into the receptacle at the front of the station.

3. Plug the power cord into a grounded wall socket. The FM-202 is protected against electrostatic discharge and must be grounded for full efficiency.

When the plug clicks , it is fully inserted.

Push the plug in as far as it will go, and try to remove it without pressing the release pin. If it stays in the receptacle it is properly seated.

Receptacle

6. OPERATION

Controls and displays

Controls

The front panel of the FM-202 soldering station has four control buttons, the process gate, the receptacle, and the card slot. The power switch is on the back panel.

• Four control buttons:

– Initiates the Tip ID entry mode. When

pressed for less than one second, the stored Tip ID is displayed. When pressed for more than one second, the Tip ID entry mode is activated.

– Initiates the temperature setting mode.

When pressed for less than one second, the stored temperature is displayed. When pressed for more than one second, the temperature entry mode is activated.

– Increases the value in the appropriate

display window.

– Decreases the value in the appropriate

display window.

Displays

The FM-202 has a three-digit display element. Depending upon the selected mode, it will display:

• Normal mode: Sensor temperature (tip temperature)

• Data entry: Selected quantity (see ‘data entry procedures’ for exact characteristics)

• Temperature scale: °C or °F, depending upon selection

• Error detection: Refer to ‘ERROR MESSAGES’ section

In addition, a single heater lamp will flash when the station has reached the desired temperature, indicating that it is ready for use.

An audible buzzer is provided to alert the operator:

• When the station has reached the set temperature. The buzzer will sound once.

• When the tip is inserted into the process gate, the buzzer will sound once when the Tip ID bar code has been read.

• When the low temperature threshold has been crossed, the buzzer will sound continuously. The buzzer will shut off once the sensed temperature returns to the acceptable range.

• When a foreign substance, an incompatible tip, or the soldering end of the tip is inserted into the FM-2021, the display will flash and the buzzer will sound continuously.

• When the auto power shutoff is activated and power to the heating element is turned off, the buzzer will sound three times.

• When the process gate cannot read the Tip ID bar code, the buzzer will sound three times.

• When a tip insert into the process gate while the tip is already in the FM-2021, buzzer will sound irregularity.

• When the tip is properly inserted into the connector, the buzzer will sound once.

NOTE:

This procedure must be followed EVERY TIME THE STATION IS TURNED ON.

1. If a tip is in the connector, remove it; remove the tip from the sleeve assembly as well.

2. Turn the power switch ON.

Turn the switch ON.

TIN error

Display

Setting temperature

3. The display will show

and the LED on

the connector will flash.

4. Enter Tip ID as follows: Insert the Tip ID end of the tip into the process gate until the buzzer sounds once. Tip ID data are displayed for one second. The display shows

. The LED indicator will stop flashing. Indicating that they are now stored. (Refer to Appendix A for manual entry.)

5. Inserting the tip: Hold the head part of the tip and insert the tip into the sleeve assembly. Push until the sleeve assembly touches the ring round the tip; at this point the tip should not be forced further into the sleeve assembly .

There are no orientation requirements.

NOTE:

Once the tip is inserted into the connector, heat control begins.

and

LED lamp at the connector begins to flash.

NOTE:

The FM-202 is preset at 750 F . at the factory . Check the temperature setting by pressing the The set temperature will be displayed for two seconds.

NOTE:

If the buzzer sounds three times when the tip is inserted into the process gate, there has been a reading error. Reinsert the tip.

CAUTION:

Refrain from inserting foreign objects, the wrong end of the tip, or incompatible tips into the process gate. Damage may result.

NOTE:

When the power has been cycled, Tip ID is no longer stored in the station and as shown at right or in Appendix A.

will flash. Reenter Tip ID

button.

6. When the set temperature is reached, the buzzer sounds and the heater lamp at the lower right of the temperature display starts blinking.

Factory settings

The FM-202 comes from the factory with the following values preset:

Temperature scale

Auto power shutoff

Low temperature alarm setting

Resetting the supervisor or operator control setting

Set temperature

Fahrenheit

disabled

300 F

Tip ID controlled with inserting the card.

750 F

Hold this part to insert tip into sleeve assembly and put into the connector.

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