Hakko FP-102 User Manual

®
High-output, temperature controlled
soldering station
Instruction Manual
Thank you for purchasing the FP-102 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 FP-102 make it applicable to a broad range of soldering applications. Please read this manual before operating the FP-102 . Keep this manual readily accessible for reference.
TABLE OF CONTENTS
1. P ACKING LIST ...............................................................1
2. SPECIFICA TIONS ..........................................................1
3. WARNINGS, CAUTIONS, NOTES AND EXAMPLES.....2
4. P AR T NAMES.................................................................3
5. INITIAL SETUP ..............................................................3
6. OPERA TION...................................................................5
7. P ARAMETER SETTINGS...............................................6
8. MAINTENANCE .............................................................7
9. ERROR MESSAGES......................................................9
10. TROUBLE SHOOTING GUIDE ....................................10
1 1. PAR TS LIST..................................................................11
12. TIP STYLES .................................................................13
13. WIRING DIAGRAM.......................................................15

1. P ACKING LIST

Please check to make sure that all items listed below are included in the FP-102 package.
FP-102 soldering station.................................1
FM-2021 connector assembly .....................1
Sleeve assembly ............................................ 1
Control card, with chain ..................................1
Control card
Card chain
Tip (not included)
Heat resistant pad...........................................1
Tip tray ............................................................1
Iron holder.......................................................1
Cleaning wire ..................................................1
Instruction manual ..........................................1
M
O
D
E L
FP-102
7
.5
7
.0
8
.0
6
.5
FP-102 Soldering station
FM-2021 Connector assembly
Iron holder
Tip tray

2. SPECIFICA TIONS

FP-102 soldering station
Power consumption Temperature range
Temperature stability
Station
Output Dimensions(W × H × D) Weight (w/o cord)
1
75 W The four segment lights on the front
panel indicate the heat range selected for the FP-102 (6.5 = ~650°F. [343°C];
7.0 = ~700°F. [371°C]; 7.5 = ~750°F. [399°C]; 8.0 = ~800°F. [427°C]).
±9°F (±5°C) at idle temperature
24 V 120 × 93 × 140 mm (4.7 × 3.7 × 5.5 in.) 1,400 g (3.1 lb.)
Heat resistant pad
Soldering iron
Power consumption Tip to ground resistance Tip to ground potential Length, less cord Weight, less cord Length of cord
NOTE:
This product is protected against electrostatic discharge. Specifications and design are subject to change without notice.
Sleeve assembly*
*Yellow, orange or blue sleeve
assembly is included.
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)
3.

W ARNINGS, 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, the tip will be HOT (between 300-450°C. [~572-840°F.]) To avoid injury or damage to personnel and items in the work area, observe the following:
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 FP-102.
Do not remove or damage the bar code sticker.
CAUTION
To prevent accidents or damage to the FP-102, be sure to observe the following:
Do not use the FP-102 for applications other than soldering.
Do not allow the FP-102 to become wet, or use it with wet hands.
Do not modify the FP-102.
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 may 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.
2

4. PART NAMES

blue
7.5
FP-102 Soldering station
Tip cleaner
MO
D EL
FP-102
7
.5
7
.0
8
.0
6.5
Control card
Card chain
Card slot
Receptacle
Tip (not included)
yellow
®
MODEL
FP-102
7.5
8.07.0
6.5
The heat range selector button
Auto power shutoff switch (on the bottom front of the case)
FM-2021 Connector assembly
6.5
green
red
8.07.0
Sleeve assembly
Iron holder
Tip tray
Heat resistant pad
3
5. INITIAL SETUP
Iron holder
Assemble as shown:
Insert the holder assembly securely into the Iron holder base.
Connector cord
Pass the connector cord through the hole in the heat resistant pad.
Soldering station
1. Insert the connector cord into the receptacle at the front of the station.
2. Plug the power cord into a grounded wall socket. The FP-102 is protected against electrostatic discharge and must be grounded for full efficiency.
Tip tray
Place spare tips in the tip tray.
Receptacle
Push the connector in as far as it will go. When the plug clicks, it is fully inserted.
4

6. OPERA TION

OPERATION
1. Turn the power switch ON.
2. A heat range indicator (one of the four segment buttons, indicating the selected range) will blink.
3. When the set temperature is reached, the buzzer alarm sounds indicating it is ready for use. The indicator lamp remains on steadily.
Control card
Changing the heat range
1. Insert the control card into the slot in the front of the unit.
As previously noted, the four segment lights on the front panel indicate the heat range selected for the FP-102 (6.5= ~650°F. [343°C]; 7.0= ~700°F. [371°C];
7.5= ~750°F. [399°C]; 8.0= ~800°F. [427°C]. The ranges are approximate values only; the actual tip temperature depends upon tip geometry and mass. These lights are indicators; one must press the heat range button, located below the indicators, to change range.
NOTE:
When not in use, place the soldering iron to the iron holder.
Each FP-102 comes with a small card, which inserts into the Card slot on the front of the unit. This card is used when changing heat ranges. Any FP-102 card can be used with any FP-102 soldering station.
CAUTION:
The control card must be inserted into the card slot in the correct direction for data to be entered.
2. Press the heat range selector button. Each time this button is pressed a different heat range indicator lamp will light. It will blink slowly until the set range is reached; once at temperature, it will remain on steadily.
3. Removing the card. When the station is on and the control card is in the station, the temperature can be changed any time.
4. When the alarm sounds and the heat range indicator lamp starts lighting, the station is ready for use.
5
®
7.5
MODEL
FP-102
The heat range selector button
8.07.0
6.5
7.5
8.07.0
6.5
When power is switched off the selected heat range is stored in memory.
Using the iron holder
Remove any excess solder from the tip by thrusting the tip into the cleaning wire. (Do not wipe the tip against the wire. This may cause molten solder to spatter.) When the wire become dirty or loaded with solder, turn the wire until a clean surface is presented. When changing the cleaning wire, lift the case top vertically to prevent solder debris from falling out.
Replacing the tip
Removing and inserting the tip:
Removing the tip: Hold the sleeve assembly to remove the connector. Remove the tip from the sleeve assembly. (If the tip is hot, hold it with the heat-resistant pad.)
Inserting the tip: Hold the head part 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. Put the tip into the connector.
Insert the new tip firmly into the connector.
1
2
W
0
0
-2
7
-
M
V
F
4
2
®
Hold the sleeve assembly at the front to remove tip.
Hold these parts to insert tip into sleeve assembly.
Hold and squeeze this part to insert into the connector.
There are no orientation requirements.
The tip can be very HOT. Use the heat-resistant pad for handling hot tips, but do not hold the hot portion of the tip, even with the pad, for a long time.

7. PARAMETER SETTINGS

Auto power shutoff
This is an optional setting. When it is activated and the soldering iron is not used for 30 minutes, the power to the heating element is shut off automatically, the alarm will sound three times and the selected heat range lamp will light slowly. When the temperature decreases to 100°C/212°F, the heat range indicator lamps light in a slow clockwise sequence. If the station is left in this mode, the
'alarm' will continue to sound every thirty minutes. To resume soldering, cycle the power switch OFF, then ON. The power will be turned on automatically if the heat range selector button is pressed before the temperature decreases to 100°C/212°F. The auto power shutoff switch is on the bottom front of the case. To turn this function ON ,set the switch to the' I ' position. (OFF is reverse.)
CAUTION:
6

8. MAINTENANCE

Tip maintenance
1. Tip temperature
High temperatures shorten tip life and may cause thermal shock to components. Always use the lowest possible temperature when soldering. The excellent thermal recovery characteristics of the FP-102 ensure effective soldering at low temperatures.
2. Cleaning
3. After use
4. When the unit is not being used and the auto power shutoff is not active.
5. Inspecting and cleaning the tip
Always clean the soldering tip before use to remove any residual solder or flux adhering to it. Use the 599B tip cleaner (provided with the FP-
102) or use a clean and moist cleaning sponge part no. A1495. Contaminants on the tip have many deleterious effects, including reduced heat conductivity, which contribute to poor soldering performance.
Always clean the tip and coat it with fresh solder after use. This guards against oxidation.
Never allow the unit to idle at a high temperature for extended periods. This will allow the tip to become oxidized. Turn the power switch OFF. If it is to be out of service for several hours, it is advisable to pull the power plug as well.
This procedure, if followed daily, will materially add to tip life. a. Set the heat range to 6.5. b. When the temperature stabilizes, clean the
tip (see 2, above) and check the condition of the tip. If the tip is badly worn or deformed, replace it.
c. If the solder plated part of the tip is covered
with black oxide, apply fresh solder, con­taining flux, and clean the tip again. Repeat until all the oxide is removed, then coat the tip with fresh solder.
CAUTION:
NEVER file the tip to remove oxides!
d. Turn the power OFF and remove the tip. Set
the tip aside to cool.
7
Checking Procedure
WARNING:
Unless otherwise directed, carry out these procedures with the power switch OFF and the power UNPLUGGED.
Check for a broken heater or
sensor
Check the grounding line
2
5
3
7
4
1
8
6
Checking the connection cord
for breakage
Black
Green
Red
White
Blue
1. Check for a broken heater or sensor
Measure the resistance across this position.
1Y100CB3
T7-D24
Verify the electrical integrity of the heater and sensor. Measure the resistance of the heater and sensor while at room temperature (15 to 25°C; 59 to 77°F). It should be 8Ω±10%. If the resistance exceeds these limits, replace the tip.
1. Unplug the connection cord from the station.
2. Measure the resistance value between Pin 2 and the tip.
3. If the value exceeds 2 (at room temperature), perform the tip maintenance described on P.7. If the value still does not decrease, check the connection cord for breakage.
1. Remove the soldering tip and the sleeve assembly.
2. Turn the front piece of the FM-2021 clockwise and remove the cover.
3. Measure the resistance values between the connector and the lead wires at the socket as follows:
Pin 1 – Red Pin 2 – Green Pin 3 – Black Pin 5 – White
If any value exceeds 0, replace the FM-2021.
8

9. ERROR MESSAGES

System Error
7.5
8.07.0
6.5
Sensor Error
7.5
8.07.0
6.5
Heater terminal short circuit
error
7.5
When the power is turned on, the system automatically checks its memory and the stored program. If a problem is found, all the heat range indicator lamps will light and the tip will not heat.
When there is the possibility that a failure has occurred in the sensor or heater (including the sensor circuit), the heat range indicator lamp will blink rapidly and the heater is shut down.
NOTE:
Sensor error also occurs if the tip is not inserted properly.
All the heat range indicator lamps will blink, and the alarm will sound continuously. Possible causes are: the tip is inserted the wrong way , an incompatible tip is inserted, or a foreign object is in the connector.
8.07.0
6.5
Soldering iron error
7.5
8.07.0
6.5
The yellow and red heat range indicator lamps will blink if the connector cord is not attached to the station OR the wrong soldering iron is connected.
CAUTION:
Do not connect the FM-2022 or FM-2023 with the FP-
102.
9

10. TROUBLE SHOOTING GUIDE

WARNING:
Before opening the FP-102, or replacing parts, be sure to disconnect the power plug. Failure to do so may result in electric shock.
The unit does not
operate when the power switch is turned on.
The tip does not heat up.
7.5
•‘Sensor error
displayed.
8.07.0
is
6.5
Solder does not wet the
tip.
The tip temperature is
too high.
The tip temperature is
too low.
CHECK : Is the plug disconnected?
ACTION
CHECK : Is the tip inserted properly?
ACTION
CHECK : Is the connection cord and/or the heater/sensor broken?
ACTION
CHECK : Is the tip contaminated with oxide?
ACTION
CHECK : Is the connection cord broken?
ACTION
CHECK : Is the tip contaminated with oxide?
ACTION
: Connect it.
: Insert the tip completely.
: See the appropriate section of this manual regarding how
to check the connection cord and/or the heater/sensor for breakage.
: Remove the oxide (see Tip maintenance on P. 7).
: See Checking the connection cord for breakage on P. 8.
: Remove the oxide (see Tip maintenance on P. 7).
The soldering iron error,
yellow and red lamp blink.
Heater terminal short
7.5
circuit error
8.07.0
is
6.5
displayed
CHECK : Is the wrong soldering iron connected? Or the FM-2021
plug disconnected?
ACTION
CHECK : Is the tip for FM-2021?
ACTION
: Turn off the power switch, re-connect the FM-2021
soldering iron, then turn on the power switch.
: Turn the power switch OFF and insert genuine FM-2021 tip.
Turn the power switch ON.
10

11. P ARTS LIST

NOTE:
Spare or repair parts do not include mounting screws, if they are not listed on the description. Screws must be ordered separately.
1
Tapping screw
2.6 × 6 (1)
Tapping screw
2.6 × 8 (3)
3
5
Tapping screw 3 × 8 (3)
Binding head tapping screw
3.5 × 45 (4)
Pan head screw M4 × 6 (2)
11
External tooth lock washer nominal size 4
2
FP-102 Station
Item
Part No.
No.
1
B2839 B2861
2
B2835B
3
4
B2836
5
B2837
6
B2838
7
B2852
8
B1319
9
B2015
10
B2103
11
B2227
12
B2224
11
M
O
D
E
L
F
P
-1
0
2
7.0
Part Name
Control card Front panel
P.W.B. (temperature control and connector)
Transformer Upper case Lower case Power switch Power cord Cord stopper Wiring board for switch Grounding plate Fuse
3
7.5
8.0
6.5
Specifications
with LED lens and shieding plate
120V
with rubber foot
3 wired cord & American plug
2A (UL)
4
Tapping screw 3 × 12 (1)
8
9
12
10
7
6
Tapping screw 4 × 12 (4)
3
4
2
1
Item No. Part No.
5
1 3
FM2021-01
,,
1
FM2021-02
2
B2770
B2765C
3
B2768C B2769C
5
3
1
2
6
5
4
4 5
B2300
Iron Holder
Item No.
1
Item No.
Part No.
6
~
634-01
Iron Holder Parts
Part No.
B2786
1
2
B2790
3
B2791
4
B2792
5
599B-02
6
599-029
7
B2756
Part Name Conversion kit Connector assembly Connector cover Sleeve assembly Sleeve assembly Sleeve assembly Tip Heat resistant pad
Part Name
Iron holder
Part Name
Holder for iron receptacle
Iron receptacle Retaining clip Iron holder base Tip cleaner Cleaning wire Tip tray
Specifications
3
is yellow
Yellow
Orange
Blue
See section
'12. TIP STYLES'
Specifications
Specifications
With screw
With rubber foot
7
12

12. TIP STYLES

21
115
(4.53)
139
(5.47)
ø5.5
(0.22)
T7-D08 SHAPE-0.8D Chisel T7-D12 SHAPE-1.2D Chisel T7-D16 SHAPE-1.6D Chisel T7-D24 SHAPE-2.4D Chisel
0.5
(0.02)
(0.12)
ø0.8
(0.03)
3
9.5
(0.37)
0.5
(0.02)
4.3
(0.17)
ø1.2
(0.05)
10
(0.39)
0.5
(0.02)
T7-D32 SHAPE-3.2D Chisel T7-D4 SHAPE-4D Chisel T7-D52 SHAPE-5.2D Chisel
(0.008)
30°
R0.2
.00
(0
(0.16)
R
0
(0.06)
ø4
(0.16)
4
7.5
(0.3)
1.2
(0.05)
T7-LI SHAPE-LI Long Sharp Conical
.2
9.5
(0.37)
T7-C1 SHAPE-1C Bevel
1.6
8)
7.9
(0.31)
ø3.2
(0.13)
0.5
(0.02)
1.6
(0.06)
T7-B2 SHAPE-2B Conical
R0.5
(0.02)
10
(0.39)
(0.2)
5
0.5
(0.02)
T7-I SHAPE-I Sharp Conical
T7-JL02 SHAPE-0.2RLB Bent T7-JS02 SHAPE-0.2RSSB Bent
7.5
(0.3)
30°
R0.2
(0.008)
9.3
(0.37)
3.5
(0.14)
(0.31)
R0.2
(0.008)
ø1
ø1.6
(0.04)
ø5.2
8
(0.06)
0
6
(0.47)
(0.2)
°
10
(0.39)
(0.28)
12.7 (0.5)
12
ø2.4
(0.09)
0.5
(0.02)
4.1
(0.16)
10
(0.39)
T7-B SHAPE-B Conical
R0.2
(0.008)
7
(0.3)
7.5
T7-J02 SHAPE-0.2RSB Bent
3.5
(0.14)
30°
R0.2
(0.008)
12
(0.47)
T7-BC1 SHAPE-1BC Bevel
ø1
(0.04)
45°
11.5
(0.45)
Unit: mm (in.)
T7-BCF1 SHAPE-1BC Bevel
(Tinned on the soldering surface only)
ø1
(0.04)
°
45
11.5
(0.45)
T7-BCF2 SHAPE-2BC Bevel
(Tinned on the soldering surface only)
ø2
(0.08)
45°
11.5
(0.45)
T7-C4 SHAPE-4C Bevel T7-CF4 SHAPE-4C Bevel
ø4
(0.16)
°
5
4
11.5
(0.45)
T7-BC12 SHAPE-1.2BC Bevel
T7-BC28 SHAPE-2.8BC Bevel
3.2(0.13)
(Tinned on the soldering surface only)
13
ø1.2
1.5 (0.06)
ø2.8(0.11)
(0.05)
60°
ø4
60
(0.69)
(0.16)
4
17.6
5
(0.45)
°
15
(0.59)
°
11.5
T7-BC15 SHAPE-1.5BC Bevel
ø1.5
(0.06)
60°
1.7 (0.07)
17
(0.67)
T7-BC3 SHAPE-3BC Bevel
ø3
(0.12)
45°
10
(0.39)
T7-K SHAPE-K Knife
ø4.7(0.19)
2
(0.08)
°
45
15
(0.59)
T7-BC2 SHAPE-2BC Bevel
ø2
(0.08)
°
5
4
11.5
(0.45)
T7-BCF3 SHAPE-3BC Bevel
(Tinned on the soldering surface only)
ø3
(0.12)
°
5
4
10
(0.39)
T7-KF SHAPE-KF Knife
ø4.6(0.18)
2.4
(0.09)
°
45
17
(0.67)
T7-KL SHAPE-KL Knife
T7-KU SHAPE-KU Knife
T7-R20 SHAPE-2.0R Slot
Unit: mm (in.)
T7-R23 SHAPE-2.3R Slot
ø4.7
(0.19)
1.5
(0.06)
45°
(0.43)
T7-R27 SHAPE-2.7R Slot
5.8
(0.23)
5.2(0.2)
(0.08)
T7-1002 SOP5.1 x 10.4
5.1
6.7(0.26)
10.4
(0.41)
(0.09)
T7-1006 SOP6.9 x 11.4
8.7(0.34)
6.9
11.4
(0.45)
(0.09)
T7-1201 PLCC13.6 x 8.5
11
(0.11)
2.7
(0.2)
2.3
(0.27)
2.3
2
5
(0.2)
4.5
(0.18)
4.5
(0.18)
ø3
(0.12)
1.2
(0.05)
45°
11
(0.43)
T7-R34 SHAPE-3.4R Slot
3.4
ø5.8(0.23)
1.8 (0.07)
1.8
(0.07)
T7-1003 SOP9.5 x 18.3
9.5
11.1(0.44)
18.3
(0.72)
3.2
(0.13)
T7-1007 SOP7.9 x 18.8
7.9
18.8
(0.74)
9.3(0.37)
3.2
(0.13)
T7-1202 PLCC10.3 x 10.3
(0.13)
(0.37)
(0.22)
(0.31)
(0.22)
(0.2)
5.5
2.0
(0.08)
1.3
(0.05)
T7-R48 SHAPE-4.8R Slot
2.3
5.2
(0.09)
T7-1004 SOP9.5 x 15.8
15.8
(0.62)
T7-1008 SOP19.5 x 10.2
5.5
10.2 (0.4)
T7-1203 PLCC12.8 x 12.8
ø4.5(0.18)
1.6
(0.06)
(0.19)
4.8
ø7.2(0.28)
1.8
(0.07)
9.5
11.1(0.44)
3.2
(0.13)
19.5(0.77)
20.9(0.82)
3
(0.12)
(0.2)
(0.37)
(0.22)
(0.24)
5.2
5.2
(0.2)
5.5
6
1.5 (0.06)
T7-1001 SOP5.1 x 4.6
4.6
(0.18)
T7-1005 SOP9.5 x 13.2
13.2
(0.52)
T7-1009 SOP13.4 x 20.5
20.5
(0.81)
T7-1204 PLCC17.9 x 17.9
2.3
ø4.6(0.18)
1.8
(0.07)
5.1
6.7(0.26)
(0.09)
11.1(0.44)
(0.13)
13.4
14.8(0.58)
4.3
(0.17)
(0.2)
2.3
9.5
3.2
(0.09)
(0.37)
(0.53)
(0.24)
5.2
(0.2)
4.5
(0.18)
5.5
(0.22)
6
8.5
9.7
(0.33)
(0.38)
13.6(0.54)
14.8 (0.58)
T7-1205 PLCC23.4 x 17.3
18.5(0.73)
17.3(0.68)
23.4(0.92)
24.6(0.97)
T7-1209 PLCC8.4 x 8.4
9.6
8.4
(0.38)
(0.33)
8.4
(0.33)
9.6
(0.38)
5.5
(0.22)
5.8
(0.23)
5.5
(0.22)
11.5
(0.45)
10.3(0.41)
10.3(0.41)
11.5
(0.45)
T7-1206 PLCC22.5 x 16.5
17.7(0.7)
16.5(0.65)
22.5(0.89)
23.7(0.93)
T7-1401 Spatula 15.7
2
(0.08)
15.7
(0.62)
7.2
(0.28)
5.5
(0.22)
(0.23)
14
(0.55)
12.8(0.5)
12.8(0.5) 14(0.55)
T7-1207 PLCC15.5 x 15.5
5.8
15.5(0.61)
16.7(0.66)
15.5(0.61)
16.7(0.66)
5.5
(0.22)
(0.2)
17.9(0.7) 19(0.75)
T7-1208 PLCC15.8 x 15.8
5
15.8(0.62) 17(0.67)
19(0.75)
17.9(0.7)
17(0.67)
15.8(0.62)
5.5
(0.22)
5.5
(0.22)
14

13. WIRING DIAGRAM

P.W.B./switch
Grounding plate
Fuse
LED4
LED5LED3
LED2
SW1
AC
TR
Power switch
BLKWHT
Transformer
SW2
P.W.B./temperature control
P.W.B./connector
HEAD OFFICE
4-5, SHIOKUSA 2-CHOME, NANIWA-KU, OSAKA, 556-0024 JAPAN TEL:+81-6-6561-3225 FAX:+81-6-6561-8466 http://www.hakko.com
AMERICAN HAKKO PRODUCTS, INC.
28920 N. AVENUE WILLIAMS VALENCIA CA 91355, U.S.A. TEL: (661) 294-0090 FAX: (661) 294-0096 Toll Free (800)88-HAKKO www.hakkousa.com
4 2 5 5 6
15
RED
RED
Nov. 2003
MA01268YU031127
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