Solder feed guide set
Teflon tube are optionally available.
(See 11. Part List in page 23)
2. SPECIFICATION
●HAKKO FU-500 (Station only)
Power consumption
Dimensions
(W × H × D)
Weight
35W
145(W)×100(H)×230(D)mm
(5.7 × 3.9 × 9.1 in.)
2.3kg (5.1 lb.)
●Solder diameter
For the HAKKO FU-500, the compatible solder wire size varies by model number.
Please check the model number of your product before ordering corresponding parts according to the Part List on page 23.
The solder diameter that can be used with the HAKKO FU-500 are shown in the table below.
Before changing the solder diameter, see "● How to change the solder diameter" on page 17.
Solder diameter (mm) 0.30.50.6(0.65)0.81.01.21.6
Up to 1kg bobbin of solder can be used.
●Feeder unit
Model number
(Compatible solder diameter)
※
Weight
※With the solder feed pulley unit, the solder feed guide
set and the teflon tube
(φ0.3 - 1.6mm)
800 g
1
※This product is protected against electrostatic discharge.
※Specifications and design are subject to change without notice.
■Electrostatic Protection
This product includes such features as electrically conductive plastic parts and grounding of the unit as measures to protect
the device to be soldered from the effects of static electricity. Be sure to observe the following instructions:
When making repairs or replacing parts, take sufficient care not to expose live electrical parts or damage insulation materials.
1.
2. Be sure to ground the unit during use.
3. WARNINGS, CAUTIONS AND NOTES
Warnings and cautions 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.
WARNING
●Turn the power off when not in use, or left unattended.
●This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance
by a person responsible for their safety.
●Children should be supervised to ensure that they do not play with the appliance.
●To prevent accidents or damage to the HAKKO FU-500, be sure to observe the following.
CAUTION
●
The cutting blade is sharp. Be careful not to cut your fingers.
●
When resin core solder that has been cut is not used, the properties of the resin (flux)
may deteriorate with time.
●
Once the solder has been cut and is inside the guide pipe, the heat from the soldering iron
may accelerate the deterioration of the resin (flux). Use solder that is inside the guide pipe
as soon as possible.
●
Do not damage the guide pipe by bending or twisting it.
●
Do not allow the tube to be bent at a severe angle. Otherwise, it will become clogged with solder.
●Keep the cutting blade and pulley clean of solder and flux using a brush or other suitable cleaning device.
●Periodically remove the guide pipe or the teflon tube and clean off any accumulated flux.
2
4. PART NAMES
●HAKKO FU-500
Setting display LCD
Power switch
Feeder unit connector
Control knob
PC interface
Slide unit connector
Robot connector
Connecting cable
connector
Power receptacle
Fuse
3
●Feeder Unit
Solder feed guide set (option)
Feeder unit cover screw
To solder reel stand
Feed position adjuster
Teflon tube (option)
CAUTION
The solder feed pulley unit with
the cutting blade is dangerous.
Be careful not to cut your fingers.
Guide tube (option)
CAUTION
※Make sure to attach this cover to prevent
a flux from entering into the feeder unit.
Solder feed pulley unit (option)
Feeder unit cover
※
Guide pipe (option)
Tube unit
4
5. INITIAL SETUP
Use a hex wrench of 2.5 mm.
Connecting components
Feeder unit
HAKKO FU-500
Feeder cable
Connecting cable
to HAKKO FU-601
●Assembling the feeder unit
Install the tube unit, the solder feed pulley unit, the solder feed guide set and the teflon tube.
Tighten the screws shown in the figure below.
Draw solder through the tube unit and supply to the feeder unit.
(Including in the HAKKO FU-601)
※Secure the bending radius of
more than 10cm to prevent
solder clogging.
※ For information about how to
install the teflon tube,
see page 17.
How to set solder
Ensure that solder is reeled out of
the top of the bobbin.
5
Tighten
Tighten
CAUTION
Tighten
Do not touch any screws than the hexagon
socket screws described in this manual.
The attachment of the solder feed pulley unit
for φ0.3mm (BX1000) is different.
Refer to the “How to set solder” in the BX1000.
Please be careful not to tighten the screw too much.
Pulley
Draw solder through the tube unit and press the end of solder
against the pulley of the solder feed pulley unit.
With this condition, start the HAKKO FU-500 to feed solder
until solder comes out of the end of the teflon tube.
●Adjusting the solder feed position
1. Loosening the adjustment screw ① will allow you to move the entire solder feed guide set as shown
in the figure below. Move the solder feed guide set to the tip.
Adjustment screw ①
2. Loosening the adjustment screw ② will allow you to move the guide pipe as shown in the figure
below. Move the guide pipe until solder comes into contact with the tip.
Adjustment screw ②
Eccentric tuning screw ③
Eccentric tuning screw③
Turning the eccentric tuning screw ③
will turn the feed position adjuster
together, allowing you to make tuning.
(This screw cannot be removed.)
Feed position adjuster
6
6. OPERATION
Auto mode
In auto mode, the unit operates according to commands from the robot.
There are two types of auto mode: PS and DS.
For more information, see the timing chart below:
・PS (Point soldering) mode
Point soldering process
tph
tps
Program No. (In)
Start solder feed (In)
tsw
Controller ready (Out)
Primary feed (Internal)
Primary back feed (Internal)
Unit down command (Out)
Upper limit detection (In)
Lower limit detection (In)
Primary heating (Internal)
Secondary feed (Internal)
Secondary back feed (Internal)
Secondary heating (Internal)
Tertiary feed (Internal)
Tertiary back feed (Internal)
Tertiaryheating (Internal)
Status signal: Form1 (Out)
Status signal: Form2 (Out)
OnOff
On
Run
Off
Off
OnOff
Off
On
On
Off
On
*When selecting a program number, set the signal P7 (MSB) to 0 (zero).
*The controller outputs either the status signal Form1 or Form2
(according to the setting made during program setting).
Program selection setup time : t
Program selection hold time : t
Start signal pulse width : t
ps > 5msec
ph > 25msec
sw > 25msec
7
・DS (Drag Soldering) Mode
Drag soldering process
t
ph
t
ps
Program No. (In)
t
Start solder feed (In)
sw
Controller ready (Out)
Primary feed (Internal)
Primary back feed (Internal)
Unit down command (Out)
Upper limit detection (In)
Lower limit detection (In)
Primary heating (Internal)
Start continuous feed (Out)
End continuous feed (In)
Secondary feed (Internal)
Secondary back feed (Internal)
Secondary heating (Internal)
Tertiary feed (Internal)
Tertiary back feed (Internal)
Tertiary heating (Internal)
Status signal:Form1 (Out)
Status signal:Form2 (Out)
On
Off
Off
On
Run
Off
Off
On
Off
On
On
Off
t
msw
t
mew
On
*When selecting a program number, set the signal P7 (MSB) to 1.
*The controller outputs either the status signal Form1 or Form2
(according to the setting made during program setting).
Program selection setup time : t
Program selection hold time : t
Start signal pulse width : t
Iron move signal pulse width : t
Iron stop signal pulse width : t
ps > 5msec
ph > 25msec
sw > 25msec
msw > 25msec
mew > 25msec
8
Robot I/F pin assignment
2.54 mm pitch 26-pin ribbon cable connector
Pin No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
No. 25No. 26
No. 1
Signal name
P0
P1
P2
P3
P4
P5
P6
P7
Start
Low_Lim
Up_Lim
Move_End
Emergency
Ready
Down
Move_Start
Feeder_Error
Iron_Ctrl_Status
Status
NC
NC
NC
IO_Vsup
DC24V_OUT
IO_GND
IO_GND
No. 2
I/O
In
In
In
In
In
In
In
In
In
In
In
In
In
Out
Out
Out
Out
Out
Out
In
Out
HAKKO FU-500 back
No. 25
No. 26
Function
Program No. LSB
Program No.
Program No.
Program No.
Program No.
Program No.
Program No.
Program No. MSB
Start solder feed
Bottom limit detection
Top limit detection
End continuous feed
Emergency stop
Controller ready
Unit down command
Start continuous feed
Feeder controller error output
HAKKO FU-601 status output
(Error or Ready)
Status signal
1) The program No. MSB (P7) is used to select point or drag soldering.
OFF : Point soldering mode
ON : Drag soldering mode
2) Top_Lim and Bot_Lim signals are ignored when the slide unit connection mode is selected to
internal mode.
3) Down signal is not output when the slide unit connection mode is selected to internal mode.
4)
9
DC24V output voltage is turned ON/OFF by interlocking with the ON/OFF state of the power switch.
Robot I/F input and output circuits
Input circuit
5.6K
1
4
2〜10mA
2
3
(24V recommended)
IO_Vsup
In
DC24V OUT 500mA Max
HAKKO FU-601 I/F
Connecting cable (6-pole 6-core modular cable)
Pin No.
1
2
3
4
5
6
RxD
TxD
Iron_Ready
Iron_GND
Iron_GND
Iron_Vcc
Signal name
I/O
In
Out
In
In
Output circuit
4
1
3
2
Out
DCV48 or less, 50 mA or less
IO_GND
Function
Incoming data
Outgoing data
HAKKO FU-601 Ready signal
HAKKO FU-601 GND
HAKKO FU-601 Vcc (5V)
It transfers status and data to and from the HAKKO FU-601.
PC I/F : USB Mini-B
The PC I/F establishes communications with PC to send and receive various information.
It is operated on a virtual COM port.
Please install the driver (freeware) to your PC from the following URL:
http://www.cypress.com/?rID=63794
From the top page, proceed as follows:
(Support > Software Tools > Software and Drivers > Microsoft Certified USB UART Driver)
1) Uploading/downloading programs
The PC I/F writes (downloads) programs created in the PC to the controller or reads in and
uploads programs to the PC.
2) Uploading/downloading the HAKKO FU-601 setting information
The PC I/F uploads or downloads the set temperature, the offset temperature and the preset
temperature of the HAKKO FU-601.
10
3) Uploading the HAKKO FU-601 tip temperature
The PC I/F reads in the iron tip temperature from the HAKKO FU-601 and uploads it to the PC.
4) Uploading the operation log
The PC I/F uploads the total number of soldering points and the total amount of fed solder to the PC.
5) Clearing the operation log.
The PC I/F clears the operation log.
The PC I/F does not operate while the feeder is run except for uploading of the tip temperature.
The display for uploading of the tip temperature is not updated while the feeder is run.
For more information about how to use, see the HAKKO FU-500 PC Link Software Instruction Manual.
The PC Link Software can be downloaded from the HAKKO Document Portal after user registration.
https://doc.hakko.com
Changing the settings
Turn on the power switch of HAKKO FU-500.
The start-up screen will be displayed, and then move to Auto Mode Standby screen.
If the HAKKO FU-500 receives a Start signal when this screen is displayed, it will start to operate
for Auto Mode.
If the HAKKO FU-500 does not receive a Start signal and the control button is pressed,
it will show the Mode Select screen.
To change the value or the cursor position, turn the control knob and then press the knob to confirm.
Mode Select
Auto Mode
SimulationMode
Test Operation
FU-500
FEEDER CONTROLLER
ESD
SAFE
Auto Mode
Standby
Control
button
Solder Feed
Program Set
Parameter Set
Log View
(3 lines are displayed at a time.)
11
●Selecting Auto Mode
When you select Auto Mode, you will return to the Auto Mode Standby screen.
If the HAKKO FU-500 receives a Start signal when this screen is displayed,
it will start to operate for Auto Mode.
Start signal
Auto Mode
received
Auto Mode
PS 00
Standby
●Selecting Simulation Mode
When you select Simulation Mode, you will enter Simulation Mode with the Simulation Mode Standby
screen shown. If the HAKKO FU-500 receives a Start signal when this screen is displayed,
it will behave in the same manner as in Auto Mode but the motor will not start (no solder will be fed).
Note that no solder feed or iron control error will be detected.
Start signal
Simulation Mode
received
Primary Feed
Simulation Mode
PS 00
Standby
Primary Feed
●Selecting Test Operation Mode
When you select Test Operation Mode, you will enter Test Operation Mode.
In this mode, the HAKKO FU-500 will start to operate in PS (point soldering) mode for operation check
or adjustment after selecting a program number.
The HAKKO FU-500 outputs the same signal to the robot as the output signal in Auto Mode.
All input signals from the robot will be ignored, but any solder feed error will be detected
and displayed.
Operation completed
※ Tens place -> Units place -> Confirm
Select
Program Number
00
Select
program No.
Test Operation
START
SET PRG NUM
START
Test Operation
PS 00
Primary Feed
Exit
Select SET PRG NUM
12
●Selecting Solder Feed
When you select Solder Feed, you will enter Solder Feed Mode.
In this mode, you will specify the solder feed speed for continuous feed of solder.
No signal will be output to the robot. All input signals from the robot will be ignored and
no solder feed error will be detected.
※Tens place -> Units place ->
Select SET FEED SPEED
One decimal place -> Confirm
Solder Feed
START
START
Solder Feed
Feed Speed
SET FEED SPEED
STOP
Exit
Setting completed
●Selecting Program Set
When you select Program Set, you will enter Program Setting Mode.
Up to 100 programs (0 to 99) can be programmed in either
PS (point soldering) or DS (drag soldering) mode.
※Tens place -> Units place -> Confirm
Select Feed Mode
PS Mode
DS Mode
Exit
Any other
than Exit
Select
Program Number
0 0
Select
program No.
10.0mm / sec
Select Parameter
Feed1
Feed Speed1
Back Feed1
Back Speed1
Heat Time1
Feed2
.
.
.
Exit
10.0
10.0
01.0
02.0
2.0
10.0
※For feed amount or feed speed, tens place -> units place -> one decimal place.
For heating time, units place -> one decimal place.
13
Primary
Feed Length
10.0mm
In Program Setting Mode, the following settings can be made:
Feed 1 :
Feed Speed 1 :
Back Feed 1 :
Back Speed 1 :
Heat Time 1 :
Feed 2 :
Feed Speed 2 :
Back Feed 2 :
Back Speed 2 :
Heat Time 2 :
Feed 3 :
Feed Speed 3 :
Back Feed 3 :
Back Speed 3 :
Heat Time 3 :
Preset # :
Status Sig :
Primary Feed Length
Primary Feed Speed
Primary Back
Feed Length
Primary Back Speed
Primary Heat Time
Secondary Feed Length
Secondary Feed Speed
Secondary Back
Feed Length
Secondary Back Speed
Secondary Heat Time
Tertiary Feed Length
Tertiary Feed Speed
Tertiary Back
Feed Length
Tertiary Back Speed
Tertiary Heat Time
■In either secondary or tertiary, setting the feed speed, feed length or heating time to 0 (zero) will
skip the corresponding feed or heating operation.
■
Setting any back speed or back feed length to 0 (zero) will skip the corresponding back feed operation.
■Note that the secondary feed length cannot be set for DS mode.
※1 The solder might not be properly fed when setting at high speed depending on type of the solder.
Contact your HAKKO representative.
※2 When the Preset Number is set to "Non", the set temperature at start-up of the program will be
used for operation.
14
●Selecting Parameter Set
When you select Parameter Set, you will enter Parameter Setting mode.
In this mode, you can specify the operation of the entire system.
Parameter Set
Feed Speed
S-U Mode
S-U Timeout
Iron Connect
Iron Status
Exit
1. Feed Speed (Specifying the feed speed in continuous feed mode)
10.0
Int
30
Con
Rdy
Feed Speed
0.1 - 99.9mm / sec
10.0mm / sec
2. S-U Mode (Selecting a slide unit connection mode)
Slide Unit
Connect Mode
Internal (Int) or External (Ext)
Int Mode
Ext Mode
3. S-U Timeout (Specifying the slide unit upper/lower limit detection timeout)
When Internal Mode is selected, all upper/lower limit
detection signals from the robot will be ignored.
Slide Unit
Time - out
5 - 99 sec
30 sec
15
4. Iron Connect (Connection status to the HAKKO FU-601)
Iron Control
Connection or Disconnection
Connect
When Not Connect is selected, preset settings can only
Connection
Disconnection
5. Iron Status (Selecting the HAKKO FU-601 Ready or Error signal)
be made in the HAKKO FU-601 and no iron controller
error is detected.
Iron Control
Status
You can select which signal HAKKO FU-601 will output
to the robot, Ready or Error.
Iron Ctrl Ready
Iron Ctrl Error
●Selecting Log View
When you select Log View, you can view the number of soldering points that have been made
and the total amount of solder that has been fed.
If you select Log Clear, you will enter the Log Clear screen. Selecting OK in this screen will
reset the count and you will enter the Mode Select screen.
If you select Cancel, you will return to the previous screen.
Operation Log
Total Point
xxxxxx p
Total Feed
xxxxxx mm
EXIT Log Clear
Log Clear
Log Clear ?
Cancel OK
Cancel
16
●How to change the solder diameter
You can change the solder diameter by replacing the teflon tube, the solder feed guide set or
the solder feed pulley unit.
The compatible solder diameters varies by model number of the HAKKO FU-500.
Please check your model number and then see the part list on the back cover of this manual when
you need some part replacement.
CAUTION
Only use compatible solder of specified size.
Failing to do so may cause a failure.
The attachment of the solder feed pulley unit
for φ0.3mm (BX1000) is different.
Refer to the “How to set solder” in the BX1000.
Loosen
Loosen
Hex wrench size : 2.5mm
●How to install the teflon tube
Solder feed guide support
Guide tube
Guide pipe
Teflon tube
Loosen
Solder feed guide nozzle
Cut
About 3 to 5 mm
Turn the solder feed guide nozzle counterclockwise and remove the solder feed guide support.
You can now install the teflon tube. Lastly, insert the guide pipe.
The teflon tube is quite long in length. Cut the excess length of the teflon tube to leave an appropriate
length (about 3 to 5 mm) from the guide pipe before use.
■As a guide, perform maintenance/cleaning when replacing the solder.
Remove any solder or flux adhered on the solder feed pulley unit using a brush or other appropriate tool.
If an insufficient cutting depth or splashing of solder balls are found in spite of the proper maintenance,
the cutting blade may have reached its end of life.
Since it is impossible to replace the cutting blade only, replace the whole solder feed pulley unit.
After soldering, flux is adhered on the guide pipe part.
Regularly wipe off the flux using alcohol.
Solder feed pulley unit
※
Teflon tube
Teflon tube in tube unit
CAUTION
※ Only the cutting blade and the teflon tube in the tube unit
are not interchangeable.
Place which is easy to adhere the solder and flux.
Cutting blade
※
CAUTION
The solder feed pulley unit with the cutting blade is dangerous.
Be careful not to cut your fingers.
18
8. ERROR MESSAGES
●Solder feed trouble error
Solder Feed
Trouble
Push Knob
●Illegal input error
Illegal
Input
Push Knob
When the solder feed sensor detects
"no solder" or "clogging", the HAKKO FU-500
will immediately stop the feed and show
this error message on the LCD along with
buzzer sound.
When an illegal input signal from the robot
is detected, the HAKKO FU-500 will
immediately stop the feed and show this
error message on the LCD along with
buzzer sound.
●Iron Controller Error
Iron
Controller Error
Push Knob
19
This error message is displayed when
the HAKKO FU-601 ready input is
"Not Ready" during Auto Mode or Manual
Program Mode.
This error will not occur in Adjustment
Mode or Continuous Feed Mode.
If the HAKKO FU-601 ready input is
"Not Ready" before Auto Mode or Manual
Program Mode is started up, the system
will not turn into error status but remain
standby status.
When this error occurs, the HAKKO FU-500
will immediately stop the feed and show this
error message on the LCD along with buzzer
sound.
●Motor Driver Error
Motor Driver
Error
●System Error
System
Error
When abnormal heating of the motor driver
detected, the HAKKO FU-500 will immediately
stop the feed and show this error message on
the LCD along with buzzer sound.
When a hardware error is detected,
the HAKKO FU-500 will immediately stop
the feed and show this error message on
the LCD along with buzzer sound.
is
●Emergency Stop
Emergency
Stop !
Push Knob
Upon receiving an emergency stop command
from the robot, the HAKKO FU-500 will
immediately stop the feed and show this error
message on the LCD along with buzzer sound.
20
9. TROUBLE SHOOTING GUIDE
●Solder cannot be fed properly./Solder Feed error is displayed.
CHECK: Is "solder clogging" or "no solder" occurred?
ACTION:
CHECK : Is the cutting blade or the pulley deposited with flux?
ACTION : Remove any flux using a brush and alcohol.
(See 7. MAINTENANCE in page 18.)
Remove any clogged solder. For "no solder" error, add new solder.
CHECK :
ACTION: Replace the part.
(See 7. MAINTENANCE in page 18.)
CHECK :Is the tube unit forced?
ACTION:Relax the tube unit.
(Secure the bending radius of more than 10 cm.)
CHECK : Is the teflon tube or the guide pipe clogged with flux?
ACTION: Remove any flux using a brush and alcohol.
CHECK :
ACTION:Replace the part with the correct one.
●Illegal Input error is displayed.
CHECK :
ACTION: Check the robot program.
●Iron Controller Error is displayed.
CHECK : Does the soldering iron have a sensor failure, too low temperature or
ACTION :Check the soldering iron.
Is the tube unit or the teflon tube contaminated, worn away and damaged?
If the problem persists, replace the part.
Is the part such as the solder feed pulley unit corresponded to the solder diameter?
(See 11. PARTS LIST in page 23.)
Is the HAKKO FU-500 received any overlapped or illegal signal from the robot?
any other faulty condition?
●Motor Driver Error is displayed.
CHECK :Does the motor or the motor driver have any faulty condition?
ACTION :Contact your HAKKO representative.
●System Error is displayed.
ACTION :Contact your HAKKO representative.
●Emergency Stop is displayed.
ACTION :Check the command from the robot.
21
10. EXPLODED VIEW
●HAKKO FU-500
●Feeder unit
22
11. PARTS LIST
For more information about replacement parts or latest information , please visit
our website (http://www.hakko.com) or HAKKO Document Portal. (see below)