Hakko Electronics FM-202 User manual

High-output, temperature controlled

soldering station

Instruction Manual

●

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.

●

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

Heat resistant pad

Iron holder

Cleaning

sponge

Power cord

FM-202

Soldering station

Control card

Card chain

Tip tray

OFF

Tip (not included) FM-2021 connector assembly

Sleeve

Sleeve stopper

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

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

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

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

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

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

Tips (not included)

2. SPECIFICATIONS

Power consumption

Temperature range

Temperature accuracy

Temperature stability

75 W (Max. 130 W)

200 –450

C (400 –840

±10

C (±18

F) of set temperature.

See Figure 1.

±5

C (±9

F) at idle temperature

●FM-202 soldering station

Power consumption

Tip to ground resistance

Tip to ground potential

Length, less cord

Weight, less cord

Length of cord

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)

●Soldering iron

Output

Dimensions

(l x w x h)

Weight

24 V

178 x 119 x 117 mm

(7.0 x 4.7 x 4.2 in)

2,700 g (5.9 lb.)

●Station

Stability: ±5

C (±9

Figure 1. Temperature accuracy and stability.

NOTE:

This product is protected against electrostatic discharge.

Specifications and design are subject to change without notice.

Accuracy: ±10

C (±18

Set temperature

Temperature

Time

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

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.

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.

4. PART NAMES

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.

Heat resistant pad

Iron holder

Cleaning

sponge

Power cord

FM-202

Soldering station

Control card

Card chain

Tip tray

Power switch

Receptacle

OFF

Fuse

Power receptacle

Process gate

Tip (not included) FM-2021 connector assembly

Sleeve

Sleeve stopper

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.

B. Connector cord

Pass the connector cord through the hole in the

heat resistant pad.

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 ac-

companying 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 -OR-

Wet the large cleaning sponge, squeeze it

dry, and put it on the iron holder base.

5. Place the spare tips in the tip tray.

C. Soldering station

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.

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

When the plug clicks ,

it is fully inserted.

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.

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 tem-

perature. 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.

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.

3. The display will show and the LED on

theconnectorwillflash.

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

nowstored.

(Refer to Appendix A for manual entry.)

5. Insertingthetip:

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 .

Therearenoorientationrequirements.

6. When the set temperature is reached, the

buzzer sounds and the heater lamp at the

lower right of the temperature display starts

blinking.

NOTE:

The FM-202 is preset at 750 F . at the factory .

Checkthetemperaturesettingbypressingthe button.

The set temperature will be displayed for two seconds.

Factory settings

The FM-202 comes from the factory with the

followingvaluespreset:

Temperature scale

Auto power shutoff

Low temperature alarm setting

Resetting the supervisor or

operator control setting

Set temperature

Fahrenheit

disabled

300 F

750 F

Tip ID controlled

with inserting the

card.

NOTE:

When the power has been cycled, Tip ID is no longer

stored in the station and will flash. Reenter Tip ID

as shown at right or in Appendix A.

Display

Setting temperature

TIN error

LED lamp at the connector begins to flash.

Turn the switch ON.

and

CAUTION:

Refrain from inserting foreign objects, the wrong end of

the tip, or incompatible tips into the process gate.

Damage may result.

NOTE:

This procedure must be followed EVERY TIME THE

STATION IS TURNED ON.

NOTE:

Once the tip is inserted into the connector, heat control

begins.

Hold this part to insert tip into sleeve assembly

and put into the connector.

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.

Example: 700 to 840

1. Insert the control card into the slot in the

front of the unit.

•The hundreds digit will begin to flash,

indicating that the unit is in the TEM-

PERATURE SET mode and data may be

entered.

2. Entering the hundreds digit

•Press the or button to set the

desired value. Only 4, 5, 6, 7, or 8 can be

selected. (In °C mode, 2, 3, or 4 can be

selected.)

When the desired value is displayed,

press the button to enter. The tens digit

will begin to flash.

3. Entering the tens digit

•Press the or button to set the

desired value. Any value from 0 to 9 can

be selected. When the desired value is

displayed, press the button to enter.

The units digit will begin to flash.

4. Entering the units digit

•Press the or button to set the

desired value. When the desired value is

displayed, press the button to enter.

The desired temperature is now entered

into the system memory and heater

control will begin.

Each FM-202 comes with a small card, which

inserts into the Card slot on the front of the unit.

This card is used when entering data for the

process control function (a temperature value is

to be changed, or data are to be entered). Any

FM-202 card can be used with any FM-202

soldering station.

●Control card

NOTE:

If power is switched off or lost during the execution of this

procedure, no data will be entered. The entire procedure

must be repeated from step 1.

CAUTION:

The control card must be inserted into the card slot in the

correct direction for data to be entered.

Press the button once.

Insert the card.

Press the or button.

Press the button once.

Press the or button.

●Changing the temperature setting

When the station is ON and the

control card is in the station, the

data entry procedure is:

a. Hold the button down for at least one

second.

b. The current temperature setting will be

displayed, then the hundreds digit will begin

to flash. This indicates that the station has

entered the temperature setting mode.

c. Follow steps 1-4 on the preceeding page.

NOTE:

When the button is pressed for less than one second,

the current temperature setting is displayed.

●Replacing the tip

Removing and inserting the tip:

Removing the tip: Hold the connector and

pull the tip and sleeve assembly out of the

connector. (If the tip is hot, hold it with the

heat-resistant pad.)

Remove the tip from the sleeve assembly.

Inserting the tip: Hold 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.

Enter Tip ID for new tip (see page 9).

Insert the new tip firmly into the connector.

(If the tip is not properly inserted, will

be displayed.)

There are no orientation requirements.

CAUTION:

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.

Remove tip from sleeve assembly

Hold this part to insert tip into sleeve assembly

and put into the connector.

7. TIP IDENTIFICATION NUMBER

●Entering the Tip ID

Method 1 –

How to read out the bar code of

the tip into the FM-202:

1. Insert the tip (connector side) into the

process gate in the front of the station.

2. Insert the tip until the buzzer sound once.

The display shows . The LED

indicator will stop flashing. Now the tip

identification number has been stored.

NOTE:

When the buzzer sounds three times is reading error, insert

the tip again.

CAUTION:

Do not insert the tip opposite side or other incompatible tip.

CAUTION:

Do not damage or remove the Tip ID bar code sticker.

Soldering tips have different thermal chara-

cteristics, depending upon their mass, shape, and

surface area. It should be obvious that the tip

temperature at idle will not be the same for a fine

tip as it will be for a heavy chisel tip, although the

set temperature may be the same for each tip. The

FM-202 processor incorporates the ability to

electronically compensate for tip geometry

variations using Tip IDs. Each FM-202 tip style has

a specific Tip ID; whenever a tip is changed, the

Tip ID should be entered into the FM-202 for most

effective process control.

There are two ways to enter Tip ID data into the

FM-202:

See below or page 6 of this manual. This procedure

is the simplest and most common.

See Appendix A of this manual, when the Tip ID is

not readable for some reason.

1Y100CB3 01

T7-D24

Part number Serial number

Bar codeTip ID

CAUTION:

When tip is inserting the FM-2021, the process gate cannot

read the bar code. If a tip insert into the process gate while

the tip is already in the FM-2021, buzzer will sound

irregularity. Remove the tip from the FM-2021 for reading the

Tip ID.

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