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 ap-

plications.

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 holde

Power cord

FM-202

Soldering station

Control card

Card chain

Tip tray

OFF

Tip (not included)

FM-2027

Connector assembly

Sleeve assembly

OFF

1. PACKING LIST

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

FM-2027 connector assembly ............................. 1

Sleeve assembly ..... ..................... .....................1

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

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

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

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

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

Tip cleaner ........................................................... 1

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

Tips (not included)

2. SPECIFICATIONS

Power Consumption

Temperature Range

Temperature Accuracy

Temperature Stability

140 W

200 – 450°C (400 – 840°F)

±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

Total Length (w/o cord)

Weight (w/o cord)

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 

(W x H x D)

Weight

24 V

119 x 117 x 178 mm 

(4.7 x 4.6 x 7.0 in)

2.7 kg (5.9 lb.)

 Station

Stability: ±5°C (±9°F)

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°F)

Set temperature

Temperature

Time

■ Electrostatic Protection

This product includes such features as electrically conductive plastic parts and grounding of the handpiece and

station as measures to protect the device to be soldered from the effects of static electricity. Be sure to observe

the following instructions:

1. The handle and other plastic parts are not insulators, they are conductors. When replacing parts or repairing,

take sufﬁcient care not to expose live electrical parts or damage insulation materials.

2. Be sure to ground the unit during use.

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-2027 or storing the FM-202.

 Do not remove or damage the bar code sticker.

WARNINGS, CAUTIONS, NOTES AND EXAMPLES

Warnings, cautions and notes are placed at critical points in this manual to direct the

operatorʼs 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.

4. PART NAMES

5. INITIAL SETUP

A. Iron holder

1. Assemble as shown:

Insert the holder assembly securely into

the Iron holder base.

Heat resistant pad

Iron holder

Power cord

FM-202

Soldering station

Control card

Card chain

Tip tray

Power

switch

Receptacle

OFF

Fuse

Power

receptacle

Process gate

FM-2027

Connector assembly

Tip (not included)

Sleeve assembly

Tip cleaner

B. Connector cord

Pass the connector cord through the hole in the

heat resistant pad.

2. Operation:

First, 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.

3. 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 ground-

ed 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.

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 sec-

ond, the stored temperature is dis-

played. 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 dis-

play:

 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 con-

tinuously. 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-2027, 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 is inserted into the process gate

while the tip is already in the FM-2027,

buzzer will sound irregularly.

 When the tip is properly inserted into the

connector, the buzzer will sound once.

NOTE:

The FM-202 is preset at 750

°F

. at the factory.

Check the temperature setting by pressing the button.

The set temperature will be displayed for two seconds.

 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



750°F

Tip ID controlled

with inserting the

card.

CAUTION:

Refrain from inserting foreign objects, the wrong end

of the tip, or incompatible tips into the process gate.

Damage may result.

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.

When a tip ID has not been entered, or when

a tip is NOT inserted into the FM-2027, the fol-

lowing procedure obtains:

1. Turn the power switch ON.

2. The display will show (Tip ID number)

and the LED on the connector will ﬂash. The

display will show the set temperature and

3. Enter tip ID as follows:

Insert the tip ID end of the tip into the pro-

cess gate until the buzzer sounds ONCE.

Tip ID data are displayed for one second.

The display then shows . The LED

indicator will stop flashing, indicating that

the data are now stored. Once the tip is

inserted into the connector, heat control

begins.

4. When the set temperature is reached, the

buzzer sounds and the heater lamp at the

lower right of the temperature display starts

blinking.

When a tip ID has been entered, or when a tip

is inserted into the FM-2027, the following pro-

cedure obtains:

1. Turn the switch ON.

2. The display will show the initial temperature

setting.

3. Heat control begins.

Tip ID displayed.

Set temperature displayed.

Turn the switch

ON.

Heat control begins.

Tip

inserted

Enter tip ID.

Insert tip

Set temperature.

Example:

700 to 840°F

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 de-

sired value. When the desired value is

displayed, press the button to enter.

The desired temperature is now entered

into the system memory and heater con-

trol 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 sol-

dering 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

 Replacing the tip

Removing the tip:

• Holding down the lock release buttons in

the sleeve assembly, pull out the tip to-

gether with the sleeve assembly from the

connector.

CAUTION:

• Be sure to keep the lock release buttons held down

while pulling out the sleeve accembly. Failure to do

so will damage the locking mechanism.

• Be sure to pull out the tip only after separating the

sleeve assembly from the connector. Otherwise, the

sleeve assembly may fall down and break.

• Holding the front end of the sleeve as-

sembly, pull out the tip.

Inserting the tip:

• Holding the front end of the tip, insert it

into the sleeve assembly.

CAUTION:

Insert the tip into the sleeve assembly until it clicks

into place. When you hear it cliks, avoid forcing the

tip into the sleeve assembly.

• Insert the “ID” end of the tip into the pro-

cess gate until the buzzer sounds so that

the tip ID can be read out.

• Insert the tip securely into the connector.

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 dis-

played, then the hundreds digit will begin to

ﬂash. This indicates that the station has en-

tered 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.

NOTE:

Improper insertion of the tip will cause to ap-

pear on the display.

CAUTION:

The tip may be hot. Avoid holding the hot tip for a long time even if using the heat-resistant pad. Otherwise burns may

result.

Remove the tip from the connector while pressing these

parts.

Hold the front part of the sleeve assembly to remove the

tip.

Hold this part to insert the tip into the sleeve assembly.

Hold this part to insert the tip into the connector.

CAUTION:

When holding the head of the tip, there is a danger of

burn. Be sure to use the heat-resistant pad.

7. TIP IDENTIFICATION NUMBER

 Entering the Tip ID

How to read out the bar code of

the tip into the FM-202:

1. Insert the tip (connector side) into the pro-

cess gate in the front of the station.

2. Insert the tip until the buzzer sound once.

The display shows . The LED indi-

cator will stop ﬂashing. Now the tip identi-

ﬁcation 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 proce-

dure 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-2027, the process gate cannot

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

the tip is already in the FM-2027, buzzer will sound irregular-

ity. Remove the tip from the FM-2027 for reading the Tip ID.

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