Hakko Electronics FM-202 User manual

®
High-output, temperature controlled
soldering station
Instruction Manual
●
Thank you for purchasing the MODEL 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 MODEL FM-202, make it applicable to a broad
range of soldering applications.
Please read this manual before operating the MODEL
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
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2006.4
MA01275JZ060425
15. WIRING DIAGRAM
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23
Copyright © 2005 HAKKO Corporation. All Rights Reserved.

22
1. Insert the card to unlock the system.
2. Press the button and hold for more
than one second.
● The station will go into Tip ID mode. The
tens place digit begins to flash. Refer to
the tip identification number marked on
the bar code sticker.
3. Entering a value in the tens place digit
● Using the or button, enter a value
in the tens place digit. When the entered
value is displayed, press the button.
The units digit begins to flash.
4. Entering a number in the units digit
● Perform the same steps used to enter the
value in the tens place digit. After entering
a number in the units digit, press the
button. The display shows will be
flashing. Now the Tip ID number has been
stored. The temperature will be controlled
using this Tip ID number.
How to enter the tip identification number into the MODEL FM-202:
NOTE:
When the button is pressed for less than one second,
the stored Tip ID number settings are displayed.
NOTE:
When tip is inserting the MODEL FM-2021 and changing
the Tip ID, no display but display the setting tem-
perature.
Example:
When the tip identification number is 07.
Press the button
for at least one second.
Press the or button.
Press the button once.
Press the button once.
14. APPENDIX A
1
Heat resistant pad
Iron holder
Power cord
MODEL FM-202
Soldering station
Control card
Card chain
Tip tray
ON
OFF
Tip (not included) MODEL FM-2021
Connector assembly
Sleeve assembly
1. PACKING LIST
MODEL FM-202 soldering station ................... 1
MODEL FM-2021 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

CAUTION
When power is ON, tip temperatures will be between 200 and 450°C. 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.
3. 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.
2
CAUTION
To prevent accidents or damage to the MODEL FM-202, be sure to observe the
following:
● Do not use the MODEL FM-202 for applications other than soldering.
● Do not allow the MODEL FM-202 to become wet, or use it with wet hands.
● Do not modify the MODEL 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.
0.5 1.6
ø3.2
5
T7-D32 SHAPE-3.2D Chisel
T7-D4 SHAPE-4D Chisel
0.5
8.5
ø4
1.2
8
7
T7-D52 SHAPE-5.2D Chisel
ø5.2
R0.2
9.5
T7-I SHAPE-I Sharp Conical
30°
3.5
R0.2
12
T7-J02 SHAPE-0.2RSB Bent
12.7
R0.2
T7-LI
7.5
30°
R0.2
9.3
T7-JL02 SHAPE-0.2RLB Bent
30°
1.6
R0.2
7.9
T7-JS02 SHAPE-0.2RSSB Bent
T7-K SHAPE-K Knife
2.4
45°
ø4.6
17
T7-KF SHAPE-KF Knife
1.5
ø4.7
45°
11
T7-KL SHAPE-KL Knife
1.2
ø3
45°
11
T7-KU SHAPE-KU Knife T7-LB SHAPE-LB Long Conical
12
R0.2
7.2
15.7
T7-1401
2
T7-1404
40 7.2
2
Unit:mm
45°
2
ø4.7
15
21

13. TIP STYLES
115
139
ø5.5
21
7.5
R0.2
T7-B SHAPE-B Conical
R0.5
10
T7-B2 SHAPE-0.5B Conical
45°
ø1
11.5
T7-BC1 SHAPE-1BC Bevel
1.1
ø1
45°
11.5
T7-BCF1 SHAPE-1BC Bevel
(Tinned on the soldering surface only)
1.1
ø2
45°
11.5
T7-BC2 SHAPE-2BC Bevel
2.1
45°
ø2
11.5
T7-BCF2 SHAPE-2BC Bevel
(Tinned on the soldering surface only)
2.1
ø3
45°
10
T7-BC3 SHAPE-3BC Bevel
3.3
10
45°
ø3
T7-BCF3 SHAPE-3BC Bevel
(Tinned on the soldering surface only)
3.3
60°
12
ø1
T７-C1 SHAPE-1C Bevel
1
45°
ø4
11.5
T7-C4 SHAPE-4C Bevel
45°
ø4
11.5
T7-CF4 SHAPE-4C Bevel
(Tinned on the soldering surface only)
0.5 3
9.5
ø0.8
T7-D08 SHAPE-0.8D Chisel
0.5
ø1.2
4.3
10
T7-D12 SHAPE-1.2D Chisel
0.5
ø1.6
3.5
10
T7-D16 SHAPE-1.6D Chisel
0.5
ø2.4
4.1
10
T7-D24 SHAPE-2.4D Chisel
Unit:mm
20
A. Iron holder
1. Assemble as shown:
Insert the holder assembly securely into
the Iron holder base.
4. PART NAMES
5. INITIAL SETUP
Heat resistant pad
Iron holder
Power cord
MODEL FM-202
Soldering station
Control card
Card chain
Tip tray
Power
switch
Receptacle
ON
OFF
Fuse
Power
receptacle
Process gate
MODEL FM-2021
Connector assembly
Tip (not included)
Sleeve assembly
Tip cleaner
3

B. Connector cord
Pass the connector cord through the hole in the
heat resistant pad.
4
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 MODEL 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.
FM-2025
24V-70W
3
2
4
5
3
2
6
4
5
7
1
Item No. Part No.

Part Name
Holder for
Specifications
• Iron Holder Parts
Item No.
~
Part No.
FH100-01
Part Name
Iron holder
Specifications
Item No. Part No.
FM2021-01
FM2021-02
B2770
B2765D
B2768C
B2769D
B2300
Part Name
Conversion kit
Connector assembly
Connector cover
Sleeve assembly
Sleeve assembly
Sleeve assembly
Tip
Heat resistant pad
Specifications
is yellow
Yellow
Orange
Blue
• Iron Holder
1
B3001
B2791
B2999
599B-02
599-029
B2756
Yellow/with screw
Blue/with rubber feet
B3000 iron receptacle
Iron receptacle
Retaining clip
Iron holder base
Tip cleaner
Cleaning wire
Tip tray
5
4
3
2
1
1
6
1
2
3
7
6
5
4
3
1 3
5
, ,
See section
'13. TIP STYLES'
19

2
1
3
4
4
8
9
10
7
5
6
75
5
Nut M2 (2)
Binding head screw
M2 x 16 (2)
Nut
M1.6 (2)
Pan head screw
M1.6 x 8 (2)
Tapping screw
Nominal size
3 x 8 (2)
Pan head screw
with spring washer
M3 x 6 (2)
Tapping screw
Nominal size 2.6 x 8 (3)
Tapping screw
Nominal size 
2.6 x 10 (4)
apping screw
External tooth
lock washer
Nominal size 4
Nut M3
(2)
Pan head screw
w/spring washer,
plain washer
M3 x 10 (2)
Pan head screw with
spring washer M4 x 6
Item
No.



Part No.
B2743
B2855
B2856
B2857
B2858
B2863
B2384
B2761
B2864
B1084
B2739
B2387
B2419
B2421
B2424
B2425
B2426
B2436
Part Name
Transformer
Transformer
Transformer
Transformer
Transformer
Transformer
Power receptacle
Fuse, 250V-3A
Fuse, 250V-1.6A
Power switch
Cover
Power cord, 3 wired cord & American plug
Power cord, 3 wired cord & American plug
Power cord, 3 wired cord but no plug
Power cord, 3 wired cord & European plug
Power cord, 3 wired cord & BS plug
Power cord, 3 wired cord & Australian plug
Power cord, 3 wired cord & Chinese plug
Specifications
120V
100V
110V
220V
230V
240V
100 - 120V
220 - 240V
100V
110 - 220V
220 - 230V
220V KTL,230V CE
230V CE
230 -240V
220V
10
11
12
13
14
15
18
Displays
The MODEL 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 ac-
ceptable range.
● When a foreign substance, an incompatible
tip, or the soldering end of the tip is inserted
into the MODEL 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 is inserted into the process
gate while the tip is already in the MODEL
FM-2021, buzzer will sound irregularly.
● When the tip is properly inserted into the con-
nector, the buzzer will sound once.
Controls and displays
6. OPERATION
Controls
The front panel of the MODEL FM-202 solder-
ing 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.
5

NOTE:
The MODEL FM-202 is preset at 350°C. at the factory.
Check the temperature setting by pressing the button.
The set temperature will be displayed for two seconds.
● Factory settings
The MODEL 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
Celsius
disabled
150°C

350°C
disabled
6
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 MODEL FM-2021,
the following 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 MODEL FM-2021, the
following procedure 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
?

XX
Enter tip ID.
Insert tip
Y
N
Set temperature.
*The MODEL FM-202 is preset at Tip ID mode at the factory.
12. PARTS LIST
14
11
12
13
15
Tapping screw
Nominal size
3 x 10 (3)
Pan head screw with
spring washer M4 x 6 (2)
External tooth 
lock washer
Nominal size 4 (2)
Pan head screw
w/spring washer, 
plain washer
M4 x 6 (4)
External
tooth
lock washer
Nominal
size 4
Spring washer
Nominal size 4 (2)
Pan head screw 
M4 x 55 (2)
Binding head screw
M3 x 6 (8)
 FM-202 Station
Item
No.



Part No.
B2749
B2741
B2742
B2869
B2870
B2871
B2915
Part Name
Control card
Front panel
Button set for control panel
P.W.B. (temperature setting,
display and process gate)
Process gate assembly
Process gate support
P.W.B. (temperature control 
and connector)
Chassis
Locking spacer 
Specifications
with control panel,
display window and slit
4 each
Set of 2
Set of 2
100 - 240V
2
1
3
4
5
8
7
9
B2740
B2757
with rubber feet
5 each
,6
6
NOTE:
Spare or repair parts do not include
mounting screws, if they are not
listed on the description. Screws
must be ordered separately.
17

● Tip ID error is dis-
played.
: Is the procedure of the entering tip identification number
correct?
: Entering correctly.
NOTE:
If reinsert the tip into the process gate and buzzer sounding three times. Try
to insert again or entering the Tip ID by hand operation.
● Heater terminal short
circuit error is dis-
played.
: Is the tip for MODEL FM-2021?
: Turn the power switch OFF and insert the genuine
MODEL FM-2021 tip. Turn the power switch ON.
NOTE:
This error does not display when not entering the Tip ID.
● The low-temperature
alarm tolerance error
occurs frequently.
: Is the tip too small for the items to be soldered?
: Use a tip with a larger thermal capacity.
:
Is the setting value for the low-temperature alarm tolerance
too low?
: Increase the setting value.
16
CHECK
CHECK
CHECK
CHECK
ACTION
ACTION
ACTION
ACTION
Example:
350 to 400°C
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 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 MODEL 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 en-
tered). Any MODEL FM-202 card can be used
with any MODEL 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.
7
Insert the card.
Press the or button.
Press the button once.
Press the button once.
Press the or button.
Press the button once.
● 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 sleeve as-
sembly 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: Before inserting the
tip; Insert the Tip ID shown the end of the
tip into the process gate until the buzzer
sounds once.
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.
Insert the new tip firmly into the connector.
(If the tip is not properly inserted, will
be displayed.)
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.
8
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.

11. TROUBLE SHOOTING GUIDE
WARNING:
● Before checking the inside of the MODEL FM-202 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.
: Is the power cord and/or the connection plug dis-
connected?
: Connect it.
CHECK : Is the fuse blown?
: Investigate why the fuse blew and then replace the fuse.
If the cause can not be determined, replace the fuse. If
the fuse blows again, send the unit in for repair.
● The tip does not heat up.
●
The sensor error is dis-
played.
CHECK : Is the tip inserted properly?
: Insert the tip completely.
CHECK : Is the connection cord and/or the heater/sensor broken?
: See the appropriate section of this manual regarding how
to check the connection cord and/or the heater/sensor for
breakage.
● Solder does not wet the
tip.
CHECK : Is the tip temperature too high?
: Set the appropriate temperature.
CHECK : Is the tip contaminated with oxide?
: Remove the oxide (see “Tip maintenance” on P. 12).
● The tip temperature is
too high.
CHECK : Is the connection cord broken?
: See “Checking the connection cord for breakage” on P. 13.
CHECK : Is the entered tip identification number correct?
: Enter the correct value.
● The tip temperature is
too low.
CHECK : Is the tip contaminated with oxide?
: Remove the oxide (see “Tip maintenance” on P. 12).
CHECK : Is the entered tip identification number correct?
: Enter the correct value.
● The soldering iron error
is displayed.
CHECK : Is the other soldering iron connected? Or the MODEL
FM-2021 plug disconnected?
: Connect the MODEL FM-2021 soldering iron.
15
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION

10. ERROR MESSAGES
● Sensor Error When there is the possibility that a failure has
occurred in the sensor or heater (including
the sensor circuit), is displayed and the
power is shut down.
NOTE:
The sensor error also occurs if the tip is not inserted
properly.
●
Low-temperature alarm
tolerance error
If the sensor temperature falls below the
difference between the current temperature
setting and the low-temperature alarm
tolerance, is displayed and the warning
buzzer sounds. When the tip temperature rises
to a value within the set tolerance, the buzzer
will stop sounding.
14
EXAMPLE:
Assume that the temperature setting is 400°C/750°F and
the tolerance 50°C/100°F. If the temperature continues to
decrease and finally falls below the value indicated below
while the heating element is on, the displayed value
starts blinking to indicate that the tip temperature has
dropped.
● Heater terminal short circuit
error
will flash, and the buzzer will sound
continuously, when the tip is inserted wrong
way round, an incompatible tip is inserted,
or a foreign object has found its way into the
connector.
EXAMPLE:
will flash, and the buzzer will sound three
times, if the process gate cannot read the Tip
ID.
will be displayed if Tip ID has not been
entered.
will be displayed if the connector cord
is not attached to the station OR the wrong
soldering iron is connected.
● Soldering iron error
350�C (400�C – 50�C) 



Low-temperature alarm tolerance
Set temperature

OR
650�F (750�F – 100�F) 



Low-temperature alarm tolerance
Set temperature

● Tip ID error
7. TIP IDENTIFICATION (TIP ID) NUMBER
● Entering the Tip ID number
9
How to read out the bar code of
the tip into the MODEL 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 bar code sticker of the
Tip ID number .
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 MODEL FM-202 processor incorporates
the ability to electronically compensate for tip
geometry variations using Tip IDs. Each MODEL
FM-202 tip shape has a specific Tip ID; whenever
a tip is changed, the Tip ID should be entered into
the MODEL FM-202 for most effective process
control.
There are two ways to enter Tip ID data into the
MODEL 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 MODEL 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 MODEL FM-2021, buzzer
will sound irregularity. Remove the tip from the MODEL
FM-2021 for reading the Tip ID.

8. PARAMETER SETTINGS
● Entering the parameters
The MODEL FM-202 has the following four
parameters:
1) °C or °F temperature display selection
2) Auto power shutoff
3) Low-temperature alarm tolerance setting
4) Supervisor or operator control setting
Once the station enters parameter mode, set the
parameters in the order shown below. Once all
the parameters have been set, normal operation
will be resumed.
(1) °C or °F temperature display 1. Turn power OFF.
2. Insert the control card into the card slot in the
front of the unit.
3. Press and hold down the button , and then
turn power ON.
4. The display will show the Tip ID for one
second. Hold the or button down until
the display shows (Celsius) or
(Fahrenheit).
When either of these are displayed, the station
is in parameter input mode.
● Pressing either the or button will
cause the display to alternate between
or .
● When the desired scale is displayed, select
by pressing the button. The system will
automatically sequence to auto power shutoff
mode.
(2) Auto power shutoff
This is an optional setting. When it is acti-
vated and the soldering iron is not used for
30 minutes, the power to the heating element
is shutoff automatically and the buzzer will
sound three times. When the temperature
decreases to 100°C/200°F the display will
show . To resume soldering, cycle the
power switch OFF, then ON. The power will
be turned on automatically if you hit any
button before the temperature decreases to
100°C/200°F.
To bypass this procedure and continue to
resetting the low temperature alarm tolerance
setting press the button once.
To change the auto power shutoff setting, the pro-
cedure is as follows.
● The display will show or when this
mode is entered.
● Using or button will change and
.
The autopower shutoff is operational only when
is selected.
● Press the button to enter the parameter.
This will store the setting in system memory and
the system will automatically sequence to the
low temperature alarm tolerance setting mode.
10
● 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
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 sen-
sor while at room temperature (15 to 25°C; 59
to 77°F). It should be 8Ω ±10%. If the resis-
tance exceeds these limits, replace the tip.
■ Check the grounding line 1. Unplug the connection cord from the station.
2. Measure the resistance value between Pin 2
and the tip.
3. If the value exceeds 2Ω (at room temperature),
perform the tip maintenance described on p.12.
If the value still does not decrease, check the
connection cord for breakage.
■ Checking the connection cord
for breakage
1. Remove the soldering tip and the sleeve as-
sembly.
2. Turn the front piece of the MODEL 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 0Ω or is , replace the
MODEL FM-2021.
■ Replacing the fuse 1. Unplug the power cord from the power recep-
tacle.
2. Remove the fuse holder.
3. Replace the fuse.
4. Put the fuse holder back in place.

  

1
4
7
2
8
5
6
3
13

9. MAINTENANCE
● Tip maintenance
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 MODEL FM-202 ensure
effective soldering at low temperatures.
2. Cleaning 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 MODEL FM-202) or use a clean and moist
cleaning sponge (part no.A1519). Contami-
nants on the tip have many deleterious effects,
including reduced heat conductivity, which
contribute to poor soldering performance.
3. After use Always clean the tip and coat it with fresh
solder after use. This guards against oxidation.
4. When the unit is not being used
and the auto power shutoff is not
active.
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.
5. Inspecting and cleaning the tip This procedure, if followed daily, will materially
add to tip life.
a. Set the temperature to 250°C (482°F).
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, con-
taining flux, and clean the tip again. Repeat
until all the oxide is removed, then coat the
tip with fresh solder.
d. Turn the power OFF and remove the tip, us-
ing the heat resistant pad. Set the tip aside
to cool.
e. Remaining oxides, such as the yellow dis-
coloration on the tip shaft, can be removed
with isopropyl alcohol.
CAUTION:
NEVER file the tip to remove oxides!
12
1. Tip temperature
(3) Resetting the low temperature
alarm tolerance setting
This unique function alerts the operator when
the sensed temperature drops below a set limit.
Should this occur, an error message
will be displayed, and the buzzer will sound
continuously. When the temperature returns
within the allowable range, the buzzer will stop.
The value is stored in the MODEL FM-202 as
described below:
To bypass this procedure, press the button
three times.
EXAMPLE:
If the set temperature is 350°C and the low temperature
alarm is 50°C, the alarm will trip when the sensed tem-
perature goes below 300°C.
NOTE:
The threshold limits are: 30 − 150°C; 60 − 300°F.
If a value outside these limits should be entered, the sys-
tem will revert to the beginning of the mode, the hundreds
digit will flash, and the procedure must be restarted.
Range of allowable low-temperature alarm
tolerance
For °C: 30 − 150°C
For °F: 60 − 300°F
1. When the station enters low-temperature
alarm tolerance setting mode, the hundreds
digit begun flashing. Enter and store the
value in the same manner as described on
page 7 “Changing the temperature setting.”
2. If you enter a value exceeding the allowable
range shown to the left, you will be brought
back to entering a value in the hundreds
digit. If this occurs, reenter a correct value.
3. Once the value is stored, the system will
automatically sequence to the resetting the
supervisor or operator control setting.
11
(4) Supervisor or operator control
setting
This mode allows control over the Tip ID data
entry to be assigned to a card-holder.
To change the control selection, proceed as
follows:
1. When the mode is entered, the display will
show or
: Tip ID cannot be entered without in-
serting the control card.
: Tip ID can be entered without insert-
ing the control card.
2. Pressing either the or button will
cause the display to alternate between
and .
3. When the desired setting is displayed, se-
lect by pressing button.
The system will exit the parameter setting
mode and begin heater control.
It is now ready for normal operation.
NOTE:
Whether the card is inserted or not, process gate works.

9. MAINTENANCE
● Tip maintenance
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 MODEL FM-202 ensure
effective soldering at low temperatures.
2. Cleaning 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 MODEL FM-202) or use a clean and moist
cleaning sponge (part no.A1519). Contami-
nants on the tip have many deleterious effects,
including reduced heat conductivity, which
contribute to poor soldering performance.
3. After use Always clean the tip and coat it with fresh
solder after use. This guards against oxidation.
4. When the unit is not being used
and the auto power shutoff is not
active.
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.
5. Inspecting and cleaning the tip This procedure, if followed daily, will materially
add to tip life.
a. Set the temperature to 250°C (482°F).
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, con-
taining flux, and clean the tip again. Repeat
until all the oxide is removed, then coat the
tip with fresh solder.
d. Turn the power OFF and remove the tip, us-
ing the heat resistant pad. Set the tip aside
to cool.
e. Remaining oxides, such as the yellow dis-
coloration on the tip shaft, can be removed
with isopropyl alcohol.
CAUTION:
NEVER file the tip to remove oxides!
12
1. Tip temperature
(3) Resetting the low temperature
alarm tolerance setting
This unique function alerts the operator when
the sensed temperature drops below a set limit.
Should this occur, an error message
will be displayed, and the buzzer will sound
continuously. When the temperature returns
within the allowable range, the buzzer will stop.
The value is stored in the MODEL FM-202 as
described below:
To bypass this procedure, press the button
three times.
EXAMPLE:
If the set temperature is 350°C and the low temperature
alarm is 50°C, the alarm will trip when the sensed tem-
perature goes below 300°C.
NOTE:
The threshold limits are: 30 − 150°C; 60 − 300°F.
If a value outside these limits should be entered, the sys-
tem will revert to the beginning of the mode, the hundreds
digit will flash, and the procedure must be restarted.
Range of allowable low-temperature alarm
tolerance
For °C: 30 − 150°C
For °F: 60 − 300°F
1. When the station enters low-temperature
alarm tolerance setting mode, the hundreds
digit begun flashing. Enter and store the
value in the same manner as described on
page 7 “Changing the temperature setting.”
2. If you enter a value exceeding the allowable
range shown to the left, you will be brought
back to entering a value in the hundreds
digit. If this occurs, reenter a correct value.
3. Once the value is stored, the system will
automatically sequence to the resetting the
supervisor or operator control setting.
11
(4) Supervisor or operator control
setting
This mode allows control over the Tip ID data
entry to be assigned to a card-holder.
To change the control selection, proceed as
follows:
1. When the mode is entered, the display will
show or
: Tip ID cannot be entered without in-
serting the control card.
: Tip ID can be entered without insert-
ing the control card.
2. Pressing either the or button will
cause the display to alternate between
and .
3. When the desired setting is displayed, se-
lect by pressing button.
The system will exit the parameter setting
mode and begin heater control.
It is now ready for normal operation.
NOTE:
Whether the card is inserted or not, process gate works.

8. PARAMETER SETTINGS
● Entering the parameters
The MODEL FM-202 has the following four
parameters:
1) °C or °F temperature display selection
2) Auto power shutoff
3) Low-temperature alarm tolerance setting
4) Supervisor or operator control setting
Once the station enters parameter mode, set the
parameters in the order shown below. Once all
the parameters have been set, normal operation
will be resumed.
(1) °C or °F temperature display 1. Turn power OFF.
2. Insert the control card into the card slot in the
front of the unit.
3. Press and hold down the button , and then
turn power ON.
4. The display will show the Tip ID for one
second. Hold the or button down until
the display shows (Celsius) or
(Fahrenheit).
When either of these are displayed, the station
is in parameter input mode.
● Pressing either the or button will
cause the display to alternate between
or .
● When the desired scale is displayed, select
by pressing the button. The system will
automatically sequence to auto power shutoff
mode.
(2) Auto power shutoff
This is an optional setting. When it is acti-
vated and the soldering iron is not used for
30 minutes, the power to the heating element
is shutoff automatically and the buzzer will
sound three times. When the temperature
decreases to 100°C/200°F the display will
show . To resume soldering, cycle the
power switch OFF, then ON. The power will
be turned on automatically if you hit any
button before the temperature decreases to
100°C/200°F.
To bypass this procedure and continue to
resetting the low temperature alarm tolerance
setting press the button once.
To change the auto power shutoff setting, the pro-
cedure is as follows.
● The display will show or when this
mode is entered.
● Using or button will change and
.
The autopower shutoff is operational only when
is selected.
● Press the button to enter the parameter.
This will store the setting in system memory and
the system will automatically sequence to the
low temperature alarm tolerance setting mode.
10
● 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
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 sen-
sor while at room temperature (15 to 25°C; 59
to 77°F). It should be 8Ω ±10%. If the resis-
tance exceeds these limits, replace the tip.
■ Check the grounding line 1. Unplug the connection cord from the station.
2. Measure the resistance value between Pin 2
and the tip.
3. If the value exceeds 2Ω (at room temperature),
perform the tip maintenance described on p.12.
If the value still does not decrease, check the
connection cord for breakage.
■ Checking the connection cord
for breakage
1. Remove the soldering tip and the sleeve as-
sembly.
2. Turn the front piece of the MODEL 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 0Ω or is , replace the
MODEL FM-2021.
■ Replacing the fuse 1. Unplug the power cord from the power recep-
tacle.
2. Remove the fuse holder.
3. Replace the fuse.
4. Put the fuse holder back in place.

  

1
4
7
2
8
5
6
3
13

10. ERROR MESSAGES
● Sensor Error When there is the possibility that a failure has
occurred in the sensor or heater (including
the sensor circuit), is displayed and the
power is shut down.
NOTE:
The sensor error also occurs if the tip is not inserted
properly.
●
Low-temperature alarm
tolerance error
If the sensor temperature falls below the
difference between the current temperature
setting and the low-temperature alarm
tolerance, is displayed and the warning
buzzer sounds. When the tip temperature rises
to a value within the set tolerance, the buzzer
will stop sounding.
14
EXAMPLE:
Assume that the temperature setting is 400°C/750°F and
the tolerance 50°C/100°F. If the temperature continues to
decrease and finally falls below the value indicated below
while the heating element is on, the displayed value
starts blinking to indicate that the tip temperature has
dropped.
● Heater terminal short circuit
error
will flash, and the buzzer will sound
continuously, when the tip is inserted wrong
way round, an incompatible tip is inserted,
or a foreign object has found its way into the
connector.
EXAMPLE:
will flash, and the buzzer will sound three
times, if the process gate cannot read the Tip
ID.
will be displayed if Tip ID has not been
entered.
will be displayed if the connector cord
is not attached to the station OR the wrong
soldering iron is connected.
● Soldering iron error
350�C (400�C – 50�C) 



Low-temperature alarm tolerance
Set temperature

OR
650�F (750�F – 100�F) 



Low-temperature alarm tolerance
Set temperature

● Tip ID error
7. TIP IDENTIFICATION (TIP ID) NUMBER
● Entering the Tip ID number
9
How to read out the bar code of
the tip into the MODEL 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 bar code sticker of the
Tip ID number .
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 MODEL FM-202 processor incorporates
the ability to electronically compensate for tip
geometry variations using Tip IDs. Each MODEL
FM-202 tip shape has a specific Tip ID; whenever
a tip is changed, the Tip ID should be entered into
the MODEL FM-202 for most effective process
control.
There are two ways to enter Tip ID data into the
MODEL 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 MODEL 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 MODEL FM-2021, buzzer
will sound irregularity. Remove the tip from the MODEL
FM-2021 for reading the Tip ID.

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 sleeve as-
sembly 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: Before inserting the
tip; Insert the Tip ID shown the end of the
tip into the process gate until the buzzer
sounds once.
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.
Insert the new tip firmly into the connector.
(If the tip is not properly inserted, will
be displayed.)
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.
8
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.

11. TROUBLE SHOOTING GUIDE
WARNING:
● Before checking the inside of the MODEL FM-202 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.
: Is the power cord and/or the connection plug dis-
connected?
: Connect it.
CHECK : Is the fuse blown?
: Investigate why the fuse blew and then replace the fuse.
If the cause can not be determined, replace the fuse. If
the fuse blows again, send the unit in for repair.
● The tip does not heat up.
●
The sensor error is dis-
played.
CHECK : Is the tip inserted properly?
: Insert the tip completely.
CHECK : Is the connection cord and/or the heater/sensor broken?
: See the appropriate section of this manual regarding how
to check the connection cord and/or the heater/sensor for
breakage.
● Solder does not wet the
tip.
CHECK : Is the tip temperature too high?
: Set the appropriate temperature.
CHECK : Is the tip contaminated with oxide?
: Remove the oxide (see “Tip maintenance” on P. 12).
● The tip temperature is
too high.
CHECK : Is the connection cord broken?
: See “Checking the connection cord for breakage” on P. 13.
CHECK : Is the entered tip identification number correct?
: Enter the correct value.
● The tip temperature is
too low.
CHECK : Is the tip contaminated with oxide?
: Remove the oxide (see “Tip maintenance” on P. 12).
CHECK : Is the entered tip identification number correct?
: Enter the correct value.
● The soldering iron error
is displayed.
CHECK : Is the other soldering iron connected? Or the MODEL
FM-2021 plug disconnected?
: Connect the MODEL FM-2021 soldering iron.
15
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
CHECK
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION
ACTION

● Tip ID error is dis-
played.
: Is the procedure of the entering tip identification number
correct?
: Entering correctly.
NOTE:
If reinsert the tip into the process gate and buzzer sounding three times. Try
to insert again or entering the Tip ID by hand operation.
● Heater terminal short
circuit error is dis-
played.
: Is the tip for MODEL FM-2021?
: Turn the power switch OFF and insert the genuine
MODEL FM-2021 tip. Turn the power switch ON.
NOTE:
This error does not display when not entering the Tip ID.
● The low-temperature
alarm tolerance error
occurs frequently.
: Is the tip too small for the items to be soldered?
: Use a tip with a larger thermal capacity.
:
Is the setting value for the low-temperature alarm tolerance
too low?
: Increase the setting value.
16
CHECK
CHECK
CHECK
CHECK
ACTION
ACTION
ACTION
ACTION
Example:
350 to 400°C
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 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 MODEL 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 en-
tered). Any MODEL FM-202 card can be used
with any MODEL 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.
7
Insert the card.
Press the or button.
Press the button once.
Press the button once.
Press the or button.
Press the button once.
● Changing the temperature
setting

NOTE:
The MODEL FM-202 is preset at 350°C. at the factory.
Check the temperature setting by pressing the button.
The set temperature will be displayed for two seconds.
● Factory settings
The MODEL 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
Celsius
disabled
150°C

350°C
disabled
6
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 MODEL FM-2021,
the following 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 MODEL FM-2021, the
following procedure 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
?

XX
Enter tip ID.
Insert tip
Y
N
Set temperature.
*The MODEL FM-202 is preset at Tip ID mode at the factory.
12. PARTS LIST
14
11
12
13
15
Tapping screw
Nominal size
3 x 10 (3)
Pan head screw with
spring washer M4 x 6 (2)
External tooth 
lock washer
Nominal size 4 (2)
Pan head screw
w/spring washer, 
plain washer
M4 x 6 (4)
External
tooth
lock washer
Nominal
size 4
Spring washer
Nominal size 4 (2)
Pan head screw 
M4 x 55 (2)
Binding head screw
M3 x 6 (8)
 FM-202 Station
Item
No.



Part No.
B2749
B2741
B2742
B2869
B2870
B2871
B2915
Part Name
Control card
Front panel
Button set for control panel
P.W.B. (temperature setting,
display and process gate)
Process gate assembly
Process gate support
P.W.B. (temperature control 
and connector)
Chassis
Locking spacer 
Specifications
with control panel,
display window and slit
4 each
Set of 2
Set of 2
100 - 240V
2
1
3
4
5
8
7
9
B2740
B2757
with rubber feet
5 each
,6
6
NOTE:
Spare or repair parts do not include
mounting screws, if they are not
listed on the description. Screws
must be ordered separately.
17

2
1
3
4
4
8
9
10
7
5
6
75
5
Nut M2 (2)
Binding head screw
M2 x 16 (2)
Nut
M1.6 (2)
Pan head screw
M1.6 x 8 (2)
Tapping screw
Nominal size
3 x 8 (2)
Pan head screw
with spring washer
M3 x 6 (2)
Tapping screw
Nominal size 2.6 x 8 (3)
Tapping screw
Nominal size 
2.6 x 10 (4)
apping screw
External tooth
lock washer
Nominal size 4
Nut M3
(2)
Pan head screw
w/spring washer,
plain washer
M3 x 10 (2)
Pan head screw with
spring washer M4 x 6
Item
No.



Part No.
B2743
B2855
B2856
B2857
B2858
B2863
B2384
B2761
B2864
B1084
B2739
B2387
B2419
B2421
B2424
B2425
B2426
B2436
Part Name
Transformer
Transformer
Transformer
Transformer
Transformer
Transformer
Power receptacle
Fuse, 250V-3A
Fuse, 250V-1.6A
Power switch
Cover
Power cord, 3 wired cord & American plug
Power cord, 3 wired cord & American plug
Power cord, 3 wired cord but no plug
Power cord, 3 wired cord & European plug
Power cord, 3 wired cord & BS plug
Power cord, 3 wired cord & Australian plug
Power cord, 3 wired cord & Chinese plug
Specifications
120V
100V
110V
220V
230V
240V
100 - 120V
220 - 240V
100V
110 - 220V
220 - 230V
220V KTL,230V CE
230V CE
230 -240V
220V
10
11
12
13
14
15
18
Displays
The MODEL 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 ac-
ceptable range.
● When a foreign substance, an incompatible
tip, or the soldering end of the tip is inserted
into the MODEL 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 is inserted into the process
gate while the tip is already in the MODEL
FM-2021, buzzer will sound irregularly.
● When the tip is properly inserted into the con-
nector, the buzzer will sound once.
Controls and displays
6. OPERATION
Controls
The front panel of the MODEL FM-202 solder-
ing 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.
5

B. Connector cord
Pass the connector cord through the hole in the
heat resistant pad.
4
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 MODEL 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.
FM-2025
24V-70W
3
2
4
5
3
2
6
4
5
7
1
Item No. Part No.

Part Name
Holder for
Specifications
• Iron Holder Parts
Item No.
~
Part No.
FH100-01
Part Name
Iron holder
Specifications
Item No. Part No.
FM2021-01
FM2021-02
B2770
B2765D
B2768C
B2769D
B2300
Part Name
Conversion kit
Connector assembly
Connector cover
Sleeve assembly
Sleeve assembly
Sleeve assembly
Tip
Heat resistant pad
Specifications
is yellow
Yellow
Orange
Blue
• Iron Holder
1
B3001
B2791
B2999
599B-02
599-029
B2756
Yellow/with screw
Blue/with rubber feet
B3000 iron receptacle
Iron receptacle
Retaining clip
Iron holder base
Tip cleaner
Cleaning wire
Tip tray
5
4
3
2
1
1
6
1
2
3
7
6
5
4
3
1 3
5
, ,
See section
'13. TIP STYLES'
19