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

1
Heat resistant pad
Iron holder
Cleaning
sponge
Power cord
FM-202
Soldering station
Control card
Card chain
Tip tray
ON
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
°
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
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
°
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

3. 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.
2
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.

1
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
ON
OFF
Fuse
Power receptacle
Process gate
Tip (not included) FM-2021 connector assembly
Sleeve
Sleeve stopper
3

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.
3
2
4
B. Connector cord
Pass the connector cord through the hole in the
heat resistant pad.
4
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.
5

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.
5

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.
6
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 ° 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
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.
7
Press the button once.
Insert the card.
Press the or button.
Press the button once.
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.
8
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
9
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.