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

1
Heat resistant pad
Iron holde
Power cord
FM-202
Soldering station
Control card
Card chain
Tip tray
ON
OFF
Tip (not included)
FM-2027
Connector assembly
Sleeve assembly
ON
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.

2
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.
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.
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
ON
OFF
Fuse
Power
receptacle
Process gate
FM-2027
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 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.
5

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.
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 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
?
XX
Enter tip ID.
Insert tip
Y
N
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.
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

 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.
8
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
9
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.