Hakko Electronics FM-202 User manual

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^HAK<^
SOLDERINO STUTION
MODEL
FM-202
High-output, temperature controlled
soidering 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.
Piease 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 N AM ES.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. TIPSTYLES .20
14. APPENDIXA.22
15. WIRING DIAGRAM.23

1. PACKING LIST
FM-202 soldering station.
FM-2027 connector assembly
Sleeve assembly.
Power cord.
Control card, with chain
Heat resistant pad
Tip tray.
Iron holder.
Tip cleaner.
Instruction manual
Tips (not inciuded)
Control card
I ^
låj
s
d OPP
FM-202
Soldering station
Card Chain
Tip (not inciuded)
Iron holde
Power cord
Tip tray
Heat resistant pad
FM-2027
Connector assembly
Sleeve assembly
2. SPECIFICATIONS
» FM-202 solderlng station
Power Consumption 140 V
Temperature Range 200 -
Accuracv: ±10®C (±18®R
Temperature Accuracy
Temperature Stability
• Station
Output _
Dimensions
(W X H X D) _
Weight _
• Soldering Iron
Power Consumption
Tip to Ground Resistance
Tip to Ground Potential
Total Length (w/o cord)
Weight (w/o cord) _
Cord
140W
200 - 450^C (400 - 840°f)
±10°C (±18®F) of set temperature
See Rgure 1. _
±5®C (±9®F) at idle temperature
Set temperature
Stability: ±5®C {±9®Fl
24 V _
119x117x178 mm
(4.7 X 4.6 X 7.0 in)
2.7 kg (5.9 Ib.)
70 W (24 V) _
<2n _
<2 mV _
188 mm (7.4 in.) with 2.4D tip _
30 g (0.067 Ib./1.07 oz.)with 2.4D tip
1.2 m (4 ft) _
Time
Figur« 1. Temperature accuracy and stability.
NOTE:
This product is protected against electrostatic discharge.
Specifications and design are subject to change without notice.
■ Electrostatic Protection ____
This product inciudes such features as electrically eondudive plastic parts aiHf g rourxlitrg of the handpiece and
station as nneasures to protect the device to be soWered from the effects of stalle electricity. Be sure to observe
the following instructions: _. . ...
1 . The handle and other plastic parts are not Inaulalora, they ara c onduclWB. When tylacing parts or repairino.
take sufficient care nd 10 axpoaa Ilve elecWoal paiew^
2. Be sure to ground the unit durfng uaa.
i

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:
A 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.
A 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.
Tum 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.
A 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 hånds.
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.
2

4. PART NAMES
Control card
FM-202
Soidering station
Process gate
Receptacle
Card Chain
Tip cleaner
Tip (not inciuded)
Iron holder
Tip tray
Power
switch
Power
receptacle
Fuse
FM-2027
Connector
assembly
Sleeve assembly
Power cord
Heat resistant pad
5. INITIAL SETUP
A. Iron holder
1. Assemble as shown;
• Insert the holder assembly securely into
the Iron holder base.

2. Operation:
First, remove any excess soider 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.
B. Connector cord
Pass the connector cord through the hole in the
heat resistant pad.
C. Soldering station _
1. I nsert 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.
When the plug ciicks,
it is fully inserted.
Receptacle
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.

6. OPERATION
Controls and displays
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.
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
Tp 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.

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 I 0D\ (Tip ID number)
and the LED on the connector will flash. The
display will show the set temperature and
{EB-
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 IS~f I 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
Turn the switch
ON.
I
I
f
Set temperature displayed
icn
Ou
▼
Set temperature.
Heat control begins.
Enter tip ID.
Insert tip
EZS--
XX
NOTE:
The FM-202 is preset at 750®F. at the factory.
Check the temperature setting by pressing the o button.
The set temperature will be dispiayed for two seconds.
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.
^CAUnON:
Refrain from inserting foreign objects, the wrong end
of the tip, or Incompatible tips into the process gate.
Damage may result. __
• Factory settings
The FM-202 comes from the factory with the
following values preset:
Temoerature scale
cm
Fahrenheit
Auto power shutoff.
1 m
■ J V ■
disabled
Low temperature alarm setting
300'’F
Resetting the supervisor or
operator control setting
FTHl
Tip ID controlted
with inserting the
card.
Set temperature
TO
750^

Control card
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 funetion (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.
• Changing the temperature
setti ng
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 A 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.
button to enter. The tens
press the _
digit will begin to flash.
3. Entering the tens digit.
• Press the A or ▼ button to set the
desired value. Any value from 0 to 9
can be selected. When th
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.
ACAUTION:
The Control card must be inserted into the card slot in the
correct direction for data to be entered. _
\\y
100
Insert the card.
Tinn
ouu
^1^
Press the
or
button
I
T
Press the
button once
Press the A or
button
I
T
HO
Press the
button once.
'1^
Press the
button once,
I
▼
I
I
J
\l/
I
^1^
I
I
.J
>01
^1^
I
I
j
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.
7

button down for at least one
When the station is ON and the
controi card is in the station, the
data entry procedure is:
a. Hold the
second.
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.
Follow steps 1-4 on the preceeding page.
NOTE:
When the Q button is pressed for less than one second,
the current temperature setting is displayed.
Replacing the tip
ACAUTION:
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.
Removing the tip:
• Holding down the look 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 fali 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 untit it clicks
into place. When you hear it diks, 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.
NOTE:
Improper insertion of the tip will cause
pear on the display.
-t to ap-
Remove the tip from the connector while pressing these
parts. ^
tr
Hold the front part of the sleeve assembly to remove the
tip.
II
\
Hold this part to insert the tip into the sleeve assembly.
Hold this part to insert the tip into the connector.

7. TIP IDENTIFICATION NUMBER
• Entering the Tip ID
Tip ID Bar code
I
T7-D24 I1Y100CB3
ail
Part number
Serial number
AcaUTION:
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.
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 l5-f I 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. _ _
/jV^CAUTION:
Do not insert the tip opposite side or other incompatible tip.
ACAUTION:
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.