Hakko Electronics FR-803 User manual

SMD Rework Station with Vacuum Pickup
Instruction Manual
●
Thank you for purchasing the HAKKO FR-803 SMD Rework Station.
This unit features:
● Digital control and display of time and temperature
● Display of air-flow rate
● Manual and automatic modes
● Built-in vacuum pickup
Please read this manual before operating the HAKKO FR-803.
Keep this manual readily accessible for reference.
●
TABLE OF CONTENTS
1. PACKING LIST ………………………………………… 1
2. SPECIFICATIONS ……………………………………… 1
3. WARNINGS, CAUTIONS, AND NOTES …………… 2
4. PART NAMES …………………………………………… 3
5. PREPARATION: ASSEMBLY AND ELECTRICAL CONNECTION …… 5
6. OPERATION …………………………………………… 8
7. PARAMETERS ……………………………………… 17
8. OFFSET SETTING METHOD ……………………… 18
9. MAINTENANCE / INSPECTION …………………… 19
10. ERRO MESSAGE ………………………………… 20
11. TROUBLESHOOTING …………………………… 20
12. OPTINAL PARTS …………………………………… 21
13. PARTS LIST / STATION …………………………… 23
13. PARTS LIST / HANDPIECE ……………………… 25
14. WIRING DIAGRAM ………………………………… 26
®

1
1. PACKING LIST
HAKKO FR-803 station ........................................... 1
Power cord .............................................................. 1
Handpiece holder .................................................... 1
Pads (ø3 mm (0.12 in.), ø5 mm (0.20 in.), ø7.6 mm (0.3 in.)) .....2 each
Vacuum pipe control knob (L) .................................. 1
Control card ............................................................. 1
Instruction manual ................................................... 1
* This product does not include a nozzle. A large
selection of nozzles are available for the HAKKO
FR-803. Select the nozzle or nozzles suitable for
the work to be performed.
Check the contents of the Hakko 852 package and
confirm that all the items listed below are included.
Control card
HAKKO FR-803 station
Handpiece holder
2. SPECIFICATIONS
Name HAKKO FR-803
Power consumption 100V-310W 110V-370W 120V-440W
220V-590W 230V-650W 240V-700W
● Station
Power consumption 100V 30 W
110-120V 40W
220-240V 50W
(Standby, 100-120V 4W, 220-240V 4W)
Capacity 5 l/min to more than 20 l/min
Control temperature 100 ~ 450°C/200 ~ 840°F (sensor)
Modes Manual/Auto
Timer 3 file/step
External dimensions 160 (W) × 145 (H) × 230 (D) mm/
6.3 × 5.7 × 9.1 in.
Weight 5 kg (11.02 lb.)
● Handpiece
Power
consumption
100V-280W 110V-330W 120V-400W
220V-540W 230V-600W 240V-650W
Total length
(w/o cord)
200mm/7.9 in.
Weight (w/o
cord)
200 g/0.44 lb.
* This product is protected against electrostatic discharge.
* Specifications and design are subject to change without
notice.
2 for each pad
Power cord
Vacuum pipe control
knob (L)

2
3. WARNINGS, CAUTIONS, AND NOTES
WARNING
Warnings and cautions 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.
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.
WARNING
To avoid damage to the unit, do not turn the power switch OFF until the pump stops automatically
by cooling down (until appears on the display) after use.
CAUTION
When the power is ON, the temperature of the hot air and the nozzle ranges from 100 to 450°C. (200
to 840°F.). To avoid injury to personnel or damage to items in the work area, observe the following:
● Do not direct the hot air toward personnel or touch the metal parts near the nozzle.
● Do not use the product near combustible gases or flammable materials.
● Advise those in the work area that the unit can reach very high temperatures and should be considered
potentially dangerous.
●
Turn the power OFF when no longer using the HAKKO FR-803 or when leaving it unattended.
● Before replacing parts or storing the unit, allow the unit to cool and then turn the power OFF.
Observe the following precautions to prevent accidents or damage to the unit.
● Do not strike the handpiece against hard surface or otherwise subject it to physical shock.
● Be sure the unit is grounded. Always connect power to a grounded receptacle.
● Do not disassemble the pump or the vacuum pump.
● Do not modify the unit.
● Use only genuine HAKKO replacement parts.
● Do not wet the unit or use the unit with wet hands.
● Remove power cord by holding the plug – not the wires.
● Do not leave the vacuum pump on for long periods of time.
● Make sure the work area is well ventilated.
● While using the HAKKO FR-803, donʼt do anything which may cause bodily harm or physical damage.

3
4. PART NAMES
Station
Handpiece
Handpiece holder
Fuse ⑩Power switch
Power receptacle
Slot for control
card
Handpiece holder
mounting screw
③Airflow meter
①File number display ②Temperature/Timer display
Handpiece holder
mounting screw
④Display steps
⑤Airflow control knob
⑥Mode selecting button
⑧Vacuum indicator
③Sensor (internal)
②Vacuum pipe
Nozzle
(not included)
①Pad
⑤Vacuum pipe control knob
④Hot air button ⑥Vacuum button
⑦AUTO, MANUAL indicator
⑨Settingbuttons

4
Station
① File number display
② Temperature/timer display
③ Airflow meter
④ Display steps
⑤ Airflow control knob
⑥ Mode selection button
⑦ AUTO/MANUAL indicator
⑧ Vacuum indicator
⑨ Setting button
⑩ Power switch
Handpiece
① Pad
② Vacuum pipe
③ Sensor (internal)
④ Hot air button
⑤ Vacuum pipe control knob
⑥ Vacuum button
This section displays files 1 to 3 in Auto mode.
This section displays a temperature and timer setting time for each
step in AUTO mode.
CAUTION
The displayed and set temperature indicates the temperatures at the
sensor.
This meter indicates the airflow rate.
This section will be lit during every step in AUTO mode.
This knob controls the airflow. The airflow can be set in the range
of 5 to 20 l/min.
This button displays and selects the MANUAL and AUTO modes.
This indicator lights the selected mode.
This indicator lights when the vacuum pump is in operation.
Use this button for setting, determining and checking the file
number, temperature, timer, etc.
This switch turns the power ON and OFF.
The pad absorbs parts.
The pad is mounted on the tip of the vacuum pipe.
This sensor detects the temperature of the hot air.
● MANUAL Mode
When the Start button is pressed, the unit begins blowing hot
air. When the Start button is pressed again, the unit begins
cooling and stops blowing hot air after reaching 100°C (200°F).
● AUTO Mode
When the Start button is pressed again, the selected AUTO
program begins.
This knob controls the length of the vacuum pipe.
This button turns the vacuum pump ON and OFF.

5
5. PREPARATION: ASSEMBLY AND ELECTRICAL CONNECTION
A. Station Assembly
● Attach the handpiece holder.
Remove the handpiece holder mounting
screw from the side of the station. Attach the
handpiece holder to the station. (Figure 1)
(The handpiece holder can be installed on
either the left or right side.)
B. Handpiece Assembly
NOTE:
The handpiece can be used with the provided vacuum
pipe control knob (L). (See figure 2.)
● Using vacuum function operative nozzle
(see page 21.)
1. Attach the nozzle.
a. Extend the vacuum pipe using the
vacuum pipe control knob. (Figure 3)
b. Remove the inside screw (M3 × 5) of the
nozzle. (Figure 4)
c. Loosen the nozzle mounting screw. Pass
the vacuum pipe through the nozzle hole
and attach the nozzle. (Figure 5)
d. Tighten the nozzle mounting screw.
2. Attach the pad.
a. Attach the pad. (Figure 7)
b. Adjust the pad to an appropriate position.
Adjust the vacuum pipe so that the pipe
and pad protrude as little as possible.
CAUTION
The nozzle and pad will be heated at high
temperature. Cool them before replacement.
CAUTION
● Vacuum pipe
Do not use excessive force.
When not using a nozzle, retract the vacuum pipe
to the shortest length. (Figure 6)
(Figure 1)
M3 × 5
(Figure 4)
(Figure2)
(Figure 3) (Figure 5)
(Figure 6)
(Figure 7)
Mounting screw
CAUTION
● Pad
The pad does not last indefinitely. When it becomes
deteriorated, replace it. Since exposure to high
temperatures causes it to deteriorate faster, Hakko
recommends it be cooled after use.

6
Power receptacle
Power cord
Handpiece holder
Power switch
● Using vacuum function inoperative nozzle
(see page 22.)
■ Attach the nozzle.
a. Retract the vacuum pipe to the shortest
length using the vacuum pipe control
knob. (See page 5, Figure 6)
b. Loosen the nozzle mounting screw.
Attach the nozzle. (See page 5, Figure 5)
c. Tighten the nozzle mounting screw.
CAUTION
The pad cannot be used with this type of nozzle.
C. Electrical Connection and Power ON
1. Connect the power cord to the power
receptacle on the back panel of the station.
(Figure 8)
2. Place the handpiece on the holder. (Figure 9)
3. Plug the power cord into a grounded wall
socket.
4. Turn the power switch ON.
(Figure 9) Top View
(Figure 8)
CAUTION
This product is ESD-protected. Be sure to use a
grounded wall socket.
CAUTION
When not in use, place the
handpiece on the holder.

7
6. OPERATION
A. Mode Selection
Insert the control card into the card slot and select
your desired mode using the mode selection button.
(Figure 10)
The HAKKO FR-803 provides the following two
modes. The AUTO mode consists of the INSTALL
and REMOVE modes.
● Manual Mode
In this mode, air and vacuum pump operation
are controlled entirely by manual operation.
NOTE:
The timer cannot be set when using MANUAL mode.
● AUTO mode
● Install Mode (AUTO) (See page 14.)
This mode is used when installing parts.
The vacuum pump will be automatically
turned OFF.
● Remove Mode (AUTO) (See page 13.)
This mode is used when removing parts.
The vacuum pump will be automatically
turned ON.
In INSTALL mode, turn ON the vacuum function
manually and align the component on the PWB.
Vacuum function automatically will turn OFF 5
seconds after starting selected the profile.
In REMOVE mode, the vacuum function automati-
cally turns ON during the last 10 seconds of the
selected profile.
Set the temperature profile shown in the following
figure in advance.
(Figure 10)
Step 1 Step 2 Step 3 Cool down
Air temperature
Timing when the vacuum pump is
turned OFF in INSTALL mode
Start
Time
Temperatue
is increasing.
Temperature
is stable.
Temperature
is stable.
Temperature
is decreasing.
When the tempera-
ture falls to 100°C
(200°F), the air stops
blowing automati-
cally.
Opend timer time
Closed timer time
Temperatue
is increasing.
10 seconds
Timing when the vacuum pump is
turned ON in REMOVE mode
5 seconds
* In REMOVE mode, turn OFF the vacuum pump manually.
Temperatue
is increasing.
Temperature
is stable.

8
6. OPERATION
HOT AIR button
VACUUM button
B. Selecting Manual Mode
The temperature/timer is displayed by .
The HAKKO FR-803 is preset at 300°C at the
factory, see page 9.
● Air Blow
1. Start
Press the HOT AIR button on the hand-
piece to start the flow of air. The hot air
blows from the tip of the nozzle, and the
temperature is controlled according to the
temperature setting.
2. Stop
Press the HOT AIR button again.
Power to the heater is shut off and cooling
begins. When the temperature falls to 100
°C. (200°F.), the air stops blowing and the
temperature display reads .
● Vacuum Function
This function is used to hold the component
securely to the pads.
1. Start
Press the Vacuum button on the hand-
piece. The vacuum pump turns ON and
the part is held by suction.
2. Stop
Press and hold the Vacuum button. The
vacuum pump turns OFF.
CAUTION
To avoid damage to the equipment, do not turn the
power switch OFF until appears on the
display.
CAUTION
Parts held by the pads are very hot. Be careful when
removing them from the pads.
To check the set temperature,
press the button .

9
6. OPERATION
C.Temperature change method in
MANUAL mode
CAUTION
Be sure to insert the control card into the card slot and
set the mode to MANUAL before changing.
Setting change in temperature
CAUTION
The temperature setting range is 100 to 450°C (200 to
840°F).
Example: Change the temperature setting from
300 to 450°C.
1. Press the button on the temperature
setting section for 1 sec. or more.
● The HUNDREDS digit flashes on the
display, indicating that the HUNDREDS digit
can be entered.
2. Enter the HUNDREDS digit.
● Use the or buttons to select your
desired value for the HUNDREDS digit.
When your desired value is displayed, press
the button. The TENS digit begins to
flash.
3. Enter TENS digit.
● Use the or buttons to select your
desired value for the TENS digit. When
your desired value is displayed, press the
button. The UNITS digit begins to flash.
4. Enter the UNITS digit.
● Select your desired value for the UNITS
digit in the same manner as for the TENS
digit. When your desired value is displayed,
press the button. displays
and indicates that the temperature setting
procedure is completed.
CAUTION
If the power is turned OFF before the temperature set-
ting procedure is completed ( is not displayed),
the new setting value will not be stored in memory.
Press the or button.
Press the button once.
Press and hold the but-
ton for more than 1 second.
Press the or button.
Press the button once
Press the button once
● Attempting to enter a value outside the setting
range will cause the display to begin flashing the
HUNDREDS digit again. Reenter a correct value.
● Both the display temperature and the tempera-
ture setting are the temperature at the sensor.
(Even with the same temperature setting, the
temperature of the hot air differs depending on
the nozzle size.)