Hakko Electronics HJ3100 User manual

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
1
- CONTENTS -
PAGE.
INTRODUCTION. 3.
CHARACTERISTICS AND SPECIFICATIONS. 4.
SAFETY. 5.
THEORY OF OPERATION. 7.
APPLICATIONS. 8.
INSTALLATION. 9.
SETTING UP THE HJ3100. 9.
OPTIONS. 10.
OPERATION. 15.
MAINTENANCE. 16.
TROUBLESHOOTING. 17.
WHERE TO GO FOR SERVICE. 19.
APPENDIX A. PARTS AND ACCESSORIES. 19.
APPENDIX B. TECHNICAL INFORMATION. 21.
OUTLINE DRAWINGS. 21.
WIRING DIAGRAMS. 22.
APPENDIX C. ACTIVATED CARBON. 23.
APPENDIX D. WARRANTY INFORMATION. 24.
ILLUSTRATIONS AND DIAGRAMS.
THE HAKKO HJ3100 FRONTISPIECE
FIGURE 1. THE HAKKO FILTER SYSTEM. 7.
FIGURE 2. REQUIRED CLEARANCES FOR INSTALLATION. 9.
FIGURE 3. BASIC HJ3100-02 INSTALLATION. 10.
FIGURE 4. 999-205 KIT INSTALLATION - LOC-LINE®ACCESSORIES. 11.
FIGURE 5. 999-206 KIT INSTALLATION - BENCH TOP HOODS. 12.
FIGURE 6. 999-207 KIT INSTALLATION - ALSIDENT®ACCESSORIES. 13.
FIGURE 7. TYPICAL INSTALLATION FOR FOUR-PORT COVER. 14.
FIGURE 8. ILLUSTRATED PARTS BREAKDOWN, HJ3100. 16.
FIGURE B-1. OUTLINE DRAWINGS. 21.
FIGURE B-2. WIRING DIAGRAMS. 22.
TABLES.
TABLE I. SPECIFICATIONS, GENERAL. 4.
TABLE II. SPECIFICATIONS, ENVIRONMENTAL. 4.
TABLE A-I. ACCESSORIES. 19-20.
TABLE A-II. ALSIDENT SYSTEM®1 ACCESSORIES. 20.
TABLE C. ACTIVATED CARBON. 23.
1A registered trademark of Alsident System AS, Hammel, Denmark. See figure 6 and table A-II.

©1997, AMERICAN HAKKO PRODUCTS, INC.
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2
AMERICAN HAKKO PRODUCTS,INC.RESERVE THE RIGHT TO CHANGE THE SPECIFICATIONS CONTAINED IN THIS
MANUAL AT THEIR DISCRETION AT ANY TIME,WITHOUT NOTICE.
For the latest specifications pertaining to the Hakko HJ3100, or any Hakko product, contact your nearest authorized
Hakko distributor, your regional Hakko manager, or American Hakko Products’ Customer Service.
Additional copies of this manual or other Hakko literature may be obtained from:
American Hakko Products, Inc.
Customer Service
25072, Anza Drive
Santa Clarita, California 91355
USA
Telephone: [phone] Toll free: [phone] Facsimile: [phone]
E-mail:
Customer Service: [email protected]
Technical: [email protected]
Marketing: [email protected]

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
3
INTRODUCTION.
Congratulations! You have purchased the most adaptableand efficient small fume extraction system on the market - the
Hakko HJ3100. To get the most out of your system, please read this manual thoroughly before installing and operating
the HJ3100. NOTE.
American Hakko Products strongly recommends that especial attention be
given the sections on ‘Safety and Applications’ and ‘Operation’.
THE PURPOSE OF FUME EXTRACTION.
Soldering work involves both metallic and organic compounds. The solders themselves contain, besides tin and lead,
various levels of zinc, arsenic, cadmium, antimony and other metals. Fluxes necessary for soldering contain activators to
enhance their cleaning properties; these activators are typically organic acids. Such compounds, when heated, release
byproducts of incomplete combustion, which in turn can contain noxious fumes, particulate matter, aerosols, and gasses.
Prolonged breathing of these contaminants can lead to both short- and long-term operator irritations and illness.
THIS MANUAL.
This manual provides the user with the basic information required to properly use and maintain the Hakko HJ3100 fume
extraction system. Spare parts and accessories are described in the Appendix.
THE HAKKO HJ3100.
The Hakko HJ3100 fume extraction unit is designed expressly for use at soldering stations. Itextracts the contaminated
air directly at the source. This contributes to a healthier and more productive work environment, and assistsinachieving
recommended health and safety requirements for local exhaust ventilation and contaminant removal.
Salient features of the Hakko HJ3100 include:
A heavy-duty, maintenance-free brushless motor adaptable to either 100/125 or 220/230VAC, 50/60 Hz
A three-stage HEPA filtering process
One to four station fume extraction capability
A wide range of accessories (see Appendix A)
Five versions of the Hakko HJ3100 are available:
The basic HJ3100, with pre-filter and HEPA/carbon filter only. This version is for 100/115VAC applications.
The HJ3100-01, an HJ3100 equipped with a 230VAC motor and supplied with two six- foot lengths of 3" neoprene
duct (999-186), two rectangular hoods (999-138) and two packets of hose clamps, two per packet (999-169).
The HJ3100-02, a basic HJ3100 supplied with two six- foot lengths of 3" neoprene duct (999-186), two rectangular
hoods (999-138) and two packets of hose clamps, two per packet (999-169).
The HJ3100-03, a basic HJ3100 equipped with a 230VAC motor
The HJ3100-04, a basic HJ3100 but fitted with the 999-182 carbon filter in lieu of the 999-137 HEPA/carbon filter.
This version is not to be used in flammable or explosive atmospheres, or for removing odors arising from the use of
flammable or explosive chemicals; Appendix C provides a list of common industrial chemicals against which an
activated carbon filter is effective.

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
4
CHARACTERISTICS AND SPECIFICATIONS.
CONTROLS.
The only control for the HJ3100 is a power switch. The motor is equipped with a thermal overload sensor, which will
turn power off should the motor temperature exceed 160 to 1800F. Units manufactured after August 15, 1997 (serial
numbers HJ3100-7001 and up) are fitted with circuit breakers as well.
TABLE I. TECHNICAL SUMMARY.
MOTOR AND BLOWER DATA.
HJ3100, -02, -04 HJ3100-01, -03
CHARACTERISTIC
@100 V. @115 V. 230 VX
INPUT VOLTAGE
100 V,50/60 HZ
115 V,50/60 HZ 230 V,50/60 HZ
CURRENT,AMPERES
4.25 3.0 1.50
POWER CONSUMPTION,WATTS
365 350 350
MOTOR POWER RATING,HP
1/5 1/5 1/5
VACUUM PUMP RATING,ONE PORT,FT3/MIN†@60 HZ
115 122 124
VACUUM PUMP RATING,TWO PORTS,FT3/MIN†
150 154 155
VACUUM PUMP RATING,TWO PORTS,FT3/MIN‡
190 202 202
VACUUM PUMP RATING,TWO PORTS,FT3/MIN♪
180 190 190
FREE STREAM AIR FLOW.WITH TWO PORT COVER
220 235 235
FREE STREAM AIR FLOW,WITH FOUR PORT COVER
260 280 280
†WITH PRE-FILTER AND 999-137 HEPA/CARBON FILTER INSTALLED.
‡WITH 999-178 PARTICULATE FILTER INSTALLED.
♪WITH PRE-FILTER AND 999-182 CARBON FILTER INSTALLED.
XFASCO 70624794, REVNA
Noise level at 2 meters (HJ3100, -01, -02):59 dBA without optional 999-171 muffler
54 dBA with optional 999-171 muffler
Filters:
Pre-filter Per Hakko specification 999-136
HEPA/carbon filter Per Hakko drawing 999-137
Particulate filter Per Hakko drawing 999-178
Carbon filter Per Hakko drawing 999-182
Dimensions (all dimensions in inches; see Figure B-1 for outline drawings):
Width 11.00
Depth 9.00
Height 18.00
Weight (approx.) including filters 18 lbs.
TABLE II. ENVIRONMENTAL SPECIFICATIONS.
AMBIENT OPERATING TEMPERATURE
0OTO 50OC(32OTO 122OF.)
STORAGE TEMPERATURE
-40OTO 125OC(-40OTO 257OF.)
AMBIENT OPERATING HUMIDITY
90% RELATIVE HUMIDITY MAXIMUM (NON-CONDENSING)
STORAGE HUMIDITY
90% RELATIVE HUMIDITY MAXIMUM (NON-CONDENSING)

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
5
SAFETY.
For maximumoperator and workplace safety, as well as optimum performance, be sure to follow all safety, application
and maintenance instructions and guidelines in this manual. Where material safety data sheets or other relevant
information is available regarding the substances and equipment generating the fumes to be extracted, read them
carefully and compare the data contained therein with the warnings and limitations in this manual.
DISCLAIMER.
American Hakko Products hereby disclaims all responsibility for any personal
injury, property damage, fine, citation, or penalty imposed by any government or
private entity resulting from any use, misuse or misapplication of this product; for
any failure of the user to regularly maintain the product according to the
instructions contained herein; or any failure of the user to adequately monitor fume
extraction exhaust air and the ambient workplace air for the presence of harmful
levels of gases, fumes and particulates.
COMPLIANCE WITH APPLICABLE ENVIRONMENTAL AND PERSONNEL SAFETY
REGULATIONS IS THE SOLE RESPONSIBILITY OF THE USER.
WARNING.
FAILURE TO COMPLY WITH THE APPLICATION AND MAINTENANCE INSTRUCTIONS,
FILTER REPLACEMENT SCHEDULES,MONITORING RECOMMENDATIONS AND SAFETY
GUIDELINES GIVEN IN THIS MANUAL,OR WITH OTHER RELEVANT PRODUCT SAFETY
INFORMATION SUCH AS MATERIAL SAFETY DATA SHEETS PROVIDED WITH THE
SUBSTANCES AND EQUIPMENT GENERATING THE FUMES TO BE EXTRACTED MAY
RESULT IN RISK OF SERIOUS INJURY,FIRE OR EXPLOSION.
SAFETY GUIDELINES.
WARNING
Fume extraction systems are not to be used as substitutes for personal protective
devices such as respirators for removing substances such as carbon monoxide,
methane, ethylene, acetylene and other potentially hazardous or noxious gases.
Failure to use such personal protective devices may result in serious injury or death.
If in doubt, consult your industrial hygienist or American Hakko Products.
For safe and effective performance, American Hakko recommends these guidelines be followed:
1. HEPA filters - hazardous particulate matter
The 999-137 filter used in the Hakko HJ3100 is certified to be a 'hospital grade' HEPA-type filter2. HEPA (High
Efficiency Particulate Air) filters will become loaded with particulates during normal operation. It must be replaced at
regular intervals to ensure proper operation. The level of use, and the amount and composition of the contaminates
peculiar to a given application, will dictate the frequency of replacement. As the filter becomes loaded, air-flow through
the system will be reduced; this will eventually become noticeable to operators at the several stations being serviced.
The exhaust air from the Hakko HJ3100 and the ambient air in the workplace should be monitored, using appropriate and
adequate measuring and detection devices, to guarantee compliance with applicable OSHA and NIOSH regulations.
2Hospital grade filters have efficiencies greater than 95% per MIL-STD-282.

©1997, AMERICAN HAKKO PRODUCTS, INC.
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6
2. Particle filters.
American Hakko offers the 999-178 cellulose particle filter as an option for the HJ3100. This filter is intended foruse in
grinding and shaping operations where dust and chips are produced. It is rated at 85% ASHRAE against particles of 1
micron and larger in size. The particle filter can be cleaned and reused up to five times; the preferred method of cleaning
is to vacuum out the detritus with an industrial vacuumcleaner. It is possible to clean the filter with water orcompressed
air. If that is the method of choice, take extreme care lest the debris find its way into the operator's eyes or the local
aquifer.
2. Activated carbon filters.
The standard filter used in the Hakko HJ3100 contains an activated carbon element built into the filter. It, too, will
become saturated with adsorbed contaminants. The activated carbon portion of the main filter unit is designed tolastthe
life of the main HEPA filter; however, if the fumes being extracted are other than soldering flux fumes, measuring the
exhaust air for the presence of such contaminants will indicate when this portion of the filter is depleted.
Hakko also offers an activated carbon filter, part number 999-182, for applications where odor removal is the prime
consideration; this is the primary filter in the HJ3100-04. This filter should be used with a pre-filter, to keep particles out
of the main filter. Refer to Appendix C.
Both carbon filters have an adsorption rating of 80-85%.
3. Pre-filters.
The pre-filter is a treated fiberglass pad, rated at 86% arrestance. It removes coarse particles fromthe intake air. Because
it traps these particles before they can reach the main HEPA/carbon filter, it will become clogged far more rapidly. It will
require more frequent replacement than will the main filter; its useful life depends upon use and the nature of
contaminants being removed.
4. Flammable vapors and gases.
If flammable vapors or gases (e. g. isopropyl alcohol used for cleaning) are present in the workplace air, even in small
concentrations, they will be adsorbed by the filters. The user has the responsibility of ensuring that such vapors orgases
do not constitute a personnel hazard.
-DANGER!-
NEVER USE THE HAKKO HJ3100 TO EXTRACT FUMES FROM HIGHLY FLAMMABLE LIQUIDS AND GASES!
THERE IS A SERIOUS RISK OF SEVERE INJURY OR DEATH DUE TO EXPLOSION OR FIRE.
Certain airborne contaminants, when in contact with activated carbon, can undergo chemical reactions resulting in
heat. The Hakko HJ3100 MUST NOT be used to extract fumes from these substances.
5. Disposing of used filters.
All used filters must be handled with care. They may contain hazardous substances such as lead, flux residue, asbestos,
organic compounds, or airborne pollutants extracted from the ambient air. Always use appropriate personal protection
equipment (protective gloves, respirators, and the like) when handling used filters, and dispose of them in plastic
containment bags. Local regulations will dictate the means of disposal.
Filters containing potentially hazardous substances must be handled with extreme caution. Use the material safety data
sheet(s) pertinent to the substance(s) and dispose of such filters per instructions fromyour local environmental authority.

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
7
THEORY OF OPERATION.
The HJ3100 is a high-mass flow, low-vacuumsystem, which means that it depends upon air flow across the work area for
effective fume extraction. Contaminated air is captured from the workplace surrounding the soldering station by the hood
or hoods, and transferred to the HJ3100 by flexible or rigid ducts. Within the HJ3100, two filters, comprising three stages
of filtering, remove the contaminants from the air. The purified air is then returned to the area where the HJ3100 is
located.
Because the HJ3100 depends upon mass flow for its operation, free flow of air must be guaranteed between the station
where fumes are to be extracted and the main filter unit. The maximumlength of flexible ductrecommendedfor greatest
efficiency is 25 feet of unimpeded 3" duct. The maximum length of rigid duct is not significant, as this duct does not
materially restrict air flow.
FILTERING.
There are three stages of filtering (Figure 1, below, illustrates the Hakko filtering process):
¾The pre-filter is made of a treated polyester material. It removes coarse particles, such as dust, that may be
suspended in the air, and thus extends the service life of the HEPA filter. Particles as small as 30 microns diameter
are trapped by the pre-filter. It should be checked at least once a week, and replaced when clogged. Under normal
conditions3this will be every two to three weeks.
¾The main HEPA/carbon filter purifies the air in two ways:
•The HEPA filter is a special case of a particulate filter. It incorporates a pleated fiberglass paper medium, thus
providing the greatest amount of surface area within the volume of the filter case. It is rated as a 'hospital grade
HEPA filter' - greater than 98% efficiency per the DOP test - and removes particles as small as 0.3 micron.
•The activated carbon filter adsorbs gases and odors from the filtered air. Adsorption efficiency is 80%.
•The main filter should be changed every four months or 640 hours of use, whichever comes first.
¾The carbon filter adsorbs gases and odors from the filtered air at an adsorption efficiency of 84%. It has a much
larger surface area than the carbon portion of the standard HEPA/carbon filter, hence a longer life. It should
always be used with a pre-filter to preclude being clogged by particulate matter.
¾The particulate filter removes particles of 1 micron diameter and larger from the air. See page 5.
3 Normal conditions’ - Defined as single-shift operation, eight hours per day, five days per week.
Figure 1a. Figure 1b. Figure 1c.
The standard Hakko filter. The Hakko activated carbon filter. The Hakko particulate filter.
incoming
air
exhaust
air
HEPA/carbon
activated
pre-filter
filter
carbon
incoming
air
pre-filter
cellulose
exhaust
air
(optional)
filter
incoming
air
exhaust
air
carbon
pre-filter
activated
filter

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
8
APPLICATIONS.
SOLDERING STATION FUME EXTRACTION.
The Hakko HJ3100 is specially engineered to remove particulate and gaseous contaminants from soldering work stations.
As many as four stations may be serviced by one HJ3100, depending upon the accessories selected. The HJ3100 is a
high-mass flow, low-vacuum system, which means that it uses air flow across the work area for effective fume
extraction. The user may choose from the following options, or mix them at need:
Bench hoods (‘plenums’) for work on printed circuit boards. Both large and small hoods are available.
Supported or free-standing hoods and nozzles for solder pots or small flow systems. These devices may be mounted on
either stiff or flexible ducting. Several types of support hardware and ducting are offered.
Articulated arms for work where flexibility is desired.
Refer to the section on ‘Setup’ for some typical layouts. Appendix A contains descriptions of the accessories available
for different applications.
PARTICULATE EXTRACTION FROM MACHINING OPERATIONS.
The Hakko HJ3100, in conjunction with the 999-178 filter,can beused to remove fine particles and dust from machining
and grinding operations, provided that these particles and dust do not contain, or are not coated by, flammable or
corrosive materials. The pre-filter must be checked more frequently when the HJ3100 is so used with a standard
HEPA/carbon filter.

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
9
INSTALLATION.
SETTING UP THE HJ3100.
These installation instructions and descriptions are perforce general, because no two installations are the same. The
sample descriptions and diagrams that follow are intended to give the user an indication of the severalways inwhich the
Hakko HJ3100 may be used. American Hakko Products will be pleased to help you arrive at the appropriate layout and
choice of accessories to fit your requirements.
Basic installation.
The Hakko HJ3100 may be installed in any location, and at any orientation, that allows access to the power switch, and
to the filters when servicing is required. Figure 2, below, gives the minimum clearances required for installation.
Following is a basic check list. Before operating the Hakko HJ3100, take note of these simple instructions:
1. Place the Hakko HJ3100 in a convenient location near an appropriate electrical outlet.
2. Ensure that exhaust air from the HJ3100 will not stir up unwanted dust, or adversely affect nearby operations.
3. Allow sufficient clearance to remove the top cover for accessto the filters. See figure A-1 for an outline drawing of the
unit.
4. Before attaching accessories to, or starting, the HJ3100, remove the top cover and verify that all filters are properly
positioned.
5. If noise in the work area is a concern, attach a 999-171 muffler to the exhaust grille of the HJ3100. This will reduce
the output noise by 5 dBA.
Figure 2.
Required clearances for installation.
Bottom of bench
11.5" (two ports)
999-189 3" Neoprene duct
minimum bend radius = 3"
16" (four ports)

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
10
OPTIONS.
The standard HJ3100 comes without any accessories, so the user can select those most suitable to the installation. For
most applications, each port of the HJ3100 can be hooked up as shown in Figure 3, below.This is a simple and direct
installation providing a good degree of flexibility. American Hakko recommends a maximum ofsixfeetofhoseperside
for maximum efficiency, although longer runs may be used effectively.
Hakko also offers several kits, incorporating the most popular accessories. Figures 4 through 6 show representative
applications of these kits. These applications are not meant to be comprehensive, as Hakko accessories may be combined
in many more configurations depending upon the application to hand. Ask your Hakko representative or American
Hakko Products for information.
Electrostatic discharge protection.
Although the probability of electrostatic discharge from the Hakko HJ3100 fume extraction system is small, many ESD-
safe accessories are provided for use where such protection is a concern. They are noted in Tables A-I and A-II,
Appendix A, AS ‘ESD’. As these accessories are conductive, setting up requires that there be no break in the circuit from
the collecting device to the main body.
Figure 3.
Basic installation (HJ3100-02 shown as an example)
HELPFUL HINTS FOR ALL INSTALLATIONS.
1. Be sure that all hose clamps (e. g. 999-169) are firmly tightened.
2. Be sure that all bench clamps (e. g. 999-188) are firmly tightened.
3. Be sure that all hoods are securely attached to their respective ducts.
4. If reducers are used (e.g. Fig. 7), put them as close as possible to the air intake (hood or other attachment).
999-169 hose clamp
2 places per side as shown
999-138 rectangular hood (standard)
HJ3100
3" I. D. duct
999-189 neoprene

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11
999-196 rectangular hood (kit -02)
HJ3100
999-189
3" neoprene duct
cut to length
999-197
adapter
999-194
LocLine hose
999-188
bench clamp, 3" coupler
999-169
3 1/2" hose clamps
r
999-195 round hood (kit -01)
Figure 4.
999-205 kit installation.

©1997, AMERICAN HAKKO PRODUCTS, INC.
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12
HJ3100
999-188
bench clamp, 3" coupler
999-169
3" hose clamps
999-189
3" neoprene duct
cut to length
999-146 clear bench-top hood (plenum) (kit -01)
999-151 ESD bench-top hood (plenum) (kit -02)
999-168 small ESD bench-top hood (plenum) (kit -03) (shown)
Figure 5.
999-206 kit installation.

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
13
HJ3100
999-189
3" neoprene duct
cut to length
999-169
3 1/2" hose clamps
999-164
articulated arm
999-163
3" to 2" reducer
999-150
2" ESD duct
cut to length
999-165 bracket
(clamp to bench
)
999-636
2 1/2" hose clamps
nozzle attaches here
(see above)
999-167 8.25" tube (kit -02)999-166 8" nozzle (kit -01) 999-170 clear hood (kit -03)
Figure 6.
999-207 kit installation.

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
14
Figure 7.
Typical installation - four port cover.
The most popular application of the four-port cover uses four examples of the 999-206-03 kit, as shown here. Any other
3" accessories may be used, save the large bench-top hoods, as the air flow with four such hoods will be marginal.
999-173 four 3" port cover
HJ3100
999-206-03 kits

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
15
OPERATION.
Operating the HJ3100 is simplicity itself. Merely plug it in, turn it on, and place the ducts and hoods as required for the
work station. No adjustment is necessary. The extractors, hoods and ducts are designed to efficiently remove soldering
fumes, dust, particles and odors.
Although the Hakko HJ3100 is one of the safest pieces of equipment available, we should like to apprise you of the
following:
CAUTION.
These basic safety measures must be observed to prevent shock, injury or fire when using
electrical devices:
¾Read these instructions thoroughly before operating the Hakko HJ3100.
¾Do not use this unit to extract flammable or explosive gases.
¾Do not use this unit to extract corrosive materials other than those found in solders and fluxes.
¾Do not expose the power cord to heat, oil or sharp edges.
¾Make sure the main unit is stable and secure.
¾Always switch the Hakko HJ3100 OFF before opening the lid.
¾Use only HAKKO replacement filters.
¾Protect the main unit from moisture.
¾Do not use the HJ3100 to extract water, water vapor or steam.

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
16
MAINTENANCE.
The filters are the only parts of the HJ3100 that need maintenance. Figure 9, below, shows the major parts of the HJ3100.
Figure 8.
Illustrated parts breakdown, Hakko HJ3100.
FILTERS.
¾The pre-filter should be checked every day under normal operating conditions, and replaced when dirty.
¾The HEPA/carbon filter, or activated carbon filter, should be replaced every four months, or 640 hours, in normal
use. ‘Normal use’ is defined as single shift 40-hour week operation.
CAUTION
THESE FILTERS CANNOT BE CLEANED.
Do not attempt to clean the pre-filters, HEPA/carbon filters, or activated carbon
filters for reuse. Cleaning the filters will only damage them severely and render
them useless. This, in turn, will result in unfiltered air being returned to the
environment. Unfiltered air can also damage the motor.
¾The particulate filter can be cleaned and reused. It is not necessary to use a pre-filter with the particulate filter.
Intervals between cleanings may vary with the application; a good sign that the filter wants cleaning is a loss of
air-flow through the pickup accessory. Recommended methods ofcleaning are, in order: 1) Vacuum out the débris
with a shop vacuum; 2) Blow the accumulated material out with clean dry air; 3) Wash the filter in clean water. If
either 2) or 3) is chosen, eye protection is suggested, and the waste must be disposed of according to local
regulations.
Hoods and ducts.
¾Hoods and ducts should be cleaned periodically to remove accumulated residue. Isopropyl alcohol is
recommended for this. The ducts usually require cleaning every four months due to build-up of flux and solder
residue inside them. This will become evident to the eye. Inspect flexible ducts for cracks and change them when
necessary.
Blower
Pre-filter
Main filter
Motor
Power switch
Circuit breaker
Top cover
Case
Bottom cover, with feet
Motor support
Power cord hole

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17
TROUBLE-SHOOTING.
Those occasions when trouble-shooting might be required are rare. However, if certain conditions occur, youmay referto
this section. The conditions requiring your attention are:
1. The unit quits running. The power switch is on but nothing happens.
a. The motor has overheated. The overtemperature switch will keep it from operating until it has cooled down.
This is usually 30 minutes. Meanwhile, you can:
i. Check each station. Make sure that the pickup ducts are not blocked.
ii. Check the air outlets at the bottom and side of the HJ3100 unit. Make sure they are not blocked.
b. There is an electrical problem that has caused a fuse to blow. There is a fuse in the motor/blower unit; later
models also have a circuit breaker on the case.
i. If the circuit breaker has blown (the reset button is exposed), DO NOT reset until you have checked the
wiring for shorts or other defects, including the inadvertent intrusion of foreign objects.
ii. Turn the HJ3100 OFF and remove the power plug from the receptacle. See the wiring diagrams in
Appendix B to verify integrity of the wiring (that loose wires, disconnected wires, broken wires &c do not exist).
2. The unit runs but does not have any air flow.
a. A station (or stations) is (are) blocked.
i. See 1 i, ii above.
ii. Inspect all flexible ducts. Make sure they are not kinked, blocked, or pinched. If they are, correct the
situation or replace the ducts.
iii. Inspect the hoods. Make sure they are not blocked or plugged.
b. There is an opening in the setup, allowing air to enter the unit.
i. Inspect all connections. Tighten or reset where necessary.
c. The blower wheel has come adrift from themotor shaft.This has been simulated during test and is exemplified
by a marked change in the sound comingfrom the HJ3100. Instead of the steady whirr of a properly operating unit, it will
be a high-pitched whirr accompanied by clanking noises. Should this be suspected:
i. Turn the HJ3100 OFF and remove the power plug from the receptacle.
ii. Set the main body on a bench and remove the screws holding the bottom cover.
iii. Remove the bottom cover.
iv. Inspect the assembly for structural integrity.
If the blower is loose, close the unit and return it to your Hakko distributor for repair.
d. The motor/blower does not turn. This becomes evident when there is no air flow and the sound made by the
HJ3100 is a hum. If this is suspected, return the HJ3100 to your Hakko distributor for repair.
3. If you encounter a problem that defies solution by these means, call your Hakko representative.
WARNING!!
DO NOT ATTEMPT TO OPEN THE HJ3100 WITH POWER APPLIED.
YOU ARE EXPOSING YOURSELF TO SERIOUS INJURY OR DEATH.

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
18
WHERE TO GO FOR SERVICE.
American Hakko Products offers design and installation assistance for HJ3100 customers. Our staff is available to aid
you in all aspects of fume extraction.
Should your Hakko HJ3100 ever need service, your local Hakko Representative should be able to meet all your needs.
For direct assistance, call Customer Service at American Hakko Products:
¾Telephone: [phone]
¾Toll free: (800) 88-HAKKO (884-2556)
¾Facsimile: [phone]
¾E-mail:
Customer Service: [email protected]
Technical: [email protected]
Marketing: [email protected]

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
19
APPENDIX A: PARTS AND ACCESSORIES.
TABLE A-I. - ACCESSORIES FOR THE HJ3100.
In keeping with American Hakko Products’ continuing dedication to product excellence, these accessories may be
changed in form, fit, or function at any time. The following accessories are offered for use with the Hakko HJ3100:
DESCRIPTION
PART NO. DESCRIPTION PART NO.
PRE-FILTER,
polyester,
pack of five
999-136
CLAMP, hose
2.5"
3.5"
ESD
999-636
999-169
FILTER
HEPA/carbon
Particle
Activated carbon
999-137
999-178
999-182
HOOD, bench top, large
(‘plenum’)
Clear
ESD
18.5" x 6.5" x 7.5"
999-146
999-151
HOOD, bench top, small
(‘mini-plenum’)
ESD only
9.0" x 4.5" x 5.5"
999-168
COVER,
3" x 2 port
3" x 4 port
ESD
999-172
999-173
DUCTING4
2" ESD
3" neoprene (ESD)
999-150
999-189
HOOD, rectangular,
3" x 8"
ESD
999-138
MUFFLER
999-171
HOOD, round
6" diameter
ESD
999-153
BENCH CLAMP
with 3" coupler
ESD
999-188
BRACKET, hood
free-standing
3.5"
ESD
999-159
REDUCER, round
3" to 2" plastic
999-163

©1997, AMERICAN HAKKO PRODUCTS, INC.
ALL RIGHTS RESERVED
20
HOSE, articulated
2.5" I. D.
'Loc-Line®
ESD
999-194
NOZZLE, round,
4.5"
'Loc-Line®
ESD
999-195
NOZZLE, rectangular
6" x 3.5"
'Loc-Line®
ESD
999-196
ADAPTER, duct
Sheet metal
'Loc-Line®
ESD
999-197
TABLE A-II.
ALSIDENT SYSTEM®ACCESSORIES.
The following Alsident System 50®ESD-safe accessories are available for use with the Hakko HJ3100. Alsident extractor hoods
are designed on the Coanda principle of laminar flow, which makes them highly efficient. Alsident extractor arms may be set and
locked in place. These accessories are available in 2" diameter only.
DESCRIPTION HAKKO
PART
NO.
DESCRIPTION HAKKO
PART
NO.
ARM, articulated 999-164 BRACKET, bench 999-165
NOZZLE, suction,
8"
999-166
TUBE, suction, 8.25"
999-167
HOOD, clear,
polycarbonate,
9.5 x 8.5"
This hood is not
ESD-safe.
999-170