Hakko Electronics FP-102 Manual de usuario

®

High-output, temperature controlled

soldering station

Instruction Manual

●

Thank you for purchasing the FP-102 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

FP-102 make it applicable to a broad range of soldering ap-

plications.

Please read this manual before operating the FP-102 . 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. PARAMETER SETTINGS ............................................... 6

8. MAINTENANCE .............................................................. 7

9. ERROR MESSAGES ...................................................... 9

10. TROUBLE SHOOTING GUIDE .................................... 10

11. PARTS LIST ................................................................. 11

12. TIP STYLES ................................................................. 13

13. WIRING DIAGRAM ....................................................... 15

HEAD OFFICE

4-5, SHIOKUSA 2-CHOME, NANIWA-KU, OSAKA, 556-0024 JAPAN

TEL:+81-6-6561-3225 FAX:+81-6-6561-8466

http://www.hakko.com

AMERICAN HAKKO PRODUCTS, INC.

28920 N. AVENUE WILLIAMS VALENCIA CA 91355, U.S.A.

TEL: (661) 294-0090 FAX: (661) 294-0096

Toll Free (800)88-HAKKO www.hakkousa.com

4 2 5 5 6

2005.10

MA01268JZ051019

13. WIRING DIAGRAM

RED

BLK

WHT

RED

SW2

LED2

LED5LED3

LED4

SW1

Power switch

Grounding plate

Fuse

P.W.B./switch

P.W.B./connector

P.W.B./temperature 

control

Transformer

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Heat resistant pad

Iron holder

FP-102 Soldering station

Control card

Card chain

Tip tray

Tip (not included) FM-2021 Connector assembly

Sleeve assembly*

7.5

6.5

8.0

7.0

MODEL

FP-102

*Yellow, orange or blue sleeve

assembly is included.

1. PACKING LIST

FP-102 soldering station ................................. 1

FM-2021 connector assembly ......................... 1

Sleeve assembly ............................................ 1

Control card, with chain ................................... 1

Heat resistant pad ........................................... 1

Tip tray ............................................................. 1

Iron holder ....................................................... 1

Cleaning wire ................................................... 1

Instruction manual ........................................... 1

2. SPECIFICATIONS

 FP-102 Soldering Station

Power Consumption

Temperature Range



Temperature Stability

75 W

The four segment lights on the front

panel indicate the heat range selected

for the FP-102 (6.5 = ~650°F. [343°C];

7.0 = ~700°F. [371°C]; 7.5 = ~750°F.

[399°C]; 8.0 = ~800°F. [427°C]).

±9°F (±5°C) at idle temperature

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  H  D)

Weight (w/o cord)

24 V

120  93  140 mm (4.7  3.7  5.5 in.)

1,400 g (3.1 lb.)

 Station

NOTE:

This product is protected against electrostatic discharge.

Specifications and design are subject to change without notice.

Please check to make sure that all items listed below are includ-

ed in the FP-102 package.

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 op-

erator, 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 be-

ing described.

EXAMPLE: An EXAMPLE is given to demonstrate a particular procedure, point or

process.

CAUTION

To prevent accidents or damage to the FP-102, be sure to observe the following:

● Do not use the FP-102 for applications other than soldering.

● Do not allow the FP-102 to become wet, or use it with wet hands.

● Do not modify the FP-102.

● 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 may 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, the tip will be HOT (between 300-450°C. [~572-840°F.])

To avoid injury or damage to personnel and items in the work area, observe the fol-

lowing:

● 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 FP-102.

● Do not remove or damage the bar code sticker.

12. TIP STYLES



Item No. Part No.



Part Name

Holder for

Specifications

• Iron Holder Parts

Item No.

Part No.

FH100-01

Part Name

Iron holder

Specifications

Item No. Part No.

FM2021-01

FM2021-02

B2770

B2765D

B2768C

B2769C

B2996

B2300

Part Name

Conversion kit

Connector assembly

Connector cover

Sleeve assembly

Tip

Heat resistant pad

Specifications

is yellow

Yellow

Orange

Blue

Green

• Iron Holder

B3001

B2791

B2999

599B-02

599-029

B2756

With screw

With rubber feet

B3000

iron receptacle

Iron receptacle

Retaining clip

Iron holder base

Tip cleaner

Cleaning wire

Tip tray

, ,

See section

'12. TIP STYLES'

4. PART NAMES

Heat resistant pad

Iron holder

FP-102 Soldering station

Control card

Card chain

Tip tray

Tip cleaner

Tip (not included)

Receptacle

Card slot

The heat range selector button

Auto power shutoff switch

(on the bottom front of the case)

FM-2021 Connector assembly

Sleeve assembly

7.5

6.5

8.0

7.0

MODEL

FP-102

7.5

6.5

8.07.0

MODEL

FP-102

7.5

6.5

green

blue

yellow

red

8.07.0

5. INITIAL SETUP

● Iron holder

● Connector cord

Pass the connector cord through the hole in the

heat resistant pad.

● Soldering station

1. Insert the connector cord into the receptacle

at the front of the station.

2. Plug the power cord into a grounded wall

socket. The FP-102 is protected against

electrostatic discharge and must be ground-

ed for full efﬁciency.

Receptacle

Push the connector in as far as

it will go. When the plug clicks,

it is fully inserted.

● Tip tray

Place spare tips in the tip tray.

CAUTION:

Be sure to turn off the power switch before connecting

or disconnecting the soldering iron. Failure to do so may

damage the P.W.B.

NOTE:

Spare or repair parts do not include

mounting screws, if they are not

listed on the description. Screws

must be ordered separately.

7.5

6.5

8.0

7.0

MODEL

FP-102

 FP-102 Station

Item

No. Part No.

B2839

B2861

B2835B

B2836

B2837

B2838

B2852

B1319

B2015

B2103

B2227

B2224

Part Name

Control card

Front panel

P.W.B. (temperature

control and connector)

Transformer

Upper case

Lower case

Power switch

Power cord

Cord stopper

Wiring board for switch

Grounding plate

Fuse

Specifications

with LED lens and

shieding plate



120V

with rubber foot

3 wired cord & American plug

2A (UL)

Tapping screw

4 � 12 (4)

Tapping screw

3 � 12 (1)

Tapping screw

3 � 8 (3)

Tapping screw

2.6 � 8 (3)

Pan head screw

M4 � 6 (2)

External tooth

lock washer

nominal size 4

Binding head

tapping screw

3.5 � 45 (4)

Tapping screw

2.6 � 6 (1)

11. PARTS LIST

10. TROUBLE SHOOTING GUIDE

WARNING:

¥ Before opening the FP-102, or replacing parts, be sure to disconnect the power plug. Failure

to do so may result in electric shock.

● The unit does not op-

erate when the power

switch is turned on.

CHECK : Is the plug disconnected?

ACTION

: Connect it.

● The tip does not heat up.

• “Sensor error”

7.5

6.5

8.07.0

is dis-

played.

CHECK : Is the tip inserted properly?

ACTION

: Insert the tip completely.

CHECK : Is the connection cord and/or the heater/sensor broken?

ACTION

: See the appropriate section of this manual regarding how

to check the connection cord and/or the heater/sensor for

breakage.

● Solder does not wet the

tip.

CHECK : Is the tip contaminated with oxide?

ACTION

: Remove the oxide (see “Tip maintenance” on P. 7).

● The tip temperature is

too high.

CHECK : Is the connection cord broken?

ACTION

: See “Checking the connection cord for breakage” on P. 8.

● The tip temperature is

too low.

CHECK : Is the tip contaminated with oxide?

ACTION

: Remove the oxide (see “Tip maintenance” on P. 7).

● The soldering iron er-

ror, yellow and red lamp

blink.

CHECK : Is the wrong soldering iron connected? Or the FM-2021

plug disconnected?

ACTION

: Turn off the power switch, re-connect the FM-2021 solder-

ing iron, then turn on the power switch.

● Heater terminal short

circuit error

7.5

6.5

8.07.0

displayed

CHECK : Is the tip for FM-2021?

ACTION

: Turn the power switch OFF and insert genuine FM-2021

tip. Turn the power switch ON.

6. OPERATION

OPERATION

1. Turn the power switch ON.

2. A heat range indicator (one of the four seg-

ment buttons, indicating the selected range)

will blink.

3. When the set temperature is reached, the

buzzer alarm sounds indicating it is ready

for use. The indicator lamp remains on

steadily.

NOTE:

When not in use, place the soldering iron to the iron

holder.

● Control card Each FP-102 comes with a small card, which

inserts into the Card slot on the front of the unit.

This card is used when changing heat

ranges

Any FP-102 card can be used with any FP-102

soldering station.

● Changing the heat range

1. Insert the control card into the slot in the

front of the unit.

As previously noted, the four segment

lights on the front panel indicate the heat

range selected for the FP-102 (6.5= ~650

°F. [343°C]; 7.0= ~700°F. [371°C]; 7.5=

~750°F. [399°C]; 8.0= ~800°F. [427¡C].

The ranges are approximate values only;

the actual tip temperature depends upon

tip geometry and mass. These lights

are

indicators

; one must press the “heat

range” button, located below the indica-

tors, to change range.

2. Press the heat range selector button. Each

time this button is pressed a different heat

range indicator lamp will light. It will blink

slowly until the set range is reached; once

at temperature, it will remain on steadily.

3. Removing the card.

When the station is on and the control card

is in the station, the temperature can be

changed any time.

4. When the alarm sounds and the heat range

indicator lamp starts lighting, the station is

ready for use.

When power is switched off the selected heat

range is stored in memory.

The heat range selector button

7.5

6.5

8.07.0

MODEL

FP-102

7.5

6.5

8.07.0

®

CAUTION:

The control card must be inserted into the card slot in the

correct direction for data to be entered.

● Replacing the tip

Removing and inserting the tip:

Removing the tip: Hold the sleeve assembly

to remove the connector.

Remove the tip from the sleeve assembly.

(If the tip is hot, hold it with the heat-resis-

tant pad.)

Inserting the tip: Hold the head part and in-

sert 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.

Insert the new tip ﬁrmly into the connector.

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.

FM-2021

24V-70W

● Using the iron holder

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.

7. PARAMETER SETTINGS

Auto power shutoff

This is an optional setting. When it is activated

and the soldering iron is not used for 30 min-

utes, the power to the heating element is shut

off automatically, the alarm will sound three

times and the selected heat range lamp will

light slowly. When the temperature decreases

to 100°C/212°F, the heat range indicator lamps

light in a slow clockwise sequence. If the sta-

tion is left in this mode, the 'alarm' will continue

to sound every thirty minutes. To resume sol-

dering, cycle the power switch OFF, then ON.

The power will be turned on automatically if the

heat range selector button is pressed before

the temperature decreases to 100°C/212°F.

The auto power shutoff switch is on the bottom

front of the case. To turn this function ON ,set

the switch to the ' I ' position. (OFF is reverse.)

Hold the sleeve assembly at the front to remove tip.

Hold these parts to insert tip into sleeve assembly.



Hold and squeeze this part to insert into the connector.



9. ERROR MESSAGES

● System Error When the power is turned on, the system au-

tomatically checks its memory and the stored

program. If a problem is found, all the heat

range indicator lamps will light and the tip will

not heat.

NOTE:

“Sensor error” also occurs if the tip is not inserted prop-

erly.

● Sensor Error When there is the possibility that a failure has

occurred in the sensor or heater (including the

sensor circuit), the heat range indicator lamp

will blink rapidly and the heater is shut down.

● Heater terminal short circuit

error

● Soldering iron error

7.5

6.5

8.07.0

All

the heat range indicator lamps will blink,

and the alarm will sound continuously. Possible

causes are: the tip is inserted the wrong way,

an incompatible tip is inserted, or a foreign ob-

ject is in the connector.

The

yellow

and

red

heat range indicator lamps

will blink if the connector cord is not attached to

the station OR the wrong soldering iron is con-

nected.

7.5

6.5

8.07.0

7.5

6.5

8.07.0

7.5

6.5

8.07.0

CAUTION:

Do not connect the FM-2022 or FM-2023 with the

FP-102.

● Checking Procedure

WARNING:

Unless otherwise directed, carry out these procedures with the power switch OFF and the power UNPLUGGED.

■ Check for a broken heater or

sensor

1. Check for a broken heater or sensor

Measure the resistance

across this position.

1Y100CB3

T7-D24

Verify the electrical integrity of the heater and

sensor.

Measure the resistance of the heater and sen-

sor while at room temperature (15 to 25°C; 59

to 77°F). It should be 8Ω ±10%. If the resis-

tance exceeds these limits, replace the tip.

■ Check the grounding line 1. Unplug the connection cord from the station.

2. Measure the resistance value between Pin 2

and the tip.

3. If the value exceeds 2Ω (at room temperature),

perform the tip maintenance described on P.7.

If the value still does not decrease, check the

connection cord for breakage.

■ Checking the connection cord

for breakage

1. Remove the soldering tip and the sleeve as-

sembly.

2. Turn the front piece of the FM-2021 clockwise

and remove the cover.

3. Measure the resistance values between the

connector and the lead wires at the socket as

follows:

Pin 1 - Red Pin 2 - Green

Pin 3 - Black Pin 5 - White

If any value exceeds 0Ω, replace the FM-2021.



  



8. MAINTENANCE

● Tip maintenance

High temperatures shorten tip life and may

cause thermal shock to components. Always

use the lowest possible temperature when sol-

dering. The excellent thermal recovery charac-

teristics of the FP-102 ensure effective solder-

ing at low temperatures.

2. Cleaning Always clean the soldering tip before use to

remove any residual solder or flux adhering

to it. Use the 599B tip cleaner (provided with

the FP-102) or use a clean and moist cleaning

sponge part no. A1519. Contaminants on the

tip have many deleterious effects, including

reduced heat conductivity, which contribute to

poor soldering performance.

3. After use Always clean the tip and coat it with fresh sol-

der after use. This guards against oxidation.

4. When the unit is not being used

and the auto power shutoff is not

active.

Never allow the unit to idle at a high temperature

for extended periods. This will allow the tip to

become oxidized. Turn the power switch OFF.

If it is to be out of service for several hours, it is

advisable to pull the power plug as well.

5. Inspecting and cleaning the tip This procedure, if followed daily, will materially

add to tip life.

a. Set the heat range to 6.5.

b. When the temperature stabilizes, clean the

tip (see 2, above) and check the condition of

the tip. If the tip is badly worn or deformed,

replace it.

c. If the solder plated part of the tip is covered

with black oxide, apply fresh solder, con-

taining ﬂux, and clean the tip again. Repeat

until all the oxide is removed, then coat the

tip with fresh solder.

d. Turn the power OFF and remove the tip. Set

the tip aside to cool.

CAUTION:

NEVER ﬁle the tip to remove oxides!

1. Tip temperature

● Checking Procedure

WARNING:

Unless otherwise directed, carry out these procedures with the power switch OFF and the power UNPLUGGED.

■ Check for a broken heater or

sensor

1. Check for a broken heater or sensor

Measure the resistance

across this position.

1Y100CB3

T7-D24

Verify the electrical integrity of the heater and

sensor.

Measure the resistance of the heater and sen-

sor while at room temperature (15 to 25°C; 59

to 77°F). It should be 8Ω ±10%. If the resis-

tance exceeds these limits, replace the tip.

■ Check the grounding line 1. Unplug the connection cord from the station.

2. Measure the resistance value between Pin 2

and the tip.

3. If the value exceeds 2Ω (at room temperature),

perform the tip maintenance described on P.7.

If the value still does not decrease, check the

connection cord for breakage.

■ Checking the connection cord

for breakage

1. Remove the soldering tip and the sleeve as-

sembly.

2. Turn the front piece of the FM-2021 clockwise

and remove the cover.

3. Measure the resistance values between the

connector and the lead wires at the socket as

follows:

Pin 1 - Red Pin 2 - Green

Pin 3 - Black Pin 5 - White

If any value exceeds 0Ω, replace the FM-2021.



  



8. MAINTENANCE

● Tip maintenance

High temperatures shorten tip life and may

cause thermal shock to components. Always

use the lowest possible temperature when sol-

dering. The excellent thermal recovery charac-

teristics of the FP-102 ensure effective solder-

ing at low temperatures.

2. Cleaning Always clean the soldering tip before use to

remove any residual solder or flux adhering

to it. Use the 599B tip cleaner (provided with

the FP-102) or use a clean and moist cleaning

sponge part no. A1519. Contaminants on the

tip have many deleterious effects, including

reduced heat conductivity, which contribute to

poor soldering performance.

3. After use Always clean the tip and coat it with fresh sol-

der after use. This guards against oxidation.

4. When the unit is not being used

and the auto power shutoff is not

active.

Never allow the unit to idle at a high temperature

for extended periods. This will allow the tip to

become oxidized. Turn the power switch OFF.

If it is to be out of service for several hours, it is

advisable to pull the power plug as well.

5. Inspecting and cleaning the tip This procedure, if followed daily, will materially

add to tip life.

a. Set the heat range to 6.5.

b. When the temperature stabilizes, clean the

tip (see 2, above) and check the condition of

the tip. If the tip is badly worn or deformed,

replace it.

c. If the solder plated part of the tip is covered

with black oxide, apply fresh solder, con-

taining ﬂux, and clean the tip again. Repeat

until all the oxide is removed, then coat the

tip with fresh solder.

d. Turn the power OFF and remove the tip. Set

the tip aside to cool.

CAUTION:

NEVER ﬁle the tip to remove oxides!

1. Tip temperature

● Replacing the tip

Removing and inserting the tip:

Removing the tip: Hold the sleeve assembly

to remove the connector.

Remove the tip from the sleeve assembly.

(If the tip is hot, hold it with the heat-resis-

tant pad.)

Inserting the tip: Hold the head part and in-

sert 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.

Insert the new tip ﬁrmly into the connector.

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.

FM-2021

24V-70W

● Using the iron holder

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.

7. PARAMETER SETTINGS

Auto power shutoff

This is an optional setting. When it is activated

and the soldering iron is not used for 30 min-

utes, the power to the heating element is shut

off automatically, the alarm will sound three

times and the selected heat range lamp will

light slowly. When the temperature decreases

to 100°C/212°F, the heat range indicator lamps

light in a slow clockwise sequence. If the sta-

tion is left in this mode, the 'alarm' will continue

to sound every thirty minutes. To resume sol-

dering, cycle the power switch OFF, then ON.

The power will be turned on automatically if the

heat range selector button is pressed before

the temperature decreases to 100°C/212°F.

The auto power shutoff switch is on the bottom

front of the case. To turn this function ON ,set

the switch to the ' I ' position. (OFF is reverse.)

Hold the sleeve assembly at the front to remove tip.

Hold these parts to insert tip into sleeve assembly.



Hold and squeeze this part to insert into the connector.



9. ERROR MESSAGES

● System Error When the power is turned on, the system au-

tomatically checks its memory and the stored

program. If a problem is found, all the heat

range indicator lamps will light and the tip will

not heat.

NOTE:

“Sensor error” also occurs if the tip is not inserted prop-

erly.

● Sensor Error When there is the possibility that a failure has

occurred in the sensor or heater (including the

sensor circuit), the heat range indicator lamp

will blink rapidly and the heater is shut down.

● Heater terminal short circuit

error

● Soldering iron error

7.5

6.5

8.07.0

All

the heat range indicator lamps will blink,

and the alarm will sound continuously. Possible

causes are: the tip is inserted the wrong way,

an incompatible tip is inserted, or a foreign ob-

ject is in the connector.

The

yellow

and

red

heat range indicator lamps

will blink if the connector cord is not attached to

the station OR the wrong soldering iron is con-

nected.

7.5

6.5

8.07.0

7.5

6.5

8.07.0

7.5

6.5

8.07.0

CAUTION:

Do not connect the FM-2022 or FM-2023 with the

FP-102.

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