Document text
@HAKKO
FAKO FM-2024
DESOLDERING TOOL
Instruction Manual
Thank you for purchasing the FM-2024 desoldering tool.
Please read this manual before operating the FM-2024.
Keep this manual readily accessible for reference.
/\, CAUTION
@ The FM-2024 cannot function by itself. It must be connected to
the Desolder Control Box (DCB), which in turn connects to the
soldering station of choice, either FM-202 or FP-102.
@ For detailed information on the FM-202 and the FP-102 soldering
stations, refer to the instruction manual for the appropriate
soldering station.
TABLE OF CONTENTS
1. PACKING LIST .......:.:e:eeeeeeeeseeeeeeeeeeeeeeeseeeeeteees 1
2. SPECIFICATIONS sess cctecceccn.deteeieectaticievecteatendves 1
3. WARNINGS, CAUTIONS AND NOTES. ...........+4+- 2
4. PART NAMES Sree cece eee 3
5. OPERATION seecscesce: ceutcoscescssueeeteeecgetcncteauennets 4
6. MAINTENANCE.............2:+22:eeceeceeeeeeeeeeeeeeeeetees 10
7. TROUBLE SHOOTING GUIDE .......:..:::::ececees 14
6 PARTS LIST fice ess 17
9. WIRING DIAGRAM ..........::::ceeceeeeeeeeeeteeteetees 19
PI heck t k that all the it listed be-
1. PACKING LIST itera ie e sure that all the items listed be
Desolder control box (DCB) ...............::cccceeeeees 1 Cleaning drill (for heating element).................. 1
Desoldering TOOT mic tomeceserecssmsscvinenneineedecoeetannsets 1 Nozzle rEMOVET..........:ccccsecceeeceececeeeeaeesaeeeneneeaes 1
NOMENON GSE a sissectcttan senate heaniinetceeicedetieorennataetslanes 1 RUDDErF TOOL sinesetcteevesceriseossinsatectsswosammageesanmiencees 2
Handle (for gun Configuration)............ccccssceceees 1 ASTM TION manual ssns 1
Filter pipe assembly ..............cceceeeceeeeeseeeeeeeeeaes 1
Desoldering tool
(Nozzle is not included)
Iron holder
f
Handle (for gun configuration) Cleaning drill (for heating element) Nozzle remover
Oo
Rubber foot
2. SPECIFICATIONS
Desolder control box Desoldering tool
650 - 840°F (350 - 450°C)
Vacuum pressure (max.) | 93 kPa (700 mmHg) (28 in. Hg)
7.09 in. (180 mm)
0.14 Ib. (65 g)
Applied air pressure 490 kPa (5.0 kgf/cm’) when in Length of cord 4 ft. (1.2 m)
use (trigger or button is pressed)
1.62 c.f.m. (46 4 /min.) NOTE
consumption The temperatures were measured using the Hakko 192
4.7 (W) x 1.8 (H) x 6.8 (D) in. soldering tester.
cord (119 x 45 x 172 mm) This product is protected against electrostatic discharge.
Weight 2.6 Ib. (1.2 kg) Specifications and design are subject to change without notice.
3. WARNINGS, CAUTIONS AND NOTES
/N WARNING
In this instruction manual, “WARNING” and “CAUTION” are defined as follows.
/\ WARNING: Misuse may potentially cause death of, or serious injury to the
user.
A/N CAUTION : Misuse may potentially cause injury to the user or physical
damage to the objects involved.
For your safety, be sure to comply with these precautions.
Failure to do so may result in serious problems.
/N CAUTION
When the power is on, the nozzle temperature is between 650°F/350°C and 840°F/450°C.
Since mishandling may lead to burns or fire, be sure to comply with the following
precautions.
@ Do not touch the metal parts near the nozzle, nearby plastic parts, or the spring iron
holder.
@ Do not use the product near flammable items.
@ Advise other people in the work area that the unit can reach a very high temperature
and should be considered potentially dangerous.
@ Turn the power off while taking breaks and when finished using the unit.
@ Before replacing parts or storing the unit, turn the power off and allow the unit to cool to
room temperature.
To prevent damage to the unit and ensure a safe working environment, be sure to comply
with the following precautions.
Use only filtered air. Adjust the pressure to 490 to 686 kPa (5.0 to 7.0 kgf/cm‘) while
allowing air to flow by pulling the trigger.
@ Do not use the unit for applications other than desoldering.
@ Do not rap the desoldering tool against the work bench to shake off residual solder, or
otherwise subject the iron to severe shocks.
@ Do not modify the unit.
@ Use only genuine HAKKO replacement parts.
@ Do not wet the unit or use the unit when your hands are wet.
@ When desoldering, ensure good ventilation for smoke.
@ While using the unit, don’t do anything which may cause bodily harm or physical dam-
age.
Lh, PART NAM ES (Refer to p.17~18 for part nos.)
DCB <Front>
DESOLDER CONTROL BOX
Power lamp
Illuminated when the power
switch is turned ON.
Receptacle Filter case cover
Connect the FM-2024 to The ceramic paper filter is
this receptacle. located inside.
Fuse holder Power switch Union
External air inlet.
<Back>
LE
Connecting cord
=) Connect to FM-202 or
Power code | j | FP-102.
MODEL FM-2024 Filter pipe assembly
Repl rtridge. - :
Be a eae Filter pipe lock button
Back holder The filter pipe assembly will be locked
Ta until this button is presssed.
HAKO yiii DESO ERING TOO!
s= MA ES @HaKo ~
2
We button
Nozzle unlock button Back holder bushing Suction start switch (when straight grip is used).
Remove the nozzle from the
grip while pressing this button.
Trigger a "= Slide button
Suction start switch To remove the gun handle, slide
(when gun style handle the button up to unlock it.
is used).
Front holder
5. OPERATION
Assembling, connection and
operation
1. lron holder
Iron holder
assembly
2. Connecting and replacing
the filter pipe
Pull the back holder (A) until it
locks, then insert the filter pipe
assembly with the opening to the
nozzle side. Ensure that the outer
surface of the filter pipe assembly
is even with the handle support.
If the filter pipe assembly is tilted,
a leak may occur.
To replace the filter pipe /\CAUTION
assembly, press back holder The surface of the filter pipe
unlock button, pull the back assembly may be very hot.
holder to lock it, change the filter
pipe assembly, then lock the filter
pipe assembly.
Replace the filter pipe assembly
in the cartridge.
Attaching
3. Attaching and replacing
the nozzle
Insert the grip fully into the
nozzle cartridge as shown in
the illustration. Once the nozzle
cartridge is inserted, it is locked
automatically.
To replace the nozzle cartridge,
insert the nozzle remover into the
flange of the nozzle cartridge and
pull.
Nozzle remover
/NCAUTION
The nozzle can be very hot. To attach or
remove the nozzle cartridge, be sure to
use the nozzle remover to preclude the
possibility of breaking the grip or cartridge.
5. OPERATION
Press the nozzle unlock button (A)
and remove the nozzle cartridge.
/\ CAUTION
The nozzle may be very hot.
The nozzle remover may be
left mounted on the end of the
straight grip when not in use to
prevent it from being misplaced.
Not sensitive to
vertical orientation
Connections /\CAUTION
= = The FP-102 is currently
1. Connect the plug from the mE sold in the U.S. market.
FM-2024 to the receptacle on the
DCB, then connect the DCB to
the soldering station as shown in
the drawing.
f-
Ş
Fully insert Receptacle
until the plug is
clicked. Q
Insert the plug until it stops,
and then pull it without
pressing the lock pin.
If this does not disconnect
the plug from the receptacle,
the plug is inserted properly.
2. Put the FM-2024 into the iron
holder
To mount the FP-102 atop the
DCB, attach two rubber feet,
which come with the FP-102, to
the bottom rear of the FP-102 to
prevent the FP-102 from falling
off.
3. Connect the hose from the
FM-2024 to the filter case cover
on the DCB.
Fully insert.
4. 4. Connect the DCB to the shop
air supply/compressor.
Use only filtered air to eliminate
the probability of dust, water,
and oil content from fouling the
mechanism.
Adjust the pressure to 490 kPa
(5.0 kgf/cm*) with the regulator
while allowing air to flow by
pressing the button (or pulling the
trigger) on the handpiece.
/\CAUTION
If you attempt to adjust the pressure
without allowing air to flow, or if the
tube size is not as specified, the
suction capability will decrease.
Ensure that the regulator shows less
than 882 kPa (9.0 kgf/cm‘) when the
trigger is turned OFF. If pressure equal
to or higher than this value is applied,
damage may result.
. Turn ON the power
Ensure that the power switch is
OFF before inserting the AC plug.
Z\CAUTION
Be sure to ground this product as it is
ESD safe by design.
Turn the power switches ON as
follows: First, the DCB; second,
the soldering station. Unless
the DCB is turned on first, an
error message will appear since
the desoldering iron remains
disconnected.
Typical
interconnections
DCB Use a tube with inner diameter of 0.16
in. (4 mm) minimum.
Use length of 9.8 ft. (8 m) maximum.
Joint +
Threaded portion Regulator Air filter
Adjust to 490 kPa Removes foreign
(5.0 kgf/cm’) matter, dust, oil
content, and water
content
outside diameter
20.24 in. (06 mm)
/\CAUTION
Be sure to use an air filter. Foreign matter in the piping
or the air supply can jam the solenoid valve, causing a
failure.
5. OPERATION
Using the desoldering iron in
the gun configuration.
To use the desoldering iron in
the gun configuration, attach the
handle to the straight grip.
To remove the handle, slide down
the button located on the rear of
the handle to unlock it, then slide
the handle toward the back of the
FM-2024.
Align the parts and slide the handle
toward the front.
The handle will be locked
automatically.
Operation /\CAUTION
In case of long shape nozzle, the nozzle temperature will be lower
1. When the FM-2024 is used with than the normal one. In order to set very precise temperature,
the FM-202, turning the power enter the nozzle ID number of| g4).
switch ON will display the nozzle
ID [_88]).
All the standard nozzles for
FM-2024 share the same ID [_ 43).
Use the standard nozzle as it is.
If a different ID was entered,
change to . Refer to the
FM-202 instruction manual for
instructions in changing the
nozzle ID.
2. Set the temperature.
Refer to the instruction manuals
for the soldering station being
used.
3. Reaching the set
temperature
After the soldering station has
reached the set temperature,
there will be an idle period of 15
seconds before the ‘ready’ alarm
sounds. This time is used to
ensure more efficient suction.
For the FM-202, pressing the
push button (or pulling the trigger)
before the alarm sounds will cause
the displayed temperature to start
blinking. Neither model should
be used until after the alarm has
sounded. However, if the nozzle
temperature is 482°F/250°C or
higher when the power is turned
ON, the idling time will be omitted.
Removing solder
Clean the nozzle end.
Be sure the nozzle tip is tinned
with clean, fresh solder.
5. OPERATION
If the nozzle tip is coated with
oxidized film or the like, its thermal
conductivity deteriorates. In contrast,
if the nozzle end is wetted with a
small amount of clean solder, its
thermal conductivity increases.
. Melt the solder.
Position the nozzle above the
lead to be desoldered as shown
in the illustration and melt the
solder.
/\CAUTION
Never allow the nozzle to touch the
board itself.
Confirm that the solder is melted.
/\CAUTION
To confirm that all solder is melted,
observe the inside of the hole and
the backside of the P.W.B. If this
is difficult to do, try slowly moving
the lead with the nozzle. If the lead
moves, the solder is melted. Never
move the lead by force. If it doesn’t
move easily, the solder isn’t yet fully
melted.
. Extract the solder.
After confirming that the solder
is completely melted, extract the
solder by pressing the button (or
squeezing the trigger)
Z\CAUTION
Never leave any solder remaining
inside the hole in the PW.B.
. Problems during
desoldering.
If solder remains, resolder the
component and repeat the
desoldering process.
mi
Nozzle
P.W.B.
Solder
Lead
Slowly move
the lead with
the nozzle.
Extract the solder by slowly
moving the lead back and forth
with the tip of the nozzle.
6. MAINTENANCE
Properly maintained, the FM-2024 desoldering tool should provide years of good service.
Efficient desoldering depends upon the temperature, and the quality and quantity of the solder and
flux. Perform the following service procedures as dictated by the conditions of the gun’s usage.
Since the desoldering tool can reach a very high temperature,
please work carefully.
Except when cleaning the nozzle and heating element, ALWAYS
turn the power switch OFF and disconnect the power plug before
performing any maintenance procedure.
Maintenance of nozzle
/\CAUTION
The desoldering tool may be
extremely hot. During maintenance,
please work carefully.
Inspect and clean the nozzle.
@ Plug in the power cord, turn the
power switch ON and let the
nozzle heat up.
/\CAUTION
The cleaning pin will not pass through
the nozzle until the solder inside the
nozzle is completely melted.
@ Clean out the hole of the nozzle
with the nozzle cleaning pin
(not included as a standard accessories).
@ |f the cleaning pin does not pass
through the hole in the nozzle,
clean with the cleaning drill.
(not included as a standard accessories).
@ Check the condition of the solder
plating on the nozzle tip.
@ Check visually if the nozzle was
eroded.
/\CAUTION
The inside hole and the surface of the
nozzle is plated with a special alloy.
Should this alloy become eroded by high-
temperature solder, the nozzle will not be
able to maintain the proper temperature.
@ If the nozzle is still in a good
condition, put some fresh solder on
the nozzle tip to protect solder plated
area from oxidation.
Cleaning with the nozzle cleaning pin
The cleaning pin passes completely
through the hole.
Cleaning with the cleaning drill
e Before cleaning
fy
e After cleaning Insert the bit while turning it clockwise.
D
Pull the drill bit out straight without turn-
ing it.
/NCAUTION
If the cleaning drill is forced into the nozzle, the
drill bit could break or be damaged.
Please use the proper size cleaning pin or cleaning
drill for the nozzle diameter.
e |f the cleaning pin and cleaning drill
does not pass through the hole in
the nozzle, replace the nozzle.
Solder plating «If the solder plating on the nozzle tip
is worn, replace the nozzle.
e If the inside hole of the nozzle is
©) eroded, replace the nozzle.
/NCAUTION
Unfortunately, it is often difficult to
observe this condition. Therefore, if
desoldering efficiency goes down
Hole is damaged and all other parts appear to be
by erosion. OK, the nozzle is probably eroded
and should be replaced.
11
6. MAINTENANCE
Cleaning the inside of
suction pipe
Move the nozzle cartridge to
the cleaning position indicated
in figure at right. Change the
position of the nozzle cartridge
before turning the power ON, to
prevent accidents.
To clean the inside of the suction
pipe, ensure that the solder
remaining in the pipe has been
completely melted.
For the cleaning of the suction
pipe, set the nozzle temperature
to 750°F/400°C or higher.
Start this cleaning after the set
temperature has been reached.
To clean the inside of the suction
pipe, insert the cleaning drill fully
into the suction pipe while turning
it clockwise. Then remove the
accumulated debris.
Check and clean the front
and back holder bushings
If foreign matter gets stuck on
the contact surface between the
front holder and the filter pipe
assembly, or between the back
holder bushing and the filter
pipe assembly, air will be sucked
into the tool, preventing normal
desoldering. Remove the solder
and flux adhering to the surface
of front holder (A) and back
holder (B) then connect the filter
pipe assembly.
If you insert the drill without
turning it or if you try to insert the
drill at an angle, the nozzle cartridge may
be broken.
[L| A
DON
Remove the cleaning drill on NS
axis with the nozzle. If it is difficult to
remove the drill, turn it slightly whilst
withdrawing it. If you forcibly remove the
drill, the cartridge may be broken.
Check the nozzle (heater/
sensor) and connecting cable.
Checking the cord assembly
Switch circuit board
Blue LED circuit board
(c}
1 Thermistor
Checking the grounding line
Checking the heater/sensor
/\WARNING
Unless otherwise specified, perform the following steps after
turning the power switch OFF and disconnecting the AC plug.
Checking the electrical continuity of the
cord assembly
1. Remove the plug of the cord assembly from the
station.
2. If the handle (for gun configuration) is attached,
remove it.
3. Remove the nozzle cartridge. For this removal, see
“Attaching and replacing the nozzle cartridge.”
4. Remove the screws for the grip and measure the
resistance between the socket terminal and the plug
pin as shown below (refer to the wiring diagram).
Plug pin 1 ——————__ Reed (Socket) 3
Plug pin 2 t+ ———__ Green (socket) 1
Plug pin 3 —M————___ Black (socket) 2
Plug pin 4 M—————__ Brown (LED circuit board)
Plug pin 5 = MW———._ White (thermistor)
Plug pin 6 —————__ Blue (switch circuit board)
If the resistance is larger than OQ or œ in any location,
replace the cord assembly.
1. Measure the resistance between plug pin 2 and the
nozzle end.
2. If the resistance value exceeds 2Q (at room
temperature), perform the maintenance for the nozzle,
which is described in page 12 of the instruction
manual for the FM-202. If this does not decrease
the value, check the electrical continuity of the cord
assembly.
Checking for electrical continuity of heater/
sensor
Measure the resistance between this
point and the heater/sensor.
Measure the resistance at room temperature (59 to 77°F ; 15
to 25°C). The normal range is 7.502 + 10%. If the resistance
is outside this range, replace the nozzle assembly.
12
6. MAINTENANCE
Checking and replacing the
ceramic paper filter (DCB)
The filter is clogged with
hardened flux.
Fit the filter case cover in
place.
13
1. Turn the filter case cover on the DCB clockwise to
unlock it, then remove the cover by pulling it straight
out.
DCB
WHAIKKO
Replace the ceramic paper filter (DCB).
After replacing the ceramic paper filter (DCB), press
the filter case cover with its tabs inserted into the
corresponding slots in the filter case then turn clockwise
to lock it.
7. TROUBLE SHOOTING GUIDE
@ To check inside or replace parts, be sure to turn the power switch OFF
and remove the AC plug to avoid electric shock.
@ No operation occurs
when the power switch is
turned ON.
@ When the power switch is
turned ON. Soldering iron
error is displayed.
e FM-202 shows [E-E].
e The indicator lamp of FP-102
blinks.
@ The nozzle is not heated.
Sensor error is displayed.
e FM-202 shows [5-E].
e The indicator lamp of FP-102
blinks.
@ The nozzle tip does not
extract solder.
075 | =101..@ :
ACTION :
07/30 E :
ACTION :
0/30 E :
ACTION :
0/30 E :
ACTION :
CHECK §&
ACTION :
CHECK
ACTION :
07/30 E :
ACTION :
0/30 E -
ACTION :
ACTION :
Is the power cord connected properly
(Soldering station and/or DCB)?
Properly connect the power cable.
Is the fuse blown out?
After identifying the cause (e.g., short-circuit
in the desoldering iron), replace the fuse.
Is the FM-2024 connected?
Connect the FM-2024.
Is the cord assembly connected properly?
Connect again while referring to “Preparation
- Assembling and Connections.”
Is the cord assembly broken?
Refer to “Checking for electrical discontinuity
of the cord assembly” in Maintenance.
: Is the nozzle cartridge fully inserted?
ACTION :
075 | =107,.@ :
Fully insert the nozzle cartridge.
Is the cord assembly broken?
Is the heater/sensor disconnected?
Refer to “Checking for electrical continuity of
cord assembly” and “Checking for electrical
continuity of heater/sensor” in Maintenance.
Is the set temperature for the nozzle too high?
Set the nozzle temperature at the
appropriate level.
Is the nozzle tip plugged or coated with
oxide?
Remove the oxide by cleaning the nozzle tip
with Hakko 599B Tip cleaner.
Has the nozzle tip deteriorated due to
corrosion?
Replace the nozzle.
14
7. TROUBLE SHOOTING GUIDE
@ The nozzle temperature is
too high.
@ The nozzle temperature is
too low.
© Error indicating low
temperature alarm setting
occurs frequently.
© is displayed
indicating heater terminal
short-circuit error.
© The solder cannot be
removed.
:
ACTION :
:
ACTION :
:
ACTION :
:
ACTION :
:
ACTION :
:
ACTION :
:
ACTION :
:
ACTION :
:
ACTION :
Is the cord assembly broken?
Refer to “Checking for electrical continuity
of connecting cable” in Maitenance.
Did you enter a wrong Nozzle ID?
The Nozzle ID for the standard nozzle is OO.
Enter it.
Is any oxide adhered to the nozzle tip?
Remove the oxide by cleaning the nozzle
end with Hakko 599B Tip cleaner.
Has the nozzle tip deteriorated due to
corrosion?
Replace the nozzle.
Did you enter a wrong Nozzle ID?
The Nozzle ID for the standard nozzle is 00.
Enter it correctly.
Is the setting for the low temperature alarm
too low?
Increase the setting.
Is the nozzle cartridge for use with the
FM-2024?
Turn the power switch OFF, press-fit the
nozzle for the FM-2024, then turn the power
switch ON.
Is the heating value insufficient?
In cases where the piece to be desoldered is
large, Hakko recommends the use of a pre-
heater to preclude the possibility of damage
to the board or components that might
occur as a result of excessively high nozzle
temperatures.
Is it difficult to get solder on the nozzle?
Refer to “Maintenance of nozzle”.
© The suction power has
decreased.
:
ACTION :
:
ACTION :
:
ACTION :
:
ACTION :
Is the inside of the nozzle or suction pipe
clogged?
Refer to “Maintenance of nozzle” and
“Cleaning the inside of suction pipe.”
Is the filter pipe full of extracted solder?
If the filter pipe is 70 - 80% full of solder,
replace the filter pipe. If the ceramic paper
filter is stiff with absorbed flux, replace the
filter.
Is solder residue stuck on the contact
surface between the front holder or the back
holder bushing and the filter pipe assembly?
Refer to “Checking and cleaning front and
back holder bushings.”
Has the ceramic paper filter (DCB)
deteriorated?
The ceramic paper filter (DCB) is full of flux,
causing a loss of suction. Refer to “Checking
and replacing the ceramic paper filter (DCB).”
16
7
8. PARTS LIST
Desolder control box
O B2068 Power cord, 3 wired
cord & American plug
Desoldering tool
a oe
Co [ms [rrontnower |
o [mss — [Backnorterbusting |
4 |B2872 Handle For gun
configuration
= B2873 Cleaning drill For heating element
B2874 Cleaning pin For 20.02 in.
(20.6 mm) nozzle
B2875 Cleaning pin For 20.08, 0.10 in.
(2.0, 2.3 mm) nozzle
B2878 Back holder A
B2879 [Fans | ooo
*Packing list for conversion kit: 1 pc each of the desoldering tool,
Handle, desolder control box, filter pipe assembly, cleaning drill, nozzle
remover and iron holder.
iron holder
@~® | 634-07 lron holder i 4
iron holder parts
B2786 Holder for iron receptacle a
B2792 Iron holder base With rubber
foot
B2881 Iron holder assembly
Nozzle
N1-L10 | Long nozzle, 0.04 in. (1.0 mm) | 0.04 in. (1.0 mm) | 0.09 in. (2.3 mm)
18
19
9. WIRING DIAGRAM
© DCB
Cord assembly
Transformer
Power switch
Cord assembly
Fuse holder
© MODEL FM-2024
LED circuit board
Switch circuit board
Blue
(CH
nN
White
76) -
Green O ai
a
EX te
Socket 3 Red
Thermistor
VHAKO
HAKKO CORPORATION Lt
HEAD OFFICE SSS
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. A
28920 N. AVENUE WILLIAMS VALENCIA CA 91355, U.S.A. La
TEL: (661) 294-0090 FAX: (661) 294-0096
Toll Free (800)88-HAKKO www.hakkousa.com
2004. 6
MA01301JU040610