HAKKO 703B
REWORK SYSTEM
TROUBLESHOOTING GUIDE
THIS TROUBLESHOOTING GUIDE IS DIVIDED INTO FOUR PARTS:
1. FLOW DIAGRAMS DEPICTING THE PROCESS OF ANALYZING THE PROBLEM OR PROBLEMS.
2. TABLES DEPICTING NORMAL VALUES FOR VARIOUS COMPONENTS.
3. ILLUSTRATIONS SHOWING WHERE AND HOW TO PERFORM CERTAIN OPERATIONS.
4. DETAILED INSTRUCTIONS FOR CERTAIN OPERATIONS.
- WARNING ALWAYS DISCONNECT THE POWER PLUG BEFORE SERVICING THE HAKKO 703B.
FAILURE SO TO DO MAY RESULT IN SEVERE ELECTRIC SHOCK.
1
1. System problems.
PROBLEM: The unit does not operate.
The power switch is turned ON; each station switch is turned ON.
The Hakko 703B does not operate and none of the temperature displays light.
NO
Is the power cord
plugged in correctly?
Insert the plug securely into the socket.
YES
NO
Is the power cord good?
Replace the power cord.
YES
NO
Is the fuse good?
Replace the fuse.
If the fuse blows again, go to page 16.
YES
Is the main power switch good?
(See Table I)
NO
Replace the switch.
YES
Is the transformer good?
(See Table II)
NO
Replace the transformer.
YES
Is the unit functioning properly?
2
NO
GO TO NEXT PAGE.
2. Error messages at turn-on.
PROBLEM: The unit turns on, but error messages are displayed.
The power switch is turned ON; each station switch is turned ON.
One or more digital displays show a system, heater, or sensor error.
System error on one
or more displays?
NO
Continue.
YES
Replace the soldering (or desoldering) PWB,
or call your Hakko representative.
Sensor error on one
or more displays?
NO
Continue.
YES
NO
Is the iron/gun cord plugged
in correctly?
Insert the plug securely
into the receptacle.
YES
NO
Is the iron/gun cord good?
(See check on page 15)
Replace the cord.
YES
NO
Is the heating unit good?
(See Tables IV and VI)
YES
Replace the soldering (or desoldering) PWB,
or call your Hakko representative.
3
Replace the heater.
(See procedure on page 13, 14)
2. Error messages at turn-on, continued.
Heater error on one
or more displays?
NO
Continue.
YES
Go to page 7.
One or more displays
do not light?
NO
Continue.
YES
NO
Is the station switch good?
(See Table III or V)
YES
Replace the soldering (or desoldering) PWB,
or call your Hakko representative.
4
Replace the switch.
3. Basic station problems.
PROBLEM: The tip or nozzle does not heat, or heats intermittently.
The power switch is turned ON; the selected station switch is turned ON.
No system, heater, or sensor error is displayed.
Is the iron/gun cord good?
(See check on page 15)
NO
Replace the cord.
YES
Is the station switch good?
(See Tables III and V)
NO
Replaced the switch.
YES
Is the heating unit good?
(See Tables IV and VI)
NO
YES
Replace the soldering (or desoldering) PWB,
or call your Hakko representative.
5
Replace the heater.
(See procedure on page 13, 14)
4. Soldering station problems.
PROBLEM: The tip does not ‘wet’.
The power switch is turned ON; the selected soldering station switch is turned ON.
No system, heater, or sensor error is displayed.
NO
Is the tip clean and free
from corrosion or oxidation?
Clean the tip.
YES
Is the temperature correct?
(Too high a temperature will
prevent proper wetting)
NO
Adjust the temperature.
(See procedure on page 7
of instruction manual)
YES
Replace the soldering PWB,
or call your Hakko representative.
PROBLEM: Soldering temperature is too low.
The power switch is turned ON; the selected soldering station switch is turned ON.
No system, heater, or sensor error is displayed.
Temperature has been set.
NO
Is the tip clean and free
from corrosion or oxidation?
Clean the tip.
YES
NO
Is the station calibration correct?
YES
Replace the soldering PWB,
or call your Hakko representative.
6
Recalibrate the station.
(See procedure on page 16
of instruction manual)
4. Soldering station problems, continued.
PROBLEM: Intermittent heater errors (flashing display).
The power switch is turned ON; the selected soldering station switch is turned ON.
No system, heater, or sensor error is displayed.
Temperature has been set.
NO
Is the tip large enough for
the work being done?
Use a larger tip.
YES
NO
Is the heater error tolerance
sufficiently board for the work
being done?
YES
Replace the soldering PWB,
or call your Hakko representative.
7
Adjust the heater error tolerance.
(See procedure on page 17
of instruction manual)
5. Desoldering problems.
PROBLEM: The station does not extract solder.
The power switch is turned ON; the station switch is turned ON.
No error codes are displayed.
The pump is working.
NO
Is the nozzle clear of solder?
(See check on page 10
of instruction manual)
Clean the nozzle.
YES
Is the heating element
clear of solder?
(See check on page 12
of instruction manual)
NO
Clean the heating element.
YES
NO
Is the spring filter clean?
(See check on page 12
of instruction manual)
Clean or replace the spring filter.
YES
Is the paper filter
on the station clean?
(See check on page 13
of instruction manual)
NO
Replace the filter.
YES
Is the paper filter in
the handpiece clean?
(See check on page 12
of instruction manual)
NO
Replace the filter.
YES
NO
Is the external tubing free
of kinks or leaks?
Repair or replace.
YES
B
8
5. Desoldering problems, continued.
B
YES
Is the internal tubing free of leaks?
NO
Repair or replace.
YES
Replace the desoldering PWB,
or call your Hakko representative.
PROBLEM: The pump does not work.
Is the handpiece switch working?
NO
Check the switch.
(See procedure on page 15)
NO
Perform maintenance as shown
on page 14 of instruction manual.
YES
Has pump maintenance
been performed?
YES
Call your Hakko representative.
9
NOTE: SEE WIRING DIAGRAM ON PAGE 24 OF THE INSTRUCTION MANUAL WHEN MEASURING TABLE I & II.
TABLE I.
MAIN POWER SWITCH CONTINUITY CHECK.
MEASURE BETWEEN
PIN 1 OF CONNECTOR C1 AND PIN 3 OF CONNECTOR A1 (BLACK WIRES)
CENTER PIN OF CONNECTOR C2 AND PIN 1 OF CONNECTOR A1 (WHITE WIRES)
SWITCH ON
SWITCH OFF
0Ω
∞ (OPEN CIRCUIT)
0Ω
∞ (OPEN CIRCUIT)
TABLE II.
TRANSFORMER RESISTANCE CHECK.
MEASURE BETWEEN
PINS 1 AND 3 OF CONNECTOR A2.
TERMINAL 2 OF THE DESOLDERING IRON SWITCH AND THE CENTER PIN OF
CONNECTOR B1.
TERMINALS 1 AND 2 OF THE DESOLDERING IRON SWITCH.
RESISTANCE READING
2.8 Ω (PRIMARY WINDING)
0.1 Ω
(0-10 V SECONDARY WINDING)
0.2 Ω
(0-24 V SECONDARY WINDING)
TABLE III.
SOLDERING STATION SWITCH CONTINUITY CHECK.
MEASURE BETWEEN
INPUT AND OUTPUT SIDES OF SWITCH WITH SWITCH OFF.
INPUT AND OUTPUT SIDES OF SWITCH WITH SWITCH ON.
RESISTANCE READING
∞ (OPEN CIRCUIT)
0Ω
TABLE IV.
SOLDERING IRON HEATER RESISTANCE CHECK.
MEASURE BETWEEN
PINS 1 AND 2 OF THE SOLDERING IRON CORD (SENSOR)
PINS 4 AND 5 OF THE SOLDERING IRON CORD (HEATER)
PIN 3 OF THE SOLDERING IRON CORD AND THE TIP
RESISTANCE READING
43 TO 58 Ω
2.5 TO 3.5 Ω
UNDER 2 Ω
TABLE V.
DESOLDERING STATION SWITCH CONTINUITY CHECK.
MEASURE BETWEEN
INPUT AND OUTPUT SIDES OF SWITCH WITH SWITCH OFF.
INPUT AND OUTPUT SIDES OF SWITCH WITH SWITCH ON.
RESISTANCE READING
∞ (OPEN CIRCUIT)
0Ω
TABLE VI.
DESOLDERING IRON/GUN HEATER RESISTANCE CHECK.
MEASURE BETWEEN
PINS 1 AND 3 OF THE DESOLDERING IRON CORD (HEATER)
PINS 2 AND 4 OF THE DESOLDERING IRON CORD (SENSOR)
RESISTANCE READING
APPROX. 9.2 Ω
APPROX. 54 Ω
NOMINAL VALUES GIVEN ARE FOR 23°C (73°F). RESISTANCE WILL INCREASE WITH TEMPERATURE.
10
3
4
2
Heating
Element
Sensor
1
5
FIGURE 1.
SOLDERING STATION CONNECTOR
Pins
6
5
1
2
3
4
FIGURE 2.
DESOLDERING STATION CONNECTOR
11
5
4
3
12
8
2
1
7
10
9
6
FIGURE 3.
907, 908 SOLDERING IRON
Heating Element (red)
Sensor (blue)
FIGURE 4.
HEATER CONNECTIONS, SOLDERING IRON
FIGURE 5.
TESTING THE SOLDERING IRON CORD
11
FIGURE 6.
907, 908 SOLDERING IRON (THE POINTS TO RUB)
24V
60W
8
11
1
6
2
5
24V
60W
9
10
9
3
7
4
FIGURE 7.
HAKKO 807 DESOLDERING IRON
Packing
Red leads
White leads
FIGURE 8.
DESOLDERING IRON FLANGE
FIGURE 10.
DESOLDERING GUN TERMINAL
Remove
the filter pipe.
Housing
Unscrew the screws.
FIGURE 9.
HAKKO 817 DESOLDERING GUN
12
PROCEDURES.
A. PRINTED WIRING BOARD TEST, REMOVAL AND REPLACEMENT, SOLDERING, DESOLDERING
1. VISUALLY INSPECT THE BOARD FOR EVIDENCE OF PHYSICAL DAMAGE (BURNS, CRACKS, LIFTED
LEADS&C)
2. CHECK THE RESISTANCE BETWEEN PINS OF THE TRIAC. THEY SHOULD BE AS FOLLOWS:
Between T1 and T2 – open circuit (∞)
Between T2 and ground – open circuit (∞)
Between T1 and ground – 150 to 400 Ω
3. REPLACE THE BOARD IF THERE ARE SIGNS OF DAMAGE, OR IF THE TRIAC RESISTANCE IS NOT AS
SHOWN.
B. PRINTED WIRING BOARD TEST, REMOVAL AND REPLACEMENT, DISPLAY
1. VISUALLY INSPECT THE BOARD FOR EVIDENCE OF PHYSICAL DAMAGE (BURNS, CRACKS, LIFTED
LEADS&C)
2. IF A DISPLAY OF DISPLAYS MALFUNCTION, REPLACE THE BOARD.
C. REPLACING HEATERS
SOLDERING IRONS:
1. CHECK FOR A BROKEN HEATING ELEMENT OR CORD ASSEMBLY.
(1) Disconnect the connecting plug.
(2) Measure the resistance value between pins 1 and 2 (the sensor). See Fig. 1. It should be
between 43 Ω and 58 Ω.
(3) Measure the resistance value between pins 4 and 5 (the heating element). See Fig. 1. It
should be between 2.5 Ω and 3.5 Ω.
If either of the two measured values are outside their acceptable ranges, it will be necessary
to replace the heating element, sensor and/or cord assembly.
(4) Measure the resistance value between pin 3 and the tip. It should be less than 2 Ω.
If it is not, there may be oxidation. Using fine sandpaper or steel wool, lightly rub the areas of
the tip indicated in Fig. 6.
2. DISASSEMBLE THE SOLDERING IRON
Disassembling the 907/908 (See Fig. 3.)
(1) Turn the nut
counterclockwise and remove the tip enclosure
and the tip .
(2) Turn the nipple
counterclockwise and remove it from the iron.
(3) Pull both the heating element
and the cord assembly
toward the tip of the iron and out
of the handle
.
(4) Pull the grounding spring
out of the sleeve.
13
3. MEASURE THE RESISTANCE
Measure the resistance when the heating element is at room temperature.
• The resistance value between the blue leads (sensor) should be between 43 Ω and 58 Ω.
• The resistance value between the red leads (heating element) should be between 2.5 Ω and
3.5 Ω.
If either of the resistance values is outside the acceptable range, replace the heating element.
After replacing the heating element, measure the following resistance values.
• Between pin 4 and pin 1 or 2.
• Between pin 5 and pin 1 or 2.
If both values are not ∞, the heating element and the sensor are touching, which will damage the
PWB.
Finally, remeasure the following resistance values to confirm that the leads are not twisted and
that the grounding spring is properly connected.
• Between pins 1 and 2 (43 Ω – 58 Ω)
• Between pins 4 and 5 (2.5 Ω – 3.5 Ω)
• Between pin 3 and the tip (under 2 Ω)
Instructions for installing a new heating element for 907/908 is included with the replacement
part.
DESOLDERING IRON:
REPLACING THE HEATING ELEMENT
The resistance values of a working heating element are 9.2 Ω between pins 1 and 3 (heating
element), and 54 Ω between pins 2 and 4 (sensor) at 23°C (73°F) — Fig. 2. If the measured
values are outside this range, replace the heating element.
(No. A1174 24V-60W heating element for Hakko 807)
1. Unplug the power cord.
2. Disassemble the heating parts.
3. Turn the back holder knob counterclockwise and pull out the filter pipe.
4. Remove the housing fastener (8) — Fig. 7.
5. Remove the screws securing the housing (10) and the flange (3), (4) — Fig. 7.
6. Remove the front holder (11) — Fig. 7.
7. Remove the screws (5), (6), (7) securing the heating element to the flange, and the screws
(1), (2).
8. Desolder the heating element and Sensor leads.
9. Secure a new heating element (24 V – 60 W) to the flange with screws (5), (6), (7). Install the
heater in such a way that the lead wires are oriented as in Fig. 8.
10. Install the front holder.
11. Resolder the heating element and sensor leads.
12. Reassemble the unit.
13. Recalibrate the temperature.
DESOLDERING GUN:
REPLACING THE HEATING ELEMENT.
CHECK THE RESISTANCE VALUE
The resistance values of a working heating element are 9.2 Ω between pins 1 and 3 (heating
element), 54 Ω between pins 2 and 4 (sensor) at 23°F (73°C) — Fig. 2. If the measured values
are outside this range, replace the heating element.
(No. A1507 24V-60W heating element for Hakko 817)
14
1.
2.
3.
4.
5.
6.
7.
8.
Unplug the cord.
Remove the nut, element cover and nozzle — Fig. 9.
Remove the screws securing the heating element to the housing — Fig. 9.
Remove the screws securing the housing and separate the housing — Fig. 9.
Remove the packing — Fig. 10.
Detach the terminal — Fig. 10.
Remove the old heating element and replace it with a new one — Fig. 10.
Reassemble the unit.
CAUTION:
Be sure to place the packing to prevent air escaping. Failure so to do will cause a loss in suction.
Never set the nozzle temperature above the maximum temperature. It will cause problems.
D. SOLDERING IRON TEMPERATURE ADJUSTMENTS
SOLDERING TEMPERATURE ADJUSTMENT: (SEE PROCEDURE ON PAGE 7 OF INSTRUCTION MANUAL)
SOLDERING STATION CALIBRATION: (SEE PROCEDURE ON PAGE 16 OF INSTRUCTION MANUAL)
HEATER ERROR TOLERANCE ADJUSTMENT: (SEE PROCEDURE ON PAGE 17 OF INSTRUCTION MANUAL)
E. DESOLDERING STATION MAINTENANCE AND REPAIR
CLEANING NOZZLE AND HEATING ELEMENT: (SEE PROCEDURE ON PAGE 11&12 OF INSTRUCTION
MANUAL)
CHECKING FILTERS: (SEE PROCEDURE ON PAGE 12 OF INSTRUCTION MANUAL)
CHECKING 807/817 SWITCH:
• Remove desoldering iron/gun cord from 703B.
• Press the switch, and measure resistance between pins 1 and 6 of the cord connector.
• The value should be 0.
• If the cord is good, replace the switch in the handpiece.
PUMP MAINTENANCE (SEE PROCEDURE ON PAGE 14 OF INSTRUCTION MANUAL).
F. TESTING THE IRON CORD
SOLDERING IRONS:
TEST METHOD 1
1. Turn the unit on.
2. Set the temperature to 480°C (899°F).
3. Without waiting for the iron to reach the set temperature, wiggle and kink the cord at various
points along the length of the cord, including in the strain relief area at the base of the iron
handle. If the heater lamp flickers, the cord is broken and should be replaced.
CAUTION:
The heater lamp will flicker if the iron temperature is allowed to reach the set temperature.
Before replacing the cord, be sure that this is not the reason for the flickering.
15
TEST METHOD 2
Check the resistance between each pin on the connecting plug and its associated wire on the
terminal board insided the handle. (See the chart below.)
All measured values should be 0 Ω. If any value is greater than 0 Ω is ∞, replace the cord.
Pin
Number
1
2
3
4
5
Wire Color
Resistance Value
Red
Blue
Green
White
Black
0Ω
0Ω
0Ω
0Ω
0Ω
REPLACING THE IRON CORD
CAUTION:
It is very important that these connections be soldered well. Poor solder joint could cause the
unit to fail.
1.
2.
3.
4.
5.
Undo the metal grip at the tabs.
Desolder the black and white heater leads.
Desolder the blue and red sensor leads.
Insert the new cord into the metal grip and bend the tabs over.
Insert the black and white heater leads and the blue and red heater leads through the holes in
the fiberboard.
6. Solder these wires to the terminal board.
DESOLDERING IRON:
Check the desoldering iron/gun cord. If it is broken, replace it with a new one. The method of
checking the cord is same as soldering iron except for the following pin No. and color of the wire.
Pin 1 — Black
Pin 2 — White
Pin 3 — Red
Pin 4 — White
Pin 5 — Green
Pin 6 — Blue
CAUTION:
There are two white wires. Check another combination if the first one is not 0.
G. REPLACING FUSE
IF THE FUSE BLOWS AGAIN:
1. Check the heating element leads of 907 iron. Twisted heating element leads may cause shortcircuit and fuse blowout. Also, check the heating element lead of 807/817.
2. Test the printed wiring board. (See procedure A)
3. Check the transformer. (See Table II)
16
Dec. 2002
MA00043JU021201
17
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