Note: " " = CKT GND

HAKKO 936 - SchematicRendered by: Tom Hammond - NØSS 26 MAR 2011 v1.7

MAIN PC BOARD

AC ON/OFF PC BOARD

VREF

VREF

VREF

VREF

IC2B

OUT

LM324

IC2A

OUT

LM324

IC2D

LM324

OUT

TRIAC DRIVERIC1

NC

B

A

C

G

F

E

D

1

3

2

4

8

7

6

5

VREF

LM324

OUT

U1C

VEE

VCC

VCC

VEE

AC

Q1

R4

T1

T2G

IC2C

ZD2

ZD1

10

9

8

11

+

_

4V+

V-

R10

C3

C2

C1

R1D3

R3

C4

C9

R13

R2R14

1

2

3+

_

+

_

R7

TEMPCTRL

5

6

7

R15

R8

R5

C5

R9

R11

SENSORPINS

SOLDERINGIRON PLUG

SLEEVE GND

HEATERPINS

R17

R16

C6R12

R6

C7

CALCTRL

12

1314

HEATERLED

1

3

5

HANDSETTIP GND

BLK

WHT

GRN

D1

D2

HOT

NEUT

GND

CHASSISGND

CHASSIS GND

SOLDERING IRON/CHASSIS GND

CHASSISGND

POWERXFMR

NEC AC05D5A TRIAC

1k

NEC* µPC1701CZero Volt Switch

NEC µPC324ALo-Pwr Quad OpAmp

220µF 50V

47µF 16V

47µF 16V

5.1Zv 500mW

5.1Vz 500mW

680

360 2Wmetal film

15k

.01/50V

.01/25V1k8

1k0

5k0ALPS RK09L1140A65 5K

(502B) LINEAR

390 1%

1M0

.01/25v

130k1%

27k01%

300

HANDSETSOCKET

1N4148

100k

5k1 1%

24k0

.01/25V

1k0 1%

180k 1%

66k5 1%

1k2

0.125V

1N4007

120VAC 24VAC

120VAC 2A

HAKKO 936 TEMPERATURE-CONTROLLEDSOLDERING STATION PC BOARD LAYOUT

Rendered by: Tom Hammond, NØSS 26 MAR 2011 v1.7

PC BOARD AS VIEWED FROM THE COPPER (SOLDER) SIDE

HAKKO 936 TEMPERATURE-CONTROLLEDSOLDERING STATION PC BOARD LAYOUT

Rendered by: Tom Hammond, NØSS 26 MAR 2011 v1.7

PC BOARD AS VIEWED FROM THE COMPONENT SIDE

HEATSINK

HAKKO 936 TEMPERATURE-CONTROLLEDSOLDERING STATION PC BOARD LAYOUT

Rendered by: Tom Hammond, NØSS 26 MAR 2011 v1.7

PC BOARD AS VIEWED FROM THE COMPONENT SIDE

HTR

LED

JP1

R4

R13R6

R7

R2

R8

R12 R10

R15

D1D2

C1

C3

C7

C2

Q1

IC1

IC2

T1 T2 G

N/C

N/C

+

+

+

+ VEE

VEE

VCC

VCC

VCC

VREF

CN1FG

1

2

3

4

5

VR2

PVR1K A

HEATSINK

HAKKO 936 TEMPERATURE-CONTROLLEDSOLDERING STATION PC BOARD LAYOUT

Rendered by: Tom Hammond, NØSS 26 MAR 2011 v1.7

PC BOARD AS VIEWED FROM THE COMPONENT SIDE

1k

100k

47uF16v

47uF16v

220uF50v

AC05DB1081

C324C

C1701C

27k 1%

5.1k 1%

1.8k

24k

680

130k 1%

390 1%

0.125v

300

5k

1N41481N4148

J

C1 220uF 50VC2 47uF 16VC3 47uF 16VC4 0.01 (103) 50V CeramicC5 0.01 (104) 25V CeramicC6 0.01 (104) 25V CeramicC7 0.1 (104) 25V CeramicC8, C10-C13 n/aC9 0.01 (104) 25V CeramicD1 4N4148 Small Sig Sil, or similarD2 Small Sig Sil, or similarD3 1N4001, or 50VDC (or higher) @ 1AIC1 NEC* PC1701C, Zero Volt SwitchIC2 NEC* C324A, Lo-Pwr Quad OpAmpQ1 NEC AC05D 5A TriacR1 360 2W 5% metal filmR2 1.8k 1/4w 5% carbon filmR3 15k 1/4w 5%R4 330 1/4w 5%R5 1.0k 1/4W 1% metal filmR6 27.0k 1/4W 1%R7 5.11k 1/4w 1%R8 390 1/4w 1%R9 66.5k 1/4w 1%R10 680 1/4w 5%R11 180.0k 1/4W 1%R12 130.0k 1/4W 1%R13 100k 1/4w 5%R14 1k 1/4W 5%R15 24k 1/4w 5%R16 12k 1/4w 5%R17 1M 1/4w 5%ZD1 5.1Vz 500mW,ZD2PVR1 TEMP ADJ POT - ALPS RK09L1140A65 5K

(502B) LINEARVR2 CAL TEMP POT - Bournes 3362P-1-501LF,

see note below

* NOTE: NEC, is now part of Renesas Electronics Corp.

NOTE: In the 936, the CAL TEMP pot is 300 Ohms, howeverwe were unable to find a pot in this physical format rated at300 Ohms, so a 500 Ohm device has been specified as asuitable substitute.

4N4148

P

carbon filmcarbon film

metal filmmetal film

metal filmmetal film

carbon filmmetal filmmetal film

carbon filmcarbon filmcarbon filmcarbon filmcarbon film

5.4Vz (measured)5.1Vz 500mW, 5.2Vz (measured)

μμ

CAL TEMP CTRL

HAKKO 936-x PC Board Parts List

ADDING AN ON/OFF LED TO HAKKO 936-XTEMP-CONTROLLED SOLDERING STATIONS

by: Tom Hammond, NØSS 03/09/2011, v.4.1

Is it turned ON or not?

By golly, it WAS, but how could you tell?

ADDING AN ON/OFF LED TO HAKKO 936-XTEMP-CONTROLLED SOLDERING STATIONS

by: Tom Hammond, NØSS rev. 03/09/2011

The Hakko 936-x line of temperature-controlled soldering stations has one flaw. It offers no real POWER ON/OFFindication. There is a red LED which illuminates when heat is being applied to the tip of the iron, but it lightsONLY when heat is being applied. As a result, if you glance at the station when no heat's being applied to the tip,you might think the device is actually turned off. I've walked off and left the soldering station running for severaldays because the red LED was extinguished when I looked at it, even though power was still applied.

Here's a fairly simple-to-install mod which will add a green LED to the right hand side of the front panel on the936. This LED will be illuminated any time power is applied to the soldering station.

1. Remove four (4) screws from the bottom of the case, and lift off the case top.

2. Remove the temperature control knob and carefully loosen the setscrew in the temp-lock mechanism.Remove the setscrew and nut and set them aside in a safe place.

3. Lift the front panel/PC board combination out of the case and carefully desolder the 6-pin (five [5] pins andone [1] lug) soldering iron cable connector from the PC board. USE CARE HERE.

4. With the 6-pin connector free of solder, hold the front panel on its sides with both bands and use your thumbto press on the shaft of the temp. control pot to push the PC board assembly away from the front panel.

4. Using Figure 1 (see next page), a scale drawing of the front panel, as an overlay of the drilling template, laythe template onto the front panel and CAREFULLY center punch and then drill a 3/16" (4.75mm) hole. Thenuse a much larger (about 1/2" / 13mm) bit (hand-held), or a hand reamer bit, to 'hollow' out a bit of the backside of the hole just drilled to allow the new LED to extend out the front of the panel just a small distance.

5. Refer to Figure 2 (next page),SOLDER SIDE of the PC board. Using a #60 (0.040") or smaller drill bit, drillfour (4) holes, as indicated, to accept the new LED (green, T1-3/4 size), and the current limiting resistor(R ,3.0k to 3.9k 1W, the exact value is not terribly critical, a metal film/oxide resistor was selected for itssmaller physical size), Mouser Electronics #

6. Once the four holes have been drilled, use a sharp knife blade and scrape away the solder mask from thetwo points indicated in Figure 2. Once these two points are cleaned of solder mask, tin the bare copper.

7. Regarding the LED... generally, there is a flat side on the base of the LED body to indicate the CATHODEside. Additionally, on most (though not all) LEDs, the CATHODE lead is the SHORTER of the two (assuminga new LED with un-cut leads).

8. ALL REMAINING STEPS REFER TO FIGURE 3 (next page). Install (BUT DO NOT SOLDER) the LED withits CATHODE lead in the hole indicated by the illustration. DO NOT BEND THE LED LEADS AND DO NOTSOLDER YET!!!

9. Insulate and bend the leads of R at right angles and at appropriate distances to allow R to drop into itsmounting holes. Raise R about 1/8" (3 mm) above the PC board and solder ONLY the lead which isconnected at the top of the resistor to the copper land.

10. BEND the bottom lead of R to the right, and around the ANODE lead of the LED. Use wire cutters to trimany excess lead length once the lead has been bent around the LED anode lead. DO NOT SOLDER YET.

11. Temporarily re-assemble the front panel and the PC board, ensuring that the 6-pin connector is properlyinserted into its PC board holes. Ensure that the front panel and the PC board are well mated and parallel toeach other, then press the green LED into its hole in the front panel so it seats properly.

12. With the new LED in place, solder the junction of R and the LED anode lead.

13. Bend the CATHODE lead of the LED flat against the PC board and so it touches the adjacent area of the PCboard from which you scraped away the solder mask. Solder the LED CATHODE to this point on the PCboard.

14. Re-solder all (6) of the 6-pin heating element connector leads.

15. Reassemble the soldering station.

L

L L

L

L

L

594-5083NW3K900J (3.9k 2W metal film).

LED (shorter)Cathode lead

Rev.: 03/09/2011 v4.1

Cut away these two sectionsof the template to allow thetemplate to fit over the temp

control bearing & heatingelement connector

Drill 3/16"(4.75mm)hole here

Figure 1.HAKKO 936-X T/C Soldering Station Front Panel

(Viewed from the FRONT SIDE)

Figure 1 - Cut out the template at right. Then cut out thetwo marked areas so the template will clear the temp.control bearing and the heating element jack when laid ontop of the front panel. Tape the template into place on theFRONT SIDE of the front panel. CAREFULLY centerpunch the point where the hole is to be drilled. Drill a3/16" (4.75mm) hole from the front. You may want to firstdrill a smaller 'pilot' hole and work up, in steps, to thelarger final hole diameter. This will often help reduce thechances of paint chipping, etc. Then, use a larger (hand-held) bit (or a reamer) from the back side to 'hollow out' theback of the hole just enough to allow the tip of the newLED to extend out the front of the front panel to the sameextent as that of the red LED. If the green LED is allowedto protrude a bit farther than the red LED, it will be morereadily noticed as you use the device in a normal workingenvironment.

GreenT1-3/4

LED with flat(cathode) sideaway from Rand bent flatagainst PC

board to touchcleaned andtinned land)

L

Anode(longer lead)

LimitingResistor (R

(Insulate Leads& raise above

PC board)

L)

Figure 2. Hakko 936-x PC board preparation(as viewed from the of the PC board)SOLDER SIDE

Figure 3. Hakko 936-x PC board - New Components(as viewed from the of the PC board)SOLDER SIDE

0.70"(17.8mm)

1.33"(33.8mm)

Bend existingpower resistorout of the way(TOP of PCB)

Drill four (4)holes (.025" to.04" dia.) inPC board atpoints shown

After drilling,scrape soldermask awayfrom this partof the land.

Scrape soldermask awayfrom this partof the land.