If you have troubles with drilling only, most probably it is due to wrong units or formatting. Usually it is stated in the service's FAQ what units and formatting it's expecting. Also, X2 is not very popular, better to avoid it.
You mean earth from a main. Afedorov has a own schematic, inspired from eevblog, published somewhere here
It's not perfect, still I'm using it with no problems so far. I don't know why, but my transformer, having separate shield winding directly connected to earth, still gives decent coupling to the secondary, so I'm having around 13VAC between tip and earth with 1M protection resistor. Though, I'm sure it's better than having direct earth connection which was played with me hard couple of times.
Faulty current temp calculation is the cause of everything else. This temperature is reset if PV->Starting || PV->NoHeaterCnt || PV->NoSensor || PV->ShortCircuit First should be false as controller is already started, Noheater and ShortCircuit also should be false as heater resistance just below 3 Ohm is correct and with no flickering, NoSensor also should be false as ADC reading seems to be fine. Between ADC value and Current Temperature is heavy floating point math happening, probably something's going wrong there. I tend to agree with minkok for a faulty MCU.
Original FW is perfectly fine. And display code modifications shouldn't be a problem. Changing PID flow is tricky. It uses timers and ISR. Timer values are calculated on init depending on AC/DC supply and AC frequency. It's start from ln 135 in main.c. The problem isn't there, messing with it is pointless. I've just tried to heat up C245 with hot air @270*C and got ADC value around 250, maybe it helps somehow. Actually, one path is remain unchecked - U16 pin 19, it's close to ground traces, maybe it is shorted to GND, ah, well, then B channel calibration would be screwed, never mind.
Well, it works, but I forgot that heater channel also have to be switched for SenseB <> Vout2- calibration. But with SChannel only configured, resistor may be connected to SenseB <> Vout1-. Should show same R 1000 as with ch A.
Can I do that for sense B, without modifying the firmware? Or do I have to modify the firmware for that?
FW modification is required. Theoretically, only SChannel parameter of NO INSTRUMENT profile have to be changed to 2, but I didn't tried it. Both current source channels are set to 128, so calibration resistor can go to either. If you have some problems with ch. B ADC value would be close to its limits.
But, I also haven't found the reason sparkybg gave why it should not be connected the other way round, like for the C210. Can anyone point me to a answer there?
It's because C210 TC is connected differently within cartridge. With C245, temp sensing is using both diff. amp. channels with ch. B going below GND, while calibration is done using ch. A only, probably the problem is with ch. B, i.e. U16 and surroundings. Is -0.6V rail OK? Having the ability to switch between channels in calibration mode will ease the input section troubleshooting.
How the beginner will realize existing of that stuff , to be able to take adequate action
Well, such a beginner shouldn't even think of assembling this project in the first place. It's pretty advanced stuff. Anyway, if the project will adopt this feature, this should be mentioned in the readme/documentation.
Actually it has 440uf, but will it be enough?... may be yes
No, it senses rectified AC, there is nothing to do with any MCU supply filtering. There is some firmware filtering, but I didn't analyze what exactly FW is doing in this regard. And it actually don't have to be that strict. If adding such a feature, power lost detection could be just blocked for a couple of mains periods, forty odd ms should be plenty to switch a relay, and not even close to VDD dropping below brown-out threshold. It's somewhat half a second power lost message is held on the display prior it shuts down. Phasing out a transformer is pretty easy, basic stuff, no big deal even for a beginner.
Good only for DC supply. On AC it would possibly be asymmetric to the transformer and it will be DC biased. Magnetics doesn't like that stuff. Again, Sparky already explained this.
Which voltages would I expect to change when I adjust current?
All the voltages along temperature measurement path. Linear dependency on current: two times less the current - two times lower the voltage. Your voltages seems perfectly fine. Only R55 separate U17:6 with ADC input, but it's unlikely the cause of the problem.
I did this with a 1k resistor and then with 10ohm resistor at Vout1- to SenseA:
It's a little bit off, but I'm sure it's due measurement/identification. At least it's not 6 times lower. It seems diff amp is working OK. Some fluctuation is normal as MCU interrupts calibration for tool ID at around 5Hz. Try to adjust the current by up/down buttons in the calibration menu and check if voltages changes accordingly. Check reference voltage on C44, should be 3V.
Forget about 1k resistor, it was only needed to check current source section, which works fine on your board.