Dangerous Prototypes Open Source Hardware

Check D11, 12 and R10. Without Q5 installed check the voltage at K of ZD1 ( 6V ). Replace Q5

So, the controller restarts gracefully, showing the "Power lost" message?

Also it should detect DC supply instead of AC, isn't it?

It's because at the fuse, you're measuring rectified but not smoothed DC (basically same as AC on the transformer, minus bridge drop), smoothed wave on C8 will be √2 times higher (minus D6, Q1 drop).

Also check R9, it have seen some overload, may be damaged.
minkok is absolutely right, should be the zeners, maybe a cold joint.

That wave is weird. Where do exactly you measured it? For a transformer output it's much like a DC wave with ripple, for board DC supply input it has too much of ripple. Maybe D6 is busted?

I would like to correct myself rewiring to switch the pump, it is not Brown and Purple but Blue and Purple.
Blue and Purple = 44K OHM  OPEN and when you press the button = 6.3R OHM, This is for the DSX80.

As always care while playing with voltages in most cases you will have only one chance and I was super close to blowing the Unisolder applying 22v to the PCB killing the switch and the components it has hidden inside somewhere which are 2 Inductors 100Uh, a capacitor 1nf  and a 44k Resistor.

Hope it helps @RRRoamer no doing my same mistake.

@RRoamer: these glitches are normal (you are not using toroidal transofmer, right?) Check the VIN and VINT signal at the MCU end.

• The 20 to 25C overshoot when first turning on the iron is a bit irritating, but completely livable.
• The much smaller (5 to 6C) overshoot when the temperature (while the iron is just resting and not soldering) is a bit more bothersome.  But again, definitely livable!
• The bigger issue is it is about 25C below the indicated temperature.

I did indeed misunderstand you!  However, I think the problem is on my back board.  I hooked it up to the scope on the 24VAC input and was getting glitches on the power as soon as it tried to power the iron.  It looks like something is shorted in the iron power circuit so as soon as it applies power to the heater, it dies.  Now I need to spend some quality time with the schematics and perhaps the microscope to see what I messed up.

I am not sure you understand what I mean, give Unisolder 24VC DC and see if you replicate the issue not the iron itself.
RePower supply minimum suggested is 24V @ 5AMP which is 30V @ 4AMP.

Glad you make work the compiler V3 but 2.50 work perfectly with no warnings/errors as suggest by Vulkan35 but as long you see build success I guess it should be fine.

@afedorov Thanks for sharing.

afedorov,

Thank you!  I will give this a try and see if I can get it compiling with the free xc32 v3.00 version this afternoon and report back.

For XC32 v3+ to work, -fgnu89-inline have to be added to the xc32-gcc Additional options. Also, in project's firmware.ld file INPUT("processor.o") should be replaced by OPTIONAL("processor.o")

@RRRoamer  Before doing any testing with the scope: 

Re-wiring make sure the wire you use is good for the current you have mine draw 3.2 amp from cold, I notice you connected the black to Vout1-.

Vout1-&+ should be for the power heater, if the jumper wire you use is good enough for the current then it does not matter since they are shorted.

If the wiring is fine what about using a bench supply with DC will it do the same?

Then, at 0 degrees celsius it should be around 20 ohms. Then c0 should be -20.

c1 = 1/0.077 = 12.98, make it 13.0

The currentA shoud be around 1.8mA, then CBandA shoud be 0 instead of 1, and CurrentA should be 37.

Offset is a bit harder. 1.8mA * 60ohms * 27 = 2.916V after the first amplifier, which means the second one's gain should be around 1, which in terms of iron profile is 256/27 = 9.218 = 9.0, which is too low.

Now instead of using 37 for the current, we use 24, and the current becomes 24*(1.225/100/256) = 1.148mA

Then 60*1.148ma*27.77 = 1,913V after the first amplifier, but this includes also the offset from the 20ohms at 0 degrees. If the offset was not there, the foltage is 40*1.148mA*27.77 = 1,275V. These 1,275V represents 500 degrees at the sensor, and shoud be amplified to 3.0V by the second amplifier, so the gain should be 3/1,275 = 2,353, which in terms of iron profile gain is 2.353/(27/256)=22.

Now the offset in the profile shoule be 20 ohms * 0.001148 * 27.77 * 27*(22/256) * 1024/3 = 505.12 = 505.

So:

CBandA = 0;
CurrentA = 24;
Gain = 22;
Offset = 505;
c0 = -20;
c1 = 13;

This is just an approximation, of course. It takes some experiments until everything gets right.

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