Dangerous Prototypes

In development => Project logs => Topic started by: sparkybg on May 14, 2015, 06:18:08 pm

Title: Really universal soldering controller
Post by: sparkybg on May 14, 2015, 06:18:08 pm
Well, here it is, at last.

[attachment=5]

The intention was to build the most universal soldering controller I can think of. It can drive any low voltage (upto 24V) iron with thermocouple or resistive sensor, in series with the heater, or separate.

Here is a short list of features:
- power: 9-28V, AC or DC
- 2 separate heater control channels
- 2 independent sensor inputs
- current source on any sensor input 3uA - 12mA, wuth 2 bands (x1, x16) and 256 steps per band
- flexible differential amplifier input selection
- amplifier gain from 0 to 750 in 256 steps
- negative offset selection in 1024 steps
- resistive instrument identification (upto 625 different instruments can be identified by 2 resistors on the connector)
- polynomial floating point voltage/resistance to temperature calculation
- wave shaping to filter out the inductive peaks from series sensor signal
- PID control with power limit
- isolated USB port for firmware updates and live data
- 128x64 OLED display with rich user interface.

Tested so far with:
- HAKKO T12/T15 (series TC)
- HAKKO FX8801 (PTC)
- PACE TD100 (series TC)
- JBC C245 (series or separate TC)
- JBC C210 (series TC)
- JBC Microtweezers (2 separate heaters, each with series TC)
- WELLER WSP80 (PTC) (This iron was sent to me by a reader of the thread for a previous version of the controller. Thanks, Jaroslaw)
- ERSA RT80 (series PTC/heater resistance)
- various chinese cheap irons with separate TC

Here are the schematics, gerbers and software (4 April 2017):
[attachment=1]
[attachment=3]
[attachment=2]
[attachment=0]

Update (4 April 2017): The PC Software is now entirely in C#, the front end is rewritten. Now you can program only the bootloader, and then use the software for firmware updates using the USB connection. The PC software also does not crash anymore when device is unplugged and plugged in the USB or turned on/off, and automatically switches to bootloader and back when uploading new firmware. Also, a legend with checkboxes is added for every data that is displayed on the graph, so you can switch it on or off. There is still pretty much work to be done on it, but at least it is much more functional now.
Added to the firmware are Pace TD100 Black and Weller WMRT profiles, some work is done on several other places. Now the firmware handles better some irons, where there was initial overshoot when heating for the first time or changing the target temperature.

Some movies:
JBC C245: https://www.youtube.com/watch?v=oTdQB4y ... e=youtu.be (https://www.youtube.com/watch?v=oTdQB4ywDOA&feature=youtu.be)
JBC C210: https://www.youtube.com/watch?v=iyz-EDf ... e=youtu.be (https://www.youtube.com/watch?v=iyz-EDf-JaY&feature=youtu.be)
T12, JBC C210, JBC Microtweezers: https://www.youtube.com/watch?v=-f0KSU0PJzc&t=70s (https://www.youtube.com/watch?v=-f0KSU0PJzc&t=70s)
Chinese T12: https://www.youtube.com/watch?v=u588sh- ... e=youtu.be (https://www.youtube.com/watch?v=u588sh-4thg&feature=youtu.be)
Weller WSP80: https://www.youtube.com/watch?v=gd_8w7l ... e=youtu.be (https://www.youtube.com/watch?v=gd_8w7l8_Bo&feature=youtu.be)
Weller WMRT: https://www.youtube.com/watch?v=eHNJuQE ... e=youtu.be (https://www.youtube.com/watch?v=eHNJuQEw6XU&feature=youtu.be)

A comparison of irons/tips used in the movies:
(http://http://dangerousprototypes.com/forum/download/file.php?id=11539&t=1)

The calibration precedure:
- Connect a resistor with well known resistance (0.1%) of around 10ohm between SENSEA and Vout1-
- Go to "CALIBRATION" submenu
- Adjust the calibration trimmer until you get value of "R" as close as possible to the resistance of the resistor, multiplied by 100 (1000 for 10ohm resistor).

On the left - calibration "fixture" with soldered 9.8ohm resistor, on the right - my connector layout:
[attachment=4]

Connections to different tips/irons:

1. HAKKO T12:
 - Outer shell, and heater negative (middle) terminal connected together to Vout1- and EARTH
 - heater positive (bottom terminal) connected to Vout1+ and SENSEA
 - 1k resistor between ID and Vout1-
 - 5.6k resistor between ID and Vout2-

2. HAKKO FX8801, HAKKO 907 (original, with PTC sensor):
- Outer shell, PTC negative  and heater negative connected to EARTH, Vout1- and SENSEB
- Heater positive connected to Vout1+
- PTC positive  connected to SENSEA
- 1k between ID and Vout1-
- 820ohm between ID and Vout2-

3. JBC C245:
 - Outer shell (green wire) connected to EARTH and SENSEB
 - Heater positive(red wire) connected to Vout1- and SENSEA
 - Heater negative(blue wire) connected to Vout1+
 - 150ohm between ID and Vout1-
 - 5.6k between ID and Vout2-

4. JBC C210:
 - Outer shell (green wire) connected to EARTH and SENSEB
 - Heater negative (middle terminal, blue wire) connected to Vout1-
 - Heater positive (smaller terminal, red wire) connected to Vout1+ and SENSEA
 - 3.0k between ID and Vout1-
 - 5.6k between ID and Vout2-

5. JBC Microtweezers:
 - Outer shell of both tips (green wire) connected to EARTH
 - Heater 1 negative (blue wire) connected to Vout1-
 - Heater 1 positive (red wire) connected to Vout1+ and SENSEA
 - Heater 2 negative (brown wire) connected to Vout2-
 - Heater 2 positive (yellow wire) connected to Vout2+ and SENSEB
 - 1.0k between ID and Vout1-

6. WELLER WSP80:
- Outer shell, PTC negative  and heater negative (white, black and brown wires) connected to EARTH, Vout1- and SENSEB
- Heater positive (blue wire) connected to Vout1+
- PTC positive (red wire) connected to SENSEA
- 120ohm between ID and Vout1-
- 5.6k between ID and Vout2-

7. ERSA RT80:
- Outer shell and Heater/PTC negative (pink and white wires) connected to EARTH, Vout1- and SENSEB
- Heater/PTC positive (black wire) connected to Vout1+ and SENSEA
- 300ohm between ID and Vout1-
- 110ohm between ID and Vout2-
Title: Re: Really universal soldering controller
Post by: ppsati on May 14, 2015, 08:52:28 pm
Thank´s "sparkybg" the best.
I'll try ...
It works with JBC HT420-A?
Title: Re: Really universal soldering controller
Post by: Erythros on May 14, 2015, 09:13:45 pm
Thank you for your work! I will definitely build it.

Will SparkySoft Ltd. sell PCBs?
Did I miss BOM? (Or if not, could you post one, please?)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 14, 2015, 09:15:36 pm
[quote author="ppsati"]
It works with JBC HT420-A?[/quote]

I don't have HT420 to try. But it is a matter of profile in the iron.c file.

When I finish the PC software you will be able to make and program user profiles without altering the iron.c file and uploading new firmware every time you need a new profile.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 14, 2015, 09:17:18 pm
[quote author="Erythros"]
Will SparkySoft Ltd. sell PCBs?
Did I miss BOM? (Or if not, could you post one, please?)[/quote]

Unpopulated PCBs - maybe. I don't know yet.

BOM will be there soom. As I said, I will update the first post from time to time with new things.
Title: Re: Really universal soldering controller
Post by: ppsati on May 14, 2015, 09:43:09 pm
[quote author="sparkybg"][quote author="ppsati"]
It works with JBC HT420-A?[/quote]

I don't have HT420 to try. But it is a matter of profile in the iron.c file.

When I finish the PC software you will be able to make and program user profiles without altering the iron.c file and uploading new firmware every time you need a new profile.[/quote]

Great "sparkybg".
When finished this project, will test ...

By the way if you have for sell the Unpopulated PCBs, I buy for sure ...
Says something , if I have to give the money win to someone, I'd rather give it to you.

Thank's for this work.
Title: Re: Really universal soldering controller
Post by: ppsati on May 14, 2015, 11:15:45 pm
Sparkybg,

Did you have a components list in Excel, as in the previous version?
Title: Re: Really universal soldering controller
Post by: SZ64 on May 14, 2015, 11:17:59 pm
[quote author="ppsati"][quote author="sparkybg"][quote author="ppsati"]

By the way if you have for sell the Unpopulated PCBs, I buy for sure ...
Says something , if I have to give the money win to someone, I'd rather give it to you.
[/quote][/quote][/quote]

I'm also doing ...;)
Title: Re: Really universal soldering controller
Post by: diogoc on May 14, 2015, 11:24:47 pm
Looks nice!
You put a lot of work on it.

Thanks for your work.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 14, 2015, 11:25:10 pm
[quote author="ppsati"]Sparkybg,

Did you have a components list in Excel, as in the previous version?[/quote]

There will be, soon.

P.S.: BOM is uploaded to the first post.
Title: Re: Really universal soldering controller
Post by: ppsati on May 14, 2015, 11:47:55 pm
[quote author="sparkybg"][quote author="ppsati"]Sparkybg,

P.S.: BOM is uploaded to the first post.[/quote][/quote]

Sparkybg,

I can´t open the file UniSolder52_BOM.xls
Somebody has the same problem?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 15, 2015, 12:00:42 am
[quote author="ppsati"][quote author="sparkybg"][quote author="ppsati"]Sparkybg,

P.S.: BOM is uploaded to the first post.[/quote][/quote]

Sparkybg,

I can´t open the file UniSolder52_BOM.xls
Somebody has the same problem?[/quote]

Try again. It should be OK now.
Title: Re: Really universal soldering controller
Post by: mrjoda on May 15, 2015, 12:06:26 am
hi sparkybg ,

in first thank you for sharing.


in second - you choose a hard way i think. Your desing is little overcomplicated. But ok is it your choice you are designer. All analog front end with DAC atc. you have can replace one ADC from analog devices with ten bucks price... For example AD7730. Yes, is it overkill like hell but you need almost none external parts.

but you know , one problem have thousands possible solution so... :)

best regarts :)
Title: Re: Really universal soldering controller
Post by: randomone on May 15, 2015, 12:23:03 am
[quote author="mrjoda"]
in second - you choose a hard way i think. [/quote]

Maybe your right. I admired the route he chose, I would also have opted for a monolithic solution, but this is no Mk1. It has software adjustable gain, offset, current sources and sinks and a host of optimizations to see the true TC signal. It works very well indeed.

I researched before opting to build this and no other open source offering comes close.

It also works on Aoyue Tweezers, Aoyue desoldering gun and a ZD-929C iron.
Title: Re: Really universal soldering controller
Post by: ppsati on May 15, 2015, 12:43:52 am
[quote author="sparkybg"]


Try again. It should be OK now.[/quote]

Thank´s Sparkybg,

Now is ok.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 15, 2015, 01:55:59 am
[quote author="mrjoda"]For example AD7730. Yes, is it overkill like hell but you need almost none external parts. [/quote]

AD7730 is no good for what I am doing, because:

- it is too slow - I have around 200 microseconds to stop the power, wait the TC voltage to come to it's real value, connect the amplifier to this voltage, wait for the amplifier to set it's putput to what I want to read, take the measurement from the adc, disconnect the amplifier from the TC, run the PID, and evenually turn the power back on. The TC on some irons is in series with the heater, remember?

- the input must be more flexible - I don't have much wires available in the connector, and it must be able to ground both inputs while the power is on. It must be able to invert the inputs, to connect them in single ended or differential mode, and negative input common mode voltage - some iron tips are connected in a way giving negative voltage (JBC C245 for example) and differentioal input is used to read them, and in the same time other irons (JBC Microtweezers) are connected in a way that the same two wires to the same connector are used as 2 separate single ended inputs.

- I need more gain steps in order to use full input of the ADC, no matter what TC is on the input - some tips TC gives 40mV at 500 degrees Celsius, some gives just 4-5mV.

- I need more offset steps. With 10bit offset steps and 10bit ADC, you have direct equality between ADC reading and offset setting - if you set the offset to a value of 100, the input falls with exactly the same amount. I am using offset correction not because the amplifiers got offset, but because PTC measurement needs offset correction to exclude the zero temperature resistance in order to use the fill ADC range for temeratures of 0-512 degrees Celsius.

And yes, I agree there are lots of parts there, but after all it is not so complicated, nor too expensive. It just needs more time to assemble.

I must admit that I didn't consider ready made analog frontend chips for this project. I will have this in mind in the future. I will even take a look at AD's site if something can be applied to a project like this.
Title: Re: Really universal soldering controller
Post by: mrjoda on May 15, 2015, 11:40:36 am
I collect lot of possible solution how to build controller. Universal controller is no my way so i searching possible solution for T12/JBC. One of them is use these lovely ADC. I am realy suprised because they are so cheap (a few types :) ) !

Better as Analog maybe will be some No Latency Delta Sigma ADCs from Linear ( LTC2410 11€  maybe ? or fast LTC2440 14€ ). Advantage is autozeroing ADC and realy little noise.


I dont want you dishonor your work,god no, its nice and i like it. I write you only another possible way. Maybe someone read this and try it :)


I dont have fear from lot of parts :) But this is not beginner project maybe will be good give warning to front of your topick. You spare yourselft from lot of "stupid" question" from beginer. I publish some project and trust me, this question will come :)


You are using PIC32. This is fu... powerfull MCU. How much power (in %) you need for one cycle (switch,measure, computation, control, display) ? Because this is like cortex M4, you may play video on this beast.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 15, 2015, 12:15:36 pm
[quote author="mrjoda"]I collect lot of possible solution how to build controller. Universal controller is no my way so i searching possible solution for T12/JBC. One of them is use these lovely ADC. I am realy suprised because they are so cheap (a few types :) ) ![/quote]
If you are making it for more than one tip, it is already an universal one. :)

I would like to see the T12 project using AD7730 you mentioned. Is it published somewhere?

[quote author="mrjoda"]
Better as Analog maybe will be some No Latency Delta Sigma ADCs from Linear ( LTC2410 11€  maybe ? or fast LTC2440 14€ ). Advantage is autozeroing ADC and realy little noise.
[/quote]
I dont'see a reason for using these. Every MCU has ADC inside it these days. My older project can handle both T12 and JBC C245 with single external autozeroing opamp that costs 3USD. It can be made to handle C210 with some modifications.

LTC24xx are also tooooo slow for my approach. Conversion time is 150 milliseconds and more. And you don't need these 24 bits of resolution anyway. The noise at these gains is several magnitudes higher than the LSB of that ADC.

[quote author="mrjoda"]
I dont want you dishonor your work,god no, its nice and i like it. I write you only another possible way. Maybe someone read this and try it :)
[/quote]
Yes, there are many possible ways for a single task in electronics. Honor/dishonor is out of question here.

[quote author="mrjoda"]
You are using PIC32. This is fu... powerfull MCU. How much power (in %) you need for one cycle (switch,measure, computation, control, display) ? Because this is like cortex M4, you may play video on this beast.[/quote]
As I said, it uses floating point calculations, waveshaping, RMS voltage/gurrent calculations and so on. This means intensive integer 32bit multiplications, shifts, and so on. For example the millivolts to temperature calculation is done using polynomial with 10 members. It does this calculation using 32bit mantissa floating point numbers and completes it in around 20 microseconds. The whole waveshaping, temperature calculation, PID and so on is completed in around 50-60 microseconds. RMS current, voltage and power calculations are done in arouns 100 microseconds. All this is done between the half periods of the mains voltage, where the voltage is less than around 3 volts. You need computational power for this. This is the bottleneck of the project, and you need a good fast MCU for this. And after all, if it costs under 10 bucks, why should I bother using slower MCU? Computational power is cheap these days. From my point of view - it is better to buy a faster MCU and write the firmware in C/C++, than using slower MCU and do a lot of optimizations and write critical parts in assembler for example.
Title: Re: Really universal soldering controller
Post by: mrjoda on May 15, 2015, 05:06:43 pm
i couldnt find any word about FPU in DS of PIC32MX564F128H... This MCU doesnt have FPU accelerator ?????
Title: Re: Really universal soldering controller
Post by: sparkybg on May 15, 2015, 05:26:27 pm
PIC32 does not have FPU, but has 32x32=> 64 2 cycle multiplication, division and barrel shift, so it handles floating point pretty well. Also, I've done some optimisations for polynomial calculations with 32bit mantissa and exponent, and calculation time is more than 3 times lower, compared to same calculation when using built in libraries for single precision floating point, and 256 times more precise. You can see the code in pid.c file.
Title: Re: Really universal soldering controller
Post by: Sjaak on May 15, 2015, 05:31:27 pm
What is the cost of this soldering controller? It looks quite complete but also costly :)
Title: Re: Really universal soldering controller
Post by: mrjoda on May 15, 2015, 05:44:09 pm
[quote author="sparkybg"]PIC32 does not have FPU, but has 32x32=> 64 2 cycle multiplication, division and barrel shift, so it handles floating point pretty well. Also, I've done some optimisations for polynomial calculations with 32bit mantissa and exponent, and calculation time is more than 3 times lower, compared to same calculation when using built in libraries for single precision floating point, and 256 times more precise. You can see the code in pid.c file.[/quote]


I am little suprised because PIC32 looks like adult MCU. I suspect FPU accelerator is basic for better MCU.I dont like PIC at all.

Do you work only with PIC ? Because STM32F4xx with FPU accelerator is a few mile better and faster and you dont need these optimalisation and cost same :) I suspect you using our SQRT... In FPU is it basic operation and take 14 clock cycles (80-100MHz) atc.

i have these question because i check your codes and are... interesting and complex.I have lot of questions because i am curious and one question produce more questions :D
Title: Re: Really universal soldering controller
Post by: sparkybg on May 15, 2015, 11:09:24 pm
Two weeks ago there was not any floating point calculation in the firmware of this project, and I didn't had any intention to use floating point in this project whatsoever. Even when I tried to use floating point without my optimizations, I was quite disappointed with the performance of built in floating point library, but after all, when I managed to make the same calculations more than 3 times faster and with considerably higher accuracy, it became an acceptable solution. :)

Microchip doesn't have any MCU with FPU in their current portfolio. When I need FPU, I am using Renesas RX630 family. There are many things that can be made better in the PICs, but there are also several benefits they offer:
- Single cheap programmer/debugger for all Microchip MCUs, from the smallest 8bit PIC10 to the largest 32bit PIC32MZ - no other manufacturer is even close to this.
- No complex programming/debugging settings, no different speeds, voltages and so on - you just plug the programmer, select the davice you are working with, hit a single button to program the device and you are ready to go.
- Only 3 wire programming interface, and all pins can be reused after programming
- Free development IDE and compilers from the same manufacturer
- Easy peripheral initialization and use, both with and without microchip libraries
- Decent and easy to work with documentation.

Both ST and Renesas have a long way to go before making a chip this easy to implement, despite clear functional advantages of some of their chips.

But anyway, STM32 FPU is single precision one. When you calculate 10 member polynomial with values from 10 bit ADC with added offset and other corrections you can reach the single precision floating point exponent limit quite easily, and some care must be taken to address this, which consumes additional CPU/FPU cycles. Yes, it will still be faster, maybe 3 to 5 times faster, but definitely not 10 to 15 times faster as stated in the STM32's floating point manual.

I am making a division, 20 multiplications and 10 additions with 32 bit mantissa and 32bit exponent in around 20-25 microseconds on 80Mhz MCU. If we take out the division, this gives around 2 microseconds for one multiply and one multiply and accumulate, which on 80Mhz CPU gives around 160 cycles. And this includes all - loading, calculation, storage, loop management and so on. It is not so bad for a MCU without FPU.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 15, 2015, 11:20:35 pm
[quote author="Sjaak"]What is the cost of this soldering controller? It looks quite complete but also costly :)[/quote]

Around 70-90 EUR per assembled set of PCB-s. It is still pretty lower then original controller from JBC for example.

All parts are available from Farnell - you can check part prices yourself if you want to.
Title: Re: Really universal soldering controller
Post by: ferdinandk on May 16, 2015, 10:54:12 am
This is just amazing. Thank you for making it public.

I've been looking over your schematics, but I didn't quite get everything sorted out, maybe you can help me:

Title: Re: Really universal soldering controller
Post by: sparkybg on May 16, 2015, 12:48:42 pm
[quote author="ferdinandk"]
Q5, ZD1, ZD2 and the surrounding circuitry look like a linear reg, but I can't find it's output node.
[/quote]
This ensures the rectified voltage never gets under 5V. You need a flat voltage on Vin while measuring the TC, otherwise the rectified voltage penetrates the upper MOSFET drain to source capcitance and gives erratic measurement.
[quote author="ferdinandk"]
does Q6 reduce the ripple on the -0.6V rail, and if so, do you have measurements for that?
[/quote]
Yes, Q6 reduces ripple and adds another step of fine regulation to around 0.6V. Both the ripple and the regulation becomes good enough for the opamps using them. I've made a measurements while prototyping, but I don't have the values right now.

[quote author="ferdinandk"]
with all your linear regs you a diode from the emitter to the base, what is it for?
[/quote]
Protection from back voltages when turning the power off. It is a common practice. The reverse emitter-base voltage of BJT is usually around only 5 volts, and base-emitter junction can be damaged easily when the output voltage becomes higher than the input on power down.

[quote author="ferdinandk"]
I think some electrolytics have the wrong polarity (C22, C8, C11, C4).[/quote]
Oh, this is because I somehow reversed the footprint of these parts. I will correct this. Thanks.
The polarity is OK on the PCB - it is only reversed on the schematics.

P.S. The polarity should be OK now. I've uploaded the correct schematics. I don't know how this happened. :)
Title: Re: Really universal soldering controller
Post by: ferdinandk on May 16, 2015, 01:12:17 pm
[quote author="sparkybg"][quote author="ferdinandk"]
Q5, ZD1, ZD2 and the surrounding circuitry look like a linear reg, but I can't find it's output node.
[/quote]
This ensures the rectified voltage never gets under 5V. You need a flat voltage on Vin while measuring the TC, otherwise the rectified voltage penetrates the upper MOSFET drain to source capcitance and gives erratic measurement.
[/quote]
I'll have to work out how the drain-source capacitance would offset the TC measurement, but I now see what you're doing there.

It's great to see so many discrete circuits, makes the design much more approachable IMHO. I haven't looked at the firmware yet, but if it's as advanced as your hardware sign me up for a pre-order :) Maybe you could order some PCBs and sell them for a profit. What  case you were planning to use?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 16, 2015, 02:45:51 pm
You can simulate it pretty easily. Spice simulation works very well simulating this.
Title: Re: Really universal soldering controller
Post by: ppsati on May 16, 2015, 03:53:45 pm
Hi, Sparkybg.

The OLED display uses the SSD1306 driver?
I´m thinking to use the 1.3 ".

Have you already decided if you gonna sell Unpopulated PCBs.
Say something.
Title: Re: Really universal soldering controller
Post by: Erythros on May 16, 2015, 04:50:17 pm
[quote author="sparkybg"]BOM will be there soom. As I said, I will update the first post from time to time with new things.[/quote]

Thanks.

[quote author="sparkybg"]
Unpopulated PCBs - maybe. I don't know yet. [/quote]

Well OK. I understand that it is probably more work than it is worth and nowadays everybody can have PCBs made cheap in China. I have just send some quotation questions to fab houses. (Just saying that people [better to say me] are interested anyway.)

BTW, the stand sensor PCB is designed for which specific holder?

What was your design idea to include SA36-11SRWA?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 16, 2015, 11:29:40 pm
[quote author="ppsati"]
The OLED display uses the SSD1306 driver?
[/quote]
Yes.

[quote author="ppsati"]
I´m thinking to use the 1.3 ".
[/quote]
Just make sure it has the same pad spacing and connections, otherwise you will have to make another PCB for the display. You will have to check if the boost regulator voltage is the same.

[quote author="ppsati"]
Have you already decided if you gonna sell Unpopulated PCBs.
Say something.[/quote]
I still don't know. I cannot send PCBs outise EU anyway - I must go to customs and so on, and I don't have enough time for this.
If Inside EU, the shipping will be something like 5-8EUR for regular air mail with tracking number.

There will be a local electronics forum meeting in a week or so, and if we decide to make a group PCB order, I will let you know.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 16, 2015, 11:36:57 pm
[quote author="Erythros"]
BTW, the stand sensor PCB is designed for which specific holder?
[/quote]
This one:
http://www.circuitspecialists.eu/csi-26 ... el-holder/ (http://www.circuitspecialists.eu/csi-2630-spare-soldering-iron-stand-with-solder-reel-holder/)

[quote author="Erythros"]
What was your design idea to include SA36-11SRWA?[/quote]
The project is made to be able to use 7 segment LED indicators instead of OLED display. But I never tried it. There is code in the firmware for this, the firmware detects if there is OLED or 7 segment, but there is 99% chance it will need some work to run properly on 7 segment. I even don't know if I will ever try it.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 16, 2015, 11:58:47 pm
[quote author="ferdinandk"]What  case you were planning to use?[/quote]

I am not planning. I am already using my older chinese station enclosures and stand.

Here's a short history of this project:

Some time ago, I bought this:
http://www.circuitspecialists.eu/solder ... r-station/ (http://www.circuitspecialists.eu/soldering/blackjack-solderwerks/bk-3000lf-70w-blackjack-solderwerks-lf-digital-solder-station/)

It had some things  I didn't like in it - it always starts at 350 degrees and does not remember the last temperature setting, and some other minor things. I replaced the MCU inside with ATTiny4313, with EEPROM in it, and wrote my own firmware for it in order to correct all the flaws.

Then I bought a second station from the same company, with the same enclosure, but lower priced model - i suspected it could be similar inside, and I had intention to rebuilt it to make it equal to the first one. But it was completely different inside, so I decided to make my own controller from scratch, using the same enclosures. This was the result:
viewtopic.php?f=56&t=5264 (http://dangerousprototypes.com/forum/viewtopic.php?f=56&t=5264)

This project was built by maybe 30 people all around the world, and I started to receive frequent questions for PTC sensor support and hot tweezer support, so I decided to make a completely universal controller you are looking at in this thread. :)

Anyway....

There is considerable interest in this project in a local electronics forum, and if we decide to make a group PCB order (even assembled), maybe I will design a dedicated sheet metal case for it if I find enough spare time to do it.
Title: Re: Really universal soldering controller
Post by: mrjoda on May 17, 2015, 12:10:21 am
if will be a good price to unassembled set of PBC i have interrest. I am in EU. I will work on my design but i need backup plan if somthing goes wrong :)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 17, 2015, 12:19:15 am
[quote author="mrjoda"]if will be a good price to unassembled set of PBC i have interrest. I am in EU. I will work on my design but i need backup plan if somthing goes wrong :)[/quote]

I suspect the price of unassembled PCB set will be around 10EUR. Maybe a little less, maybe a little more - it depends on quantity and PCB maker.
Title: Re: Really universal soldering controller
Post by: giovannirat on May 17, 2015, 12:46:35 am
A big thank you to sparkybg for sharing his great work.

As I am not so familiar with soldering SMD parts I am interested also in assembled PCB's.

So, if you would sell assembled PCB's at a reasonable price, please let me know.
Title: Re: Really universal soldering controller
Post by: ppsati on May 17, 2015, 12:55:09 am
[quote author="sparkybg"]
I still don't know. I cannot send PCBs outise EU anyway - I must go to customs and so on, and I don't have enough time for this.
If Inside EU, the shipping will be something like 5-8EUR for regular air mail with tracking number.

There will be a local electronics forum meeting in a week or so, and if we decide to make a group PCB order, I will let you know.[/quote]

Thank´s, Sparkybg.
I had seen the vcc is 7V to 15V, just make a small change, the rest is the same.

The PCBs, thank you if you have any to sell me I paid no matter the customs.

I apologize for this question.
But already thought about doing this project for Arduino?
 :) ...
Title: Re: Really universal soldering controller
Post by: ppsati on May 17, 2015, 01:06:58 am
[quote author="ppsati"][quote author="sparkybg"]
I still don't know. I cannot send PCBs outise EU anyway - I must go to customs and so on, and I don't have enough time for this.
If Inside EU, the shipping will be something like 5-8EUR for regular air mail with tracking number.

There will be a local electronics forum meeting in a week or so, and if we decide to make a group PCB order, I will let you know.[/quote]

Thank´s, Sparkybg.
I had seen the vcc is 7V to 15V, just make a small change, the rest is the same.

The PCBs, thank you if you have any to sell me I paid no matter the customs.

I apologize for this question.
But already thought about doing this project for Arduino?
 :) ...[/quote]

Sparkybg, sorry,
But you do not live in Bulgaria?
Because I live in Portugal, both belong to the European Union, there is no problem with the customs.

Regards.
Title: Re: Really universal soldering controller
Post by: Erythros on May 17, 2015, 01:44:14 am
[quote author="sparkybg"][quote author="Erythros"]
BTW, the stand sensor PCB is designed for which specific holder?
[/quote]
This one:
http://www.circuitspecialists.eu/csi-26 ... el-holder/ (http://www.circuitspecialists.eu/csi-2630-spare-soldering-iron-stand-with-solder-reel-holder/)
[/quote]

Thanks. That settle it that I will have to do my own.

To another note: I was doing some sourcing today and for 3 boards (front, back, oled) I was getting quotation about  80 USD delivered for 10 boards. (Actually from 80 USD for economical run to 200 USD for "best material" - same fabhouse, I do not know the difference, because specified parameters were the same.)  So if you will be doing your own group buy with bigger number of pieces, you could get better prices. (I will have to decide tomorrow if I am going to place that order as I do not really need ten pieces.)

Just my thoughts.
Title: Re: Really universal soldering controller
Post by: snstak on May 18, 2015, 02:03:56 pm
Hi, there is a mistake, may be, in the file with schematics: front and back are the same...
Title: Re: Really universal soldering controller
Post by: sparkybg on May 18, 2015, 05:42:18 pm
[quote author="snstak"]Hi, there is a mistake, may be, in the file with schematics: front and back are the same...[/quote]

It is corrected now.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 18, 2015, 05:46:08 pm
[quote author="Erythros"]

To another note: I was doing some sourcing today and for 3 boards (front, back, oled) I was getting quotation about  80 USD delivered for 10 boards. (Actually from 80 USD for economical run to 200 USD for "best material" - same fabhouse, I do not know the difference, because specified parameters were the same.)  So if you will be doing your own group buy with bigger number of pieces, you could get better prices. (I will have to decide tomorrow if I am going to place that order as I do not really need ten pieces.)

Just my thoughts.[/quote]

I didn't decided yet where will I order the PCBs - local company, chinese company, or EU company. If we agree to make an order for assembled PCBs, probably it will be a local company. That does not mean that we will order only assembled boards, in fact for now the order seems to be something like 30 unassembled PCBs and 30 assembled PCBs.
Title: Re: Really universal soldering controller
Post by: carpin on May 19, 2015, 02:20:04 am
Thanks sparkybg for this super station board
Title:
Post by: Circuiteromalaguito on May 19, 2015, 03:07:28 am
Are there videos of this beauty working?
Title: Re:
Post by: sparkybg on May 19, 2015, 09:07:22 am
[quote author="Circuiteromalaguito"]Are there videos of this beauty working?[/quote]

https://www.youtube.com/watch?v=ZL6S3AktidY (https://www.youtube.com/watch?v=ZL6S3AktidY)
https://www.youtube.com/watch?v=kzWc8O9cr8k (https://www.youtube.com/watch?v=kzWc8O9cr8k)
https://www.youtube.com/watch?v=-f0KSU0PJzc (https://www.youtube.com/watch?v=-f0KSU0PJzc)
Title: Re: Really universal soldering controller
Post by: mrjoda on May 19, 2015, 02:39:16 pm
can you post some video where you soldering with iron and where we can see how is temperature stable ? Some sheet of copper or power transistor or something ?

you can write me to one set of unnasembled PCBs, 10€ +/- for set is a good price :)

I have one idea, can you do some modification for encoder ? For example these 3 buttons will be direct temperature memory and with encoder you can set temperature, controll menu and other functions ? I think these buttons arent so good as encoder. You have some free pins i think encoder is a good "option feature".
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on May 19, 2015, 03:10:31 pm
[quote author="mrjoda"]can you post some video where you soldering with iron and where we can see how is temperature stable ? Some sheet of copper or power transistor or something ?

you can write me to one set of unnasembled PCBs, 10€ +/- for set is a good price :)

I have one idea, can you do some modification for encoder ? For example these 3 button will be direct temperature memory and with encoder you can set temperature, controll menu and other functions ? I think these button arent so good as encoder. You have some free pins i think encoder is a good "option feature".[/quote]
I was going to ask the same!

How does it detect each soldering iron? How are adapted?

Maybe you can get a review from a site such as EEVblog, he can probably buy it or some of their forum users do a little crowdfunding.

Dave is an australian EE and does extensive video reviews and teardowns of everything.  Dave did some hardware (uCurrent is quite popular), but more confused on videos and participatrs The Amp Hour. He's a bit of an angry nerd and is somewhat politically incorrect, but I'm sure he will be supportive to a hobby project that can make soldering stations more affordable to hobbyists.

Is it Open Hardware? What about putting it at GitHub?
Title: Re: Really universal soldering controller
Post by: TilmanBaumann on May 19, 2015, 04:30:21 pm
[quote author="Circuiteromalaguito"]
How does it detect each soldering iron? How are adapted?
[/quote]
I was wondering the same. But it turns out that is described on the first page in the feature list.

- resistive instrument identification (upto 625 different instruments can be identified by 2 resistors on the connector)

I had already suspected ID chips and the like. But honestly, resistors are so much more easy. :)

You have to change the plug adapter anyway to be fit. Might as well add two resistors in the process.

[quote author="Circuiteromalaguito"]
Is it Open Hardware? What about putting it at GitHub?[/quote]
Good suggestion. If real collaboration is actually going to happen.

I would love to build one for me. But I would prefer to buy a kit. Or at least the bord.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 19, 2015, 10:59:53 pm
[quote author="mrjoda"]can you post some video where you soldering with iron and where we can see how is temperature stable ? Some sheet of copper or power transistor or something ?
[/quote]
I dont have the equipment for this. Temperature stability is as stable as I was able to gat it - it is a question only of firmware and PID coefficients.
[quote author="mrjoda"]
I have one idea, can you do some modification for encoder ? For example these 3 buttons will be direct temperature memory and with encoder you can set temperature, controll menu and other functions ? I think these buttons arent so good as encoder. You have some free pins i think encoder is a good "option feature".[/quote]

As I mentioned earlier, I made the PCB-s of the project for specific enclosures I already had. That's why it uses buttons.

And, it is not that as bad as you thing it is. You will see if you build one. There are 3 fast temperature settings, and they are changed with single click of a button. I am working with these temperatures 99% of the time.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 19, 2015, 11:04:41 pm
[quote author="Circuiteromalaguito"][quote author="mrjoda"]can you post some video where you soldering with iron and where we can see how is temperature stable ? Some sheet of copper or power transistor or something ?

you can write me to one set of unnasembled PCBs, 10€ +/- for set is a good price :)

I have one idea, can you do some modification for encoder ? For example these 3 button will be direct temperature memory and with encoder you can set temperature, controll menu and other functions ? I think these button arent so good as encoder. You have some free pins i think encoder is a good "option feature".[/quote]
I was going to ask the same!

How does it detect each soldering iron? How are adapted?

Maybe you can get a review from a site such as EEVblog, he can probably buy it or some of their forum users do a little crowdfunding.

Dave is an australian EE and does extensive video reviews and teardowns of everything.  Dave did some hardware (uCurrent is quite popular), but more confused on videos and participatrs The Amp Hour. He's a bit of an angry nerd and is somewhat politically incorrect, but I'm sure he will be supportive to a hobby project that can make soldering stations more affordable to hobbyists.

Is it Open Hardware? What about putting it at GitHub?[/quote]

I know who Dave is. :) I even have some posts on his forum. Me and Dave are both big fans of JBC, so I don't expect big surprises if I send him a set. I've spend much time optimizing profiles for the JBC irons and I can say they will perform no worse than on original station.
Title: Re: Really universal soldering controller
Post by: mrjoda on May 19, 2015, 11:11:09 pm
Code: [Select]
I dont have the equipment for this. Temperature stability is as stable as I was able to gat it - it is a question only of firmware and PID coefficients.

no need some precision measurement, video like your others will be enough, only put iron (JBC or Hakko T12) to sheet of copper or coin . We will see how good reaction have controller :)


encoder - you told me yet about enclosure i accept that of course. My idea for you was add some connector for encoder and modify SW for that, for example with one jumper - connect - use buttons , jumper disconnect - encoder is using - buttons are direct temp. memory
Title: Re: Really universal soldering controller
Post by: Erythros on May 19, 2015, 11:34:25 pm
[quote author="mrjoda"]encoder - you told me yet about enclosure I accept that of course. My idea for you was add some connector for encoder and modify SW for that, for example with one jumper - connect - use buttons , jumper disconnect - encoder is using - buttons are direct temp. memory[/quote]

I was thinking about it either. Encoder could be nice. But the controller is version 5.2. On videos there is model 5.0. So there probably was one iteration more. That is lot of experimentation. (Moreover that being mark 5.) As we do not have CAD files, only gerbers, to remade whole board with encoder connection would provide gigantic number of possible f**k ups you could do. So better take what somebody else was so nice to prove and be happy about that.

[quote author="TilmanBaumann"] was wondering the same. But it turns out that is described on the first page in the feature list.

- resistive instrument identification (upto 625 different instruments can be identified by 2 resistors on the connector)

I had already suspected ID chips and the like. But honestly, resistors are so much more easy. :)
[/quote]

I remember that sparkybg had some fancy to use 1-wire connected MCU to do the identification. Which is little overkill. I can see the need for MCU when you want to connect somethinkg like accelometer or gyroscope as I have seen Kurtz Ersa doing for sleep function.

[quote author="Circuiteromalaguito"]Is it Open Hardware? What about putting it at GitHub?[/quote]

Not everything has to be on Github. But stating some license would clarify the issue. Something like "do make it, do not sell it" or "do as you please, I do not care".

[quote author="sparkybg"]As I mentioned earlier, I made the PCB-s of the project for specific enclosures I already had. That's why it uses buttons.[/quote]

That case is not so bad. It basically is 100x100xsomething box. The biggest problem is to find some toroidal transformer which which would have d=100mm. So far I have found that these smaller diameter and higher toroid cores are mostly for bigger output (about 250VA).
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on May 19, 2015, 11:37:55 pm
[quote author="sparkybg"][quote author="Circuiteromalaguito"][quote author="mrjoda"]can you post some video where you soldering with iron and where we can see how is temperature stable ? Some sheet of copper or power transistor or something ?

you can write me to one set of unnasembled PCBs, 10€ +/- for set is a good price :)

I have one idea, can you do some modification for encoder ? For example these 3 button will be direct temperature memory and with encoder you can set temperature, controll menu and other functions ? I think these button arent so good as encoder. You have some free pins i think encoder is a good "option feature".[/quote]
I was going to ask the same!

How does it detect each soldering iron? How are adapted?

Maybe you can get a review from a site such as EEVblog, he can probably buy it or some of their forum users do a little crowdfunding.

Dave is an australian EE and does extensive video reviews and teardowns of everything.  Dave did some hardware (uCurrent is quite popular), but more confused on videos and participatrs The Amp Hour. He's a bit of an angry nerd and is somewhat politically incorrect, but I'm sure he will be supportive to a hobby project that can make soldering stations more affordable to hobbyists.

Is it Open Hardware? What about putting it at GitHub?[/quote]

I know who Dave is. :) I even have some posts on his forum. Me and Dave are both big fans of JBC, so I don't expect big surprises if I send him a set. I've spend much time optimizing profiles for the JBC irons and I can say they will perform no worse than on original station.[/quote]
Great! Let the party happen!

JBC are from Barcelona, Spain. There's a few good tech stuff in my country, not just wine food and parties :rofl:

What about Open Hardware and GitHub?
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on May 19, 2015, 11:38:02 pm
Delete
Title: Re: Really universal soldering controller
Post by: sparkybg on May 19, 2015, 11:40:13 pm
The case is 130x110x95. At least 3 different 100-120VA torogidal transformers from various manufacturers can go in there.

For example, one of them is polish INDEL.

I am using this transformer:
http://www.tme.eu/en/details/tst100w_24 ... st100013/# (http://www.tme.eu/en/details/tst100w_24v/toroidal-transformers/indel/tst100013/#)
Title: Re: Really universal soldering controller
Post by: TilmanBaumann on May 19, 2015, 11:42:02 pm
Well 1-Wire ID chips are cheap jelly beans parts.
One could even consider saving cal data on a EPROM in the iron.
But yea, its overkill nevertheless. :)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 19, 2015, 11:47:55 pm
[quote author="TilmanBaumann"]Well 1-Wire ID chips are cheap jelly beans parts.
One could even consider saving cal data on a EPROM in the iron.
But yea, its overkill nevertheless. :)[/quote]

MCU or EEPROM with temperature sensor in the handle is very interesting approach. The TC cold junction is in the iron's handle, so if you read it there, you will get some more accuracy on irons with TC sensor.

And, yes, the ID hardware is made to be able to read  1-wire data. However, the firmware cannot do this for the moment, and I don't know if I will ever make it to do this.
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on May 20, 2015, 12:02:26 am
[quote author="sparkybg"]The case is 130x110x95. At least 3 different 100-120VA torogidal transformers from various manufacturers can go in there.

For example, one of them is polish INDEL.

I am using this transformer:
http://www.tme.eu/en/details/tst100w_24 ... st100013/# (http://www.tme.eu/en/details/tst100w_24v/toroidal-transformers/indel/tst100013/#)[/quote]
What's so cool about toroidal transformers? I can borrow regular ones, but not these.
Title: Re: Really universal soldering controller
Post by: TilmanBaumann on May 20, 2015, 12:03:35 am
[quote author="sparkybg"]
MCU or EEPROM with temperature sensor in the handle is very interesting approach. The TC cold junction is in the iron's handle, so if you read it there, you will get some more accuracy on irons with TC sensor.
[/quote]
Oh dear. I hadn't even considered cold junction devices.
Yea, no kidding those would benefit greatly.
In fact Maxim has a nice 1-Wire thermocouple amp with cold junction compensation and all that jazz. ;)

PTC based devices would not benefit. And I suspect those are the majority of devices?
But I think you have greater goals. One board to rule them all.
And I absolutely love the idea. :)
In the end it's just software. Keep it open and stuff will happen... ;)

PS: Looks like thermocouples are quite common. I guess I jumped to conclusions.
Title: Re: Really universal soldering controller
Post by: mrjoda on May 20, 2015, 12:10:18 am
weller  have directly in handle Cold junction sensor, ADC for temperature and opamp, maybe acc or gyro, i cant identify IO. I have picture but i cant find it.
Title: Re: Really universal soldering controller
Post by: Erythros on May 20, 2015, 12:14:45 am
[quote author="sparkybg"]The case is 130x110x95. At least 3 different 100-120VA torogidal transformers from various manufacturers can go in there.

For example, one of them is polish INDEL.

I am using this transformer:
http://www.tme.eu/en/details/tst100w_24 ... st100013/# (http://www.tme.eu/en/details/tst100w_24v/toroidal-transformers/indel/tst100013/#)[/quote]

Well, I was thinking about buying aluminium square tube (jäckl) which can be had in 120X120X4 or 100X100X4 custom length cut. Mill into it some grooves. Put the the front PCB on front panel, back on back panel and toroid between them. Maybe mill tipping display holder. Rubber legs on bottom.

I have sent some requests for quotes on toroidal front. Sometimes custom is on par with of the shelf. (In price department.)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 20, 2015, 12:19:04 am
[quote author="Circuiteromalaguito"]
What's so cool about toroidal transformers?[/quote]

Many things, but for me the most important one is the much lower leakage inductance.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 20, 2015, 12:24:14 am
[quote author="TilmanBaumann"]
Yea, no kidding those would benefit greatly.
[/quote]
Well. not so greatly. But the benefit is clear enough.

[quote author="TilmanBaumann"]
In fact Maxim has a nice 1-Wire thermocouple amp with cold junction compensation and all that jazz. ;)
[/quote]
Which again is not swutable for a project like this. It is too slow for series thermocouple devices.

[quote author="TilmanBaumann"]
PTC based devices would not benefit. And I suspect those are the majority of devices?
[/quote]
IMHO, exactly the opposite. :) For example, the majority ot integrated heater tips are series thermocouple ones. This includes JBC, HAKKO, Weller and so on.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 20, 2015, 12:32:43 am
[quote author="mrjoda"]weller  have directly in handle Cold junction sensor, ADC for temperature and opamp, maybe acc or gyro, i cant identify IO. I have picture but i cant find it.[/quote]

Many manufacturers do have such irons in their portfolio. ERSA for example.

For reading the temperature in the handle - I meant reading the cold junction temperature there. The rest can be done in the station. For example, I am reading the room temperature on the controller's PCB near the air inlet of my enclosure. And I can say there is not significant difference in the accuracy of the iron temperature in winter (at room temperature around 18-20 degrees) and in summer (at room temperatures upto 28-30 degrees). So the temperature sensor in the handle is not mandatory for normal indoor use of the controller.
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on May 20, 2015, 10:18:48 am
[quote author="sparkybg"][quote author="Circuiteromalaguito"]
What's so cool about toroidal transformers?[/quote]

Many things, but for me the most important one is the much lower leakage inductance.[/quote]
What advantages does it have it cant be solved by Faraday effect of a proper metal case? I'm an electronics newbie, I very probably missed something.

There's much controversy about Toroidal transformers being a fashion trend.


http://www.soundstage.com/maxdb/maxdb071998.htm (http://www.soundstage.com/maxdb/maxdb071998.htm)
http://www.raftabtronics.com/TECHNOLOGY ... fault.aspx (http://www.raftabtronics.com/TECHNOLOGY/ElectromagneticBasics/ToroidalTransformerBasics/tabid/112/Default.aspx)
http://www.avellindberg.com/transformer ... notes2.htm (http://www.avellindberg.com/transformers/tech_notes/tech_notes2.htm)
http://sound.westhost.com/power-supplie ... r-series-r (http://sound.westhost.com/power-supplies.htm#xfmr-series-r)

What about...
[align=centet:][attachment=0][/align:]
?

I understand if you don't want it for personal reasons, but it can be an amazing community project for the DIY scene!

What do you think about using CERN's OHL (http://http://www.ohwr.org/projects/cernohl/wiki)?

Ideally, it would be nice to remake the schematic and PCB design in KiCad, because Altium is expensive and using Open Source would make it more open too. CERN's involvement is making things more exciting too!

There's some tools to convert Altium files to KiCad (I assume you are using it by looking at schematics).

This tool can assist the process:
https://github.com/thesourcerer8/altium2kicad (https://github.com/thesourcerer8/altium2kicad)
http://http://www.eevblog.com/forum/open-source-kicad-geda/translating-altium-to-kicad-(altium2kicad)/

Someone converted uCurrent to KiCad, it seems manually:
http://ludzinc.blogspot.com.au/2014/04/ ... nyhow.html (http://ludzinc.blogspot.com.au/2014/04/whats-all-this-kicad-stuff-anyhow.html)
http://ludzinc.blogspot.com.au/2014/05/ ... -gaps.html (http://ludzinc.blogspot.com.au/2014/05/closing-kicad-gaps.html)
Title: Re: Really universal soldering controller
Post by: Sjaak on May 20, 2015, 01:23:37 pm
Did cleanup of doubleposts in this topic.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 20, 2015, 03:18:21 pm
[quote author="Circuiteromalaguito"]there's some obsession with toroidal transformers in DIY these days [/quote]

When one transformer has several times lower leakage inductance, and is more compact for the same power, this is not contradictory, but objective decision.
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on May 20, 2015, 04:27:13 pm
[quote author="sparkybg"][quote author="Circuiteromalaguito"]there's some obsession with toroidal transformers in DIY these days [/quote]

When one transformer has several times lower leakage inductance, and is more compact for the same power, this is not contradictory, but objective decision.[/quote]

I get it. Thanks!
Title: Re: Really universal soldering controller
Post by: neslekkim on May 20, 2015, 05:29:02 pm
Is it easy to mount the toroid inside the solderingstation housing?
Title: Re: Really universal soldering controller
Post by: mrjoda on May 20, 2015, 06:30:03 pm
one screw with one cup and two rubber rings...
Title:
Post by: TilmanBaumann on May 20, 2015, 06:58:56 pm
Guys you are still talking about transformers. Just saying.
Title: Re: Really universal soldering controller
Post by: neslekkim on May 20, 2015, 08:13:05 pm
[quote author="mrjoda"]one screw with one cup and two rubber rings...[/quote]

I know that, but I don't know availble room and placement in that cabinet
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on May 21, 2015, 08:43:20 am
[quote author="mrjoda"]can you post some video where you soldering with iron and where we can see how is temperature stable ? Some sheet of copper or power transistor or something ?

you can write me to one set of unnasembled PCBs, 10€ +/- for set is a good price :)

I have one idea, can you do some modification for encoder ? For example these 3 buttons will be direct temperature memory and with encoder you can set temperature, controll menu and other functions ? I think these buttons arent so good as encoder. You have some free pins i think encoder is a good "option feature".[/quote]
I was going to post some example vídeos...

https://youtu.be/OLcLOmV0bL8 (https://youtu.be/OLcLOmV0bL8)
https://youtu.be/5uiroWBkdFY (https://youtu.be/5uiroWBkdFY)
https://youtu.be/H3-TfdZVBCc (https://youtu.be/H3-TfdZVBCc)
https://youtu.be/fYz5nIHH0iY (https://youtu.be/fYz5nIHH0iY)
https://youtu.be/b9FC9fAlfQEjuvy (https://youtu.be/b9FC9fAlfQEjuvy)
[quote author="mrjoda"]can you post some video where you soldering with iron and where we can see how is temperature stable ? Some sheet of copper or power transistor or something ?

you can write me to one set of unnasembled PCBs, 10€ +/- for set is a good price :)

I have one idea, can you do some modification for encoder ? For example these 3 buttons will be direct temperature memory and with encoder you can set temperature, controll menu and other functions ? I think these buttons arent so good as encoder. You have some free pins i think encoder is a good "option feature".[/quote]
I was going to post some example vídeos...

https://youtu.be/OLcLOmV0bL8 (https://youtu.be/OLcLOmV0bL8)
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on May 21, 2015, 08:44:14 am
[quote author="mrjoda"]can you post some video where you soldering with iron and where we can see how is temperature stable ? Some sheet of copper or power transistor or something ?

you can write me to one set of unnasembled PCBs, 10€ +/- for set is a good price :)

I have one idea, can you do some modification for encoder ? For example these 3 buttons will be direct temperature memory and with encoder you can set temperature, controll menu and other functions ? I think these buttons arent so good as encoder. You have some free pins i think encoder is a good "option feature".[/quote]


The main ideas of my proposals:

* Prototype showing detaillidly  all the internals while working, showing voltages, frequencies and temperatures while working.
->Maybe this would require a smart use of PiP and using multi-camera or whatever other way (logging.and putting data in post-production?), but too much work to do it for just one person..

* Real usage under different conditions
- THT and big junction solderings.
-SMT and THT mixed PCBs to populated PCBs with those pin filled ones.
- Desoldering using solder wick. Not sure if your controller can drive a desoldering tip too.

* Different soldering tips for each of the same tests, repeating each one of them on the same conditions:
- HAKKO: T12/T15, FX8801...
- PACE: TD100....
- JBC: C245, C210, Microtweezers.
- WELLER: WSP80.
- Others if possible.

I know, this is very time consuming. So I hope test could be made by all community members instead of just you, some of them can have better measurement tools for temperature and such. You may publish your projects in other forums if you are allowed and wish to do it, so you'll get more reviews.

If you want: I can help you setup a WordPress site or a github one, the last one is easier but more limited.

I wrote too much for now. I'll wait for your replies, take all the time you would need! I don't care to wait at all!

If I get incomes this summer (I hope!), I would like to buy an unpopulated PCB, a toroidal transformer and get some good soldering tips for it (THT and SMT work).

I'll try to see if I can use the same transformer for a DIY lab (linear?) adjustable PSU on the same case (and maybe share the OLED display too?), because I'll not use both devices at once and could provide some portability.

I would be very thankful if you reply all them, despite some might not be the ones I would like to receive.

Thanks in advance! ;)
Title: Re: Really universal soldering controller
Post by: Sjaak on May 21, 2015, 10:31:47 am
Another cleanup of double/tripple post.

@circuiteromalaguito: please use the delete button in the webbrowser next time. Please consider also using that for posting. This is the last time I clean up your mess (offical warning)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 21, 2015, 03:32:30 pm
[quote author="Circuiteromalaguito"]
* Prototype showing detaillidly  all the internals while working, showing voltages, frequencies and temperatures while working.
->Maybe this would require a smart use of PiP and using multi-camera or whatever other way (logging.and putting data in post-production?), but too much work to do it for just one person..
[/quote]
There will be a brief explanation of the project internals and way of work in a first post when I got enough time to do it. Then I will answer any specific questions, if I can. Sorry, but I cannot do nothing more. I am not making my living out of this project, so that's the way it is.

[quote author="Circuiteromalaguito"]
* Real usage under different conditions
- THT and big junction solderings.
-SMT and THT mixed PCBs to populated PCBs with those pin filled ones.
- Desoldering using solder wick. Not sure if your controller can drive a desoldering tip too.
[/quote]
I am not going to teach someone how to solder or desolder things. :) There are numerous movies, and documents on this in the internet.

And yes, as mentioned in the first post, this controller can handle any soldering iron with TC or resistive sensor, and resistive heating element, as long as heater's resistance is more than 1 ohm. Any iron (soldering or desoldering) in this category can be controlled.

[quote author="Circuiteromalaguito"]
* Different soldering tips for each of the same tests, repeating each one of them on the same conditions:
- HAKKO: T12/T15, FX8801...
- PACE: TD100....
- JBC: C245, C210, Microtweezers.
- WELLER: WSP80.
- Others if possible.
[/quote]
When you decide what iron you will choose, look at manufacturer's site about movies and documentation. There's plenty of this stuff there. This controller won't be (or at least can be made to) much different than original. It depends solely on iron's profile constants.
I can, of course give some advises, but they would be a result of my personal opinion. As I mentioned, am a big fan of JBC. :) And I work with JBC C245 most of the time. I have C210 and microtweezers also. PACE TD100 is comparable, the tips are very nice and cheaper than JBC, but the handle is a bit expensive, so at the moment I don't have one. I am not ready to give 150EUR for something I won't use most of the time. :)

[quote author="Circuiteromalaguito"]
I know, this is very time consuming.
[/quote]
Indeed. I can provide support only when specific case is provided. I am far from providing a lectures or something like this. I don't have that much time.

[quote author="Circuiteromalaguito"]
If you want: I can help you setup a WordPress site or a github one, the last one is easier but more limited.
[/quote]
Thanks. But I am a WEB applications developer, so I do know how to do this. I just don't have enough time to support it. Maybe some day I will, I don't know.
Title: Re: Really universal soldering controller
Post by: jinzo on May 21, 2015, 05:37:44 pm
That's awesome, amazing work!
I would be interested in PCBS, KITS or even assembled units (depending on price of assembly :D).

I know I'm preaching to the choir, but could you please decide on a licence and licence your work? That would be really great.
I'm a web dev myself and a beginner in electronics, but if I can help you in any way...

P.S: Are you planing to look into any hot air stuff? :P
Title: Re: Really universal soldering controller
Post by: sparkybg on May 22, 2015, 02:48:50 pm
[quote author="jinzo"]
I know I'm preaching to the choir, but could you please decide on a licence and licence your work?
[/quote]
It will probably be CC BY-NC-SA license:
https://creativecommons.org/licenses/by ... /legalcode (https://creativecommons.org/licenses/by-nc-sa/4.0/legalcode)

[quote author="jinzo"]
P.S: Are you planing to look into any hot air stuff? :P[/quote]
Not for now.
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on May 22, 2015, 02:51:21 pm
[quote author="jinzo"]That's awesome, amazing work!
I would be interested in PCBS, KITS or even assembled units (depending on price of assembly :D).

I know I'm preaching to the choir, but could you please decide on a licence and licence your work? That would be really great.
I'm a web dev myself and a beginner in electronics, but if I can help you in any way...

P.S: Are you planing to look into any hot air stuff? :P[/quote]

Indeed! It's so nice it's done! I would love to get a kit when I get some money, I hope to get some job this summer!

Maybe controlling the hot air would be possible? I hope so!

But probably controlling a vacuum system would require more work. I've seen some people doing DIY vacuum systems with a fridge motor or an electric motor.

http://www.teaser.fr/~amajorel/desolder/ (http://www.teaser.fr/~amajorel/desolder/)
http://www.avdweb.nl/composites/vacuum-pump-diy.html (http://www.avdweb.nl/composites/vacuum-pump-diy.html)
http://alfred73electronics.blogspot.com ... ation.html (http://alfred73electronics.blogspot.com/2007/03/home-made-smt-desoldering-station.html)
http://sablewolfsden.blogspot.com.es/20 ... 1.html?m=1 (http://sablewolfsden.blogspot.com.es/2013/11/diy-desoldering-station-for-under-70_11.html?m=1)
http://www.eevblog.com/forum/projects/a ... ner-level/ (http://www.eevblog.com/forum/projects/a-simple-electrical-powered-vacuum-desolder-suction-pump-beginner-level/)

This work is too much work for a one-man hobby project, so making it all-in-onr can be an extreme pipe dream.

I'm really amazed he's not into EE but web development. He's very good skilled, I envy him! :D
Title: Re: Really universal soldering controller
Post by: savril on May 22, 2015, 06:51:36 pm
If you do sell PCBs, coun't me in. I already have a JBC CD-2BD and really like it. I was dreaming at their tweezers but that would mean selling my other kidney for another station, thanks for preventing this.

If you really are about the performance of a JBC station, that's a great job ! I'm impressed.
I was interested by DIY soldering station and your design is the best I have seen.

For the JBC cartdriges, does your controller support hot swap ?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 22, 2015, 06:58:36 pm
[quote author="savril"]
For the JBC cartdriges, does your controller support hot swap ?[/quote]

Yes. It supports how swap of cartridges, and it supports hot swap of entire instruments.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 22, 2015, 07:48:55 pm
[quote author="savril"]
If you really are about the performance of a JBC station, that's a great job ![/quote]

Show me a movie of your station while heating up, and I will show you a movie from mine.

P.S.: Here is it, heating up, and then heating TO247's thermal pad:
https://www.youtube.com/watch?v=oTdQB4y ... e=youtu.be (https://www.youtube.com/watch?v=oTdQB4ywDOA&feature=youtu.be)

P.S.: Chinese fake T12 on the same ТО247 thermal pad:
https://www.youtube.com/watch?v=u588sh- ... e=youtu.be (https://www.youtube.com/watch?v=u588sh-4thg&feature=youtu.be)
Title: Re: Really universal soldering controller
Post by: Erythros on May 22, 2015, 08:45:42 pm
[quote author="sparkybg"]
P.S.: Here is it, heating up, and then heating TO247's thermal pad:
https://www.youtube.com/watch?v=oTdQB4y ... e=youtu.be (https://www.youtube.com/watch?v=oTdQB4ywDOA&feature=youtu.be)[/quote]

Nice. That is the 5.2 version or the 5.0 as shown in previous videos? (With changed OLED colour.) I have problem reading the silkscreen.

It is my first project where I will be using 0.1% resistors.  So I am thinking about temperature coefficient. But given normal temperature range I imagine that ± 25ppm/°C, which gives |0.1%| at |40°C| will be fine?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 22, 2015, 10:31:55 pm
[quote author="Erythros"]
Nice. That is the 5.2 version or the 5.0 as shown in previous videos? (With changed OLED colour.) I have problem reading the silkscreen.
[/quote]
Slightly modified 5.0 front on 5.2 back. :) But the performance of 5.0 and 5.2 is the same anyway.

[quote author="Erythros"]
It is my first project where I will be using 0.1% resistors.  So I am thinking about temperature coefficient. But given normal temperature range I imagine that ± 25ppm/°C, which gives |0.1%| at |40°C| will be fine?[/quote]

The important thing here is being equal. When you put the PCB on higher temperature, all the resistors goes up or down together, so the gain stays the same (well, sort of...). So, yes, 25ppm/c is enough.
Title: Re: Really universal soldering controller
Post by: Erythros on May 23, 2015, 12:14:05 am
[quote author="sparkybg"]
The important thing here is being equal. When you put the PCB on higher temperature, all the resistors goes up or down together, so the gain stays the same (well, sort of...). So, yes, 25ppm/c is enough.[/quote]

Good to know, thanks. Given the fact that 10 ppm/°C resistors are about 6 times more expensive than 25 ppm/°C resistors. My worry was that there is some hidden absolute reference. But thinking about it, that would be probably stupid.

[quote author="sparkybg"]
Slightly modified 5.0 front on 5.2 back. :) But the performance of 5.0 and 5.2 is the same anyway.[/quote]

I was little selfish in that regard. I was interested if there is working 5.2 prototype as I wouldn't want to end up with 20 leaky cup mats.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 23, 2015, 12:54:36 am
I woupdn't publish something, if I'm not sure it works. The differences on the front between 5.0 and 5.2 are very small. Two capacitors are added, with very small effect, different connector to back PCB is used, one terminal of the mcu is connected to 3.3v instead of ground (this was a bug in 5.0), and one additional jumper is added, to support OLED's reset pin. What you are looking at tthe movies is a 5.0 PCB with all this applied to it, so it is in fact a 5.2. The main differences between 5.0 and 5.2 are on the back and OLED PCBs, and still they are interchangeable.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 23, 2015, 12:03:16 pm
Weller WSP80 movie added in furst post.
Title: Re: Really universal soldering controller
Post by: lapas on May 23, 2015, 08:51:27 pm
Very great project indeed! I would be interested in buying either assembled or not PCB.

Two questions:
1. Is your soldering station able to utilize the full potential of 24V 200W iron?
2. Is your soldering station compatible with Weller WXP series irons? Can it read standby sensor and control status LED (see the attached image)?

Btw, it looks like it heats up just as fast as original Weller station: https://youtu.be/sU-inkTwVps?t=184 (https://youtu.be/sU-inkTwVps?t=184)

(http://http://i.snag.gy/IwNGg.jpg)
Title: Re: Really universal soldering controller
Post by: Erythros on May 23, 2015, 09:33:33 pm
[quote author="lapas"]
2. Is your soldering station compatible with Weller WXP series irons? Can it read standby sensor and control status LED (see the attached image)?

Btw, it looks like it heats up just as fast as original Weller station: https://youtu.be/sU-inkTwVps?t=184 (https://youtu.be/sU-inkTwVps?t=184)
[/quote]

Have you looked at http://https://github.com/FlyGlas/WMRP or http://http://www.martin-kumm.de/wiki/doku.php?id=Projects:SMD_Solderstation? It looks like TC with common ground. Do you know how the handle communicate with the stand controller? (I realize that it will be in sketch of the first controller.)

[quote author="lapas"]
Is your soldering station able to utilize the full potential of 24V 200W iron?
[/quote]

There is 5A fuse on second PCB.
The traces are only 7 mm. (You would need 2 or more oz.)
The http://http://store.comet.bg/en/Catalogue/Product/16841/ are only 5A.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 23, 2015, 10:49:42 pm
[quote author="lapas"]
1. Is your soldering station able to utilize the full potential of 24V 200W iron?
[/quote]
It is limited to 6A RMS. So, at 24V it will be able to support around 140W - there are at least one diode drop in the power supply path.

[quote author="lapas"]
2. Is your soldering station compatible with Weller WXP series irons? Can it read standby sensor and control status LED (see the attached image)?
[/quote]
It cannot read or control eny vendor specific electronics in the handle. So in order to use this handle you will have to connect the heater and the sensor directly, which means all the electronics in the handle will do nothing.

[quote author="lapas"]
Btw, it looks like it heats up just as fast as original Weller station: https://youtu.be/sU-inkTwVps?t=184 (https://youtu.be/sU-inkTwVps?t=184)
[/quote]
WD1000M uses WMRP soldering iron, which is again series thermocouple iron tip. I don't have WMRP Iron so there is no profile for it in the firmware, but it can be created pretty easily.

...and, JBC C210 is better in any respect - it heats up MUCH faster, and it is more compact than WMRP.
And, I've found pretty big number of complaints of WMRP's reliability. I will sooon upload a video of JBC C210  on my controller.

P.S.: Here's the video: https://www.youtube.com/watch?v=iyz-EDf ... e=youtu.be (https://www.youtube.com/watch?v=iyz-EDf-JaY&feature=youtu.be)
I would like to see a competitor outperforming it. :) And this is with C210-003 tip, which is really, really small, for soldering small SMD parts like 0402, and even 0201. And it still melts a considerable amount of solder on the TO247's pad. This is pretty amazing iron, if you ask me.
Title: Re: Really universal soldering controller
Post by: carpin on May 23, 2015, 11:13:30 pm
Sparkybg if you have PCB's I am interested
Thank you
Title: Re: Really universal soldering controller
Post by: sparkybg on May 23, 2015, 11:38:53 pm
[quote author="carpin"]Sparkybg if you have PCB's I am interested
Thank you[/quote]

I will let you know when I am ready to order PCBs.
Title: Re: Really universal soldering controller
Post by: Deus on May 24, 2015, 12:13:33 am
Great job sparky.
Add me too for the pcbs.

Just to be sure, the design fits a BK 3000LF 70W BlackJack solder station?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 24, 2015, 11:10:26 am
[quote author="Deus"]Great job sparky.
Add me too for the pcbs.

Just to be sure, the design fits a BK 3000LF 70W BlackJack solder station?[/quote]

Yes, I am using this enclosure. Kust the back panel is changed, but I have drawing for it - you can order it laser cut from sheet metal.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 24, 2015, 11:11:19 am
A comparison of different irons and tips:
[attachment=0]
Title: Re: Really universal soldering controller
Post by: neslekkim on May 24, 2015, 03:23:28 pm
[quote author="sparkybg"][quote author="Deus"]Great job sparky.
Add me too for the pcbs.

Just to be sure, the design fits a BK 3000LF 70W BlackJack solder station?[/quote]

Yes, I am using this enclosure. Kust the back panel is changed, but I have drawing for it - you can order it laser cut from sheet metal.[/quote]

Add me to the list also.
I wonder if I have seen other solderstations with the same enclosure, would be nice to get it as cheap as possible since everything inside would be thrown out :)
Title: Re: Really universal soldering controller
Post by: r3dpandaz on May 24, 2015, 08:19:58 pm
Hi Sparky,

I see the demo video on solder tips, Im interested with this beautiful solder, would you like to sell one whole piece working proto? I use alot of soldering, mostly small pitch QFP but never had pro tools before, thanks
Title: Re: Really universal soldering controller
Post by: tmatthewj on May 24, 2015, 10:15:50 pm
Hi sparkybg and Hi guys!

My first question is for those who use jbc c245 with the non genuine jbc station.
How do you change the tip? On the original jbc desk stand there is a metal tip changer. But if I build a controller and buy a t245 handle with some cartridges then i won't have this little tool for tip change. Or you use a simple plier to change?

Second question is also for those who has custom solution. :)
How do you store tips?
I saw this solution, but it's expensive.
http://www.jbctools.com/sc-b-extractor- ... t-959.html (http://www.jbctools.com/sc-b-extractor-inserter-cartridge-magazine-product-959.html)
I am thinking about building a similar stand for my cartridges. In this way I could change the tips easily.

Third question is for You sparkybg.
What if I use 24V 6-8A switch mode power supply instead of toroidal transformer? Will it change anything about the controller behavior or the stability or the tip life?

thx
tmatthewj
Title: Re: Really universal soldering controller
Post by: sparkybg on May 24, 2015, 10:36:12 pm
[quote author="tmatthewj"]Hi sparkybg and Hi guys!

My first question is for those who use jbc c245 with the non genuine jbc station.
How do you change the tip? On the original jbc desk stand there is a metal tip changer. But if I build a controller and buy a t245 handle with some cartridges then i won't have this little tool for tip change. Or you use a simple plier to change?
[/quote]
I am using a sheet of printer paper, folded many times.

[quote author="tmatthewj"]
Second question is also for those who has custom solution. :)
How do you store tips?
I saw this solution, but it's expensive.
http://www.jbctools.com/sc-b-extractor- ... t-959.html (http://www.jbctools.com/sc-b-extractor-inserter-cartridge-magazine-product-959.html)
I am thinking about building a similar stand for my cartridges. In this way I could change the tips easily.
[/quote]
Get a piece of aluminum, drill several holes in it, and you are done.

[quote author="tmatthewj"]
Third question is for You sparkybg.
What if I use 24V 6-8A switch mode power supply instead of toroidal transformer? Will it change anything about the controller behavior or the stability or the tip life?
[/quote]

As stated in the first post, it works with 9-24V, AC, or DC. But I recommend using a toroidal transformer in order to avoid any grounding difficulties some (if not most) SMPS have.
Title: Re: Really universal soldering controller
Post by: tmatthewj on May 24, 2015, 10:57:43 pm
OK
I will use a toroidal transformer.
But what grounding difficulties? (sorry for dumb question)
Title: Re: Really universal soldering controller
Post by: neslekkim on May 24, 2015, 11:14:32 pm
[quote author="tmatthewj"]
My first question is for those who use jbc c245 with the non genuine jbc station.
How do you change the tip? On the original jbc desk stand there is a metal tip changer. But if I build a controller and buy a t245 handle with some cartridges then i won't have this little tool for tip change. Or you use a simple plier to change?
[/quote]

An JBC stand would be an investment anyway, then you could connect that, and use the automatic poweroff for the tip when changing tips, I hope it's possible to use the external stand atleast.
But you can use the same rubbermats as they use on other irons, like on the hakko fx951 and the metcal (atleast I think I have seen it used there also)

[quote author="tmatthewj"]
How do you store tips?
I saw this solution, but it's expensive.
http://www.jbctools.com/sc-b-extractor- ... t-959.html (http://www.jbctools.com/sc-b-extractor-inserter-cartridge-magazine-product-959.html)
I am thinking about building a similar stand for my cartridges. In this way I could change the tips easily.
[/quote]

I bougth an hakko holder: https://instagram.com/p/3FEfk1jOgA/ (https://instagram.com/p/3FEfk1jOgA/)
It's heavy and compact, wanted to get the JBC tool, but it's too expensive, and too roomy..
Title: Re: Really universal soldering controller
Post by: sparkybg on May 24, 2015, 11:17:06 pm
[quote author="tmatthewj"]OK
I will use a toroidal transformer.
But what grounding difficulties? (sorry for dumb question)[/quote]

It is a bit hard to explain. In short using SMPS, you've got several times higher probabilities of something going wrong with the earth. Moreover, since JBC tips have connection in them between the outer shell (which must be grounded) and one of the terminals, you should not grund the SMPS, but the tip itself. But most of the SMPS I've used, have a capacitor between one of the output terminals and ground/enclosure, so it needs a little thinking/experimentation where exactly to put tha grounding and how to connect the wires between the power supply and controller, in order to avoid ground loops and some other things.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 24, 2015, 11:21:29 pm
The JBC tip holder of the link can be made pretty easily with lased cutting machine. I don't know how much it costs, but I definitely wouldn't pay mode than 20-30EUR for it.
Title: Re: Really universal soldering controller
Post by: Erythros on May 24, 2015, 11:49:49 pm
[quote author="tmatthewj"]Hi sparkybg and Hi guys!

My first question is for those who use jbc c245 with the non genuine jbc station.
How do you change the tip? On the original jbc desk stand there is a metal tip changer. But if I build a controller and buy a t245 handle with some cartridges then i won't have this little tool for tip change. Or you use a simple plier to change?[/quote]

Do you own original JBC or is this theoretical question? Because I have only seen the changing by stand on video but I always thought that I would rather use the silicone pad Metcal's stations come with. On one side it is nice that it cuts power but it didn't look very usable.

[quote author="tmatthewj"]Second question is also for those who has custom solution. :)
How do you store tips?
I saw this solution, but it's expensive.
http://www.jbctools.com/sc-b-extractor- ... t-959.html (http://www.jbctools.com/sc-b-extractor-inserter-cartridge-magazine-product-959.html)
I am thinking about building a similar stand for my cartridges. In this way I could change the tips easily.
[/quote]

I store tips in plastic bag, but I am using wooden stand for tweezers, pliers, scalpels and syringes with flux which looks little bit like stand for pipes. I wasn't that hard to make but I guess that it depends on your skills.

[quote author="neslekkim"]I bougth an hakko holder: https://instagram.com/p/3FEfk1jOgA/ (https://instagram.com/p/3FEfk1jOgA/)
It's heavy and compact, wanted to get the JBC tool, but it's too expensive, and too roomy..[/quote]

From what it's made of? The T12 tip are running relatively low so it got me thinking about printing something similar.

BTW, do you anybody have some experience with Weller WMRT 12V/80W desoldering tweezers? I may be able to get them for reasonable price.
Title: Re: Really universal soldering controller
Post by: neslekkim on May 25, 2015, 01:05:22 am
[quote author="Erythros"]
Do you own original JBC or is this theoretical question? Because I have only seen the changing by stand on video but I always thought that I would rather use the silicone pad Metcal's stations come with. On one side it is nice that it cuts power but it didn't look very usable.
[/quote]

The jbc stand is very usable for changing tips, I have both an compact station with inbuilt stand, and an DI station with external stand, using the groves in the stand to change tips works very well.

[quote author="Erythros"]
[quote author="neslekkim"]I bougth an hakko holder: https://instagram.com/p/3FEfk1jOgA/ (https://instagram.com/p/3FEfk1jOgA/)
It's heavy and compact, wanted to get the JBC tool, but it's too expensive, and too roomy..[/quote]

From what it's made of? The T12 tip are running relatively low so it got me thinking about printing something similar.
[/quote]

What do you mean with running low?, low temperature?, the T12 tips are almost cold on th eend, so that should work ok I guess, if you have weight in the bottom so it doesnt tip over.

The hakko piece is solid aluminium I think.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 25, 2015, 09:11:10 am
[quote author="Erythros"]
BTW, do you anybody have some experience with Weller WMRT 12V/80W desoldering tweezers? I may be able to get them for reasonable price.[/quote]

If you are planning to drive them with this controller, you will have to find out yourself how they must be connected, and then create a profile for them.

JBC microtweezers are an alternative. And maybe a better one - they seems smaller on the photos, and are again 80W (2x40W). They work extremely well form 0201 upto "D" package (never tried something bigger). And it seems they are a bit cheaper.
Title: Re: Really universal soldering controller
Post by: Ensil on May 27, 2015, 07:33:46 pm
Just dropping in to say what a great project this is!
Title: Re: Really universal soldering controller
Post by: Erythros on May 27, 2015, 10:20:27 pm
[quote author="neslekkim"]
What do you mean with running low?, low temperature?, the T12 tips are almost cold on th eend, so that should work ok I guess, if you have weight in the bottom so it doesnt tip over.

The hakko piece is solid aluminium I think.[/quote]

Yes, I meant temperature. Aluminium is nice but you have to anodize it. (Which is incredibly simple, but you need the pigment.) That take me to: Do you know how hot are the JBC C245 tips? Can you take them out of the T245A just by hand?

[quote author="sparkybg"]
If you are planning to drive them with this controller, you will have to find out yourself how they must be connected, and then create a profile for them.

JBC microtweezers are an alternative. And maybe a better one - they seems smaller on the photos, and are again 80W (2x40W). They work extremely well form 0201 upto "D" package (never tried something bigger). And it seems they are a bit cheaper.[/quote]

By "reasonable" price I meant about 1/4 of the current price of JBC microtweezers. (I take it that we are talking about PA120-A.)

If I get them then I will try to use this controller. But that's if.
Title: Re: Really universal soldering controller
Post by: neslekkim on May 27, 2015, 10:37:16 pm
[quote author="Erythros"][quote author="neslekkim"]
What do you mean with running low?, low temperature?, the T12 tips are almost cold on th eend, so that should work ok I guess, if you have weight in the bottom so it doesnt tip over.

The hakko piece is solid aluminium I think.[/quote]

Yes, I meant temperature. Aluminium is nice but you have to anodize it. (Which is incredibly simple, but you need the pigment.) That take me to: Do you know how hot are the JBC C245 tips? Can you take them out of the T245A just by hand?
[/quote]

Newer tried that, the tip is far inside the handle, and it is very tight, so I did not want to burn my fingers. But the back end of the tip is cold, but like I mentioned earlier, and small rubber matt would work ok.

I don't know where you come from, but I bought lot of hakko stuff from this ebayseller: http://stores.ebay.com/NEI-Lamps-and-Electronics (http://stores.ebay.com/NEI-Lamps-and-Electronics)
I would ask him if he could get the B2300 heat resistent pad, and the B2756 Tip tray, I bought the tip tray there, I paid $20 for the tray, and that is worth it in my eyes, if he had more in stock at that moment, I would have bought an extra.
He got me various things that is not on his list on ebay, because I needed some spareparts for my FR300.
Title: Re: Really universal soldering controller
Post by: savril on May 28, 2015, 09:04:51 pm
[quote author="sparkybg"][quote author="savril"]
If you really are about the performance of a JBC station, that's a great job ![/quote]

Show me a movie of your station while heating up, and I will show you a movie from mine.

P.S.: Here is it, heating up, and then heating TO247's thermal pad:
https://www.youtube.com/watch?v=oTdQB4y ... e=youtu.be (https://www.youtube.com/watch?v=oTdQB4ywDOA&feature=youtu.be)

P.S.: Chinese fake T12 on the same ТО247 thermal pad:
https://www.youtube.com/watch?v=u588sh- ... e=youtu.be (https://www.youtube.com/watch?v=u588sh-4thg&feature=youtu.be)[/quote]

Sorry for the delay, I didn't have the JBC at hand when you first wrote. I took a small video, available here: https://youtu.be/8glanxybxEM (https://youtu.be/8glanxybxEM) . I took it with my phone and I've not edited it so its a little rough.
I didn't have a TO247 on hand so I've done it on a SOT-223. The thermal mass is clearly not comparable but it could give you an idea of how the JBC work.

The JBC seem slower to update its screen but seem to achieve the same stability as you, I think the PID update faster than the screen. But yours seem faster to update and less prone to overshoot.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 28, 2015, 10:35:35 pm
From what I can see, the JBC controller shows the target temperature once it reaches it. I hate this. I am always showing the real temperature (although a little filtered) on my devices. And I like the fast updates - my multimeter (Agilent U1272A) has a fast update also, so I'm used to it. :)

C245 is my favorite tip, so I spend much time optimising the PID coefficients for it. Nevertheless, I think it can be made a bit better.

I think some overshoot in favor of smaller undershoots is actually a good think, but It is always a compromise - my PID should work well on 9-28V, and I had to make a small compromises for it to be stable from the lowest to the highest input voltage.

Thank you for the video. :)
Title: Re: Really universal soldering controller
Post by: fredboivin on June 04, 2015, 09:44:26 pm
Hi, very interesting project!

Do you know how JBC does its sleep and tip changing poweroff? In this, you are doing it with an IR sensor, but I'd like to know how has JBC implemented it.

Thanks!
Title: Re: Really universal soldering controller
Post by: sparkybg on June 04, 2015, 09:58:05 pm
[quote author="fredboivin"]Hi, very interesting project!

Do you know how JBC does its sleep and tip changing poweroff? In this, you are doing it with an IR sensor, but I'd like to know how has JBC implemented it.

Thanks![/quote]

As far as I know, they have a switch in the stand. My controller also can work with a switch in the stand.
Title: Re: Really universal soldering controller
Post by: neslekkim on June 04, 2015, 10:05:44 pm
No switch, but the metal on the front of the iron, and the casing of the tip connects to the metal on the stand, and the tip ejector.
Title: Re: Really universal soldering controller
Post by: savril on June 11, 2015, 03:34:19 pm
[quote author="neslekkim"]No switch, but the metal on the front of the iron, and the casing of the tip connects to the metal on the stand, and the tip ejector.[/quote]

There's no contact check I think with the tip ejector because it continue to heat while I remove the tip (and make contact with the tip ejector). As soon as there is no contact inside the iron with the cartdridge, the station detect it (because there's no longer a conductive path).

I have a question about Rgnd1 on front PCB. It join the grounds of both sides of the ADuM3160 with a 10M resistor in 2512 format. In this format, it likely to be a 2,5W resistor. So it seem to be designed to withstand like 5kV at 5mA, like an ESD discharge. I have'nt seen a similar design before.

If this resistor was connected to the iron ground and the mains earth pin, I would have understand It would be to have the iron ESD safe. But why did you put it with the ADuM and connected with ESD ? Why haven't you used a TVS diode like in other part of your design ?

I'm not questionning your design, I'm just a begginner trying to understand.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 11, 2015, 03:53:50 pm
Both the controller and the computer you are connecting it to may or may not have a connection to earth/ground, so it is there to provide a weak coupling between two sides to prevent too large voltage there in case one device has ground connection, and another one does not.

There are several 2512 resistors on the market, specified to withstand 3kV voltage on them, so that's why it is 2512. You may put 1M, 3M, 5M, 10M resistor there or leave it without resistor at all. It will still work, but I think the reliability is a bit higher when the resistor is there.
Title: Re: Really universal soldering controller
Post by: Erythros on June 14, 2015, 12:28:36 am
Well, I got ordered PCBs in my post. They are not bad, but not 100%, however will work nicely.
[attachment=0]
When seen in natura it looks really packet. Made me realize that hot air reworking will be probably needed. Which is kind of ironic, given that I wanted nice soldering iron in first place and now I will have to buy el cheapo hot air to build soldering station. Well that is life I guess. Now I will have to talk to friend with CO2 laser about making some stencils.

I still have some questions about BOM:

Not sure I get the Ja, Jb, Jc, Jd, Je, Jg resistors with 0 value. It looks like they are parallel to the ULN2003 (by the gerbers).

The ULN2003L specifically the L in the end. That is some specific model? Because I could not find it. Only LV which is low U and I model which is in opposition to the note in BOM about it being high U,I model.

Also you have there in BOM on lines 90 and 92 two zener diodes 3V and one 3.0V - I take guess that they are the same.

The WSL3637 is 0.003 ohms?

The 60V in TVS is reverse standoff voltage?

Will have to finalize order and choose some nice eshop, Farnell is on most items terribly expensive.

I have received OLED display modules from China. I ordered the 0.96 and 1.3 inch models. Let me tell you these are tiny. I first received the 1.3 inch model and my basic reaction was that I will use the bigger one when it arrive. It was quite shock when I realized that that was the bigger one. And they use SH1106 instead of SSD1306 which is specified in BOM which is similar IC but it has matrix of 132x64 so you have to offset the image.

Don't know what to do, they seem incredibly small. Probably will go to the 1.3 route, bigger ones uses different IC pinout and I already have the backplane PCB.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 14, 2015, 10:01:55 am
[quote author="Erythros"]Well, I got ordered PCBs in my post. They are not bad, but not 100%, however will work nicely.[/quote]

PCBs looks pretty nice.

[quote author="Erythros"]
When seen in natura it looks really packet. Made me realize that hot air reworking will be probably needed. Which is kind of ironic, given that I wanted nice soldering iron in first place and now I will have to buy el cheapo hot air to build soldering station. Well that is life I guess. Now I will have to talk to friend with CO2 laser about making some stencils.
[/quote]
You can make them in the kitchen oven, if you have stencils. :) However, I made them purely with soldering iron. No hot air whatsoever. Just get yourself a decent flux. I am using BGA no-clean flux.

[quote author="Erythros"]
Not sure I get the Ja, Jb, Jc, Jd, Je, Jg resistors with 0 value. It looks like they are parallel to the ULN2003 (by the gerbers).
[/quote]
ULN2003 and Ra-Rg are have to be there if you use 7 segment LED indicators. If you use OLED, the ULN2003 is not mounted, and Ja-jg and Ra-Rg are all just solder jumpers. If you look at their footprints, you will notice the pads are pretty close to each other in order to make easily a solder jumpers out of them.

The ULN2003L specifically the L in the end. That is some specific model? Because I could not find it. Only LV which is low U and I model which is in opposition to the note in BOM about it being high U,I model.

[quote author="Erythros"]
Also you have there in BOM on lines 90 and 92 two zener diodes 3V and one 3.0V - I take guess that they are the same.
[/quote]
Yes these are the same.

[quote author="Erythros"]
The WSL3637 is 0.003 ohms?
[/quote]
You can use 0.003 and 0.004 ohms. On the schematics there's a table what the resistor values of the amplifier are for 0.003 and 0.004 shunt.

[quote author="Erythros"]
The 60V in TVS is reverse standoff voltage?
[/quote]
Yes.

[quote author="Erythros"]
I have received OLED display modules from China. I ordered the 0.96 and 1.3 inch models. Let me tell you these are tiny. I first received the 1.3 inch model and my basic reaction was that I will use the bigger one when it arrive. It was quite shock when I realized that that was the bigger one. And they use SH1106 instead of SSD1306 which is specified in BOM which is similar IC but it has matrix of 132x64 so you have to offset the image.
Don't know what to do, they seem incredibly small. Probably will go to the 1.3 route, bigger ones uses different IC pinout and I already have the backplane PCB.[/quote]

If the pad layout and the voltages are the same, you can use another controller, but you will also have to modify the firmware to support it. The commands and the initialization of every OLED controller chip is different. So if you ask me - get a SSD1306 OLED.
Title:
Post by: Circuiteromalaguito on June 14, 2015, 08:55:40 pm
Just a silly question that maybe was replied before...

Can a 7seg and OLED displays be used at same time? Is the firmware ready for that?

The idea is to use a big 7seg display for temperature and maybe other important stuff (change iron? Sleep mode? OFF?) because of greater visibility.
Title: Re:
Post by: sparkybg on June 14, 2015, 09:49:19 pm
[quote author="Circuiteromalaguito"]Just a silly question that maybe was replied before...

Can a 7seg and OLED displays be used at same time? Is the firmware ready for that?

The idea is to use a big 7seg display for temperature and maybe other important stuff (change iron? Sleep mode? OFF?) because of greater visibility.[/quote]

No, they cannot. They are sharing MCU legs, and 2 of the transistors for OLED common anodes are providing the power to the OLED.

In fact, I never tried the 7 segments on this version. There are routines for 7 segment in the firmware, it can detect if 7 segment or OLED is present, but probably the firmware will need some work/debug to use 7 segment. Older versions of the controller are using only 7 segment.
Title: Re: Really universal soldering controller
Post by: Erythros on June 15, 2015, 06:14:58 pm
[quote author="sparkybg"]
PCBs looks pretty nice.
[/quote]

Yes, I was little worried about drilling accuracy. But that turned out fine. The soldermask is little off but that should not make a problem, because it does not actually cover the pads. It is little strange that vias on front PCB are actually better looking and partially exposed. On the back PCB they are covered with soldermask which creates little bubbles (which is not so pretty). But on the other side of back PCB there are somevias which are similar to vias on front PCB (more on photo.) My personal guess is that it is result of existence of drill drawing and guide in front PCB gerber files (as this is seen in all 10 copies of each design, not just one board.) The silkscreen is good I think but I have seen on internet photos with comparable print and comments ranging from not much to horrible. So...[attachment=0]

[quote author="sparkybg"]You can make them in the kitchen oven, if you have stencils. :) However, I made them purely with soldering iron. No hot air whatsoever. Just get yourself a decent flux. I am using BGA no-clean flux.
[/quote]

I was thinking of somethink similar as I have old oven in kitchen I am going to renovate soon. I would still need to mock up some form of controller as to not heat it more that the 260°C limit electronics parts seem to have. I have this (http://http://www.tme.eu/en/Document/c10d0c56b3f9f80a77cb6775d527cdf9/sn96pb36ag62_dte.pdf) paste and if I am reading the profile correctly it approaches this limit point.

I am not sure my hand would be still enough not to scrape IC packages with hot iron. BTW I am using KINGBO RMA-218 from China (Aliexpress) and hard rosin dissolved in alcohol with glycerine for SMT work and so far it worked quite well combined with Stannol HF32 S-Sn60Pb39Cu1 0.32mm wire. But I have not yet made too much. Truth is I have been little leery about investing 30 EUROs into brand flux from reliable supplier.

[quote author="sparkybg"]You can use 0.003 and 0.004 ohms. On the schematics there's a table what the resistor values of the amplifier are for 0.003 and 0.004 shunt.[/quote]

Ah, of course. I was little confused as on the back schematics these is hard-coded value of 0.003.

[quote author="sparkybg"][quote author="Erythros"]
The 60V in TVS is reverse standoff voltage?
[/quote]
Yes.[/quote]
Ok, after this I have found that the note Tranzorb actually means name of product line from VISHAY.

[quote author="sparkybg"]If the pad layout and the voltages are the same, you can use another controller, but you will also have to modify the firmware to support it. The commands and the initialization of every OLED controller chip is different. So if you ask me - get a SSD1306 OLED.[/quote]
That's given. Looking how it is solved in u8glib pretty much proved that it is just shifted. The SH1106 has matrix 132x64 so they just place the 128x64 in the middle so it is shifted by two points from left and right. And playing with it I can see two points width bar on right side when driving as SSD1306. But it will be surest to gen panel with SSD1306. I just seems so tiny, even the 1.3 inch version. But then the bigger ones (2.4) are expensive: about 20 USD per panel - that seems little excessive for soldering station (like the colour LCD on newer JBCs).

BTW, is there some hidden design factor for use of IPD053N08N3 or should similar N channel MOSFET with similarly low Rds(on) and values of Id, Vds, Vgs and Pd also fit the bill?

[quote author="Circuiteromalaguito"]Can a 7seg and OLED displays be used at same time? Is the firmware ready for that?

The idea is to use a big 7seg display for temperature and maybe other important stuff (change iron? Sleep mode? OFF?) because of greater visibility.[/quote]

I don't think I get the idea behind this. The OLED has very nice viewing angles. And it is just soldering station - there is not much information you would need displayed.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 16, 2015, 12:16:55 am
[quote author="Erythros"]
BTW, is there some hidden design factor for use of IPD053N08N3 or should similar N channel MOSFET with similarly low Rds(on) and values of Id, Vds, Vgs and Pd also fit the bill?
[/quote]
The important parameters are package, Rds(on), Vds, and gate threshold voltage. Nothing more.

[quote author="Erythros"]
I don't think I get the idea behind this. The OLED has very nice viewing angles. And it is just soldering station - there is not much information you would need displayed.[/quote]
You need nothing more than temperature, but no one will refuse the power bar and indication, instrument indication, error explanation, and parameter menu. I just decided to try it out. Both the size and price for 3pcs 7 segment indicators + driving IC is comparable to an 0.96 OLED + boost chip behind it. And once you get used to it, the 7 segment version looks awful.

The same is with color display - if it is cheap enough for a company like JBC, why not put it in there. There are MCU-s with internal TFT controller on the market. And 3.5inch TFT is definitely cheap enough. It starts around $10 on ebay, which means it is even cheaper for a company. If I ever make another revision of the controller, I will put a 3.5 inch TFT+ touch screen in it. You have $10 display, $10 MCU controlling the whole thing, and no mechanical switches whatsoever. When you add to this the panel of the box, which will be considerably simpler to manufacture and with less parts, you may end up with a cheaper solution using a color TFT instead of 7 segment or OLED + switches/encoders.
Title: Re: Really universal soldering controller
Post by: carpin on June 22, 2015, 12:06:31 am
Sparkybg is a ultrasonic transmitter difficult to ad?

Ultrasonic Soldering Iron
http://http://www.mecstech.com/en/product/ultrasonic-soldering/ultrasonic-soldering-iron/?ckattempt=1

https://www.youtube.com/watch?v=ZLzrdCzeM5g (https://www.youtube.com/watch?v=ZLzrdCzeM5g)
Title: Re: Really universal soldering controller
Post by: sparkybg on June 22, 2015, 10:22:00 am
Everything other than resistive heater cannot be controlled and is impossible to add.

Moreover, It is impossible to make universal controller for frequency specific devices.
Title: Re: Really universal soldering controller
Post by: Erythros on June 26, 2015, 09:28:21 pm
So I had the stencils cut on laser and it didn't turn out so well. It is usable but there are some quite big problems. It was tried with 0.1 mm transparency (for laser printers) and 0.2 mm one for general office use. The main probles is with size – as I made the drawing from soldermask gerber I didn't resize it to small enough size. Also given how my gerber viewer exported the layer to SVG and DXF, most pads were polygons with circles in corners, when shrinking it created even more complex forms. Which sadly turned out to be problematic. Mainly on the power back board – stencil for this turned out to be pretty unusable. There are starting holes outside of rectangle (as seen  in photo). But I also tried to lasercut stencil for another board I am planning to build – one with special gerber file for stencil with true rectangles and that turned out fine so I am hopeful that with more time customizing my drawing (mainly making polynoms into rectangles) in AutoCAD I will be able to get good results. Definitely will try again.

[attachment=0]
[attachment=1]

I also ordered parts. Of cource some weren't in stock and some items weren't even in catalogue so will still probably need to order from Farnell (well, local distributor when in vicinity to save on postage). Not sure if I will get the parts currently not in stock as this is TME and they are quite arrogant about fulfilling orders, but I got the bulk today.

I made some observations about BOM:

The FZT605 darlington array is SOT223 but the footprint on board looks like it could also accomodate DPAK. (Also in the illustration it looks like DPAK.) Quite interesting (at least for me), any reason for it? I was planning to use NZT605 from Fairchild but maybe something in DPAK would be better.

What are you using as the J5 RJ11v header (in BOM as 8 pin, actually just 6 pin with holding holes)? I found header which could fit in TE Connectivity catalogue. Not sure if I will use it or do it some other way.

By measuring I concluded that I can solder diodes in miniMELF package onto pads for SOD123 (which use diodes specified in BOM). The illustration also shows miniMELF. And it is much sipler to buy diode in miniMelf that SOD123.

Still I will have to study datasheets of most of the diodes or buy them from Farnell. But I don't think  that they are so specific as to be problematic to substitude.

In BOM there is pot BOURNS 3362. I think that 3362 is leaded version and the pads on PCB are for SMD. I ordered 3364X and it fits.

For anybody ordering diodes for rectification, I could't find SR580 anywhere alse than Comet. So it it just diode I ordered some other model. Only it is P600 package and there in not enough room for it to put flan on PCB. The TVS is also P600 so I will put 3 diodes on PCB and 2 on them creating pyramide. Will look interesting.

Don't know if I am just looking in wrong slaces but the SMD 0805 27kohm 0.1% resistor seems pretty hard to find. Only Farnell seems to have them. TME stocks only 27.4kohm.

Looking at L1 maybe the reason for the so much covered vias on back board (about which I was complaining in my previous post) is that some chinese worker actually thought about it. The pads on the coil are huge and expand beyond the pads on PCB, so if the vias on PCB were even little uncovered there would be chance for short. Very interenting.

[quote author="sparkybg"]
The same is with color display - if it is cheap enough for a company like JBC, why not put it in there. There are MCU-s with internal TFT controller on the market. And 3.5inch TFT is definitely cheap enough. It starts around $10 on ebay, which means it is even cheaper for a company. If I ever make another revision of the controller, I will put a 3.5 inch TFT+ touch screen in it. You have $10 display, $10 MCU controlling the whole thing, and no mechanical switches whatsoever. When you add to this the panel of the box, which will be considerably simpler to manufacture and with less parts, you may end up with a cheaper solution using a color TFT instead of 7 segment or OLED + switches/encoders.[/quote]

You are probably right. The price difference is small. But still and maybe because of this I think that it is marketing move. JBC uses it on higher models. (Not the single handle version one.) Metcal (or Thermaltronics) is using simple 1602 display and it is enought. But then they have the 13.56MHz curie point heating technology as selling article. JBC is in the resistive heating pond which is so far lot more competitive with chinese manufacturers so it needs to separate itself better and the color LCD probably produces nice enge.

I am little leery of touch interface on soldering station. I can see myself trying to change temperature or other settings while holding soldering pen as cigarette with fingerpads dancing on touchscreen. And that is good way how to stab the touchscreen with hot iron and I am not sure cheap screen from China most people like me will be able to get theirs chubby finger on will be able to withstand it.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 27, 2015, 09:52:22 am
[quote author="Erythros"]
The FZT605 darlington array is SOT223 but the footprint on board looks like it could also accomodate DPAK. (Also in the illustration it looks like DPAK.) Quite interesting (at least for me), any reason for it? I was planning to use NZT605 from Fairchild but maybe something in DPAK would be better.
[/quote]
The footprint is compatible both with DPAK and SOT223.

[quote author="Erythros"]
What are you using as the J5 RJ11v header (in BOM as 8 pin, actually just 6 pin with holding holes)? I found header which could fit in TE Connectivity catalogue. Not sure if I will use it or do it some other way.
[/quote]
The connector is 6 pin. It is used for sensor in the stand. 2 additional connections on the schematic are for 2 big holding holes.

[quote author="Erythros"]
By measuring I concluded that I can solder diodes in miniMELF package onto pads for SOD123 (which use diodes specified in BOM). The illustration also shows miniMELF. And it is much sipler to buy diode in miniMelf that SOD123.
[/quote]
Again, the footprint is compatible with both footprints. I think miniMELF is harder for machine soldering, so I made it compatible with both.

[quote author="Erythros"]
Still I will have to study datasheets of most of the diodes or buy them from Farnell. But I don't think  that they are so specific as to be problematic to substitude.
[/quote]
Some of the diodes are critical, specificaly these in sot23 package. They should be with small enough reverse current. They should not be Schottky, LL4148 are OK, for example, but these are made from various manufacturers with pretty different reverse currents, so I decided to use other diodes with similar ratings.

[quote author="Erythros"]
In BOM there is pot BOURNS 3362. I think that 3362 is leaded version and the pads on PCB are for SMD. I ordered 3364X and it fits.
[/quote]
It was 3362 some time ago, the I changed it. I will correct this in the BOM and schematics. The PCBs should be OK. The new part is SMD, as you already mentioned.

[quote author="Erythros"]
For anybody ordering diodes for rectification, I could't find SR580 anywhere alse than Comet. So it it just diode I ordered some other model.
[/quote]
SR580 means "Schottky rectifier, 5A, 80V". There's nothing special about these diodes. Just use 5A 80V Schottky.

[quote author="Erythros"]
 Only it is P600 package and there in not enough room for it to put flan on PCB. The TVS is also P600 so I will put 3 diodes on PCB and 2 on them creating pyramide. Will look interesting.
[/quote]
Do not solder them close to the PCB. Solder 2 of them 1mm from the PCB, and another two 5-6mm from the PCB. The cooling is much better this way.

[quote author="Erythros"]
Don't know if I am just looking in wrong slaces but the SMD 0805 27kohm 0.1% resistor seems pretty hard to find. Only Farnell seems to have them. TME stocks only 27.4kohm.
[/quote]
As I said, I am buying parts from Farnell. Mouser for example also has them in stock. There are some areas TME doesn't have good stock in. Maybe Digikay also has them. You can buy 100pcs of 1% 27K resistors and maybe you will find around 10pcs 0.1% in them. You will have to measure them with good enough resistance meter of course.

Looking at L1 maybe the reason for the so much covered vias on back board (about which I was complaining in my previous post) is that some chinese worker actually thought about it. The pads on the coil are huge and expand beyond the pads on PCB, so if the vias on PCB were even little uncovered there would be chance for short. Very interenting.

[quote author="Erythros"]
Metcal (or Thermaltronics) is using simple 1602 display and it is enought.[/quote]
Metcal does not need display at all. There is nothing to display on it. :) The power supply of their stations just provides the needed HF power to the tip and nothing more. My the way, it is with pretty poor efficiency, maybe around 10-20%. Thet's why it is so big.

[quote author="Erythros"]
I am little leery of touch interface on soldering station. I can see myself trying to change temperature or other settings while holding soldering pen as cigarette with fingerpads dancing on touchscreen. And that is good way how to stab the touchscreen with hot iron and I am not sure cheap screen from China most people like me will be able to get theirs chubby finger on will be able to withstand it.[/quote]
Well you are working this way, and I am not. :) Again - everyone has his own opinions when making decisions how to work with his station, and what station to work with. Touchscreen is only one of the possibilities, pretty easy to manufacture. I am far from thinking it will suit everyone's behavior.
Title: Re: Really universal soldering controller
Post by: giovannirat on June 28, 2015, 12:52:09 pm
Hi sparkybg,

I would like to ask you if there is a date for providing assembled (or spare) PCB's of your great universal soldering controller ?

Thank you for any update....
Title: Re: Really universal soldering controller
Post by: mrjoda on June 28, 2015, 04:46:43 pm
Erythros - 6pin RJ connector is RJ12
Title: Re: Really universal soldering controller
Post by: SZ64 on June 29, 2015, 12:30:52 am
[quote author="sparkybg"]

If the pad layout and the voltages are the same, you can use another controller, but you will also have to modify the firmware to support it. The commands and the initialization of every OLED controller chip is different. So if you ask me - get a SSD1306 OLED.[/quote]

For all OLEDs (0.96 ", 1.3") applies, the offset is derived
on size, not on the wiring:
SSD1306 -> 0.96"-> H-Offset = 0
SH1106 ->  1.3" -> H-Offset = 2
Title: Re: Really universal soldering controller
Post by: sparkybg on June 29, 2015, 09:46:02 am
[quote author="giovannirat"]Hi sparkybg,

I would like to ask you if there is a date for providing assembled (or spare) PCB's of your great universal soldering controller ?

Thank you for any update....[/quote]

I don't know yet. Sorry.
Title:
Post by: Circuiteromalaguito on July 09, 2015, 04:00:24 pm
This is a bit of curiosity and referencing another forum...

Does other soldering stations use toroidal transformers?

Hakko FX-888D does not use it. Why?

http://www.eevblog.com/forum/index.php?topic=4137.0 (http://www.eevblog.com/forum/index.php?topic=4137.0)
Title: Re:
Post by: sparkybg on July 10, 2015, 08:31:44 am
[quote author="Circuiteromalaguito"]
Hakko FX-888D does not use it. Why?
[/quote]

Some people are driving BMW, other Mercedes. Why?
Title: Re: Re: Re:
Post by: Circuiteromalaguito on July 10, 2015, 10:10:37 am
[quote author="sparkybg"][quote author="Circuiteromalaguito"]
Hakko FX-888D does not use it. Why?
[/quote]

Some people are driving BMW, other Mercedes. Why?[/quote]


I have no idea of cars, I don't like to drive and even lack a driver's license. But I suppose you mean it's related to saving costs. Am I right?

Do you know other soldering stations using toroidal transformers?
Title: Re: Re: Re:
Post by: sparkybg on July 10, 2015, 10:33:11 am
[quote author="Circuiteromalaguito"]
Do you know other soldering stations using toroidal transformers?[/quote]

Why should I care what others are using? The controller works with any decent transformer, toroidal or not.
Title: Re: Re: Re: Re:
Post by: Circuiteromalaguito on July 10, 2015, 11:12:33 am
[quote author="sparkybg"][quote author="Circuiteromalaguito"]
Do you know other soldering stations using toroidal transformers?[/quote]

Why should I care what others are using? The controller works with any decent transformer, toroidal or not.[/quote]


 Okay. I just wanted to know if others use it. I just was curious about it and the possible reasons behind it.

I'm sorry a lot if I annoyed you!
Title: Re: Re: Re: Re:
Post by: neslekkim on July 10, 2015, 12:14:07 pm
[quote author="Circuiteromalaguito"]
 Okay. I just wanted to know if others use it. I just was curious about it and the possible reasons behind it.
[/quote]

http://tortran.com/toroidal_transformer_advantages.html (http://tortran.com/toroidal_transformer_advantages.html)
Title: Re: Re: Re: Re: Re:
Post by: Circuiteromalaguito on July 13, 2015, 12:17:13 am
[quote author="neslekkim"][quote author="Circuiteromalaguito"]
 Okay. I just wanted to know if others use it. I just was curious about it and the possible reasons behind it.
[/quote]

http://tortran.com/toroidal_transformer_advantages.html (http://tortran.com/toroidal_transformer_advantages.html)[/quote]


Nice.

I get interested at weird details, I know.

Some Hakko FX-888D use toroidal transformers...
https://youtu.be/QK3pTam0Gkk (https://youtu.be/QK3pTam0Gkk)

This one did soldering station + power supply, powered by a toroidal transformer...

http://www.edaboard.com/thread225116.html (http://www.edaboard.com/thread225116.html)
Title: Re: Really universal soldering controller
Post by: Freya on July 21, 2015, 08:58:36 pm
Hi,
if somebody doesn't mind explaining me the Q1 darlington circuit in power supply branch I will appreciate it. I have been looking into datasheet for LM2675M-ADJ but there is not mention of darlington transistor. I don't understand. Also how much power does it dissipate? The datasheet for FZT605 says 1.2W but with sufficient copper it can reach 2W and the copper filling there is big.
Title: Re: Really universal soldering controller
Post by: sparkybg on July 21, 2015, 10:48:16 pm
Q1 provides upto around 35V DC voltage to the LM2675. Maximum rating of LM2576 is 45V and recomended upto 40V. When you are using 24V transformer, the peak voltage after the rectivier is 34V. But this is at 230V mains. Maximum standart mains voltage is 264V, and this will give 24*264/230 = 27.6V, with peak 38.9V. Add another 10-15% when the consumption from the trensformer is low, and you will have close to 45V peak voltage after the rectifier - well above the maximum recommended input voltage of LM2576.

It usualy stays quite cool. It will dissipate some heat when extreme input voltage is present, but it will not be too much. The whole thing consumes around 1.5-2W, and when 36V input to the LM2675 this is 56mA. If the input rectified voltage is at the extreme 45V, this will give 9V on the darlington, and the dissipation will be around 0.5W. And this is pretty pessimistic calculation. In the real world, even at the extreme cases, it will never reach more than 0.2-0.3W.

The dissipation is close to zero when DC power is used. Both AC and DC rating of the project is 9-26V, and when 26V DC is used, the voltage on the darlington is around 1.5V, so the dissipation will be under 0.15W.
Title: Re: Really universal soldering controller
Post by: tmatthewj on July 22, 2015, 05:34:41 pm
Hi sparkybg,

What do you think about this transformer?
http://kepfeltoltes.hu/150609/P1030861_ ... es.hu_.jpg (http://kepfeltoltes.hu/150609/P1030861_www.kepfeltoltes.hu_.jpg)
Is it enough for the normal operation of the controller with the t245 solder iron?
I found this case on an auction site and i think it would be a good housing for the controller. It was an ersa micro-con 60 iA.
Title: Re: Really universal soldering controller
Post by: tmatthewj on July 22, 2015, 06:41:13 pm
Better view:
http://kepfeltoltes.hu/150609/P1030860_ ... es.hu_.jpg (http://kepfeltoltes.hu/150609/P1030860_www.kepfeltoltes.hu_.jpg)
Title: Re: Really universal soldering controller
Post by: sparkybg on July 22, 2015, 09:59:36 pm
It is just 80W. The controller is limited to 120W for Т245, but this power is just when it heats up, for about 7-8 seconds. If it can withstand this stress, it is OK, but I cannot say just looking at the picture. I am running it with 120W toroidal transformer.
Title: Re: Really universal soldering controller
Post by: tmatthewj on July 22, 2015, 10:45:36 pm
Thank you for the answer.
It only cost about 10 euros, the transformer and the case. I think it's cheap, so maybe I give it a try.
I don't know, maybe the case is too small for the PCB-s.
Title: Re: Really universal soldering controller
Post by: SZ64 on July 26, 2015, 08:10:14 pm
Hi sparkybg,

I have the following IC's:
MAX6030AEUR-T - IC VREF SERIES 3.0V 500µA ±0,2% 20ppm/°C SOT23-3
MAX6035AAUR30 - IC VREF SERIES 3.0V  10mA ±0,2% 30ppm/°C SOT23-3
MAX6063AEUR-T - IC VREF SERIES 3.0V  5mA ±0,2% 20ppm/°C SOT23-3
... Can I use one of those as a substitute for REF3030 ?

LM4051AEM3-1.2+; as a substitute for LM4041CIM3-1.2+T ?

SUD50P08-25L-E3 or SQD50P08-25L-GE3; as a substitute for SUD50P10 ?
Title: Re: Really universal soldering controller
Post by: sparkybg on July 26, 2015, 11:20:35 pm
[quote author="SZ64"]Hi sparkybg,

I have the following IC's:
MAX6030AEUR-T - IC VREF SERIES 3.0V 500µA ±0,2% 20ppm/°C SOT23-3
MAX6035AAUR30 - IC VREF SERIES 3.0V  10mA ±0,2% 30ppm/°C SOT23-3
MAX6063AEUR-T - IC VREF SERIES 3.0V  5mA ±0,2% 20ppm/°C SOT23-3
... Can I use one of those as a substitute for REF3030 ?
[/quote]
Max6035 - maybe. But it is still 10mA maximum output current vs 25mA for REF3030.

[quote author="SZ64"]
LM4051AEM3-1.2+; as a substitute for LM4041CIM3-1.2+T ?
[/quote]
Yes, but make sure you select the correct pinout.

[quote author="SZ64"]
SUD50P08-25L-E3 or SQD50P08-25L-GE3; as a substitute for SUD50P10 ?[/quote]

SUD50P08 seems OK.
Title: Re: Really universal soldering controller
Post by: protonoob on August 26, 2015, 09:22:02 am
i have received some funding a little over $500 and wanted to make some PCBs
i am familiar with smd soldering but may want to have a dedicated company make the populated PCB

pcb design is very new to me so when i am contacting the company to get it made, do they supply components and all materials and which files do i send them from the post

since i obviously need help i would be willing to make a larger order and sell them at cost to a few members in the thread

i would probably go with taiwan, korea, eu or usa and stay away from china
Title: Re: Really universal soldering controller
Post by: sparkybg on August 26, 2015, 09:26:32 am
[quote author="protonoob"]when i am contacting the company to get it made, do they supply components and all materials and which files do i send them from the post[/quote]

Every company is different. You will have to ask them what data they need for this.
Title: Re: Really universal soldering controller
Post by: protonoob on August 26, 2015, 10:22:55 am
could somebody help me with these errors for receiving a quote from this site https://www.my4pcb.com/ (https://www.my4pcb.com/)
http://www.awesomescreenshot.com/image/ ... 03965ff59c (http://www.awesomescreenshot.com/image/518372/ccbfbd5ee72b02f9e659c503965ff59c)
Title: Re: Really universal soldering controller
Post by: Ashfaque on August 27, 2015, 09:43:39 am
Hello Everyone,

What an amazing find! Thanks a lot for sharing your work with the world, sparkybg. :) I really appreciate it. So much so that I'm preparing a price quote. It's going to take a bit of time though. Could you please give a rough estimate of a populated PCB?

Bests,

Ashfaque
Title: Re: Really universal soldering controller
Post by: sparkybg on August 27, 2015, 09:49:18 am
[quote author="Ashfaque"]Hello Everyone,

What an amazing find! Thanks a lot for sharing your work with the world, sparkybg. :) I really appreciate it. So much so that I'm preparing a price quote. It's going to take a bit of time though. Could you please give a rough estimate of a populated PCB?

Bests,

Ashfaque[/quote]

In my country it is around 75-80EUR per set of assembled PCBs.
Title: Re: Really universal soldering controller
Post by: Ashfaque on August 27, 2015, 10:11:44 am
Thanks again, sparkybg! :)
Title: Re: Really universal soldering controller
Post by: Ashfaque on August 29, 2015, 03:51:09 pm
Hi Sparky,

I'm a bit confused as to which header pins to order. I'm quite a novice. I'd be grateful if you can recommend me something from Digikey, Mouser, or Farnell for the following items:

Designator -> Comment -> Quantity -> Package -> Description (as per your BOM file)
J1 -> 24VAC -> 1 unit -> 1x2x4.2 -> Header, 2-Pin
J2 -> IRON     ->   1 unit -> 2x2x4.2 -> Header, 4-Pin
J3, J9 -> PWR -> 2  units -> 2x2x4.2 -> Header, 4-Pin
J4, J8 -> CNTR -> 2  units -> 2x5x2.54 -> Header, 10-Pin
J5 -> HOLDER -> 1 unit -> RJ11V -> Header, 8-Pin
J6 -> SENSOR -> 1 unit -> CI31-3 -> Header, 3-Pin
J7 -> 24VDC -> 1 unit -> 1x2x4.2 -> Header, 2-Pin
P1, P2, PD1 -> Header 5 -> 3 unit -> 1x5x2.54 -> Header, 5-Pin

Bests,

Ashfaque
Title: Re: Really universal soldering controller
Post by: sparkybg on August 29, 2015, 10:37:31 pm
You have picture of both boards in the first post. Can't you figure out what the connectors are from there?

The problem is, every manufacturer has his own nomenclature for the same (or compatible) connectors, and I am buying these from local seller. Cvilux in my case. Molex makes them too.
Title: Re: Really universal soldering controller
Post by: Ashfaque on August 30, 2015, 07:11:16 am
I'll look into Molex then. I have an Economics background. Hence lack some simple know-hows.

Bests,

A
Title: Re: Really universal soldering controller
Post by: SZ64 on August 31, 2015, 09:18:42 pm
Hi Sparky,

Is it true that the voltage VCC is 3.3V? According to Formula Vout = 1.21 * (1 + R2 / R1) voltage is correct 5.00V. I think it's a mistake at R4, instead 1K5 should be 2K7 and then the voltage is exactly 3.316V.

add:

I completed the PCB and now I need iron connection diagrams (Hakko T-12, Hakko 907 Heating element A1321 and Zhongdi desoldering gun ZD-552).
Title: Re: Really universal soldering controller
Post by: protons on September 07, 2015, 12:27:47 pm
sparkybg, It is mean for both boards assembled with ic

In my country it is around 75-80EUR per set of assembled PCBs.
Title: Re: Really universal soldering controller
Post by: sparkybg on September 07, 2015, 12:43:50 pm
[quote author="protons"]sparkybg, It is mean for both boards assembled with ic

In my country it is around 75-80EUR per set of assembled PCBs.[/quote]

Yes. This is total cost per set of assembled PCBs, excuding the OLED and some of the connectors, but it is easy to hand solder them.
Title: Re: Really universal soldering controller
Post by: sparkybg on September 07, 2015, 12:45:33 pm
[quote author="SZ64"]Hi Sparky,

Is it true that the voltage VCC is 3.3V? According to Formula Vout = 1.21 * (1 + R2 / R1) voltage is correct 5.00V. I think it's a mistake at R4, instead 1K5 should be 2K7 and then the voltage is exactly 3.316V.

add:

I completed the PCB and now I need iron connection diagrams (Hakko T-12, Hakko 907 Heating element A1321 and Zhongdi desoldering gun ZD-552).[/quote]

Black PCBs looks pretty neat. :)

I will have to look at my connectors tonight. Sorry for the delay, but I was on vacation these days.
Title: Re: Re: Really universal soldering controller
Post by: Circuiteromalaguito on September 07, 2015, 04:04:05 pm
[quote author="sparkybg"][quote author="SZ64"]Hi Sparky,

Is it true that the voltage VCC is 3.3V? According to Formula Vout = 1.21 * (1 + R2 / R1) voltage is correct 5.00V. I think it's a mistake at R4, instead 1K5 should be 2K7 and then the voltage is exactly 3.316V.

add:

I completed the PCB and now I need iron connection diagrams (Hakko T-12, Hakko 907 Heating element A1321 and Zhongdi desoldering gun ZD-552).[/quote]

Black PCBs looks pretty neat. :)

I will have to look at my connectors tonight. Sorry for the delay, but I was on vacation these days.[/quote]


Hey!

How do you connect a desoldering gun? Do you use some vacuum device? Or are you talking about other kind of device?

Thanks in advance!
Title: Re: Re: Really universal soldering controller
Post by: SZ64 on September 07, 2015, 08:54:00 pm
Quote
Hey!

How do you connect a desoldering gun? Do you use some vacuum device? Or are you talking about other kind of device?

Thanks in advance!

very easily ;)
I have the following 2 vacuum pumps:
1) THOMAS Diaphragm Pump 1420VP/12VDC (serie 1420 JADE): -0.78 Bar -> very, very quiet pump
2) "noname" (at eBay € 28): -0.80 Bar -> louder than THOMAS!
Title: Re: Really universal soldering controller
Post by: SZ64 on September 10, 2015, 03:32:49 pm
[quote author="sparkybg"]...

Connections to different tips/irons:


1. HAKKO T12:
 - Outer shell, and heater negative (middle) terminal connected together to Vout1- and GND
 - heater positive (bottom terminal) connected to Vout1+ and SENSEA
 - 1k resistor between ID and Vout1-
 - 5.6k resistor between ID and Vout2-

2. JBC C245:
 - Outer shell (green wire) connected to GND and SENSEB
 - Heater positive(red wire) connected to Vout1- and SENSEA
 - Heater negative(blue wire) connected to Vout1+
 - 150ohm between ID and Vout1+
 - 5.6k between ID and Vout2+

3. JBC C210:
 - Outer shell (green wire) connected to GND and SENSEB
 - Heater negative (middle terminal, blue wire) connected to Vout1-
 - Heater positive (smaller terminal, red wire) connected to Vout1+ and SENSEA
 - 3.0k between ID and Vout1-
 - 5.6k between ID and Vout2-

4. JBC Microtweezers:
 - Outer shell of both tips (green wire) connected to GND
 - Heater 1 negative (blue wire) connected to Vout1-
 - Heater 1 positive (red wire) connected to Vout1+ and SENSEA
 - Heater 2 negative (brown wire) connected to Vout2-
 - Heater 2 positive (yellow wire) connected to Vout2+ and SENSEB
 - 1.0k between ID and Vout1-[/quote]


Hi sparkybg,
is the correct connections for Iron HAKKO T-12?
When these connections, the display shows that I have a "JBC MicroTweezers" connected, which is not true.

Best regarts :)
Title: Re: Really universal soldering controller
Post by: sparkybg on September 10, 2015, 03:39:17 pm
Check the resistor connections and values. Something is wrong there. The controller knows what is plugged in using these resistors.

More specifically, you have a problem with the 5.6k resistor, or you have a short or open circuit somewhere.
Title: Re: Really universal soldering controller
Post by: SZ64 on September 11, 2015, 02:01:53 am
[quote author="sparkybg"]Check the resistor connections and values. Something is wrong there. The controller knows what is plugged in using these resistors.
[/quote]
Hi sparkybg,

I checked resistors and values are:
1K0 -> my: 0.999 KOhm
5K6 -> my: 5.606 KOhm

So, all in the green area ;)

[quote author="sparkybg"]
More specifically, you have a problem with the 5.6k resistor, or you have a short or open circuit somewhere.[/quote]


before I take apart the PCB board, I would have liked to tried HAKKO 907 iron-connection, but I offer you to these iron-connection diagram.

p.s.: I have the two set completes and both show me the same :(
Title: Re: Really universal soldering controller
Post by: sparkybg on September 11, 2015, 09:00:54 am
I was s little busy these days. I will update the first post with HAKKO FX8801 and Weller WSP80 connections tonight.
Title:
Post by: Circuiteromalaguito on September 11, 2015, 03:33:57 pm
Thanks a lot for your project. It looks really interesting!


About UniSolder in EEvBlog

I know to have been saying it before, so this will be the last time I post it:

Would you like to put your updated post project of this forum in EEvBLOG too?

I see many reasons:

- It would be interesting more people look at your design and have a nice techie discussion about it.

- People could provide feedback or improvements such as supporting more soldering tools in the firmware or other stuff.

- Your project could have more exposure, others could enjoy your project and you could sell more kits.


Get it reviewed by Dave L. Jones aka "That Crazy Aussie Bloke"

 It would be amazing if Dave could build one and try it or get one for teardown and testing. I'm sure many of us can make a little crowdfunding to pay for a fully assembled version to send it to him, I'm sure it could be an important cost to you.

I hope to not broke some rule by mentioning other forum!

About basing my mini project in your design:

I plan to use your design in an all-in-one portable lab suitcase with alarm.

I have many reasons to do it, like organization and avoid  stealing me. Long story, but I often forget things due to my ADHD.

I'll put my plans later in both forums ;)
Title: Re: Really universal soldering controller
Post by: SZ64 on September 15, 2015, 10:30:19 pm
Hi sparkybg,

You have indeed perish in labor ;-)
Just say that you are well.
...

I managed to finally all up and running as it should. One back-pcb of the three sets is defective / not working properly, the remaining (three front and two back) is all right.

What I've noticed that when I FW recompile, programming a PIC with these new FW get different display text (look at the picture), why?
Title: Re: Really universal soldering controller
Post by: sparkybg on September 16, 2015, 08:52:54 am
I will correct this. I forgot to delete some test code in the firmware, that's why the text is different. I will upload the latest corrected firmware tonight.

The controller is working properly. Just the text is different. There are some floating point calculations in the last firmware which I tested, that's why there are numbers appearing on the top.
Title: Re: Really universal soldering controller
Post by: sparkybg on September 16, 2015, 10:03:32 pm
- updated the firmware with correct instrument name display
- added gerber files for combined PCB (front+back+OLED). It may be cheaper to fabricate this way.
Title: Re: Really universal soldering controller
Post by: SZ64 on September 16, 2015, 10:47:02 pm
[quote author="sparkybg"]- updated the firmware with correct instrument name display
- added gerber files for combined PCB (front+back+OLED). It may be cheaper to fabricate this way.[/quote]

thx sparkybg !

p.s.: I am still waiting for Hakko 907 iron-connection and if possible please to Zhongdi desoldering gun ZD-552 ;-))
Title:
Post by: Circuiteromalaguito on September 16, 2015, 11:03:14 pm
Hello.

Thanks a lot for your project!

Your project is what I really wanted, a very flexible soldering controller with lots of possibilities. I really like to build things myself and analyze to understand them, but I need to earn the skills and the path is sometimes too difficult. Fortunately, things are getting better.

Projects like yours sincerely provide me a lot of motivation and inspiration to go forward. I appreciate a lot your contribution, people like you make me remember there's others that deserve to be appreciated.

- Wouldn't you mind sharing the Altium files to convert them to KiCad and modify them?
* Of course, all copyright and license will be the same.
** I understand your copyright assignment and your non-commercial license. You really deserve it.

* I would like to design at least my own PCB to put it in some kind of portable toolbox-lab.

* If you don't agree: Things will be harder, but not impossible.
** Anyway, I'll politely respect your decision if you disagree about me designing my own PCB.
** I don't want to do something that might upset or hurt you in some way, so I ask you for permission.

* If you agree about replicating your elaborated design in KiCad but not providing the Altium files for whatever reason:
** I'll keep moving forward and do it even if it takes me a lot of time.
**  I need to fit a bunch of stuff on the same box, so the board needs to be redesigned and adapted to a new approach.

* If you provide it:
* t will make the process a lot easier by using Altium2KiCad.
** Despite I might need to fix possible converting issues and modify the PCB to my needs, this will make things a lot easier.
** Maybe I'll need to create new components for KiCad, I'll see it as a learning experience.

- About Altium versus KiCad:

* I understand Altium is a lot more powerful than KiCad these days, but not economically affordable for most of us.
** I prefer to use and promote KiCad because of this and not having vendor lock-in.
** I understand you might consider switching to KiCad a very backwards and unpleasant experience, you must be very used to this powerful but expensive tool. ** This way, more people could experiment on your design and learn from it.
** Anyway, you can still keep using your great tool. I can sync your PCB changes to the KiCad "port" if you need it at all, but it seems the hardware already seems quite robust.

- Have you considered putting it in GitHub too? People could make their own versions easier and provide contributions
* Version control might be useful to spot bugs too, maybe you use it internally.
* On the other hand, the firmware has infinite possibilities, specially on supporting more devices. I would love to learn about that in the future and contribute to it.

- My reasons:
* I want to manufacture this complex board as a personal challenge with the help of my new vocational school and try to fit many stuff in a small space.
* I would love to have a portable lab-toolbox in a strong and comfortable suitcase to:
** Not have back pains.
** Avoid theft.
** Never miss stuff I need to do and the required stuff,  enforce organization.
** Do most of my stuff everywhere, so I can travel to see my girlfriend or while work breaks if I get a job.

- Most of this project will only be possible if I get a job.

* Failed students don't deserve scholarships, despite the former vocational school was very negligent and hostile to me.
** I'll work hard to earn some bucks and make my "pseudoprojects" based on others.
* I'm not going to be defeated by the former bastards that made my life worse, it's time to learn from it and progress up better than ever!


- I hope to do a great contribution like yours some day in the future, after I learn enough for it.
* I'm a copyleft hippie but and still low productive one, I confess it.

- My new vocational school is a lot better than my previous one:
* They seen very open to personal initiatives, proposals and develop own projects.
* I have been very lucky to this change, because they seem very positive people that tries to understand and motivate us all time.
* They are very flexible about choosing our tools, they have dual boot Windows/Linux in their computers.
* Their teaching way is a lot more near to the Active Learning approach.
** Unfortunately, our government and specially the one of my province are bureaucratic and unrealistic with a retarded approach and insane methods.
** Baskes are dramatically a lot better at vocational schools.

- Despite I want to follow the DIY way as a personal and learning challenge, I would like to contribute when I get some money.
* Do you accept donations?
* Do you have a wish list? If so, please publish it somewhere.

[quote author="SZ64"][quote author="sparkybg"]- updated the firmware with correct instrument name display
- added gerber files for combined PCB (front+back+OLED). It may be cheaper to fabricate this way.[/quote]

thx sparkybg !

p.s.: I am still waiting for Hakko 907 iron-connection and if possible please to Zhongdi desoldering gun ZD-552 ;-))[/quote]

Patches and donations are welcomed ;)


Thanks a lot!!!!!!!

Kind regards!
Title: Re: Really universal soldering controller
Post by: Freya on September 17, 2015, 05:16:07 pm
[quote author="sparkybg"]Q1 provides upto around 35V DC voltage to the LM2675. Maximum rating of LM2576 is 45V and recomended upto 40V. When you are using 24V transformer, the peak voltage after the rectivier is 34V. But this is at 230V mains. Maximum standart mains voltage is 264V, and this will give 24*264/230 = 27.6V, with peak 38.9V. Add another 10-15% when the consumption from the trensformer is low, and you will have close to 45V peak voltage after the rectifier - well above the maximum recommended input voltage of LM2576.

(...).[/quote]

Thank you for detailed explanation. Helped a lot.
Title: Re: Really universal soldering controller
Post by: Freya on September 17, 2015, 05:20:04 pm
[quote author="SZ64"]Hi sparkybg,

You have indeed perish in labor ;-)
Just say that you are well.
...

I managed to finally all up and running as it should. One back-pcb of the three sets is defective / not working properly, the remaining (three front and two back) is all right.

What I've noticed that when I FW recompile, programming a PIC with these new FW get different display text (look at the picture), why?[/quote]


What is your plan for troubleshooting/debugging that board? Can it be that it does not read the 5.6k resistor? How is the functioning board acting when the 5.6k resistor is not connected?
Title: Re: Really universal soldering controller
Post by: sparkybg on September 17, 2015, 08:29:53 pm
[quote author="Freya"]
What is your plan for troubleshooting/debugging that board? Can it be that it does not read the 5.6k resistor? How is the functioning board acting when the 5.6k resistor is not connected?[/quote]

One of the lower MOSFETs is constantly on, regardless of the signal from MCU. It can be either the connections, the MOSFET driver the MOSFET itself, or the logic chip. For example if the signal from the MCU is shorted to ground, the effect will be exactly like this.

The "HSEL" line is responsible for this - try to trace the signal from the MCU(terminal 3, RE7) to the logic (U3, 74hc02) and the MOSFET driver (U2, TC4428A). Look for broken trace or shortcut to ground or 3.3V.
Title: Re: Really universal soldering controller
Post by: SZ64 on September 17, 2015, 11:00:19 pm
[quote author="Freya"]

What is your plan for troubleshooting/debugging that board? Can it be that it does not read the 5.6k resistor? How is the functioning board acting when the 5.6k resistor is not connected?[/quote]


In my case it was the U3 (74HC02D) defect. I have replaced the U3 and all is now fine ;)
Title: Re: Really universal soldering controller
Post by: sparkybg on September 18, 2015, 12:08:18 am
The first post is updated with connections for Hakko FX8801/907 and Weller WSP80.
Title: Re: Really universal soldering controller
Post by: sparkybg on September 18, 2015, 12:16:09 am
Circuiteromalaguito, for now I am not sharing more than I've already shared. You have the schematics and you can rewrite them in your CAD in a few days. And this is nothing compared to thinking it out 5 times (5.2 times, exactly :) ), and designing and debugging the PCB several times. This is what I share - a working project with schematics PCBs and software. If someone wants to use it to develop his own version/clone, I will gladly provide any help I can, but that someone must be ready to do some work himself.
Title: Re: Really universal soldering controller
Post by: SZ64 on September 18, 2015, 02:44:32 pm
[quote author="sparkybg"]The first post is updated with connections for Hakko FX8801/907 and Weller WSP80.[/quote]

sparkybg, thank you very much!
Title: Re: Really universal soldering controller
Post by: Freya on September 18, 2015, 03:11:41 pm
[quote author="SZ64"][quote author="Freya"]

What is your plan for troubleshooting/debugging that board? Can it be that it does not read the 5.6k resistor? How is the functioning board acting when the 5.6k resistor is not connected?[/quote]


In my case it was the U3 (74HC02D) defect. I have replaced the U3 and all is now fine ;)[/quote]

That is the better option. These things are cheap. BTW is it possible to test it in circuit? IE try to put voltages on imput and look at output without possibility of harm? (I think it should be, right?)
Title: Re: Really universal soldering controller
Post by: Freya on September 18, 2015, 03:25:28 pm
[quote author="sparkybg"]The first post is updated with connections for Hakko FX8801/907 and Weller WSP80.[/quote]

Sparky, I am looking at iron.c (with iron.h for comments) trying to figure out how to add support for another iron types. I have old ERSA which I have not yet been able to throw out and would like to try to add it.

Could you, please, show me in the direction how to do it?

Thanks. And I am in no hurry, I will have to build it first.
Title: Re: Really universal soldering controller
Post by: SZ64 on September 18, 2015, 08:20:44 pm
[quote author="Freya"]

That is the better option. These things are cheap. BTW is it possible to test it in circuit? IE try to put voltages on imput and look at output without possibility of harm? (I think it should be, right?)[/quote]


of course I first tested the IC (pin-to-pin) and the test result is: pin 7 (GND) with pins 1, 3, 4, 5, 6 and 13 was a short-circuit (should just pin 3,6 and 7 to be short-circuited), and this was the reason why I replaced the chip.
Title: Re: Re: Really universal soldering controller
Post by: Circuiteromalaguito on September 20, 2015, 04:10:19 am
[quote author="sparkybg"]Circuiteromalaguito, for now I am not sharing more than I've already shared. You have the schematics and you can rewrite them in your CAD in a few days. And this is nothing compared to thinking it out 5 times (5.2 times, exactly :) ), and designing and debugging the PCB several times. This is what I share - a working project with schematics PCBs and software. If someone wants to use it to develop his own version/clone, I will gladly provide any help I can, but that someone must be ready to do some work himself.[/quote]


It's okay and fair.

I'll work hard to make the schematic in KiCad first and be sure it's correct. I'll provide the results here.

Then I'll try to do the PCB layout after planning what to put in the chosen suitcase and future upgradability. I'll provide my versions here too.

I would love advices and suggestions from others, of course.

Next post will be about my schematic.

Thanks a lot!

PS: Would it be derivative work?
Title: Re: Really universal soldering controller
Post by: sparkybg on September 20, 2015, 10:24:30 am
Please open your own thread for your clone. This thread is for my implementation.
Title: Re: Really universal soldering controller
Post by: SZ64 on September 20, 2015, 03:58:40 pm
information for all users who want SLEEP-sensor board alone to do but have difficulties with the procurement of
IR receivers RPM7140 and IR Transmitter KM4457F3C:

• Instead of the  RPM7140 (ROHM) can use TSOP4840 (VISHAY)
• Instead of the  KM4457F3C (Kingbright) can use CQX48, TSKS5400S (VISHAY) or IRL80A (OSRAM)

All of these above replacement parts I tested and everything works fine ;)
Title: Re: Re: Really universal soldering controller
Post by: Circuiteromalaguito on September 20, 2015, 05:27:47 pm
[quote author="sparkybg"]Please open your own thread for your clone. This thread is for my implementation.[/quote]

Sorry Sparky, I didn't want to annoy you. I just wanted to explain my derivate project and intentions.

I just want your explicit consent to make this "clone" because I respect a lot to you, your design and efforts. I don't consider this pseudoproject to be a clone, but a fork.

If I'm able to reach my goals and you authorize me, I'll sync all your  changes and use the same firmware if you agree. I hope to learn enough to contribute in the future if possible.

I just would like to have clear all terms about this, such as licenses and such. I'll agree whatever decision you make about it, you deserve it. But you deserve to be mentioned, if course.

I consider your project something very interesting to use and understand it. I think it's an extremely flexible soldering station.

I'm not as skilled as you, but I would like improve my skills at EDA software with my fork and learn by solving issues. I want to go the DIY way to make a custom solution to my personal needs, even if that means lots of efforts.

I'm not going to contaminate this thread again about my "toy" based on your great project. I'll write a new post about it when I have some really relevant results and make a short reference if you agree too.

I can delete or edit the already written posts with irrelevant information directly related to your project. I would prefer it to reduce noise, but I like to know if you agree on it

Thanks a lot for everything!

Kind regards.
Title: Re: Really universal soldering controller
Post by: sparkybg on September 20, 2015, 08:24:41 pm
You can make any clones, you can use my schematics and firmware, end everything else, as soon as you are not making any profit out of it.
Title: Re: Re: Really universal soldering controller
Post by: Circuiteromalaguito on September 21, 2015, 12:57:00 am
[quote author="sparkybg"]You can make any clones, you can use my schematics and firmware, end everything else, as soon as you are not making any profit out of it.[/quote]

Of course not. It's my personal DIY project. Thanks a lot!
Title: Re: Really universal soldering controller
Post by: SZ64 on September 21, 2015, 01:14:12 am
Hi sparkybg,

you're not a "SPEAKER" via software to "OFF" set?
I ask because in general I have not heard any sound / beep ... nothing.
I'm interested in what all the "SPEAKER" reports / signals?
...
Am excited and want a credit for the success of the project
 pronounce!!!
[/i]
Title: Re: Really universal soldering controller
Post by: sparkybg on September 21, 2015, 01:39:53 am
[quote author="SZ64"]Hi sparkybg,

you're not a "SPEAKER" via software to "OFF" set?
I ask because in general I have not heard any sound / beep ... nothing.
I'm interested in what all the "SPEAKER" reports / signals?
...
Am excited and want a credit for the success of the project
 pronounce!!!
[/i][/quote]

Sorry, but my english is not good enough to understand this? Please say it simpler. :) I'm not joking,
Title: Re: Really universal soldering controller
Post by: SZ64 on September 21, 2015, 02:04:49 am
Hi sparkybg,

sorry if I brought in confusion.
I wanted to say the SPEAKER/BUZZER to me does not work, so I asked if it is turned off via software. I do not know whether it was a mistake for me or not.
And finally I wanted to say: one big, big compliment for this your very successful project.

P. S .: my english is "made by Google" ;-))
Title: Re: Really universal soldering controller
Post by: sparkybg on September 21, 2015, 02:14:03 am
[quote author="SZ64"]
Is it true that the voltage VCC is 3.3V? According to Formula Vout = 1.21 * (1 + R2 / R1) voltage is correct 5.00V. I think it's a mistake at R4, instead 1K5 should be 2K7 and then the voltage is exactly 3.316V.[/quote]

Yes, it is 3.3V, and it is my mistake. When I use LM2675, I usualy take non-adjustable part and in the same time I am providing the option on the PCB to use adjustable part.

Because adding 2.7k resistor will add extra component value to the BOM, I will replace the regulator with LM2675M-3.3 and the upper resistor with 0ohm. If you take a closer look at the PCB, the upper resistor footprint is a little different - the pads are closer to each other so a solder jumper can be made easily.

Thanks for mentioning this.

I will soon provide general rules for connection and identification of any new instrument in the first post.

Generaly, for separate sensor connection, the sensor-, heater- and outer shell are connected to Vout1-, GND and SENSEB, heater + to Vout1+ and sensor+ to SENSEA. Any single heater instrument needs 2 resistors for identification and any 2 heater instrument needs only one resistor for identification, connected between ID and Vout1-.

On Vout1- you can use only even IDs from the "ResID.xls" file in the software.rar. On Vout2- you can use any resistor from the table. The odd IDs on Vout1- are reserved for built in profiles in the firmware. Somewhere in the future, when I got enough time, I will finish the PC software and the firmware in order to create custom profiles easily, adjust PID parameters in real time, and store these profiles in the EEPROM. But I cannot tell when I will be able to do this. For now, you will have to add  your profiles to the firmware and recompile it every time it changes. It is not so hard, but is pretty annoying - I know.
Title: Re: Really universal soldering controller
Post by: sparkybg on September 21, 2015, 02:17:41 am
[quote author="SZ64"]Hi sparkybg,

sorry if I brought in confusion.
I wanted to say the SPEAKER/BUZZER to me does not work, so I asked if it is turned off via software. I do not know whether it was a mistake for me or not.
And finally I wanted to say: one big, big compliment for this your very successful project.

P. S .: my english is "made by Google" ;-))[/quote]

Oh, I see.

If you soldered Q20 and D17 on the PCB, remove them. You should be able to hear some beeps then.

These were provided for DC(integrated generator) buzzer. If the buzzer is inductive or piezzo, you don't need these.

I will mention this on the schematics also. Thanks.
Title: Re: Really universal soldering controller
Post by: SZ64 on September 21, 2015, 02:44:54 am
[quote author="sparkybg"]

If you soldered Q20 and D17 on the PCB, remove them. You should be able to hear some beeps then.

These were provided for DC(integrated generator) buzzer. If the buzzer is inductive or piezzo, you don't need these.

I will mention this on the schematics also. Thanks.[/quote]

hi sparkybg,
thx for the guide, now this works great!
Title: Re: Really universal soldering controller
Post by: Freya on September 21, 2015, 03:14:00 pm
[quote author="sparkybg"]
I will soon provide general rules for connection and identification of any new instrument in the first post.

Generaly, for separate sensor connection, the sensor-, heater- and outer shell are connected to Vout1-, GND and SENSEB, heater + to Vout1+ and sensor+ to SENSEA. Any single heater instrument needs 2 resistors for identification and any 2 heater instrument needs only one resistor for identification, connected between ID and Vout1-.

On Vout1- you can use only even IDs from the "ResID.xls" file in the software.rar. On Vout2- you can use any resistor from the table. The odd IDs on Vout1- are reserved for built in profiles in the firmware. Somewhere in the future, when I got enough time, I will finish the PC software and the firmware in order to create custom profiles easily, adjust PID parameters in real time, and store these profiles in the EEPROM. But I cannot tell when I will be able to do this. For now, you will have to add  your profiles to the firmware and recompile it every time it changes. It is not so hard, but is pretty annoying - I know.[/quote]

I think that that is answer to my request, right? The new table in ResID.xls file is lot more readable already. The software way would be nicer but the current method is no problem either. You just have to do it once.

So I am happy to wait for explanation and manual for connection. So far studying PID and TC theory helped to shine some light at some values in iron.h.
Title: Re: Really universal soldering controller
Post by: SZ64 on October 20, 2015, 03:20:10 pm
my design of front/back plate.
• front/back plate size: 147 x 107 mm
• case size: 150 x 200 x 110 mm

Case is ordered and should arrive in a few days.
case link:
https://www.conrad.at/de/universal-geha ... 20454.html (https://www.conrad.at/de/universal-gehaeuse-stahl-aluminium-schwarz-150-x-200-x-110-gss05-1-st-520454.html)
I look forward to drilling/milling with my mini PROXXON ;)

p.s.: for any proposal for improvement I am very grateful!
Title: Re: Really universal soldering controller
Post by: radioelf on October 23, 2015, 07:03:39 pm
Hi,
I use IC MAX31856 reading thermocouple,  you know the type thermocouple used in the JBC?.
Thank you
Title: Re: Really universal soldering controller
Post by: sparkybg on October 23, 2015, 07:36:45 pm
[quote author="radioelf"]Hi,
I use IC MAX31856 reading thermocouple,  you know the type thermocouple used in the JBC?.
Thank you[/quote]

It is non-standart thermocouple. Also, the thermocouple is different on C245 and C210.
Title: Re: Really universal soldering controller
Post by: radioelf on October 25, 2015, 05:25:15 am
OK, Thank
Title: Re: Really universal soldering controller
Post by: protons on October 28, 2015, 09:31:19 am
Hi, thanks sparkybg for good project
I soldered circuit boards with elements except of PIC32. Anyone can help with pic programming. In Previously I have only programējis atmega IC.
Anyone can tell from first post attach file, firmware file which must be written in the Pic ic.
It is possibility if I solder PIC ic in board and then Program Pic ic through the USB port.
What's of available free program should be used to progrmm pic32 Ic.
As I understand it is the opportunity after run soldering station is watch online soldering iron temperature on the computer screen, opened a programa to see it(what programm i need open for this).
Please someone explained me
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on November 06, 2015, 08:07:03 pm
[quote author="sparkybg"][quote author="SZ64"]
Is it true that the voltage VCC is 3.3V? According to Formula Vout = 1.21 * (1 + R2 / R1) voltage is correct 5.00V. I think it's a mistake at R4, instead 1K5 should be 2K7 and then the voltage is exactly 3.316V.[/quote]

Yes, it is 3.3V, and it is my mistake. When I use LM2675, I usualy take non-adjustable part and in the same time I am providing the option on the PCB to use adjustable part.

Because adding 2.7k resistor will add extra component value to the BOM, I will replace the regulator with LM2675M-3.3 and the upper resistor with 0ohm. If you take a closer look at the PCB, the upper resistor footprint is a little different - the pads are closer to each other so a solder jumper can be made easily.

Thanks for mentioning this.

I will soon provide general rules for connection and identification of any new instrument in the first post.

Generaly, for separate sensor connection, the sensor-, heater- and outer shell are connected to Vout1-, GND and SENSEB, heater + to Vout1+ and sensor+ to SENSEA. Any single heater instrument needs 2 resistors for identification and any 2 heater instrument needs only one resistor for identification, connected between ID and Vout1-.

On Vout1- you can use only even IDs from the "ResID.xls" file in the software.rar. On Vout2- you can use any resistor from the table. The odd IDs on Vout1- are reserved for built in profiles in the firmware. Somewhere in the future, when I got enough time, I will finish the PC software and the firmware in order to create custom profiles easily, adjust PID parameters in real time, and store these profiles in the EEPROM. But I cannot tell when I will be able to do this. For now, you will have to add  your profiles to the firmware and recompile it every time it changes. It is not so hard, but is pretty annoying - I know.[/quote]

Oh, I didn't know that! Are you planning to update your files and such? I'm sure you're pretty busy IRL...
Title: Re: Really universal soldering controller
Post by: protonoob on November 09, 2015, 10:59:57 am
[quote author="SZ64"]my design of front/back plate.
• front/back plate size: 147 x 107 mm
• case size: 150 x 200 x 110 mm

Case is ordered and should arrive in a few days.
case link:
https://www.conrad.at/de/universal-geha ... 20454.html (https://www.conrad.at/de/universal-gehaeuse-stahl-aluminium-schwarz-150-x-200-x-110-gss05-1-st-520454.html)
I look forward to drilling/milling with my mini PROXXON ;)

p.s.: for any proposal for improvement I am very grateful![/quote]

looks great, how much did the case cost
Title: Re: Really universal soldering controller
Post by: tmatthewj on November 19, 2015, 05:53:47 pm
Hi sparkybg!

Can I use your controller to drive 2 irons, like one t245 and t210 jbc irons. (and maybe on different temperatures)
Just because you wrote in the first post that it has "2 separate heater control channels".
Title: Re: Really universal soldering controller
Post by: dumitruv on November 20, 2015, 12:22:48 pm
Hey Sparky,

I'm trying to understand what's the circuit between D12 and D11 doing on the back board. I guess is only used for AC input.

Thanks
Title: Re: Really universal soldering controller
Post by: sparkybg on November 25, 2015, 10:43:03 am
[quote author="tmatthewj"]Hi sparkybg!

Can I use your controller to drive 2 irons, like one t245 and t210 jbc irons. (and maybe on different temperatures)
Just because you wrote in the first post that it has "2 separate heater control channels".[/quote]

No you won't be able to do so. It is electrically possible, but the controller's firmware is made to control 1 instrument with one or two heaters with separate sensors to the same temperature. For example, JBC microtweezers.

Although you can add iron profile to control one C210 and one C245 tip simultaneously, they will be driven to the same temperature.
Title: Re: Really universal soldering controller
Post by: sparkybg on November 25, 2015, 10:53:03 am
[quote author="dumitruv"]Hey Sparky,

I'm trying to understand what's the circuit between D12 and D11 doing on the back board. I guess is only used for AC input.

Thanks[/quote]

As I already explained it several times, D12-C13-Q5-R9-D11 circuit makes a plateau on the bottom end of the rectified AC power, exactly where the measurement are made.  Otherwise the AC power voltage penetrates through the Drain-Source capacitance of the MOSFETs and adds an error to the measurements, despite the low input impedance of series TC (several ohms). The error can be more than 50-70 degrees on low voltage TCs like C210.

And, yes, it is only used for AC input, but it will not make any trouble when DC input is used, so I suggest you to put these components on the PCB anyway. Sooner or later you will understand that the toroidal mains transformer is the best possible power source for an iron.
Title: Re: Really universal soldering controller
Post by: protons on November 26, 2015, 09:53:12 am
Sparkeybg or anyone Please  can help with pic programming.
What hex file i need to progrmmed in IC
In first post attach file, what firmware(HEX) file must be written in the Pic ic.
In folder i found four hex files with name: US_sensor.X.production, US_Firmware.X.production, US_Firmware.X.production, US_BootLoader.X.production.

Please someone explained me or other file need to programm in PIC IC
Title: Re: Really universal soldering controller
Post by: sparkybg on November 26, 2015, 10:17:09 am
If you are not planning to use bootloader, then use this:
UniSolder52_software.rarfrontUS_Firmware.XdistPIC32_Standaloneproduction
US_Firmware.X.production.hex


Or, you can upload the bootloader:
UniSolder52_software.rarfrontUS_BootLoader.XdistPIC32production
US_BootLoader.X.production.hex


...and then upload this firmware using the USB port and PC software:
UniSolder52_software.rarfrontUS_Firmware.XdistPIC32_with_bootloaderproduction
US_Firmware.X.production.hex
Title: Re: Really universal soldering controller
Post by: protons on November 26, 2015, 03:22:59 pm
For programming I use PICKIT2 and can connect with this PIC32MN564, what PC software you mean?
Title: Re: Really universal soldering controller
Post by: sparkybg on November 26, 2015, 08:10:51 pm
[quote author="protons"]For programming I use PICKIT2 and can connect with this PIC32MN564, what PC software you mean?[/quote]

Use PukKit2 and upload the standa alone hex for now.
Title: Re: Really universal soldering controller
Post by: tmatthewj on November 27, 2015, 02:22:32 pm
Hi sparkybg,

I assembled one set of your station.
When i connected the boards together and gave them power, nothing happened.
I search the problem for hours, and I think it was the fault of the power supply. The feedback pin of LM2675M-ADJ was set by R3 47k and R4 1.5k, so the output was  5V.
I think the PIC did not like it. :)
Now I am on my way to the school's research laboratory so I am going to check the PIC too.
I just wanted to share it with you. Maybe it is a mistake it the schematics.
Title: Re: Really universal soldering controller
Post by: tmatthewj on November 27, 2015, 09:54:32 pm
I checked the PIC and it is alive. The PICKIT 3 can recognize it.
I burned in the UniSolder52_softwarefrontUS_Firmware.XdistPIC32_StandaloneproductionUS_Firmware.X.production.hex file.
Is it the right one?
Title: Re: Really universal soldering controller
Post by: sparkybg on November 28, 2015, 12:07:22 am
Yes, it is.
Title: Re: Really universal soldering controller
Post by: tmatthewj on November 28, 2015, 07:53:31 am
Thank you!
And what do you think about the power supply feedback pin setup? (my previous previous message)
Can I use it without the holder connected?
Title: Re: Really universal soldering controller
Post by: sparkybg on November 29, 2015, 12:10:54 am
Yes, it can be user without "active" holder connected. The controller can detect if active holder is connected to it.

Yes, the resistors in PS feedback is for 5V. It is my mistake. It happened because I use 3.3V version of the  regulator, and not adjustable one. I will correct it. Just calculate the resistors for 3.3V using the datasheet and put them on.
Title: Re: Really universal soldering controller
Post by: tmatthewj on November 30, 2015, 05:53:44 pm
Hi sparkybg,

I checked based on the gerbers and schematics, that the 4 pin iron connector pinout is:
[attachment=0]

Then I connected the two ID resistors as you wrote for C245 and nothing happened.
After I moved the resistors to the negative outs and C245 appeared on display. :)

So maybe I did something wrong, but I think the connection diagram of C245 has a mistake.
If it has, what should be the proper connection of the iron?

Thank you.
Title: Re: Really universal soldering controller
Post by: sparkybg on December 01, 2015, 02:07:42 am
Yes, you are right. The resistors is always between ID and Vout-, not Vout+. I corrected it in the first post.

Thanks.
Title: Re: Really universal soldering controller
Post by: tmatthewj on December 01, 2015, 02:25:55 pm
Why is the C245 heater positive on the Vout1- and why not on Vout1+  ?
All of other iron's positive on positive output.
Or it is not a problem if it is swapped?

Is there a general rule, how to connect a random iron? (If I want to try another ones with this controller.)
Title: Re: Really universal soldering controller
Post by: sparkybg on December 01, 2015, 02:55:36 pm
[quote author="tmatthewj"]Why is the C245 heater positive on the Vout1- and why not on Vout1+  ?[/quote]
Because the controller reads C245 TC between outer shell and one of the electrodes, not as series thermocouple, and the TC gives negative voltage this way :)
Just connect it this way. This is unique connection for C245. No other tip has this characteristic.

[quote author="tmatthewj"]
Is there a general rule, how to connect a random iron? (If I want to try another ones with this controller.)[/quote]

If series thermocouple, connect like T12. If separate sensor, connect like HAKKO FX8801/907 or Weller WSP80.

Of course, you must add another ID resistors and a profile for your iron.
Title: Re: Really universal soldering controller
Post by: tmatthewj on December 02, 2015, 10:29:59 am
Thank you!
Title: Re: Really universal soldering controller
Post by: tmatthewj on December 04, 2015, 11:21:26 pm
Hi,

I have a little problem. I have no connector and enclosure now, so I soldered all wires on the PCB for first test. When no cartridge plugged in the t245 handle, then the controller recognizes it as a c245 and "heater open". It is OK.
But when I plug in any of my cartridges it is immediately says "no instrument".
On the picture you can see my ugly first test condition... :)
Do you have any idea why I got this problem?
(I hope it is just a silly mistake that I have made...)
[attachment=0]
Title: Re: Really universal soldering controller
Post by: sparkybg on December 04, 2015, 11:44:21 pm
Remove the orange wire!
Title: Re: Really universal soldering controller
Post by: tmatthewj on December 05, 2015, 12:00:47 am
OK.
I suspected it... :)
But I don't understand the connection you wrote on the first page.
"Outer shell (green wire) connected to GND and SENSEB"
In this way it will be just connected to SENSEB.
Title: Re: Really universal soldering controller
Post by: sparkybg on December 05, 2015, 12:34:23 am
GND and input- are not the same.

1. The power lines of the controller's power source should not have galvanic connection to Earth/Ground
2. GND on the cpntrollers PCB is not EARTH.
3. The outer shell of the irons is connected to EARTH, not to the controller's GND.
Title: Re: Really universal soldering controller
Post by: tmatthewj on December 05, 2015, 12:46:16 am
Thank you for the explanation. :)
Is it necessary to connect it to the earth or just a safety reason?
Title: Re: Really universal soldering controller
Post by: sparkybg on December 05, 2015, 12:47:16 am
Safety. Both for you and for the components you are soldering. Especially if you are using a DC power supply.

I've corrected the first post. GND changed to EARTH now. My mistake.
Title: Re: Really universal soldering controller
Post by: tmatthewj on December 05, 2015, 11:47:15 am
I know it is almost a cliche to say, but I have to...
I am amazed by the c245 heat transfer capability, even if I use a small tip, it has no problem with bigger solder joints or ground planes.
Fantastic! =)
Again, Thank you Sparkybg for your work.
Title: Re: Really universal soldering controller
Post by: overheater on December 06, 2015, 02:57:40 am
Hello,

so it looks very strong, that I have found "my" next solder station! - This one!! I built my last one about 30 years ago and it still works with a Ersa TE50.

But what is the best way to get one?

@ sparkybg,
do you have planned to sell PCBs (populated or unpopulated) in the next time? I know that this question has been asked in the past but there is gone a lot of time since then.....

@ all,
is there someone who built this station and has a PCB-set left for me?

or are there enough people (10) who wants to build one and we can get the PCBs together? 

In the worst case - if we have to pay a tax - I estimate the cost of about 60 Euro for ten sets including shipping - all to one person.
That would be 6 Euro for one PCB-set plus shipping to the several persons - from a good manufacturer. (I can show you photos from other PCBs).

If everyone does the PCBs as one piece from a local dealer the cost may increase a lot.

best from Germany
Klaus
Title: Re: Really universal soldering controller
Post by: tmatthewj on December 06, 2015, 11:09:44 am
Try this manufacturer. It is reasonably priced, and have good quality.
http://www.elecrow.com/services-c-73.html (http://www.elecrow.com/services-c-73.html)
Title: Re: Really universal soldering controller
Post by: dumitruv on December 09, 2015, 12:53:39 am
I have 3 sets available. I don't want to steal the thread, PM me if interested.
Title: Re: Really universal soldering controller
Post by: sparkybg on December 12, 2015, 12:40:13 pm
I've updated the gerbers for "full" (bulk gerbers with all PCB excluding sensor) version. There was a problem with pads for the OLED on the OLED sub-board. On separate versions of the gerbers there was no problem.
Title: Re: Really universal soldering controller
Post by: mrjoda on December 13, 2015, 12:48:16 am
cca 6-10€ for both PCBs ? let me in
Title: Re: Really universal soldering controller
Post by: Sheldoniq on December 14, 2015, 03:51:59 pm
First, congratulations to the author's good work.
You do not have an overview of parameters of individual solder tips/iron?
Any as
Why do I ask?
Finishing work on his own project.
Primarily regarding RF power supply for the induction soldering tips (Metcal)
Secondary for HAKKO T12/T15  solderig tips.
Maybe I added support for additional  solder tips/iron, but I need to know the parameters.
Title: Re: Really universal soldering controller
Post by: grigorilin on December 14, 2015, 06:34:39 pm
[quote author="dumitruv"]I have 3 sets available. I don't want to steal the thread, PM me if interested.[/quote]
Hello dumitruv,
You have a PM.
Title: Re: Really universal soldering controller
Post by: dumitruv on December 17, 2015, 04:53:51 am
I responded to the PMs and 3 days later I still have one in my outbox. The PM is almost impossible to use. Please be patient. And sorry Sparky for posting here again but I just wanted people to know that I respond but the system is very slow.
Title: Re: Really universal soldering controller
Post by: Sjaak on December 17, 2015, 07:40:25 am
The pm will be in the outbox till it is read. It works kinda as read indication of your pm.
Title: Re: Really universal soldering controller
Post by: carpin on December 20, 2015, 07:32:17 pm
[quote author="grigorilin"][quote author="dumitruv"]I have 3 sets available. I don't want to steal the thread, PM me if interested.[/quote]
Hello dumitruv,
You have a PM.[/quote]
Shipping from Canada to the Netherlands to expensive, shipping + tax 32 cad dollar.
Title: Re: Really universal soldering controller
Post by: dumitruv on December 21, 2015, 10:58:35 am
[quote author="carpin"][quote author="grigorilin"][quote author="dumitruv"]I have 3 sets available. I don't want to steal the thread, PM me if interested.[/quote]
Hello dumitruv,
You have a PM.[/quote]
Shipping from Canada to the Netherlands to expensive, shipping + tax 32 cad dollar.[/quote]

There's also a 10 CAD option in a padded envelope or 7 CAD in a letter envelope with some hard paper backing, both without tracking.

32 CAD is with tracking and receiving acknowledge and I agree it is expensive. Canada Post is known for excessive pricing as everything else is in Canada. Just because we can..........
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on January 02, 2016, 04:56:26 pm
Are there anyone in Europe with PCBs? I'll try to finish recreating the project with KiCad, but I'm having some issues and really need a soldering station. The low end ones aren't so good for me, I'm not totally convinced by Hakko and Ersa ones.

I wonder about adding desoldering to the device. There are relatively cheapo desoldering station, so I can cannibalize the components. I wonder if the soldering station would need to be aware of the desoldering function in order to improve the process or just a switch to desoldering pump would be enough.
Title: Re: Really universal soldering controller
Post by: Sjaak on January 03, 2016, 11:31:15 am
You can get cheap pcb from china to europe. I.e. the new dirtypcbs.com for 10*10 is 12$.

For the controller it doesnt matter; it is still a lug of metal that needs to be a certain temperature...
Title: Re: Really universal soldering controller
Post by: BadAd84 on January 04, 2016, 12:29:01 pm
I will have some spares for people when my order arrives.

Based in the UK, so anyone over here can get them with cheap shipping.
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on January 04, 2016, 04:46:27 pm
@Postby Sjaak

I know, but it can take too many weeks until it arrives. I need a soldering station, but I'm not convinced at all by the cheap chinese ones I tried.

I might get the cheapest one and a heat gun, but I'm thinking about replacing the PCB and putting UniSolder on it.

@BadAd84

When did you made the order? I lack a proper soldering tool and I already burned my hands with my pen soldering iron.

Would you solder me the most difficult components? I'll try if someone helps me with them, but I'm not sure about that.
Title: Re: Really universal soldering controller
Post by: BadAd84 on January 04, 2016, 06:20:49 pm
They were ordered 2-3 days ago. Lead time is 5 days and 3 days for dhl delivery.

I cant solder any components to the boards, as I have not sourced any of the parts yet.

However, why dont you buy the BK2000+ (which is the iron I currently use and have done for years just fine), you can build the unisolder and then you can swap the PCB into the case (unisolder was intended for this case!)
Title: Re: Really universal soldering controller
Post by: Sjaak on January 04, 2016, 11:58:56 pm
[quote author="Circuiteromalaguito"]@Postby Sjaak

I know, but it can take too many weeks until it arrives. I need a soldering station, but I'm not convinced at all by the cheap chinese ones I tried.

I might get the cheapest one and a heat gun, but I'm thinking about replacing the PCB and putting UniSolder on it.
[/quote]

I combine some designs PCBs and use the China or HK DHL option, which takes about 3 days for shipping (plus the 5 days for manufacturing the PCB and 0-2 for dirtypcbs.com to send them off to the board house) AFAIK they send them on Monday, Wednesday and Friday to the boardhouse. Adding more PCBs wont add much to the cost as PCBs are fairly light, so it is fairly cheap. Also combinable with other goodies from the dev-site store ( dev.dangerousprototypes.com ).

BTW for desoldering PTH I use my own t12 controller with a K tip  and soldersucker. I use leaded 60/40 to get more solder on it and lower the melting point (assuming unleaded solder) and suck the excess solder up. Most things come off nicely without the need for a separate device.

If you have difficulty in soldering smd try the solderpaste/reflow oven route. However soldering finepitched smd components is quite satisfying and easier then you might guess. Try searching on youtube for some tutorials. Most of the magic is done by adding lots of flux and not by solderingskills ;)
Title: Re: Really universal soldering controller
Post by: sparkybg on January 05, 2016, 12:28:46 am
[quote author="Sjaak"]BTW for desoldering PTH I use my own t12 controller with a K tip  and soldersucker. I use leaded 60/40 to get more solder on it and lower the melting point (assuming unleaded solder) and suck the excess solder up. Most things come off nicely without the need for a separate device.[/quote]

I also used this for desoldering. But, believe me, get a decent desoldering gun - the differene is HUGE. I can cannibalize an old PC main board (multile ISA/VESA/PCI slots, back connectors, memory connectors) maybe within a hour, even if the PCB itself must be preserved from any damage. I am using ZD-915 station for this. It costs around 100EUR and works really well. There are better options as well of course - from HAKKO and several other manufacturers. Some of them with integrated suction pump in the gun itself - you only need mains socket around, and nothing more.
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on January 06, 2016, 08:05:52 pm
[quote author="sparkybg"][quote author="Sjaak"]BTW for desoldering PTH I use my own t12 controller with a K tip  and soldersucker. I use leaded 60/40 to get more solder on it and lower the melting point (assuming unleaded solder) and suck the excess solder up. Most things come off nicely without the need for a separate device.[/quote]

I also used this for desoldering. But, believe me, get a decent desoldering gun - the differene is HUGE. I can cannibalize an old PC main board (multile ISA/VESA/PCI slots, back connectors, memory connectors) maybe within a hour, even if the PCB itself must be preserved from any damage. I am using ZD-915 station for this. It costs around 100EUR and works really well. There are better options as well of course - from HAKKO and several other manufacturers. Some of them with integrated suction pump in the gun itself - you only need mains socket around, and nothing more.[/quote]


It seems interesting! Desoldering is extremely painful for me :(

I tried to make an order, but the costs are too expensive...
Title: Re: Really universal soldering controller
Post by: Sjaak on January 06, 2016, 10:44:04 pm
Dunno where you are placing your order, but on http://dev.dangerousprototypes.com/store/pcbs (http://dev.dangerousprototypes.com/store/pcbs) I get a 10x10cm pcb for $12 with $26 DHL 3-5 days shipping to .nl. I'm expecting the same prices to Italy (?)
Title: Re: Really universal soldering controller
Post by: BadAd84 on January 07, 2016, 08:38:40 pm
Hes ordering 10x 10 PCBs. so thats 100 pcb price.
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on January 07, 2016, 10:43:39 pm
[quote author="BadAd84"]Hes ordering 10x 10 PCBs. so thats 100 pcb price.[/quote]


Sorry for me being a dumb, I did think that meaned the size.

I used the elecrow service.

Is this okay?

[attachment=0]
Title: Re: Really universal soldering controller
Post by: Sjaak on January 07, 2016, 11:28:20 pm
Don't think you need a stencil..
Title: Re: Really universal soldering controller
Post by: Wolfram on January 08, 2016, 11:25:28 pm
I want to know if i can use SSD1306 display module or i must switch it for another one ?
Thanks
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on January 09, 2016, 12:21:23 am
[quote author="Sjaak"]Don't think you need a stencil..[/quote]


Okay. Now I'll need a way to solder SMD chips without destroying them. I'm still an awful solder :(

What does it mean Protopack +-10.

The price is for one PCB plus the stencil I can opt to not get it, right? I'm confused as hell, sorry for being so dumb...
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on January 09, 2016, 10:14:08 am
[quote author="sparkybg"][quote author="Sjaak"]BTW for desoldering PTH I use my own t12 controller with a K tip  and soldersucker. I use leaded 60/40 to get more solder on it and lower the melting point (assuming unleaded solder) and suck the excess solder up. Most things come off nicely without the need for a separate device.[/quote]

I also used this for desoldering. But, believe me, get a decent desoldering gun - the differene is HUGE. I can cannibalize an old PC main board (multile ISA/VESA/PCI slots, back connectors, memory connectors) maybe within a hour, even if the PCB itself must be preserved from any damage. I am using ZD-915 station for this. It costs around 100EUR and works really well. There are better options as well of course - from HAKKO and several other manufacturers. Some of them with integrated suction pump in the gun itself - you only need mains socket around, and nothing more.[/quote]


Sorry for the multiple messaging and parallel conversations...

I just found these desoldering stations have issues wih the power supply, firmware and it seems the pump system.

It seems that someone developed a firmware for it, the device uses some clone of the 8051 that is programmable. Did you use it?
[attachment=4]
[attachment=3]

[attachment=2]

[attachment=1]

[attachment=0]


http://www.edaboard.com/thread229060.html (http://www.edaboard.com/thread229060.html)
https://translate.google.com/translate? ... edit-text= (https://translate.google.com/translate?sl=auto&tl=en&js=y&prev=_t&hl=es&ie=UTF-8&u=http%3A%2F%2Fforum.iwenzo.de%2Fzd-915-entloetstation-display-tot--t55914.html&edit-text=)
https://translate.google.com/translate? ... edit-text= (https://translate.google.com/translate?sl=de&tl=en&js=y&prev=_t&hl=es&ie=UTF-8&u=http%3A%2F%2Fwww.mikrocontroller.net%2Ftopic%2F304452&edit-text=)
https://translate.google.com/translate? ... edit-text= (https://translate.google.com/translate?sl=de&tl=en&js=y&prev=_t&hl=es&ie=UTF-8&u=http%3A%2F%2Fwww.mikrocontroller.net%2Ftopic%2F180960&edit-text=)


 http://www.eevblog.com/forum/chat/displ ... g-station/ (http://www.eevblog.com/forum/chat/displaycontrol-board-for-zd915-deoldering-station/)
http://forum.iwenzo.de/zd-915-entloetst ... 55914.html (http://forum.iwenzo.de/zd-915-entloetstation-display-tot--t55914.html)
Title: Re: Really universal soldering controller
Post by: Wolfram on January 09, 2016, 01:36:04 pm
i really need to know if i can use SSD1306 display instead of the the UG-2864HSWEG01.
The problem is that i can't find the UG-2864HSWEG01 so im think to replace it with the SSD1306.
Title: Re: Really universal soldering controller
Post by: Sjaak on January 09, 2016, 04:19:19 pm
[quote author="Wolfram"]i really need to know if i can use SSD1306 display instead of the the UG-2864HSWEG01.
The problem is that i can't find the UG-2864HSWEG01 so im think to replace it with the SSD1306.[/quote]

AFAIK they are the same. Be aware some displays are using an almost identical controllerchip but one that react a bit different. I had some trouble when I had manufactured my controller and had the other OLED chip.
Title: Re: Really universal soldering controller
Post by: Sjaak on January 09, 2016, 04:59:45 pm
[quote author="Circuiteromalaguito"][quote author="Sjaak"]Don't think you need a stencil..[/quote]


Okay. Now I'll need a way to solder SMD chips without destroying them. I'm still an awful solder :(

What does it mean Protopack +-10.

The price is for one PCB plus the stencil I can opt to not get it, right? I'm confused as hell, sorry for being so dumb...[/quote]

I answered the PCB question in the other topic.

Dunno if you got already a soldering iron, assuming you have.. For SMD you need to add lots of flux and it will be a lot easier. Do a search on youtube for soldering smd to see the techniques. I couldn't solder it many years ago until I added copious amounts of flux.
Title: Re: Really universal soldering controller
Post by: dumitruv on January 14, 2016, 03:03:12 am
Hi Sparky,

Not sure if anybody asked this question, I couldn't find any answer in the trail. I just received the parts and I did an oven trial with the OLED board but without soldering the display itself. I powered up the board and the OLEDVCC comes to about 12.3V
I look in the display module specification and absolute maximum for Vcc is 11V, DC Characteristics says VCC 9.5V max when supplied externally. Is there a reason why you went that high or just a design error?

Thanks
Title: Re: Really universal soldering controller
Post by: sparkybg on January 14, 2016, 08:57:03 am
[quote author="dumitruv"]Hi Sparky,

Not sure if anybody asked this question, I couldn't find any answer in the trail. I just received the parts and I did an oven trial with the OLED board but without soldering the display itself. I powered up the board and the OLEDVCC comes to about 12.3V
I look in the display module specification and absolute maximum for Vcc is 11V, DC Characteristics says VCC 9.5V max when supplied externally. Is there a reason why you went that high or just a design error?

Thanks[/quote]

The display I am using wants 12V. If your display wants 9V, you will have to correct the booster feedback resistors.
Title: Re: Really universal soldering controller
Post by: BadAd84 on January 19, 2016, 06:44:03 pm
Boards arrived.
[s:]I have 7 spare, £8 per board (it was the all in one gerber) + shipping.  PM me if you want one of them.[/s:]

Edit: Boards all gone
Title: Re: Really universal soldering controller
Post by: neslekkim on January 19, 2016, 07:02:51 pm
Per board?, did you order all of them?, two-three different ones?
Title: Re: Really universal soldering controller
Post by: BadAd84 on January 19, 2016, 10:58:54 pm
[s:]I used the gerber that is all 3 boards in one.

I didnt use OSHPark (would cost more than price I am offering) but you can see a render here: https://dl.dropboxusercontent.com/u/284 ... solder.png (https://dl.dropboxusercontent.com/u/28488139/unisolder.png)

So its £8 + shipping for what PCB's you need.

Specs of boards:

 - Layer Size : 2 Layer PCB 10cm x 15cm Max
  - E-Test: 100% E-Test
  - Thickness: 1.6 MM
  - Surface Finish: Immersion Gold (ENIG)
  - PCB&SilkScreen Color: Blue PCB (White Silkscreen)
  - Process Time: 5 Working Days
  - Quantity: 10
  - Copper Thickness: 1 oz
  - PCB Copy: 1 Copy in 1 PCB

Please do not reply in this thread anymore. If you want one of my surplus boards, PM me.[/s:]

Edit: All surplus boards gone.
Title: Re: Really universal soldering controller
Post by: dumitruv on January 26, 2016, 12:59:42 am
Hi Sparky,

I fired up my boards successfully just to see something on the screen, no iron yet, I'm missing some components. I have few question though:

1. Only the "PIC32_Standalone" firmware works, "PIC32_with_bootloader" doesn't work. How do you use the one "with bootloader"?
2. How do you use the PC software to update the firmware? I suppose only the one "with bootloader" can be updated over USB.
3. If I want to connect two Hakko T15 what would be the parameters in "Iron.c" and the ID resistors? I understand they work at the same temperature and that's OK.

Thanks
Title: Re: Really universal soldering controller
Post by: flork on January 26, 2016, 02:51:13 am
Hello, i just register to ask about this great project, i looking to buy my first soldering station, and this will be awesome, my skills arent that great yet, so it is possible to buy finished pcb? maybe someone with skills can prepare one for me? i from EU
Title: Re: Really universal soldering controller
Post by: sparkybg on January 26, 2016, 09:18:46 am
[quote author="dumitruv"]Hi Sparky,

I fired up my boards successfully just to see something on the screen, no iron yet, I'm missing some components. I have few question though:

1. Only the "PIC32_Standalone" firmware works, "PIC32_with_bootloader" doesn't work. How do you use the one "with bootloader"?
2. How do you use the PC software to update the firmware? I suppose only the one "with bootloader" can be updated over USB.
3. If I want to connect two Hakko T15 what would be the parameters in "Iron.c" and the ID resistors? I understand they work at the same temperature and that's OK.

Thanks[/quote]

Both firmware is working. When using bootloader, you must upload the "PIC32_bootloader" only, and upload the "PIC32_with_bootloader" using the USB and the PC software.

...but, the PC sofware is far even from beta version and it uses fixed path for HEX and probably it won't work for you unless you edit the path in the source. I will have to fix this when I got the time, but lately I am pretty busy programming for a living so I cannot say when it will be ready.
Title: Re: Really universal soldering controller
Post by: Sniffer on January 26, 2016, 02:54:37 pm
[quote author="BadAd84"]I used the gerber that is all 3 boards in one.


So its £8 + shipping for what PCB's you need.

Specs of boards:

 - Layer Size : 2 Layer PCB 10cm x 15cm Max
  - E-Test: 100% E-Test
  - Thickness: 1.6 MM
  - Surface Finish: Immersion Gold (ENIG)
  - PCB&SilkScreen Color: Blue PCB (White Silkscreen)
  - Process Time: 5 Working Days
  - Quantity: 10
  - Copper Thickness: 1 oz
  - PCB Copy: 1 Copy in 1 PCB

Please do not reply in this thread anymore. If you want one of my surplus boards, PM me.[/quote]

Thans for the details.
Title: Re: Really universal soldering controller
Post by: dumitruv on January 29, 2016, 04:31:50 am
Hi Sparky,

I finally got all my parts and I tested the station using 24V DC from a bench power supply and a Hakko T15. I don't have a transformer big enough yet.
I set it to 350C but it overshot up to around 380C then went down to 330C. It keeps oscillating around 350C and finally it stabilizes at 350C +/-2 -3 C but if I touch a big piece of metal it starts oscillating all over again.
Is this normal? It doesn't seem to bounce that much in your videos. Is it because of DC?

Thanks!
Title: Re: Really universal soldering controller
Post by: sparkybg on January 29, 2016, 09:11:09 am
I don't know if it is because of DC. I will have to try.

Keep in mind that some chinese T15 tips are nasty, especially when powered for the first time. Set it to 400, and leave it for a minute or two, then set it at 350 and solder. Because you are using DC, don't connect earth yet, or if it is connected, there should not be any connetcion between negative supply and ground in the power supply - the only connection between them must be in the handpiece connector.
Title: Re: Really universal soldering controller
Post by: Sjaak on January 29, 2016, 10:06:44 am
[quote author="sparkybg"]I don't know if it is because of DC. I will have to try.

Keep in mind that some chinese T15 tips are nasty, especially when powered for the first time. Set it to 400, and leave it for a minute or two, then set it at 350 and solder. Because you are using DC, don't connect earth yet, or if it is connected, there should not be any connetcion between negative supply and ground in the power supply - the only connection between them must be in the handpiece connector.[/quote]

Also the chinese T12 have this problem. even the 'improved' versions :D
Title: Re: Really universal soldering controller
Post by: sparkybg on January 29, 2016, 11:49:15 am
Chinese T12 and chinese T15 are equal. Moveover - original T12 and T15 are equal.
Title: Re: Really universal soldering controller
Post by: dumitruv on January 29, 2016, 01:28:40 pm
[quote author="sparkybg"]I don't know if it is because of DC. I will have to try.

Keep in mind that some chinese T15 tips are nasty, especially when powered for the first time. Set it to 400, and leave it for a minute or two, then set it at 350 and solder. Because you are using DC, don't connect earth yet, or if it is connected, there should not be any connetcion between negative supply and ground in the power supply - the only connection between them must be in the handpiece connector.[/quote]

It is not chinese tip, it is genuine Hakko T15 that was used with Hakko station for some time.
I tried with and without ground (in the hand piece) and the bridge is not connected between negative and earth ground at the power supply side. I get the same result. I bet it is related to PID parameters.
I think T12 and T15 are identical is just they are sold in different areas (Europe vs Americas).
 I will try to post a video in the weekend.
Title: Re: Really universal soldering controller
Post by: sparkybg on January 29, 2016, 01:37:01 pm
[quote author="dumitruv"]I bet it is related to PID parameters.[/quote]

It is possible, but my first guess is that it has something to do with DC. I haven't tried my station on DC for a long time and it may have a bug on DC supply. The latest firmware changes were sensor reading optimizations on AC supply, but AC and DC sensor reading uses same code so maybe something is wrong with it. I will check it out.
Title: Re: Really universal soldering controller
Post by: dumitruv on January 30, 2016, 08:05:24 pm
[quote author="dumitruv"][quote author="sparkybg"]I don't know if it is because of DC. I will have to try.

Keep in mind that some chinese T15 tips are nasty, especially when powered for the first time. Set it to 400, and leave it for a minute or two, then set it at 350 and solder. Because you are using DC, don't connect earth yet, or if it is connected, there should not be any connetcion between negative supply and ground in the power supply - the only connection between them must be in the handpiece connector.[/quote]

It is not chinese tip, it is genuine Hakko T15 that was used with Hakko station for some time.
I tried with and without ground (in the hand piece) and the bridge is not connected between negative and earth ground at the power supply side. I get the same result. I bet it is related to PID parameters.
I think T12 and T15 are identical is just they are sold in different areas (Europe vs Americas).
 I will try to post a video in the weekend.[/quote]

Video uploaded here:
https://www.youtube.com/watch?v=j5XqF5n ... e=youtu.be (https://www.youtube.com/watch?v=j5XqF5ncl5A&feature=youtu.be)

First part is the calibration with a precise 10 Ohm resistor then I plug the iron and you can see the temperature stabilizing after quite awhile. Once it stabilizes I touch the wet sponge and it goes out of whack again.
Title: Re: Really universal soldering controller
Post by: dumitruv on January 30, 2016, 10:17:18 pm
[quote author="sparkybg"][quote author="dumitruv"]I bet it is related to PID parameters.[/quote]

It is possible, but my first guess is that it has something to do with DC. I haven't tried my station on DC for a long time and it may have a bug on DC supply. The latest firmware changes were sensor reading optimizations on AC supply, but AC and DC sensor reading uses same code so maybe something is wrong with it. I will check it out.[/quote]

I understand that you focused on AC and that you consider transformer the best choice.
The reason why I insist on using DC is first because your project supports it and second because I have a bunch of brand new laptop type power supplies 19V, 3.42A that were not needed in a project at work and I saved them. They are easy to open and hack to disconnect the ground from negative (I just remove a 0 Ohm resistor) and I can leave them at 19V or modify them to output 24V only by replacing an 0805 resistor. This way I save about 40 CAD, the price of a toroidal transformer. And if I install two in parallel I can use double iron or tweezers.

By the way, could you consider a double T12/T15 option in the iron.c next time you recompile the code? It is very useful with SMD components. I prefer two irons to hot tweezers.

Thanks!
Title: Re: Really universal soldering controller
Post by: sparkybg on January 30, 2016, 11:46:45 pm
Hm... I just tried it with several chinese and one original T12/T15 tips on AC - it behaves normally. It must be because of DC. I will investigate.
Title: Re: Really universal soldering controller
Post by: sparkybg on January 31, 2016, 12:04:48 am
No, it's not a bug. I've just tried it. The PID needs to be tuned a bit - it is a bit more "nervous" on DC then AC.

...and, the wet sponge has nothing to do with normal soldering. Try normal soldering - it will be a bit better. It is always a compromise between overshoots and the speed of reaction.

..and, the last but not the least - many controllers doesn't show the real temperature once they reach it, so the "stability" they have is only on the display - in the real world, the same thing happens - you just cannot see it on the display.

Anyway, I will try to tune the PID coefficients a bit when I got the time.
Title: Re: Really universal soldering controller
Post by: dumitruv on January 31, 2016, 04:52:48 am
[quote author="sparkybg"]No, it's not a bug. I've just tried it. The PID needs to be tuned a bit - it is a bit more "nervous" on DC then AC.

...and, the wet sponge has nothing to do with normal soldering. Try normal soldering - it will be a bit better. It is always a compromise between overshoots and the speed of reaction.

..and, the last but not the least - many controllers doesn't show the real temperature once they reach it, so the "stability" they have is only on the display - in the real world, the same thing happens - you just cannot see it on the display.

Anyway, I will try to tune the PID coefficients a bit when I got the time.[/quote]

Thanks Sparky!
Actually I tried it with AC , I opened my Hakko 936 and I connected to its transformer and I get pretty much the same result. I'm thinking that my long cables may play a role. I left the wires quite long to trim them when I pick a box.

What about the double iron question?
Title: Re: Really universal soldering controller
Post by: sparkybg on January 31, 2016, 10:42:25 am
[quote author="dumitruv"]
What about the double iron question?[/quote]

It is a single instrument controller and will stay this way. However, a profile can be created to control two T12 tips at the same time, with the same temperature. The tips will work with half power.
Title: Re: Really universal soldering controller
Post by: dumitruv on January 31, 2016, 11:37:54 pm
[quote author="sparkybg"]No, it's not a bug. I've just tried it. The PID needs to be tuned a bit - it is a bit more "nervous" on DC then AC.

...and, the wet sponge has nothing to do with normal soldering. Try normal soldering - it will be a bit better. It is always a compromise between overshoots and the speed of reaction.

..and, the last but not the least - many controllers doesn't show the real temperature once they reach it, so the "stability" they have is only on the display - in the real world, the same thing happens - you just cannot see it on the display.

Anyway, I will try to tune the PID coefficients a bit when I got the time.[/quote]

I tried to fiddle around with the parameters today and it is significantly more stable for me with PID_DGain=12 and  PID_OVSGain=8.
Title: Re: Really universal soldering controller
Post by: maxxim on February 01, 2016, 11:29:05 am
Hi to everyone
Title: Re: Really universal soldering controller
Post by: hristonev on February 02, 2016, 07:03:55 am
Hi, I'm interested about one board. PM me if you still have.
Title: Re: Really universal soldering controller
Post by: Jsnyder on February 05, 2016, 04:56:48 am
I had a question regarding the inductors L1, L2 in the BOM, did these need a specific a current/resistance rating? For L1  I'm looking at 680ma, and L2 is 320ma, will these work? Also am I correct in assuming that you recommend the fixed 3v3 part for the switching reg (LM2675M-3.3)?  I'm also interested in a pcb set if anybody has any spares, or is planning to get any more produced. Please PM me
~Jon
Title: Re: Really universal soldering controller
Post by: dumitruv on February 09, 2016, 01:13:01 am
Hi Sparky,

I did some experiments with 63/37 solder wire to see where I am with the temperatures. I tried 2 irons, a genuine Hakko T15 and a Chinese 907 that works well with Hakko 936.
With the Chinese 907 the display shows about 33C more and with Hakko T15 it shows about 39C more above the eutectic melting point of 183C.
Is there a way I can tune it up a bit? What parameters should I play with to lower a bit the reading? I don't have  a tester to see where it is on the high side.

Thanks
Title: Re: Really universal soldering controller
Post by: sparkybg on February 09, 2016, 08:49:02 am
[quote author="Jsnyder"]I had a question regarding the inductors L1, L2 in the BOM, did these need a specific a current/resistance rating? For L1  I'm looking at 680ma, and L2 is 320ma, will these work? Also am I correct in assuming that you recommend the fixed 3v3 part for the switching reg (LM2675M-3.3)?  I'm also interested in a pcb set if anybody has any spares, or is planning to get any more produced. Please PM me
~Jon[/quote]

Any inductor with specified package will do. Preferable shielded. L2 is a bit larger than needed anyway.

I recommend using fixed regulator because it is easier to do so. You you use adjustable, you will need two more resistor values in the BOM.
Title: Re: Really universal soldering controller
Post by: sparkybg on February 09, 2016, 08:59:20 am
[quote author="dumitruv"]Hi Sparky,

I did some experiments with 63/37 solder wire to see where I am with the temperatures. I tried 2 irons, a genuine Hakko T15 and a Chinese 907 that works well with Hakko 936.
With the Chinese 907 the display shows about 33C more and with Hakko T15 it shows about 39C more above the eutectic melting point of 183C.
Is there a way I can tune it up a bit? What parameters should I play with to lower a bit the reading? I don't have  a tester to see where it is on the high side.

Thanks[/quote]

I suspect there's an offset somewhere. The front PCB should be at near room temperature - there's a temperature sensor on it. If it is close to warm objects (i.e. warmed up laptop power supply for example) it will show higher temperature than real. Or, there's a problem with the temperature sensor. Thermocouple irons needs a "cold junction" temperature, and this temperature is added to the reading. If this temperature has an error in it, it will add this error to the temperature reading.

Can you upload a photo of your working prototype?

Also, bear in mind that some T15 tips are not as precise as they should. There can be upto 25-30 degrees difference between different chinese tips and more than 10-15 degrees  difference between original tips.
Title: Re: Really universal soldering controller
Post by: dumitruv on February 10, 2016, 02:37:46 am
[quote author="sparkybg"][quote author="dumitruv"]Hi Sparky,

I did some experiments with 63/37 solder wire to see where I am with the temperatures. I tried 2 irons, a genuine Hakko T15 and a Chinese 907 that works well with Hakko 936.
With the Chinese 907 the display shows about 33C more and with Hakko T15 it shows about 39C more above the eutectic melting point of 183C.
Is there a way I can tune it up a bit? What parameters should I play with to lower a bit the reading? I don't have  a tester to see where it is on the high side.

Thanks[/quote]

I suspect there's an offset somewhere. The front PCB should be at near room temperature - there's a temperature sensor on it. If it is close to warm objects (i.e. warmed up laptop power supply for example) it will show higher temperature than real. Or, there's a problem with the temperature sensor. Thermocouple irons needs a "cold junction" temperature, and this temperature is added to the reading. If this temperature has an error in it, it will add this error to the temperature reading.

Can you upload a photo of your working prototype?

Also, bear in mind that some T15 tips are not as precise as they should. There can be upto 25-30 degrees difference between different chinese tips and more than 10-15 degrees  difference between original tips.[/quote]

The temperature sensor seems to work fine, its output is within specified range and it responds to temperature variations.
There's nothing hot close to the board, it stays at room temperature.
I have attached two pictures, not sure if this is what you're looking for.
You can also see the front PCB in the video that I posted, link above.
Is there a service menu where I can see the ambient temperature and other raw values?
What is "T:" in the calibration menu?
Title: Re: Really universal soldering controller
Post by: sparkybg on February 10, 2016, 09:55:54 am
"T:" is replaced with "ROOM:" in the new firmware version, and displays the room temperature. I will upload it soon.

Disconnect the iron, leave it to cool down to room temperature, then go to the calibration menu, then connect the iron - tell me what the ADC says.

I suppose your controller is calibrated with 10ohm resistor?
Title: Re: Really universal soldering controller
Post by: dumitruv on February 10, 2016, 01:10:02 pm
[quote author="sparkybg"]"T:" is replaced with "ROOM:" in the new firmware version, and displays the room temperature. I will upload it soon.

Disconnect the iron, leave it to cool down to room temperature, then go to the calibration menu, then connect the iron - tell me what the ADC says.

I suppose your controller is calibrated with 10ohm resistor?[/quote]

The controller is calibrated with 10 ohm resistor, see attached.
For me T stays at zero all the time in the calibration menu.
See the next picture for ADC. It oscillates around 38 with Hakko T15.
Title: Re: Really universal soldering controller
Post by: sparkybg on February 10, 2016, 01:28:33 pm
Hm, it should be around 30, I think. I will try it tonight on my controller. I will check the temperature of my original hakko tip also.

Could you please check the resistance of the tip you are using, at the connector of the handpiece to the controller?

Here's the formula for ADC: (1.225V/(1600*256))*Current*Rheater*750*(Gain/256)*(1024/3V) so, for a 9 ohm heater resistance and current of 10 it should be 1.225/(1600*256)*10*9*750*(114/256)*(1024/3)=30.68

...but anyway, 8 on ADC is around 4 degrees, so it should not be the main reason, for +30degrees if it is offset.

When using 63/37 solder, you must melt some quantity on the tip and then clean the tip 3-4 times in order to remove the lead free solder from it. Then you must melt some 63/37 solder on it, and set the temperature down slowly until it totaly solidifies. Then raise the temperature slowly (i.e. set + 4 degrees and wait for some time, say 10-20 seconds) until it starts to melt. Then set the temperature at 2 degrees lower, wait for some time and check if the solder is solid, then raise again with 2 degrees, wait for some time and check if the solder starts to melt at the contact between the solder and the tip (the solder is solid but "slides" on tip when you gently push it). When you find the point with solid solder sliding on tip, this is  183 degrees celsoud +/- a degree or two. If you set the temperature up 2 degrees and wait for some time, the solder will melt and will partly solidify if you touch it with a screwdriver or bigger piece of solder. This is around 185-187 degrees celsius.

...and the T15 tips are not so precise - HAKKO gives them +/-10 degrees Celsius on their controller. Chinese are even worse - I found out that from nearly 50 tips I have, they can be sorted in two groups with +/- 7-8 degrees between each other in the group, and around 30 degrees Celsius between two groups. So the settings in the profile is more or less a compromise between all the tips I have.
Title: Re: Really universal soldering controller
Post by: sparkybg on February 10, 2016, 06:44:12 pm
Yes, it is 29 on my controller, running on DC.

The on T12/T15 profile:

Gain:114;
SoftGain:1024;
SoftOffset:0;
c0:0;
c1:57.01;

Are you sure the 10ohm resistor for the calibration you are using is at least with 1% tolerance?
Title: Re: Really universal soldering controller
Post by: sparkybg on February 10, 2016, 07:32:56 pm
I also did a little test with several tips (original and chinese) The original tip melts the 63/37 solder displaying 202-204 degrees, and one of the chinese tips melts it at 162 degrees on display. So, the setting is clearly a compromise.

You can correct it agdusting the "gain" parameter in the T12 profile, but if you are planning to use chinese tips there is a possibility for considerably higher tip temperature from display.

For K thermocouple iron (chinese Hakko 907) it is the same - maybe the thermocouple is not as precise as it shoud be. Because I don't have a K thermocouple iron at the moment, I am using calculated coefficients for thermocouple and gain from K thermocouple datasheets on the net. You can adjust it the same way - correct the "gain" setting in the profile.

...but anyway the ADC in the calibration display should be around 30 for 9 ohm heater resistance. I don't know why it is 38 on your controller. Try setting the "current" to 128, using the + and - buttons and tell me what the ADC and R shows. This way we will be able to see if it is an offset or gain error.
Title: Re: Really universal soldering controller
Post by: dumitruv on February 11, 2016, 02:40:40 am
[quote author="sparkybg"]Hm, it should be around 30, I think.[/quote]

Funny thing is, it is around 30 - 31, I must have been sleepy this morning. It moves too fast so maybe I read it 38 by mistake. Looking at more pictures from this morning the reading is close to 30.

[quote author="sparkybg"]Could you please check the resistance of the tip you are using, at the connector of the handpiece to the controller?[/quote]

8.3633 Ohm measured with Fluke 8845A with 4 wires.

[quote author="sparkybg"]When using 63/37 solder, you must melt some quantity on the tip and then clean the tip 3-4 times in order to remove the lead free solder from it. Then you must melt some 63/37 solder on it, and set the temperature down slowly until it totaly solidifies. Then raise the temperature slowly (i.e. set + 4 degrees and wait for some time, say 10-20 seconds) until it starts to melt. Then set the temperature at 2 degrees lower, wait for some time and check if the solder is solid, then raise again with 2 degrees, wait for some time and check if the solder starts to melt at the contact between the solder and the tip (the solder is solid but "slides" on tip when you gently push it). When you find the point with solid solder sliding on tip, this is  183 degrees celsoud +/- a degree or two. If you set the temperature up 2 degrees and wait for some time, the solder will melt and will partly solidify if you touch it with a screwdriver or bigger piece of solder. This is around 185-187 degrees celsius.[/quote]

That's exactly what I did.

[quote author="sparkybg"]...and the T15 tips are not so precise - HAKKO gives them +/-10 degrees Celsius on their controller. [/quote]

That's quite disappoint for Hakko brand. Probably is the series resistance that throws them out because the thermocouples are way better than that.

[quote author="sparkybg"]Are you sure the 10ohm resistor for the calibration you are using is at least with 1% tolerance?[/quote]

I selected one from a bunch of MF 1% resistors:
9.9987 measured with Fluke 8845A with 4 wires
9.9983 measured with HP 3478 with 4 wires. Pretty close.

[quote author="sparkybg"]For K thermocouple iron (chinese Hakko 907) it is the same - maybe the thermocouple is not as precise as it shoud be. Because I don't have a K thermocouple iron at the moment, I am using calculated coefficients for thermocouple and gain from K thermocouple datasheets on the net. You can adjust it the same way - correct the "gain" setting in the profile.[/quote]

I don't think genuine Hakko 907 has thermocouple. Mine is indeed chinese from Ebay but works fine with genuine Hakko 936 station. The sensor measures around 50+ ohms cold and goes up when I hold it in my hand. I think it is PTC and I set the ID to FX8801.

[quote author="sparkybg"]Try setting the "current" to 128, using the + and - buttons and tell me what the ADC and R shows. This way we will be able to see if it is an offset or gain error.[/quote]

ADC: 360
R: 824
This is with T15. Why is T: always zero?
Title: Re: Really universal soldering controller
Post by: sparkybg on February 11, 2016, 09:55:06 am
[quote author="dumitruv"]
Funny thing is, it is around 30 - 31, I must have been sleepy this morning. It moves too fast so maybe I read it 38 by mistake. Looking at more pictures from this morning the reading is close to 30.
[/quote]
It's OK then. :)

[quote author="dumitruv"]
8.3633 Ohm measured with Fluke 8845A with 4 wires.
[/quote]
This is OK too.

[quote author="dumitruv"]
That's quite disappoint for Hakko brand. Probably is the series resistance that throws them out because the thermocouples are way better than that.
[/quote]
Series resistance is not a problem. My controller compensates for it. It is non-standard thermocouple using heater wire for one of the metals and pure nickel for other. I believe it is Nickel-Nichrome thermocouple. But nichrome is not meant to play thermocouple role and very small differences in the chemical composition can give substantial errors. I doubt that Hakko are using custom made wire - pretty expensive stuff.

It is not the brand, it is the physics. These all contribute to tolerances:
- Heater wire chemical composition
- You measure TC temperature, when controlling the heater, not the tip temperature. But solder on the tip measures tip's temperature. Yes, the contact between TC and tip can be pretty good, but not perfect. Moreover different tips have different temperature gradients between TC and tip syrface
- TC needs cold junction. The perfect TC measurement can be done only in the handpiece itself with TC wires soldered directly to the thermometer PCB close to amplifier, and the cold junction temperature must be measured there too. But the real solution is far from this. The cold junction temperature is measured in the controller, and you have wires with different material from handpiece to controller.
- If the iron is with PTC sensor, all the cold junction problems disappear, but you cannot put the sensor close enough to the tip's surface - in most cases it is between the heater and the tip and the thermal contact between the heater, PTC and the tip cannot be made as close as when you use series thermocouple. So practically there will always be some thermal gradiant between the tip,  heater, and sensor.

If you want precise temperature, you must use only one instrument, only one tip and calibrate the controller/profile for this exact setup. Although, better precision than +/-10 degrees will give you practically nothing anyway.

[quote author="dumitruv"]
I selected one from a bunch of MF 1% resistors:
9.9987 measured with Fluke 8845A with 4 wires
9.9983 measured with HP 3478 with 4 wires. Pretty close.
[/quote]
This is much more than enough. :) It is not the value that must be exactly 10 ohms. You just need to know the the resistance with enough precision. For example, you can use 11 ohms resistor - on the calibration menu you must calibrate the controller to show 1100 for R.

With current of 128 (which is 1.225*128/1600*256 = 382.8 microamps) you are in the middle of the current source's pot where the pot's precision is best, with gain of 128 (which is 750*128/256=375) which is again in the middle of gain pot where it's precision is best, 10 ohm resistor will give 3.828 millivolts on it, and this will give 1.436V on ADC input, which is around 490 on 10 bit ADC, again pretty close to the center value of 512 where the ADC has best precision. In fact 10.449 is the perfect value, but it will give you nothing more than 8-12ohm resistor.


[quote author="dumitruv"]
I don't think genuine Hakko 907 has thermocouple. Mine is indeed chinese from Ebay but works fine with genuine Hakko 936 station. The sensor measures around 50+ ohms cold and goes up when I hold it in my hand. I think it is PTC and I set the ID to FX8801.
[/quote]

Genuine Hakko 907 is PTC. But there's many chinese copies with TC.
Anyway - I used original FX8801 heater on chinese 907 TC handpiece to measure the PTC resistance at different temperatures and to create profile for it. So, it is not 907 and it is not chinese. You may tune "Gain" (preferably) or "c0" in the profile to fit your iron - I doubt the chinese fake 907 is as precise as the original one. And again - there can be a difference between the origina 907 and original FX8801.

[quote author="dumitruv"]
ADC: 360
R: 824
[/quote]
This is also OK.

[quote author="dumitruv"]
This is with T15. Why is T: always zero?[/quote]

T is not a temperature or something. I think It will be nonzero only on AC power - I was displaying the time between comparator interrupt and zero cross point when using AC power while debugging the last version of the firmware. It has no practical value to anyone but me. :) The room temperature will be displayed there in the next firmware revision.
Title: Re: Really universal soldering controller
Post by: Wolfram on February 15, 2016, 01:01:40 am
Me and my friend from russia ,we want to know if it's really hard to replace that 3 buttons with an multifunctional encoder,we think that this will make the station more simple and also less complicated in terms of pcb space and mounting in a diy case .
Title: Re: Really universal soldering controller
Post by: sparkybg on February 15, 2016, 08:45:53 am
The controller is made to fit this enclosure:
(http://http://www.circuitspecialists.eu/media/catalog/product/cache/1/image/500x500/9df78eab33525d08d6e5fb8d27136e95/b/k/bk2000_-1.jpg)

It's not so hard to make it use encoder. The firmware must updated to include this functionality using the same 3 inputs the buttons use.
Title: Re: Really universal soldering controller
Post by: Wolfram on February 15, 2016, 06:31:35 pm
[quote author="sparkybg"]The controller is made to fit this enclosure:
(http://http://www.circuitspecialists.eu/media/catalog/product/cache/1/image/500x500/9df78eab33525d08d6e5fb8d27136e95/b/k/bk2000_-1.jpg)

It's not so hard to make it use encoder. The firmware must updated to include this functionality using the same 3 inputs the buttons use.[/quote]

we are not good programmers and in our case the pcb and the rest will be fitted in some kind of alluminium case like this one here :
(http://http://i.imgur.com/t2SUpfl.jpg)
so at this point as we are not good programmers ,we need someone to help us to make this encoder working properly.
Title: Re: Really universal soldering controller
Post by: sparkybg on February 15, 2016, 06:57:32 pm
I am not planning to make any hardware and firmware updates soon, unless bug fixes are necessary. It is not because I don't want to - I just don't have time for this.

You can easily make front panel out of laser cut stainless steel to fit both the enclosure and the PCB. You can make a PVC sticker for the front panel. I don't see how adding the circular encoder with button will make your task easier.

Controlling the controller will be a bit more easier than with 3 buttons, but as I said I made it for exact enclosure which already had everything ready on the front panel.

...maybe some day I will have the time to make it on single PCB and with color touchscreen display, but it will not be in the near future.
Title: Re: Really universal soldering controller
Post by: Wolfram on February 15, 2016, 08:09:54 pm
[quote author="sparkybg"]I am not planning to make any hardware and firmware updates soon, unless bug fixes are necessary. It is not because I don't want to - I just don't have time for this.

You can easily make front panel out of laser cut stainless steel to fit both the enclosure and the PCB. You can make a PVC sticker for the front panel. I don't see how adding the circular encoder with button will make your task easier.

Controlling the controller will be a bit more easier than with 3 buttons, but as I said I made it for exact enclosure which already had everything ready on the front panel.

...maybe some day I will have the time to make it on single PCB and with color touchscreen display, but it will not be in the near future.[/quote]

ok no problem ,just asking :)
Title: Re: Really universal soldering controller
Post by: rozubv on February 22, 2016, 10:18:20 am
Hello all,

First, I want to congratulate Sparky for his amazing project that I'm following with great interest.

Second, if anyone from Europe has a set of PCB's available, please send me a PM.
I am looking to buy between one and three sets of PCB's.

If not, I am willing to consolidate a few requests from interested people living in Europe and place an order to the PCB fab.

John,
Romania
Title: Re: Really universal soldering controller
Post by: Evgeny1 on February 23, 2016, 11:10:17 pm
Good afternoon!
I have a question, I can not do a step-up DC-DC on the FAN5331, and use the built-in display SSD1306 converter Switched Capacitor?
Capacitors on display between 1mkF conclusions 2-3 and 4-5.
(The scheme can not post as I am a new user, but they can not post links.)
I have a device with a display SSD in 1306 there is no step-up converter for OLEDVCCIN, and everything is powered by a 3.3V display itself generates the necessary voltage integrated inverter Switched Capacitor. Can I here to do a step-up DC-DC, and use the built-in display? Will work?

I apologize if put unclear, it is difficult to write on English- use google translate.
Title: Re: Really universal soldering controller
Post by: sparkybg on February 24, 2016, 09:26:48 am
You will have to make anothet OLED PCB to use the internal regulator. And maximum brightness of the display will not be available when you use the internal regulator, so a small firmware correction will also be needed.
Title: Re: Really universal soldering controller
Post by: Evgeny1 on February 24, 2016, 09:16:35 pm
ok
Title: Re: Really universal soldering controller
Post by: Wolfram on February 26, 2016, 11:44:04 am
i really love this project ,but im forced in any case to blame 1 thing about it.
i dont understood why the author have choosen pic32 istead of the more cheaper/economical stm or atmel chip .
i mean :
to program pic32 we (i too) must to buy an expensive programmer which cost around something like 45-50 euros.
with stm you can go at least for 5 or 20 bucks for he's programmer,with atmel too(maybe also less).
i really hope that in the next version of unisolder the chip: pic32
will be replaced with 1 more economical like stm or atmel.
+ i hope there will be also added the encoder with 3 fuction :rotate right ,left and button.
however the replacement of this expensive chip for one more economical will remain the most important of improvements to do on this project.
Title: Re: Really universal soldering controller
Post by: Sjaak on February 26, 2016, 12:05:43 pm
A quick search for a pickit clone on ebay comes up with the cheapest being 14.50 USD with free shipping.. And if you are really really cheap get an Arduino clone from ebay and use that to program the pic32: http://www.microchip.com/forums/m653443.aspx (http://www.microchip.com/forums/m653443.aspx) or get a member of a local hackerspace or a forum member to program it for you.

I personally think the pic32 is overkill and choosed another micro for this (also PIC ;P) but we should be greatefull sparky did this and is willing to help people built his project with the builts.
Title: Re: Really universal soldering controller
Post by: sparkybg on February 26, 2016, 12:09:52 pm
This project never meant to be "el-cheapo" solution, but universal one. And still it is considerably cheaper than many chinese stations, not to mention JBC, Weller and so on.

The chip costs 5EUR. PICKit3 programmer costs 11USD and programs ALL of microchip's MCUs from PIC10 to PIC32MZ. Tell me about more economical solution with the same performance. Atmel? Make a calculation for me, please. :)

Moreover, all the parts for this controller costs around 80-90EUR at Farnell (and Farnell is definitely not the cheapest place to get them), and the 5EUR MCU is not even the most expensive part inside it.

Next version, if any, will use even PIC32MZ. And there's a reason for this. Look at the source - there's a floating point polynomial for temperature, RMS calculation for voltage, current and power of the iron and so on.

...and, about STM - these are cheap to buy, yes, but Mictochip's documentation is light years ahead, compared to ST, Renesas, Atmel and... you name it.
Title: Re: Really universal soldering controller
Post by: sparkybg on February 26, 2016, 12:20:46 pm
[quote author="Sjaak"]
I personally think the pic32 is overkill and choosed another micro for this (also PIC ;P) but we should be greatefull sparky did this and is willing to help people built his project with the builts.[/quote]

Even PIC32MX has some bottlenecks on his project. Look at the source.

Yes, If some compromises are made, considerably cheaper MCU can be used, but again - this will set the price down by 1-3 EUR. Is it worth extra time to write assembly code and do optimizations and compromises? I don't think so.

The previous version (not published) of this controller used PIC18. And I spend a long hours to get it work and do a small part of calculations this controller makes. That's why I switched to PIC32 - USB PIC24 that can do the job is not cheaper then this exact PIC32.
Title: Re: Really universal soldering controller
Post by: Wolfram on February 26, 2016, 12:46:51 pm
[quote author="sparkybg"][quote author="Sjaak"]
I personally think the pic32 is overkill and choosed another micro for this (also PIC ;P) but we should be greatefull sparky did this and is willing to help people built his project with the builts.[/quote]

Even PIC32MX has some bottlenecks on his project. Look at the source.

Yes, If some compromises are made, considerably cheaper MCU can be used, but again - this will set the price down by 1-3 EUR. Is it worth extra time to write assembly code and do optimizations and compromises? I don't think so.

The previous version (not published) of this controller used PIC18. And I spend a long hours to get it work and do a small part of calculations this controller makes. That's why I switched to PIC32 - USB PIC24 that can do the job is not cheaper then this exact PIC32.[/quote]

pic programmer for pic32 cost around 14 $ ??
where ?
Title: Re: Really universal soldering controller
Post by: Sjaak on February 26, 2016, 12:57:05 pm
A soldering iron controller can be made in many many different ways and how to realize it is all about the requirements. For me it is to keep the tip (just one type) at a certain temperature +- couple degrees with a slick readout, for you it is to control every possible tip spot-on at a certain temperature. Both can be used to solder ICs on PCBs ;)

I admire your work and think you made a wonderful controller, but too much features IMHO.
Title: Re: Really universal soldering controller
Post by: Sjaak on February 26, 2016, 12:58:03 pm
[quote author="Wolfram"]
...

pic programmer for pic32 cost around 14 $ ??
where ?[/quote]

http://www.ebay.com/sch/i.html?_from=R4 ... ne&_sop=15 (http://www.ebay.com/sch/i.html?_from=R40&_sacat=0&LH_BIN=1&_nkw=pickit+clone&_sop=15)
Title: Re: Really universal soldering controller
Post by: sparkybg on February 26, 2016, 01:01:41 pm
[quote author="Wolfram"]
but stm32f4 is very powerful ,why not to use that ?[/quote]

STM32F401RBT6 costs 0.3EUR less than PIC32MX564F128H, where's the difference?

I can get PIC32 to life 5 minutes after I solder it - there's no need to read how to program it, there's no need to think what compiler/ide/programmer/librari I will have to use/buy - everything comes from one place, for free.

As I already said, STM32 is cheap to buy, but much more complex and time consuming to bring to life in many aspects. I like the simplicity of Microchip's concept about programming and documentation. For sure there are many better chips then PIC32 on the market, but the price of the chip is not everything that should be considered.
Title: Re: Really universal soldering controller
Post by: sparkybg on February 26, 2016, 01:02:55 pm
[quote author="Sjaak"][quote author="Wolfram"]
...

pic programmer for pic32 cost around 14 $ ??
where ?[/quote]

http://www.ebay.com/sch/i.html?_from=R4 ... ne&_sop=15 (http://www.ebay.com/sch/i.html?_from=R40&_sacat=0&LH_BIN=1&_nkw=pickit+clone&_sop=15)[/quote]


And here (11USD):
http://www.ebay.com/itm/1PC-PICKit-3-PI ... Sw~gRV1TQ4 (http://www.ebay.com/itm/1PC-PICKit-3-PICKit3-Programmer-PIC-Kit3-PIC-Simulator-Emluator-With-USB-Cable-/301724453191?hash=item46402dc947:g:bWkAAOSw~gRV1TQ4)

There's no reason to use PicKit2 anymore.
Title: Re: Really universal soldering controller
Post by: dumitruv on February 28, 2016, 01:59:59 am
Somebody asked about using an LCD instead of OLED. I tried with an LCD that I had in my monkey box and it didn't work so I took the challenge to make it work. Here's the result.

https://www.youtube.com/watch?v=maHOO12lgTg (https://www.youtube.com/watch?v=maHOO12lgTg)
Title: Re: Really universal soldering controller
Post by: DinikS on February 28, 2016, 02:05:55 pm
Hej alla. sparkybg, nice project I really like it. It's a chance to recover my dead soldering station. In this case it will be needed to rebuild a little bit front panel. What do you think is it possible to use transformer from this station?
Guys, if somebody has spare bare boards set please PM me. I don't live in EU but a best friend of mine is living in Lithuania.
Title: Re: Really universal soldering controller
Post by: sparkybg on February 28, 2016, 07:20:25 pm
If the transformer is 24V and around 100-120W, with decent leakage inductance, you will be able to use it. The controller works even with transformer from my old  chinese soldering station, and it is awful in many respects - it heats up a lot, even without any power consumption from it, and it has very bad leakage inductance.
Title: Re: Really universal soldering controller
Post by: DinikS on February 28, 2016, 09:01:19 pm
[quote author="sparkybg"]If the transformer is 24V and around 100-120W, with decent leakage inductance...........[/quote]
sparkybg, thanks for the answer. Transformer has no any label on it. At first glance It's 80-100W and It has two outputs 24V and 12V but I'm ashamed I don't know how to measure leakage inductance.
Title: Re: Really universal soldering controller
Post by: sparkybg on February 28, 2016, 09:41:00 pm
[quote author="DinikS"][quote author="sparkybg"]If the transformer is 24V and around 100-120W, with decent leakage inductance...........[/quote]
sparkybg, thanks for the answer. Transformer has no any label on it. At first glance It's 80-100W and It has two outputs 24V and 12V but I'm ashamed I don't know how to measure leakage inductance.[/quote]

Short 24V secondary and measure inductance of the primary. Than short also 12V secondary (keep 24V secondary shorted), and measure again primary inductance. Then we will compare them to my chinese transformer.
Title: Re: Really universal soldering controller
Post by: Wolfram on February 29, 2016, 03:41:42 pm
my main problem about this station is :to find an good non chinese transformer for it
anyone  can helps me ?
Thanks
P.S im living in italy
Title: Re: Really universal soldering controller
Post by: sparkybg on February 29, 2016, 04:02:02 pm
Just get 125VA toroidal transformer no matter chinese or not - the leakage inductance will be several times lower than most conventional ones, and many times lower than this controller can handle.

The controller just wants decent transformer, nothing more. Any transformer that stays cool enough under no load will be enough. Staying cool means it is made without making too many compromises just to bring price 50 cent down.
Title: Re: Really universal soldering controller
Post by: DinikS on February 29, 2016, 08:09:04 pm
[quote author="sparkybg"]
Short 24V secondary and measure inductance of the primary. Than short also 12V secondary (keep 24V secondary shorted), and measure again primary inductance. Then we will compare them to my chinese transformer.[/quote]
I measured: 24V secondary shorted- primary 123 mH, 24V and 12V shorted - no changes 123mH
Just in case picture of transformer and measuring tool attached
Title: Re: Really universal soldering controller
Post by: sparkybg on February 29, 2016, 11:05:44 pm
Hm... pretty close to my chinese transformer.

Connect primary to mains, and leave it for a hour or so. Check the temperature then. If it is considerably warmer than room temperature (more than 20 degrees Celsius higher than room temperature), better look for better transformer.

...but anyway, what is stopping you to try it connected to the controller? The controller will not fail no matter what power supply you are using. It may show some instabilities and errors when measuring the temperature, but nothing more.
Title: Re: Really universal soldering controller
Post by: DinikS on March 01, 2016, 11:31:43 am
Yes you are right nothing stops me to try. The only thing I have no assembled controller yet ))))
Thanks you for help
Title: Re: Really universal soldering controller
Post by: tolit02 on March 04, 2016, 08:46:14 pm
hi to all im a new member

can i ask what is the of resistor inside weller wsp80
Title: Re: Really universal soldering controller
Post by: tolit02 on March 04, 2016, 08:48:34 pm
hi to all im a new member

can i ask what is the of resistor inside weller wsp80
Title: Re: Really universal soldering controller
Post by: Wolfram on March 04, 2016, 09:27:20 pm
so i wanna seriously do your project ,but i have some problems with pcb's
so today i was gone to pcb way ,i've load your archive with your schematics (gerber)
later im getting an error which says me that the file is not valid ,LOOOOL WTF ?????
Another my problem is that i don't know how really i must to set-up the options inside the settings panel to make my pcb from them .
pls help me someone ,because im getting sick ,im a really beginner so im sorry if i losting your time with my dumbasses questions.
P.S the pcb on oshpark.com (https://oshpark.com/shared_projects/9ppq14FO (https://oshpark.com/shared_projects/9ppq14FO)) is already to expensive for me ,+-100 dollars for 3 pcb's
Title: Re: Really universal soldering controller
Post by: sparkybg on March 05, 2016, 12:02:08 am
I've just downloaded gerbers from the first post and everything looks OK. I don't know what might cause your problems.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 05, 2016, 12:03:51 am
[quote author="tolit02"]hi to all im a new member

can i ask what is the of resistor inside weller wsp80[/quote]

T = -313.5 + 14.288 * R
Title: Re: Really universal soldering controller
Post by: tolit02 on March 05, 2016, 01:18:38 am
hi sir can you explain i dont understand this T = -313.5 + 14.288 * R thank you
Title: Re: Really universal soldering controller
Post by: sparkybg on March 05, 2016, 01:23:48 am
[quote author="tolit02"]hi sir can you explain i dont understand this T = -313.5 + 14.288 * R thank you[/quote]

This is the temperature (degrees Celsius) equation for Weller WSP80 soldering iron. T=temperature, R=resistance. What more to explain?
Title: Re: Really universal soldering controller
Post by: tolit02 on March 05, 2016, 01:25:22 am
i open my weller wsp80 pencil and i see a resistor on the wire but i dont know what type of resistor and what is the value
Title: Re: Really universal soldering controller
Post by: sparkybg on March 05, 2016, 01:38:12 am
[quote author="tolit02"]i open my weller wsp80 pencil and i see a resistor on the wire but i dont know what type of resistor and what is the value[/quote]

I don't know what resistor are you talking about. Post a picture please.
Title: Re: Really universal soldering controller
Post by: Iwanushka on March 05, 2016, 01:53:20 am
Hi,

I've placed order for some PCBs and will have around 7 spare sets, they should be with me (in EU) in a month or something like that (depends how fast is snail mail).
Title: Re: Really universal soldering controller
Post by: tolit02 on March 05, 2016, 02:02:18 am
wsp80 picture sir  sparkybg
Title: Re: Really universal soldering controller
Post by: sparkybg on March 05, 2016, 10:58:51 am
[quote author="tolit02"]wsp80 picture sir  sparkybg[/quote]

Oh, now I saw my iron has it too.

I suppose it is some kind of calibrating resistor for the PTC. Because PTC is not ideal, maybe they are using this resistor to compensate for manufacturing tolerances of the PTC sensor in order to get better accuracy.

It is connected in parallel with the PTC sensor on my iron. It may be connecter in series for others, I don't know.

But anyway - you shouldn't care about it.
Title: Re: Really universal soldering controller
Post by: tolit02 on March 05, 2016, 01:44:12 pm
do you know the value of this i check the in google some say its 1k resistor how about you sir what do you think the value
Title: Re: Really universal soldering controller
Post by: sparkybg on March 05, 2016, 07:06:34 pm
I suspect it is different on every iron. There is "1693" written on mine, which I suppose is 169K.

Why do you care so much about this resistor?
Title: Re: Really universal soldering controller
Post by: tolit02 on March 05, 2016, 09:40:11 pm
ok...do you have close up picture sir thank you
Title: Re: Really universal soldering controller
Post by: sparkybg on March 05, 2016, 09:46:35 pm
[quote author="tolit02"]ok...do you have close up picture sir thank you[/quote]

No, I don't.

Again, why this resistor is such a big concern for you?
Title: Re: Really universal soldering controller
Post by: tolit02 on March 05, 2016, 11:58:40 pm
i have a extra weller wsd81 without pencil. i like to convert it to hakko pencil but i have a problem in temperature
 thats why i want to know the value of resistor

do you have any idea how to convert this weller wsd81 so that i can use hakko pencil
Title: Re: Really universal soldering controller
Post by: sparkybg on March 06, 2016, 10:47:20 am
[quote author="tolit02"]i have a extra weller wsd81 without pencil. i like to convert it to hakko pencil but i have a problem in temperature
 thats why i want to know the value of resistor

do you have any idea how to convert this weller wsd81 so that i can use hakko pencil[/quote]

Hakko FX8801 has equation T=-165.5 + 3.985 * R - there is absolutely no way to convert this to WSD81's equation, no matter what resistor you are using and how you connect it. The absolute resistance of HAKKO FX8801 is 3 times lower, and the temperauure gradient is 4 times lower.
Title: Re: Really universal soldering controller
Post by: proteus on March 13, 2016, 10:57:13 pm
Sparkybg thanks for your work. Top job. I have a pcb and want to make a device. I do not know how to program a PIC32MX564F128H-I / PT, can you explain to me.  I have a couple programmer with adapters for pic32.Or is it better to use PICKIT3 programmer?Thank you and best regards from Croatia
Title: Re: Really universal soldering controller
Post by: sparkybg on March 14, 2016, 10:11:01 am
There is header on the front PCB, called "PD1". The pinout is standart for PIC programming. I am using PICKit3, and it is a matter of one mouse click in MPLAB X to program it. The same header is present on sensor PCB.

Program it with "standalone" for now. There will be update of the PC software soon and then you will be able to upload the bootloader with PICKit3 and then update it using the USB port.
Title: Re: Really universal soldering controller
Post by: proteus on March 14, 2016, 10:31:05 am
[quote author="sparkybg"]There is header on the front PCB, called "PD1". The pinout is standart for PIC programming. I am using PICKit3, and it is a matter of one mouse click in MPLAB X to program it. The same header is present on sensor PCB.

Program it with "standalone" for now. There will be update of the PC software soon and then you will be able to upload the bootloader with PICKit3 and then update it using the USB port.[/quote]

Sparkybg  thank you for the quick response.
Best regards
Title: Re: Really universal soldering controller
Post by: ppsati on March 20, 2016, 12:06:40 am
Good evening to all.
I wonder if anyone here have any PCB populated or unpopulated for sale?
If anyone has please send me a PM.

Best Regards, from Portugal.
Title: Re: Really universal soldering controller
Post by: proteus on March 20, 2016, 01:37:05 am
[quote author="ppsati"]Good evening to all.
I wonder if anyone here have any PCB populated or unpopulated for sale?
If anyone has please send me a PM.

Best Regards, from Portugal.[/quote]

PCBs can get from the company  www.pcb.hr (http://www.pcb.hr)
For me, they created a pcb.
Title: Re: Really universal soldering controller
Post by: dinoslmn on March 20, 2016, 09:28:30 am
What is minimum order for this PCB set ?
Thank
Title: Re: Really universal soldering controller
Post by: proteus on March 20, 2016, 10:46:42 am
[quote author="dinoslmn"]What is minimum order for this PCB set ?
Thank[/quote]

1 set PCB
Title: Re: Really universal soldering controller
Post by: mani99 on March 20, 2016, 06:29:27 pm
Hi sparky,

I'm ordering parts from Farnell/Digikey and have a few questions:

I have 0603 1% 1/10W resistors for most values, can I use those instead of 0805 or is the slightly lower power rating an issue? I'll be ordering the 0.1% ones in 0805

I've made these substitutions as the originals weren't available, are these ok?
D6, D7, D12    SS310A    >  CDBA3100-HF
D9, D11, D13  1N4007  >  S1M-E3/61T (recommended replacement)


The zener diodes matching the BOM available at Digikey differ in impedance, reverse leakage current and power rating. What are the optimal values?

I can't post links as a new user, but there are ~10 matches for ZD1,2,4 / ZD3 / ZD5,6,7 respectively, you can paste the following after digikey.com to view them

product-search/en/discrete-semiconductor-products/diodes-zener-single/1377034?k=&FV=1c0002%2C400151%2Cfff40015%2Cfff8030a%2Ce600210&mnonly=0&newproducts=0&ColumnSort=1000011&page=1&stock=1&quantity=10&ptm=0&fid=0&pageSize=25

product-search/en/discrete-semiconductor-products/diodes-zener-single/1377034?k=&FV=1c0002%2C400151%2Cfff40015%2Cfff8030a%2Ce600218&mnonly=0&newproducts=0&ColumnSort=1000011&page=1&stock=1&quantity=10&ptm=0&fid=0&pageSize=25

product-search/en/discrete-semiconductor-products/diodes-zener-single/1377034?k=&FV=1c0002%2C400151%2Cfff40015%2Cfff8030a%2Ce6001fd&mnonly=0&newproducts=0&ColumnSort=1000011&page=1&stock=1&quantity=10&ptm=0&fid=0&pageSize=25


I also have a JBC stand (AD8245) I'd like to use as a sensor for sleep detection. Have you used this method before or just optical detection? The pinout is available at the eevblog forum:
/forum/testgear/jbc-soldering-iron-stand-wiring/

Thanks!
Title: Re: Really universal soldering controller
Post by: sparkybg on March 21, 2016, 12:37:42 am
[quote author="mani99"]Hi sparky,

I'm ordering parts from Farnell/Digikey and have a few questions:

I have 0603 1% 1/10W resistors for most values, can I use those instead of 0805 or is the slightly lower power rating an issue? I'll be ordering the 0.1% ones in 0805
[/quote]
I think you can. Only the amplifier input resistors are power critical, but far away from nominal 0805 power rating, so 0603 should be OK even there.

[quote author="mani99"]
I've made these substitutions as the originals weren't available, are these ok?
D6, D7, D12    SS310A    >  CDBA3100-HF
[/quote]
OK

[quote author="mani99"]
D9, D11, D13  1N4007  >  S1M-E3/61T (recommended replacement)
[/quote]
OK

[quote author="mani99"]
The zener diodes matching the BOM available at Digikey differ in impedance, reverse leakage current and power rating. What are the optimal values?
[/quote]
Just get zeners in specified package. All the zeners in the same package are similar (or should be), no matter who makes them.

[quote author="mani99"]
I also have a JBC stand (AD8245) I'd like to use as a sensor for sleep detection. Have you used this method before or just optical detection? The pinout is available at the eevblog forum:
/forum/testgear/jbc-soldering-iron-stand-wiring/
Thanks![/quote]

"SLEEP" signal has 3K pull-up to 3.3v and thats all. You can use any switch or any other device that shorts SLEEP to GND when the iron is in the stand.
Title: Re: Really universal soldering controller
Post by: Iwanushka on March 21, 2016, 07:57:31 pm
[quote author="ppsati"]Good evening to all.
I wonder if anyone here have any PCB populated or unpopulated for sale?
If anyone has please send me a PM.

Best Regards, from Portugal.[/quote]
Hi,

I will have a few spare sets for front, back, oled pcbs, in a few weeks waiting for them to arrive from HK.
Title: Re: Really universal soldering controller
Post by: ppsati on March 21, 2016, 09:38:37 pm
[quote author="Iwanushka"][quote author="ppsati"]Good evening to all.
I wonder if anyone here have any PCB populated or unpopulated for sale?
If anyone has please send me a PM.

Best Regards, from Portugal.[/quote]
Hi,

I will have a few spare sets for front, back, oled pcbs, in a few weeks waiting for them to arrive from HK.[/quote]

Thank´s Iwanushka.
Title: Re: Really universal soldering controller
Post by: protons on March 21, 2016, 10:01:22 pm
Hi, some one please help with solution for station,
Solder all components to PCB, programm PIC controler(use pic kit3 and MPLAB IPE v3.20)
file: US_Firmware.X.production.hex.
Power on, nothing is on the screen (power 24V, I=0,02A).
Change to Oleds. Oleds i buy in ebuy links:
http://www.ebay.com/itm/160879914739?_t ... EBIDX%3AIT (http://www.ebay.com/itm/160879914739?_trksid=p2057872.m2749.l2649&ssPageName=STRK%3AMEBIDX%3AIT)

Please some one can give voltage levels on ports header 5 - P1 and P2.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 21, 2016, 10:13:15 pm
You must use "softwarefrontUS_Firmware.XdistPIC32_StandaloneproductionUS_Firmware.X.production.hex". This is stand alone version of the firmware.

The "PIC32_with_bootloader" folder is the firmware that is used when updates are uploaded with bootloader,


I don't know which "header 5" are you talking about, but if PICKit3 told you that everything is OK with programming, then the problem might be elsewhere.
Title: Re: Really universal soldering controller
Post by: BadAd84 on March 21, 2016, 10:49:23 pm
Hi,

Which resistors are critical that they are 0.1% tolerance?

I see a few that dont seem like they need to be 0.1% (I.e. OLED module)
Title: Re: Really universal soldering controller
Post by: proteus on March 22, 2016, 12:50:36 am
Hello everyone. Looking for PCB for this project. Conversation with my supplier can contact him via e-mail for orders pcb.
http://www.pcb.hr/ (http://www.pcb.hr/)
mail. itd-tim@zg.t-com.hr (http://mailto:itd-tim@zg.t-com.hr)
Title: Re: Really universal soldering controller
Post by: mani99 on March 22, 2016, 02:01:23 am
[quote author="sparkybg"]
Just get zeners in specified package. All the zeners in the same package are similar (or should be), no matter who makes them.[/quote]
Ok, the values varied by up to 10x so I thought I'd ask.

[quote author="sparkybg"]
"SLEEP" signal has 3K pull-up to 3.3v and thats all. You can use any switch or any other device that shorts SLEEP to GND when the iron is in the stand.[/quote]
In a previous post you said the tip should be isolated from PCB ground but the stand sensor pin would be shorted to earth with the iron in the stand. Any ideas for connection?
Title: Re: Really universal soldering controller
Post by: protons on March 22, 2016, 07:54:00 am
Header 5 is lable in OLED schematic two ports for OLED board connection,

Please some one can give voltage levels on ports header 5 - P1 and P2.
Also what is OLEDVCC voltage level.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 22, 2016, 09:12:31 am
[quote author="BadAd84"]Hi,

Which resistors are critical that they are 0.1% tolerance?

I see a few that dont seem like they need to be 0.1% (I.e. OLED module)[/quote]

Not all are critical, but if I use different, the lines in the BOM for the resistors would be doubled. ;)
Title: Re: Really universal soldering controller
Post by: sparkybg on March 22, 2016, 09:19:45 am
[quote author="mani99"]
"SLEEP" signal has 3K pull-up to 3.3v and thats all. You can use any switch or any other device that shorts SLEEP to GND when the iron is in the stand.[/quote]
In a previous post you said the tip should be isolated from PCB ground but the stand sensor pin would be shorted to earth with the iron in the stand. Any ideas for connection?[/quote]

Pay attention: GND and EARTH are not the same!!! ;) GND is controller's common and does not have connection to EARTH. EARTH is... well... EARTH, taken from the mains plug. :) The stand should not be connected to EARTH in any way, or at least the tip of the iron should be connected to EARTH only at iron's connector (according to connections, mentioned in the first post) and nowhere else.
Title: Re: Really universal soldering controller
Post by: BadAd84 on March 22, 2016, 12:05:26 pm
[quote author="sparkybg"][quote author="BadAd84"]Hi,

Which resistors are critical that they are 0.1% tolerance?

I see a few that dont seem like they need to be 0.1% (I.e. OLED module)[/quote]

Not all are critical, but if I use different, the lines in the BOM for the resistors would be doubled. ;)[/quote]


Yes, I can tell they are not all critical. Could you please tell me which ones MUST be 0.1% though?

Thanks :)
Title: Re: Really universal soldering controller
Post by: sparkybg on March 22, 2016, 12:09:56 pm
[quote author="BadAd84"][quote author="sparkybg"][quote author="BadAd84"]Hi,

Which resistors are critical that they are 0.1% tolerance?

I see a few that dont seem like they need to be 0.1% (I.e. OLED module)[/quote]

Not all are critical, but if I use different, the lines in the BOM for the resistors would be doubled. ;)[/quote]


Yes, I can tell they are not all critical. Could you please tell me which ones MUST be 0.1% though?

Thanks :)[/quote]

Only front PCB 0.1%  resistors that are on signal path and current sources are critical.
Title: Re: Really universal soldering controller
Post by: MadBekon on March 22, 2016, 05:48:48 pm
Hi fellas!
Just placed an order for a set of boards. Black + ENIG.
If someone is interested, it should be available in 2-3 weeks.
Title: Re: Really universal soldering controller
Post by: mani99 on March 23, 2016, 12:56:18 am
[quote author="sparkybg"][quote author="mani99"]
"SLEEP" signal has 3K pull-up to 3.3v and thats all. You can use any switch or any other device that shorts SLEEP to GND when the iron is in the stand.[/quote]
In a previous post you said the tip should be isolated from PCB ground but the stand sensor pin would be shorted to earth with the iron in the stand. Any ideas for connection?

Pay attention: GND and EARTH are not the same!!! ;) GND is controller's common and does not have connection to EARTH. EARTH is... well... EARTH, taken from the mains plug. :) The stand should not be connected to EARTH in any way, or at least the tip of the iron should be connected to EARTH only at iron's connector (according to connections, mentioned in the first post) and nowhere else.[/quote]

Yes, I understood that :)

JBC obviously uses the tip for switching while having a connection from the tip to earth.
See the teardown: https://www.youtube.com/watch?v=PjEYI5WsLBI (https://www.youtube.com/watch?v=PjEYI5WsLBI)

A few screenshots:
2-pin connector for the holder/tip changer on the far right: https://i.imgur.com/n4IGoQx.jpg (https://i.imgur.com/n4IGoQx.jpg)
Earth/tip connection (not 100% on tip but what else could it be?): https://i.imgur.com/aoCHDr0.jpg (https://i.imgur.com/aoCHDr0.jpg)
The whole board: https://i.imgur.com/gKi8a7p.jpg (https://i.imgur.com/gKi8a7p.jpg)

I was just wondering if this type of detection could be (easily) accomplished with your controller, while still maintaining the separation. It's the way I'd prefer as I wouldn't have to modify my stand, align switches etc. If it's a pain I'll use another method.
Title: Re: Really universal soldering controller
Post by: ppsati on March 23, 2016, 01:01:24 am
Hi, Sparkybg.

Do you think possible to use this iron from weller (WXDP 120) in this soldering station.
This is an iron with analog to digital conversion.
See the photos.
I apologize for the amount of photos

Regards.
Title: Re: Really universal soldering controller
Post by: ppsati on March 23, 2016, 01:13:13 am
I forgot this one.
Title: Re: Really universal soldering controller
Post by: alinrosioru on March 23, 2016, 08:22:37 am
Dear Sparkybg are from Romania and I am struggling for some time to control a JBC 245 (which I did get) and so far I have not managed than with an interface that knows only resistor in series with the thermocouple. Since the heating element did use than 2 wire and less ground wire that is common at JBC. Also searching the net I came across this forum and you realized you (I find it best). I was interested if you could help me with wiring populated and what pret.Scuze for English but live google translator.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 23, 2016, 09:34:44 am
[quote author="mani99"]

JBC obviously uses the tip for switching while having a connection from the tip to earth.
See the teardown: https://www.youtube.com/watch?v=PjEYI5WsLBI (https://www.youtube.com/watch?v=PjEYI5WsLBI)

A few screenshots:
2-pin connector for the holder/tip changer on the far right: https://i.imgur.com/n4IGoQx.jpg (https://i.imgur.com/n4IGoQx.jpg)
Earth/tip connection (not 100% on tip but what else could it be?): https://i.imgur.com/aoCHDr0.jpg (https://i.imgur.com/aoCHDr0.jpg)
The whole board: https://i.imgur.com/gKi8a7p.jpg (https://i.imgur.com/gKi8a7p.jpg)

I was just wondering if this type of detection could be (easily) accomplished with your controller, while still maintaining the separation. It's the way I'd prefer as I wouldn't have to modify my stand, align switches etc. If it's a pain I'll use another method.[/quote]

Does any of the stand wires have connection with the stand's body? Is the stand body metallic?

The only requirement is that the EARTH should not have connection to the GND on my controller and that's all. And this is because there is a MOSFET and shunt between the tip's negative supply and controller's GND. If you make connection between tip's outer shell and EARTH, and in the same time you make a connection between controller's GND and EARTH, the controller won't be able to read the shunt and will act as if the MOSFET is always on.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 23, 2016, 09:38:31 am
[quote author="ppsati"]Hi, Sparkybg.

Do you think possible to use this iron from weller (WXDP 120) in this soldering station.
This is an iron with analog to digital conversion.
See the photos.
I apologize for the amount of photos

Regards.[/quote]

You will be able to use this iron if you remove all the electronics and connect the tip's heater and sensor directly to my controller. You will have to find out what voltage TC returns, if it is a TC sensor, or what resistance the sensor has if it is PTC/NTC sensor.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 23, 2016, 09:42:03 am
[quote author="alinrosioru"]Dear Sparkybg are from Romania and I am struggling for some time to control a JBC 245 (which I did get) and so far I have not managed than with an interface that knows only resistor in series with the thermocouple. Since the heating element did use than 2 wire and less ground wire that is common at JBC. Also searching the net I came across this forum and you realized you (I find it best). I was interested if you could help me with wiring populated and what pret.Scuze for English but live google translator.[/quote]

There is not a resistor in series with thermocouple. The thermocouple is in series with the heater. However, C245 thermocouple can be read both as a series and separate one. TC voltage is available both between the heater terminals and between one of them and outer shell, but you will have to use differential amplifier able to read negative voltages if you want to read it as a separate sensor, as I do in my controller.

Reading a series thermocouple properly is not so easy task either because there are offsets and a bunch of other "interesting" stuff happening when the TC has a heater current flowing through.

Make my controller and you will be able to control any iron with TC or resistive sensor. I've spend many hours to make it do it properly. It is not so easy to explain it all. I can answer specific questions only.
Title: Re: Really universal soldering controller
Post by: alinrosioru on March 23, 2016, 11:50:05 am
I want to say heater but google translate resistor. i want to make your controler but in romania is hard and many money to spend for a PCB, only for 100 pcs start process. I ask to bay from you and how money you want for pcb populate?
Title: Re: Really universal soldering controller
Post by: sparkybg on March 23, 2016, 12:15:33 pm
You can buy unpopulated PCB from someone that has or will have surplus set. At least two users writing in this thread  are waiting for their PCBs to arrive.
Title: Re: Really universal soldering controller
Post by: Iwanushka on March 23, 2016, 03:39:27 pm
sparkybg,

can this digital pot MCP4651-503E/ST be replaced with something else? Non of the europe distributors stock it, only digikey has it, but shipping is 60usd for 1$ part, plus all the import taxes/customs paper work will be another 40+euro..
Title: Re: Really universal soldering controller
Post by: sparkybg on March 23, 2016, 03:56:44 pm
[quote author="Iwanushka"]sparkybg,

can this digital pot MCP4651-503E/ST be replaced with something else? Non of the europe distributors stock it, only digikey has it, but shipping is 60usd for 1$ part, plus all the import taxes/customs paper work will be another 40+euro..[/quote]

Farnell has MCP4651-104, and it is OK. It is the same, just 100K instead of 50K.
Title: Re: Really universal soldering controller
Post by: HeaveNAkirA on March 24, 2016, 08:55:26 am
very nice project i m looking forward to make one. Anyone have design it for 2 tips , or can it even work with 2 tips from different brads lets say hakko and jbc or something like that or it need a lots of coding to do so ?
Title: Re: Really universal soldering controller
Post by: sparkybg on March 24, 2016, 09:24:27 am
[quote author="HeaveNAkirA"]very nice project i m looking forward to make one. Anyone have design it for 2 tips , or can it even work with 2 tips from different brads lets say hakko and jbc or something like that or it need a lots of coding to do so ?[/quote]

If you read the thread carefully you will findout that the controller can recognize more than 500 different instrumens. In the first post there is a list of currently supported irons:
Quote
Tested so far with:
- HAKKO T12/T15 (series TC)
- HAKKO FX8801 (PTC)
- PACE TD100 (series TC)
- JBC C245 (series or separate TC)
- JBC C210 (series TC)
- JBC Microtweezers (2 separate heaters, each with series TC)
- WELLER WSP80 (PTC) (This iron was sent to me by a reader of the thread for a previous version of the controller. Thanks, Jaroslaw)
- various chinese cheap irons with separate TC

It can drive ANY TC or resistive sensor iron. You only have to make a profile for it if it is not in the list of currently supported devices and recompile the firmware. In the near future you will be able to make profiles using the PC software also.

If you are asking if it can controll 2 irons in the same time - yes it can, but with same temperature, with maximum of 72W (24V 3A) per tip, and you definitely will have to make profile for them, if it is posible (some tips are incompatible to each other).

But the controller is meant to control 1 instrument with 1 or 2 tips (JBC microtweezers for example) and that's will no change ever.
Title: Re: Really universal soldering controller
Post by: HeaveNAkirA on March 24, 2016, 11:45:51 am
yes i meant to say at the same time (not the same brand - let say hakko - weller, hakko - jbc , jbc - weller), same temps are not a problem i need it for same cheap pens with other type of tips, i don't want to change the tips too often

p.s and i read the thread
Title: Re: Really universal soldering controller
Post by: Iwanushka on March 25, 2016, 02:42:36 am
[quote author="HeaveNAkirA"]yes i meant to say at the same time (not the same brand - let say hakko - weller, hakko - jbc , jbc - weller), same temps are not a problem i need it for same cheap pens with other type of tips, i don't want to change the tips too often

p.s and i read the thread[/quote]

I stand to be corrected, but you can only use two identical heaters which will be set to the same temp.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 25, 2016, 09:21:04 am
[quote author="Iwanushka"]
I stand to be corrected, but you can only use two identical heaters which will be set to the same temp.[/quote]

No, you can use different heaters. There is a separate sub-profile in the iron's profile for each heater/tip, and each heater is controlled completely independently from the other one. Only the temperature setting is common and maximum amperage per heater is halved - the controller can handle 6A and you can use maximum of 3A per heater when two heaters are connected.
Title: Re: Really universal soldering controller
Post by: dumitruv on March 25, 2016, 05:45:38 pm
Hi Sparky,

I come back to temperature. I wonder if you ever tested the real temperature of the tips. I just got my thermometer from Banggood last week and it shows way lower than the OLED display as I mentioned in one of my previous posts. I checked again the values of all resistors, the ICs, the voltages and everything seems to be in its place. I programmed your posted software again thinking that I messed with some values when I tinkered with the LCD and PID parameters.... nothing. Here are some pictures. The first one is my Hakko 936 set to 400C. The other three are Unisolder set to 250, 300 and 350C with genuine Hakko T15.

I tried to play a bit with the gain and soft gain in iron.c but the temperature doesn't seem to change.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 25, 2016, 09:27:29 pm
Update: new firmware and PC software uploaded:
 - New waveshaping technique, working better on most tips, especially C210/Microtweezers
 - Some iron parameter profiles corrected a bit
 - Some things changed when on DC power supply
 - PC software slides for gain and PID parameters are working now
 - Some issues with live data corrected
 - Added profile for ERSA RT80 (Heater is also  PTC)
Title: Re: Really universal soldering controller
Post by: sparkybg on March 25, 2016, 09:33:00 pm
[quote author="dumitruv"]Hi Sparky,

I come back to temperature...[/quote]

Try the new firmware. ;)

As I said before, T12/T15 profile is a compromise between chinese and original tips. Playing with gain won't change anything, because the firmware first calculates the TC millivolts or PTC resistance, and the calculation eliminates the hardware gain and offset. You must play with "c1" polynomial coefficient in order to change millivolts-to-temperature conversion.
Title: Re: Really universal soldering controller
Post by: dumitruv on March 26, 2016, 03:10:48 am
[quote author="sparkybg"][quote author="dumitruv"]Hi Sparky,

I come back to temperature...[/quote]

Try the new firmware. ;)

As I said before, T12/T15 profile is a compromise between chinese and original tips. Playing with gain won't change anything, because the firmware first calculates the TC millivolts or PTC resistance, and the calculation eliminates the hardware gain and offset. You must play with "c1" polynomial coefficient in order to change millivolts-to-temperature conversion.[/quote]

Sparky you rock!
It was better with the new software but still not perfect. After I experimented with C1 coefficient though , the temperature is bang on.
The values that work for me are 45.5 for T15 and 3.60513... for Hakko 907.
I also increased a bit PID Gain to 8 and Overshoot gain to 10 for T15.
And I got the PC software working. Compiled with Visual Studio.

Thanks a lot!!
Title: Re: Really universal soldering controller
Post by: sparkybg on March 26, 2016, 12:06:30 pm
Try to calibrate the temperature with 63/37 solder (183 degrees Celsius melting temperature) and with pure lead (327.5 degrees Celsius melting temperature). You will find out that thermometer you are using  is not as precise as you expect it to be. ;) I also have it. You can find pure lead thin wire in fisherman's shops.Just make sure it is real lead, not lead-free wire. The other source maybe chemical laboratory consumable shops.

Another possibility, witch I haven't tried, is to use pure Zink (419.5 degrees Celsius meling point).

Using pure metals or eutectic metal alloys (63/37 solder is such alloy) for calibration is the most accurate method for calibration you can use.

Next, for T15, try your other tips, especially if they are with different shape. Probably you will find out that there are some differences between tips. Try to calculate a mean value for C1 for all of the tips you have.
Title: Re: Really universal soldering controller
Post by: afedorov on March 26, 2016, 08:18:45 pm
Hi everyone!
First of all, many thanks to sparkybg for your hard work.
I have two questions:
1. I've planned to buy parts from Farnell, and they have bat46wh in flat-lead package, which seems to be incompatible with gull-wing footprint - am I right? They also have bat46w in sod123, but this part provide less current capability, have lesser Ir and larger Vf - can it be placed instead *wh version?
2. R55, R56 - can it be regular 5% tolerances? Seems it's not a part of any dividers (only ADC load).
Title: Re: Really universal soldering controller
Post by: dumitruv on March 26, 2016, 08:47:21 pm
[quote author="sparkybg"]Try to calibrate the temperature with 63/37 solder (183 degrees Celsius melting temperature) and with pure lead (327.5 degrees Celsius melting temperature). You will find out that thermometer you are using  is not as precise as you expect it to be. ;) I also have it. You can find pure lead thin wire in fisherman's shops.Just make sure it is real lead, not lead-free wire. The other source maybe chemical laboratory consumable shops.
[/quote]

I tried wit 63/37 and the temperature is about 10C higher. I'm happy with that for now.
I'll figure out a way to check the thermometer.

[quote author="sparkybg"]
Another possibility, witch I haven't tried, is to use pure Zink (419.5 degrees Celsius meling point).
.[/quote]

I don't want to play with zinc, I understand its fumes are quite toxic.

[quote author="sparkybg"]
Next, for T15, try your other tips, especially if they are with different shape. Probably you will find out that there are some differences between tips. Try to calculate a mean value for C1 for all of the tips you have.[/quote]

Actually I tried multiple shapes and sizes and there's a difference of up to 20C, I know that. The biggest difference seems to be between fine tips and big tips. All the fine tips seem to be close to each other. Anyway, soldering is not an exact science, 10 - 20C is not the end of the world. I'm happy that I have control and multiple methods to calibrate the temperature. Once I put it in a case I'll do more fine tuning.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 27, 2016, 01:40:14 am
[quote author="afedorov"]Hi everyone!
First of all, many thanks to sparkybg for your hard work.
I have two questions:
1. I've planned to buy parts from Farnell, and they have bat46wh in flat-lead package, which seems to be incompatible with gull-wing footprint - am I right? They also have bat46w in sod123, but this part provide less current capability, have lesser Ir and larger Vf - can it be placed instead *wh version?
2. R55, R56 - can it be regular 5% tolerances? Seems it's not a part of any dividers (only ADC load).[/quote]

1. As far as I can see, Farnell's BAT46WH is in SOD123 package. Where is the problem? Moreover,  the footprint I am using in the PCB is compatible with both SOD123, SOD323, and SOD80/miniMELF.
2. No, R55 and R56 are not critical. You can use even 20% resistors there.

...but, regular for me is 1% tolerance, not 5% tolerance. So all other resistors must be 1%, including the ID resistors in the iron's connector. It may work with 5% also, but I've never tried this.

Moreover, the old 5% tolerance resistors are usually carbon film resistors and 1% resistors are usually thin metal film resistors. Metal film resistors are superior in many aspects, not just the resistance tolerance. For example, they give less noise. So I strongly suggest that any resistor in signal path to be metal film one. This includes sensor signal path, current shunt signal path and input voltage signal path. The ID resistors MUST be 1%.
Title: Re: Really universal soldering controller
Post by: afedorov on March 27, 2016, 10:47:59 am
Thanks for answer, sparkybg!
[quote author="sparkybg"]Where is the problem?[/quote]
The problem is NXP's bat46wh at Farnell is flat-leaded - leads go under the body slightly and pad spacing in recommended footprint is less than in regular SOD123, and since under D8, D10, D14 and D15 ground plane resides, only solder mask preventing it to short to ground. I think I'll go with bat46w in regular package.

[quote author="sparkybg"]So I strongly suggest that any resistor in signal path to be metal film one.[/quote]
I've checked my old 5% 0805 kit and indeed it is carbon film, will replace it with 1%.
Title: Re: Really universal soldering controller
Post by: kasas on March 28, 2016, 04:42:18 am
just waiting for a potential group buy... just dropping in a comment as a placeholder.
Title: Re: Really universal soldering controller
Post by: MadBekon on April 04, 2016, 09:19:59 am
Do you think there is a chance that station will work properly with a DC-DC converter like this:
http://http://www.aliexpress.com/item/150W-DC-DC-Boost-Converter-10-32V-to-12-35V-6A-Step-Up-Power-Supply-Module/32580881262.html
stepping up from 18V battery pack?
Title: Re: Really universal soldering controller
Post by: sparkybg on April 04, 2016, 10:30:40 am
Better use the battery pack directly connected to controller.

I cannot comment nor speculate if it will work or not with any particular SMPS. It works with my old 12V AT power supply and it works with chinese 24V 200W power supply also.

However, as I mentioned several times already - toroidal mains transformer is the best possible power source for this controller, if you are using it at home. Battery is also always OK if connected only to the controller and if it can give enough current and voltage - it must be able to power the iron you are using and have at least 7-8V voltage on it while doing this.
Title: Re: Really universal soldering controller
Post by: MadBekon on April 04, 2016, 12:13:39 pm
I agree 100% about transformers.
What I'm actually thinking to do is to add a battery connector at the back of soldering station, so it can easily become a portable solution. Using ie 18V 4Ah would be so handy if you want to solder some places without extension cord. Just as an additional option, not instead of AC supply.
I'm sooooo much waiting for all parts so i can start assembling your design.
When I'm done testing with battery pack i will share results, maybe someone would like to make that option as well.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 04, 2016, 12:41:22 pm
It will be OK I think. Some irons may not be as powerful on 18V as on 24, but some other will be able to give all they can. On 18V the controller himself can give around 110W of power as long as the heater is with low enough resistance. C210 for example will work with its full power down to 10V and lower. Most of the tips (you can see this in the profiles) are software limited to their nominal power. The next limitation is the current the controller can give (6A, as I mentioned).  The PID algorithm compensates for different volages, so this also should not be a problem whatsoever.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 06, 2016, 07:20:39 pm
sold.
Title: Re: Really universal soldering controller
Post by: wailer on April 07, 2016, 06:17:08 pm
[quote author="kasas"]just waiting for a potential group buy... just dropping in a comment as a placeholder.[/quote]


There is a kit for the components?
I'm desperate, the; My working tool is broken (JBC ADVANCED 2700) and Unisolder solution is beautiful ..
Title: Re: Really universal soldering controller
Post by: sparkybg on April 08, 2016, 09:11:54 am
For now there is not. But all the parts are available from Farnell.
Title: Re: Really universal soldering controller
Post by: wailer on April 08, 2016, 06:54:28 pm
Thanks for the answer, and for the project ..
I hope in a buying group
Title: Re: Really universal soldering controller
Post by: mig12 on April 08, 2016, 07:08:29 pm
[quote author="Iwanushka"]sold.[/quote]
Would it be possible to order more?
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 08, 2016, 10:06:15 pm
[quote author="mig12"][quote author="Iwanushka"]sold.[/quote]
Would it be possible to order more?[/quote]

a few pages back someone else made an order for boards and will have surplus PCBs.
Title: Re: Really universal soldering controller
Post by: afedorov on April 09, 2016, 12:28:38 am
How critical the performance of U17?
Can it be replaced with MCP6V08-E/SN or MCP6V01-E/SN (half a slew rate, half a bandwidth, doubled input noise)?
Farnell have MCP6V28 in MSOP only right now.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 09, 2016, 12:42:42 am
You can check mouser europe (if your order is above 50e before tax shipping is free, there are no customs to pay too), in Eu you can also try ELFA/distrelec
Title: Re: Really universal soldering controller
Post by: afedorov on April 09, 2016, 12:53:22 am
[quote author="Iwanushka"]You can check mouser europe (if your order is above 50e before tax shipping is free, there are no customs to pay too), in Eu you can also try ELFA/distrelec[/quote]
Ah, yes! I forgot about Mouser. Thanks for pointing out.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 09, 2016, 01:12:07 am
[quote author="afedorov"]How critical the performance of U17?
Can it be replaced with MCP6V08-E/SN or MCP6V01-E/SN (half a slew rate, half a bandwidth, doubled input noise)?
Farnell have MCP6V28 in MSOP only right now.[/quote]

The critical part of all opamps in the project is the self-zeroing feature, common mode going below zero, rail-to-rail output, and at least 800Khz bandwidth.

Both 01/02/03, 06/07/08 and 26/27/28 series will work. I've used the parts from these families that were cheapest when I made the prototype. Today maybe the prices are different than nearly 2 years ago. So just buy the cheapest ones that you can find today and everything will be OK.

About MSOP8 - most of the times it can be soldered on SOIC8 footprint - you just have to bend it's terminals a bit and use some more solder. I've done this many times without any problems so far.
Title: Re: Really universal soldering controller
Post by: afedorov on April 09, 2016, 01:42:43 am
[quote author="sparkybg"]you just have to bend it's terminals a bit[/quote]
Right! How can I don't figured it out...
Title: Re: Really universal soldering controller
Post by: MadBekon on April 09, 2016, 11:10:08 am
I just finalized order for parts.
In my case order was combined order Mouser (most ICs) and TME (discreet rcls).
All ICs were available on hand.
Order from Mouser took 5 days from US to Poland.
Were just not happy with prices of resistors / capacitors, that is why I got those from TME.

I'm still waiting for PCBs to come, hopefully next week.
I shall have some avalable for 12euros if someone is interested.
(I see all the time questions about boards in this post)
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 11, 2016, 06:22:52 pm
Sparkybg,

Can you shed some light on what parts are not needed when using OLED, so far I've got this

1. U9 - ULN2003L is not needed, instead Ja-Jg jumpers or 0r resistors must be instslled.
2. Ra-Rg for LED is 47R, for OLED should be jumper or 0R resistors
3. What about Q14, Q15, Q16, Q17 which ones are needed?
4. Are there any other parts that are not needed for OLED?

Also maybe you can share altium files (most important pcb project) it would save lots of time troubleshooting with altium pcb viewer vs using gerber viewer.

Thank You!
Title: Re: Really universal soldering controller
Post by: afedorov on April 11, 2016, 06:41:57 pm
Another question, now about U15 :)
Is it required to use EEPROM version?

And hypothetical consideration for future versions:
Why not use J4/J8 for powering the controller? Prerequisites are:
Using MiniFit is overkill for 1A, header/IDC/26AWG can handle it
It's safer than using two identical connectors for HV and LV at power PCB
less PCB space requirement
single connector to front board
Adding four additional pins (14 pin connector) to pin 1 side 3.3V, 0.6V GND, GND (1,2,3,4) wouldn't interfere with other signals, I believe.

Cons:
requires good quality 26AWG ribbon cable
though, voltage drop @1A would be ~0.05V
Title: Re: Really universal soldering controller
Post by: sparkybg on April 11, 2016, 09:29:21 pm
[quote author="Iwanushka"]Sparkybg,

Can you shed some light on what parts are not needed when using OLED, so far I've got this

1. U9 - ULN2003L is not needed, instead Ja-Jg jumpers or 0r resistors must be instslled.
2. Ra-Rg for LED is 47R, for OLED should be jumper or 0R resistors
3. What about Q14, Q15, Q16, Q17 which ones are needed?
4. Are there any other parts that are not needed for OLED?

Also maybe you can share altium files (most important pcb project) it would save lots of time troubleshooting with altium pcb viewer vs using gerber viewer.

Thank You![/quote]

Q15, Q17 and UL2003N are not needed, and that's it. Ra-Rg are shorted with solder (the footpring is made to be able to short it easy), Ja-Jg are also shorted with solder - again the footprint is made for this to be easy. Also, if you look at the back of front pcb, there are soldermask-free areas around some of the 7-segment indicator terminals - you must short the legs to the ground using these areas.


I cannot share Altium files. Altium is not free software. Also, I must prevent copying and modifying to some degree, otherwise any (chinese) huckster will be able to abuse my project without any electronics knowledge.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 11, 2016, 09:44:53 pm
[quote author="afedorov"]Another question, now about U15 :)
Is it required to use EEPROM version?
[/quote]
You can use 4551 instead, but it was not available when I made the controller.

[quote author="afedorov"]
And hypothetical consideration for future versions:
Why not use J4/J8 for powering the controller? Prerequisites are:
Using MiniFit is overkill for 1A, header/IDC/26AWG can handle it
It's safer than using two identical connectors for HV and LV at power PCB
less PCB space requirement
single connector to front board
Adding four additional pins (14 pin connector) to pin 1 side 3.3V, 0.6V GND, GND (1,2,3,4) wouldn't interfere with other signals, I believe.

Cons:
requires good quality 26AWG ribbon cable
though, voltage drop @1A would be ~0.05V[/quote]

It is not bacause of the current flowing through it, but because of the lower resistance it has. I had problems with this in the previous versions. That's why on this version there is a separate doubled signal ground line, and doubled power ground line, and that's why the connectors are far from each other. You don't need power currents flowing near the microvolt measuring circuitry - very low voltage drops here and there makes pretty nasty noises.
Title: Re: Really universal soldering controller
Post by: afedorov on April 11, 2016, 11:22:25 pm
Thanks a lot for explaining, sparkybg!
Title: Re: Really universal soldering controller
Post by: tto4ka on April 13, 2016, 09:56:26 am
[quote author="mig12"][quote author="Iwanushka"]sold.[/quote]
Would it be possible to order more?[/quote]
If to whom it is interesting I also I made a quantity of boards which will come to me in 7-10 days, and also several sets of all components on a PCB.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 13, 2016, 09:48:49 pm
Guys,

What connector is used on JBC T245, need to buy a socket for that thing, and I don't have the Iron at the moment.

Edit: socket is Hirose RPC1-12RB-6P(71)
Title: Re: Really universal soldering controller
Post by: idar66 on April 14, 2016, 05:49:15 am
hi if was too pay someone to make this for me, just finished box i would get my own handpieces, if anyone has one or is willing to make one for me i would be very appreciative, ie im happy to pay someone so it is worth there time and effort, thanks idar66
Title: Re: Really universal soldering controller
Post by: alinrosioru on April 14, 2016, 08:23:55 am
Tto4ka, i am interesting for one set of PCB and all component for them. How money you want and you can shipping to romania?
Title: Re: Really universal soldering controller
Post by: afedorov on April 14, 2016, 06:07:14 pm
Could anyone tell me cable diameter of JBC T245?

Thanks!
Title: Re: Really universal soldering controller
Post by: MadBekon on April 14, 2016, 06:30:20 pm
Outer insulation 4mm,
Internal wires insulation - 3 x 1.15mm
Wires gauge around AWG 22 - 0.64mm
Title: Re: Really universal soldering controller
Post by: afedorov on April 14, 2016, 08:15:00 pm
I've just noticed - ID input is completely unprotected, link goes from "high" voltage iron connector straight into MC pin.
Maybe it is worth to attach 1K resistor with reversed low leakage schottky to VCC between R24 and MC pin, it should not disturb ADC readings.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 14, 2016, 08:39:03 pm
You are right, but It is connected this way because I wanted to be able to connect 1-wire MCU or EEPROM there. The logic that controlls the power mosfets prevents any possibility of wrong upper MOSFET turn on, so the only way a problem can occur there is a short circuit between the ID and one of the Vout pins, with power turned on. This can be easily prevented with good insulation, but even if it happens, the MCU will not turn the power on, because the voltage on the ID pin will be out of specification for valid IDs.
Title: Re: Really universal soldering controller
Post by: afedorov on April 14, 2016, 09:10:51 pm
Oh, digital identification, got it.
Even with this in mind, resistor value may be lowered to 100 to match input low voltage of 0.5V, either value will act like a fuse when ID shorted to Vout+
ID is always connected, so accident shorting ID to Vout+ when upper switch is turned on will instantly burns out pin, port or even MCU.
I think some basic protection is better than no protection at all.
Also it may be a n-mosfet between R24 and ID input - G to 3.3V, S to MC, D to ID input (like in I2C level converter, which is good only for ADC identification)
Title: Re: Really universal soldering controller
Post by: sparkybg on April 14, 2016, 09:29:41 pm
[quote author="afedorov"]Oh, digital identification, got it.
Even with this in mind, resistor value may be lowered to 100 to match input low voltage of 0.5V, either value will act like a fuse when ID shorted to Vout+[/quote]

1-wire means both power and data on the same  wire. For example, the Microchip protocol for this is made with enough up time in order to provide power to the device. I don't know if it will work with 100ohm in series with it.
Title: Re: Really universal soldering controller
Post by: afedorov on April 14, 2016, 09:37:30 pm
For I2C it is even recommended to attach small series resistors to smooth line spikes, and since Rpup is on other side of resistor it should be OK. 1Wire act similarly, but with a stronger pull up to power the device.
I will get some 1W to check this.

UPD:
Tested iButton with 100 Ohm series resistor and it reads and writes just fine.
Title: Re: Really universal soldering controller
Post by: on4top on April 20, 2016, 03:10:29 am
Following this tread ..

I wonder if the if the weller LR21 and MLR21 supported ?
I have both .. but only 1 WECP20 station ..
Title: Re: Really universal soldering controller
Post by: dan4ik on April 21, 2016, 02:09:54 pm
Hi guys, Can somebody make pictures of assembled front and display boards top and bottom sides? I'm newbie in electronics but eager very much to assemble this controller.
Thanks
Title: Re: Really universal soldering controller
Post by: sparkybg on April 21, 2016, 02:43:07 pm
[quote author="on4top"]Following this tread ..

I wonder if the if the weller LR21 and MLR21 supported ?
I have both .. but only 1 WECP20 station ..[/quote]

If their sensor is PTC/NTC or thermocouple, the controller can drive them, but you will have to make profiles for them (amplifier input configuration, measurement curretnt, gain, offset, polinomial coefficients).

...or you can send them to me, I will make profiles, and return them to you.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 21, 2016, 02:47:40 pm
[quote author="dan4ik"]Hi guys, Can somebody make pictures of assembled front and display boards top and bottom sides? I'm newbie in electronics but eager very much to assemble this controller.
Thanks[/quote]

There are already several pictures of assembled units back in the thread. How will they help you to assemble yours?
Title: Re: Really universal soldering controller
Post by: dan4ik on April 21, 2016, 05:08:10 pm
[quote author="sparkybg"]
There are already several pictures of assembled units back in the thread. How will they help you to assemble yours?[/quote]
Yes I know I saw that pictures but dysplay covers some area of board and I can't see which components should be mounted and which not. Or may be there is a list of components which shouldn't be mounted?
Sorry for stupid requests but as I said I'm a newbie.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 21, 2016, 06:12:53 pm
[quote author="dan4ik"][quote author="sparkybg"]
There are already several pictures of assembled units back in the thread. How will they help you to assemble yours?[/quote]
Yes I know I saw that pictures but dysplay covers some area of board and I can't see which components should be mounted and which not. Or may be there is a list of components which shouldn't be mounted?
Sorry for stupid requests but as I said I'm a newbie.[/quote]

I've explained it 2 times already, last time maybe 10-15 posts ago. (page 27) ;)
Title: Re: Really universal soldering controller
Post by: on4top on April 22, 2016, 12:11:28 am
[quote author="sparkybg"][quote author="on4top"]Following this tread ..

I wonder if the if the weller LR21 and MLR21 supported ?
I have both .. but only 1 WECP20 station ..[/quote]

If their sensor is PTC/NTC or thermocouple, the controller can drive them, but you will have to make profiles for them (amplifier input configuration, measurement curretnt, gain, offset, polinomial coefficients).

...or you can send them to me, I will make profiles, and return them to you.[/quote]

will see .. maybe first try to solder a working pcb  :-)

It seems to be a PTC according to this  -> http://remotesmart.wikidot.com/weller-wecp-20 (http://remotesmart.wikidot.com/weller-wecp-20)
Title: Re: Really universal soldering controller
Post by: dan4ik on April 22, 2016, 09:29:28 am
[quote author="sparkybg"]
I've explained it 2 times already, last time maybe 10-15 posts ago. (page 27) ;)[/quote]
Thank you I found that.
Could I ask one more stupid question. Which components should be mounted there (Pls see on the picture)
Title: Re: Really universal soldering controller
Post by: sparkybg on April 22, 2016, 09:36:01 am
If you look closely, the pads of these footprints are made close to each other in order to be shorted easily with solder. The little ones inside the ULN2003 foorprint must be shorted with solder too.
Title: Re: Really universal soldering controller
Post by: radutyu on April 23, 2016, 10:12:11 am
I want one pcb without parts shipping to Romania, great job
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 24, 2016, 03:31:19 am
sparkybg,

I've assembled back board, checked output voltages and saw something strange:Note input voltage is +24VDC
1) -0.6V output stays at -0.34V,
2) +12V output stays at +14-14.2V, EDIT: LTSpice simulation shows +14.58V output, so maybe everything is okay with this one.

Any ideas what could be wrong? power consumption looks okay, PSU says 10mA so for sure it's less than 20mA, there was no current spikes on turn-on nor any magic smoke escaped.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 24, 2016, 11:54:25 am
[quote author="Iwanushka"]sparkybg,

I've assembled back board, checked output voltages and saw something strange:Note input voltage is +24VDC
1) -0.6V output stays at -0.34V,
2) +12V output stays at +14-14.2V, EDIT: LTSpice simulation shows +14.58V output, so maybe everything is okay with this one.
[/quote]

 -0.6V will go to -0.6V when you attach the front board. It needs some current on the +3.3V line in order to go to -0.6V.

+14.2V on +12V line is not a problem. This is the lower MOSFETs gate control voltage. The gates can sustain +/-20V, and the gate driver can sustain 18V, so anything far enough from 18V is OK there.
Title: Re: Really universal soldering controller
Post by: protons on April 25, 2016, 10:02:05 pm
Hi,
some one can give voltage levels in pins A1/VDD(Q14 drain) and A3/VDD(Q16 drain) when OLED module is take out from main PCB.
I have change two oleds because not get information on oled when power on.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 26, 2016, 12:12:30 am
[quote author="protons"]Hi,
some one can give voltage levels in pins A1/VDD(Q14 drain) and A3/VDD(Q16 drain) when OLED module is take out from main PCB.
I have change two oleds because not get information on oled when power on.[/quote]

3.3V. Q16 and Q14 are just switches with very low on resistance.

Also, consider this:
[quote author="sparkybg"]...Also, if you look at the back of front pcb, there are soldermask-free areas around some of the 7-segment indicator terminals - you must short the legs to the ground using these areas...[/quote]
Title: Re: Really universal soldering controller
Post by: MadBekon on April 26, 2016, 09:33:01 pm
Hi, I also received my boards and started assembling.
After assmbling Back boards, and powering on I got 5V. After replacing divider to 3K and 1.8K i got 3.23V.
Is it enough for PIC?

Maybe it would be worth mentioning that in first post, update schematic and BOM.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 26, 2016, 10:50:58 pm
3.23V will be OK.

I've changed the schematics to use 3.3V instead ot ADJ version of the switcher some time ago, but somehow forgot to upload it.
Now there's a table in the schematic PDF showing what the feedback resistors should be for both versions.

Thanks for mentioning it.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 27, 2016, 12:48:53 am
[quote author="MadBekon"]Hi, I also received my boards and started assembling.
After assmbling Back boards, and powering on I got 5V. After replacing divider to 3K and 1.8K i got 3.23V.
Is it enough for PIC?

Maybe it would be worth mentioning that in first post, update schematic and BOM.[/quote]

replace R4 1.5k resistor with 2.7k, leave R3 as in BOM 4.7k and you will get 3.313V
Title: Re: Really universal soldering controller
Post by: dumitruv on April 27, 2016, 01:02:27 am
I used LM2674-3.3V instead of LM2675 with 220uH and it works well. I just found it in my monkey box and I decided to give it a try and it seem to work well.

Sparky,
Is there a reason behind using a 1A IC instead of a 500mA one? It is 2$ cheaper.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 27, 2016, 01:26:35 am
[quote author="dumitruv"]I used LM2674-3.3V instead of LM2675 with 220uH and it works well. I just found it in my monkey box and I decided to give it a try and it seem to work well.

Sparky,
Is there a reason behind using a 1A IC instead of a 500mA one? It is 2$ cheaper.[/quote]

I didn't had an estimate of the final current consumption, so I decided to use 1A version. And it gets a little warm after a hour or so. So I suspect the 0.5A version will get a bit warmer. I don't like a warm parts on my devices. If you look at the power mosfets and the shunt resistor, they are pretty overspecified also. In fact the warmest parts are the rectifier diodes when there's a heavy load on C245 tips. Maybe around 50-55 degrees Celsius. But his happens when I submerge the tip in a pot of cold isopropyl alcohol. This measn full 140 watts for 10 seconds or so...


...and I bought these from a local distributor. 2674 is 1.74USD and 2675 is 2.14USD, so the difference here is only 0.4USD, and if I buy 5pcs, the difference becomes 0.3USD.

Moreover, on farnell's site 2675 is 2.86EUR and 2674 is 3.29EUR - the 1A part is cheaper than 0.5A part.

So it seems it is a reseller-dependant issue.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 27, 2016, 02:34:46 am
[quote author="sparkybg"][quote author="dumitruv"]I used LM2674-3.3V instead of LM2675 with 220uH and it works well. I just found it in my monkey box and I decided to give it a try and it seem to work well.

Sparky,
Is there a reason behind using a 1A IC instead of a 500mA one? It is 2$ cheaper.[/quote]

I didn't had an estimate of the final current consumption, so I decided to use 1A version. And it gets a little warm after a hour or so. So I suspect the 0.5A version will get a bit warmer. I don't like a warm parts on my devices. If you look at the power mosfets and the shunt resistor, they are pretty overspecified also. In fact the warmest parts are the rectifier diodes when there's a heavy load on C245 tips. Maybe around 50-55 degrees Celsius. But his happens when I submerge the tip in a pot of cold isopropyl alcohol. This measn full 140 watts for 10 seconds or so...
[/quote]

for this power diodes are bad, but at least you are using schottky diodes, not that cheap stuff, I will be replacing schottky bridge with a FET bridge a.k.a ideal diodes to decrease power dissipation.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 27, 2016, 09:16:09 am
[quote author="Iwanushka"]not that cheap stuffш[/quote]
SR580 costs around 0.10USD here. It is cheap indeed. :)

[quote author="Iwanushka"]
, I will be replacing schottky bridge with a FET bridge a.k.a ideal diodes to decrease power dissipation.[/quote]

It will give you next to nothing. The controller is limited to 6A RMS. When soldering, the diodes stays cool (under 40 degrees). Only when peak power from the iron is needed, and the iron is over 100W,  they become a little warm.

Moreover, the voltage after the bridge must have a valley around 5V - there is a circuit for this in the back PCB. Using MOSFET-s may produce some problems there.
Title: Re: Really universal soldering controller
Post by: MadBekon on April 27, 2016, 01:59:03 pm
OK, so I powered up and seems all is good.
except, that i'm getting around 20' offest (280 instead of 300) and for some time at the beginning i get info that there is a short present in handle.

Any tip on troubleshooting?
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 27, 2016, 03:31:06 pm
[quote author="sparkybg"][quote author="Iwanushka"]not that cheap stuffш[/quote]
SR580 costs around 0.10USD here. It is cheap indeed. :)

[quote author="Iwanushka"]
, I will be replacing schottky bridge with a FET bridge a.k.a ideal diodes to decrease power dissipation.[/quote]

It will give you next to nothing. The controller is limited to 6A RMS. When soldering, the diodes stays cool (under 40 degrees). Only when peak power from the iron is needed, and the iron is over 100W,  they become a little warm.

Moreover, the voltage after the bridge must have a valley around 5V - there is a circuit for this in the back PCB. Using MOSFET-s may produce some problems there.[/quote]

sparkybg,

My plan is to change this project a bit, so I can have 2 separate outputs @ max power, in this case FETs will come in handy, I don't like wasting power...
Title: Re: Really universal soldering controller
Post by: sparkybg on April 27, 2016, 03:43:49 pm
[quote author="Iwanushka"]
My plan is to change this project a bit[/quote]

This will be major redesign, not a small change. And, if you use the same transformer for both irons, you will have problems (difference in) with temperature reading when the other iron is on and when it is off, and who knows what more - the firmware will need a major redesign also. You will need a separate amplifiers for each heater. You will have various ground and current loops here and there... ...and so on...

Better make 2 separate controllers, if you ask me. As I did. Many manufacturers are doing the same - common enclosure with two separate controllers inside, with two separate transformers. Sometimes optically isolated from the control panel.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 27, 2016, 04:58:38 pm
[quote author="sparkybg"][quote author="Iwanushka"]not that cheap stuffш[/quote]
SR580 costs around 0.10USD here. It is cheap indeed. :)
[/quote]

Insane price, farnell wants like 75 euro cent +VAT, mouser wants 50 euro cent + VAT for each, so if we compare 1N4 crap that I can get locally for like 5 euro cents, schottky  diodes are expensive :)
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 27, 2016, 04:59:57 pm
[quote author="sparkybg"][quote author="Iwanushka"]
My plan is to change this project a bit[/quote]

This will be major redesign, not a small change. And, if you use the same transformer for both irons, you will have problems (difference in) with temperature reading when the other iron is on and when it is off, and who knows what more - the firmware will need a major redesign also. You will need a separate amplifiers for each heater. You will have various ground and current loops here and there... ...and so on...

Better make 2 separate controllers, if you ask me. As I did. Many manufacturers are doing the same - common enclosure with two separate controllers inside, with two separate transformers. Sometimes optically isolated from the control panel.[/quote]

Will see with what I will come up in the end, at first I need to find time to finish your solution, and there are no issues using one transformer with two controllers either.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 27, 2016, 08:41:13 pm
[quote author="Iwanushka"]and there are no issues using one transformer with two controllers either.[/quote]

Yes, there is, because the transofmer voltage drops down when heater is ON. An you will have some trouble to get where the zero point is. It can be solver by rewriting the firmware, but it is a pain in the ass to make it work.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 27, 2016, 08:41:58 pm
[quote author="MadBekon"]OK, so I powered up and seems all is good.
except, that i'm getting around 20' offest (280 instead of 300) and for some time at the beginning i get info that there is a short present in handle.

Any tip on troubleshooting?[/quote]

What handle and what power supply are you using? Does it show "heater short circuit", or "sensor short circuit", and for how much time does it show it?

Do you have earth connection or not?
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 27, 2016, 09:21:44 pm
[quote author="sparkybg"][quote author="Iwanushka"]and there are no issues using one transformer with two controllers either.[/quote]

Yes, there is, because the transofmer voltage drops down when heater is ON. An you will have some trouble to get where the zero point is. It can be solver by rewriting the firmware, but it is a pain in the ass to make it work.[/quote]

sparkybg,

we can always use transformer with two secondaries, anyway back to topic, first of all I want to apologize for the stupid question that will follow, but I have severe spinal damage and painkillers don't do a squat for me at the moment, thus may brain is half-dead and I'm having difficulties simulating part of the circuit in my brain. So the question: Back board, input is around 23.8-24VDC, after the bridge I get about 23.3VDC so far so good, but at C8/C11 (just before lm2675 input) I get 22VDC, so we have 2x P-N junction drop, looked at the protection circuit with my half-dead brain, and somehow I think that it shouldn't do anything while Vin is below 36VDC, so my question is am I wrong or do I have issues in my board?

Thank you!
Title: Re: Really universal soldering controller
Post by: sparkybg on April 27, 2016, 09:32:25 pm
[quote author="Iwanushka"]
we can always use transformer with two secondaries
[/quote]
And it's voltage will again drop down when another secondary is in use.

[quote author="Iwanushka"]
Back board, input is around 23.8-24VDC, after the bridge I get about 23.3VDC so far so good, but at C8/C11 (just before lm2675 input) I get 22VDC, so we have 2x P-N junction drop, looked at the protection circuit with my half-dead brain, and somehow I think that it shouldn't do anything while Vin is below 36VDC, so my question is am I wrong or do I have issues in my board?
[/quote]

This is quite normal. It is not a protection circuit, but  linear preregulator when the input is higher than 36 volts. But you still have one base-emitter and one diode drop even when it is under 36 volts, so this is completely normal and your board is OK.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 27, 2016, 10:16:12 pm
[quote author="protons"]Hi,
some one can give voltage levels in pins A1/VDD(Q14 drain) and A3/VDD(Q16 drain) when OLED module is take out from main PCB.
I have change two oleds because not get information on oled when power on.[/quote]

Check your OLED's datasheet some require 9V supply and some require 12V, OLED board provides 12.3V supply, if your OLED is 9V it might be damaged, and for 9V you can replace R68 with 4.7K and R66 with 30K which will give 9.08V supply for OLED, which should be safe. Or you can keep R66 at 27K and replace R68 with 4.3K which will give 8.95V
Title: Re: Really universal soldering controller
Post by: overheater on April 27, 2016, 11:07:32 pm
Hello Sparky,

I have ordered and got nearly all of the parts, except the IPD053N08. Digikey says: out of stock and end of life.

Unfortunately they didn't send an information before shipping nor they sent an replacement.
So I'm trying to get another Fet - but which one?
I red an old answer to this question but how close should the needed values be at the original?
I figured out for example the IRF 3205S:
http://www.reichelt.de/IRF-3205S/3/inde ... H=irf3205s (http://www.reichelt.de/IRF-3205S/3/index.html?&ACTION=3&LA=446&ARTICLE=41602&artnr=IRF+3205S&SEARCH=irf3205s)

and the IRF1404S:
http://www.reichelt.de/IRF-1404S/3/inde ... H=irf1404s (http://www.reichelt.de/IRF-1404S/3/index.html?&ACTION=3&LA=446&ARTICLE=41599&artnr=IRF+1404S&SEARCH=irf1404s)

Sparky, would you please have a look at these if I cold take one of them as replacement
They have data-sheets there if needed.

many thanks for the project 

Klaus
Title: Re: Really universal soldering controller
Post by: sparkybg on April 27, 2016, 11:38:11 pm
[quote author="overheater"]
I figured out for example the IRF 3205S:
http://www.reichelt.de/IRF-3205S/3/inde ... H=irf3205s (http://www.reichelt.de/IRF-3205S/3/index.html?&ACTION=3&LA=446&ARTICLE=41602&artnr=IRF+3205S&SEARCH=irf3205s)
[/quote]
Too low voltage. You need at least 75V part, if you are using 24V transfomer for power supply, which, as I stated before, is the best possible power source for this controller.

[quote author="overheater"]
and the IRF1404S:
http://www.reichelt.de/IRF-1404S/3/inde ... H=irf1404s (http://www.reichelt.de/IRF-1404S/3/index.html?&ACTION=3&LA=446&ARTICLE=41599&artnr=IRF+1404S&SEARCH=irf1404s)
[/quote]
Same here.

MOUSER has plenty of IPD053N08 in stock. Farnell has it too.

The important features are 75V Vds minimum and around 0.01ohm resistance, or lower. Higher resistance alternatives such as IRF2807S may also work, but I cannot tell how warm will they get.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 28, 2016, 12:29:44 am
[quote author="overheater"]Hello Sparky,

I have ordered and got nearly all of the parts, except the IPD053N08. Digikey says: out of stock and end of life.

Unfortunately they didn't send an information before shipping nor they sent an replacement.
So I'm trying to get another Fet - but which one?
I red an old answer to this question but how close should the needed values be at the original?
I figured out for example the IRF 3205S:
http://www.reichelt.de/IRF-3205S/3/inde ... H=irf3205s (http://www.reichelt.de/IRF-3205S/3/index.html?&ACTION=3&LA=446&ARTICLE=41602&artnr=IRF+3205S&SEARCH=irf3205s)

and the IRF1404S:
http://www.reichelt.de/IRF-1404S/3/inde ... H=irf1404s (http://www.reichelt.de/IRF-1404S/3/index.html?&ACTION=3&LA=446&ARTICLE=41599&artnr=IRF+1404S&SEARCH=irf1404s)

Sparky, would you please have a look at these if I cold take one of them as replacement
They have data-sheets there if needed.

many thanks for the project 

Klaus[/quote]
Hi,

http://uk.rs-online.com/web/p/mosfet-tr ... s/8259437/ (http://uk.rs-online.com/web/p/mosfet-transistors/8259437/)
http://uk.farnell.com/infineon/ipd053n0 ... dp/1775574 (http://uk.farnell.com/infineon/ipd053n08n3-g/mosfet-n-ch-90a-80v-pg-to252-3/dp/1775574)
http://eu.mouser.com/ProductDetail/Infi ... fSfw%3d%3d (http://eu.mouser.com/ProductDetail/Infineon-Technologies/IPD053N08N3GATMA1/?qs=sGAEpiMZZMshyDBzk1%2fWiwkux6%252b2oWnVaIhXzUTrDES14%2fglMb%2fSfw%3d%3d)
Title: Re: Really universal soldering controller
Post by: MadBekon on April 28, 2016, 12:31:14 am
It says "heater short circuit" at the beginning of heating. After while it's gone and temperature ramps up without any problem.
Handle is JBC T245 supplied from 150W 24V Indel trafo.
[quote author="sparkybg"]
What handle and what power supply are you using? Does it show "heater short circuit", or "sensor short circuit", and for how much time does it show it?

Do you have earth connection or not?[/quote]
Title: Re: Really universal soldering controller
Post by: dumitruv on April 28, 2016, 12:48:36 am
[quote author="sparkybg"][quote author="overheater"]
I figured out for example the IRF 3205S:
http://www.reichelt.de/IRF-3205S/3/inde ... H=irf3205s (http://www.reichelt.de/IRF-3205S/3/index.html?&ACTION=3&LA=446&ARTICLE=41602&artnr=IRF+3205S&SEARCH=irf3205s)
[/quote]
Too low voltage. You need at least 75V part, if you are using 24V transfomer for power supply, which, as I stated before, is the best possible power source for this controller.

[quote author="overheater"]
and the IRF1404S:
http://www.reichelt.de/IRF-1404S/3/inde ... H=irf1404s (http://www.reichelt.de/IRF-1404S/3/index.html?&ACTION=3&LA=446&ARTICLE=41599&artnr=IRF+1404S&SEARCH=irf1404s)
[/quote]
Same here.

MOUSER has plenty of IPD053N08 in stock. Farnell has it too.

The important features are 75V Vds minimum and around 0.01ohm resistance, or lower. Higher resistance alternatives such as IRF2807S may also work, but I cannot tell how warm will they get.[/quote]

I used IPD068N10N3.
Title: Re: Really universal soldering controller
Post by: protons on April 28, 2016, 10:26:18 am
Sparybg, Iwanushka thanks for help, now i get 12V for Oled VCC.
Anyway program PIC32 firmware - standalone and turning on the station nothing on the screen.
When I programs PIC32 with bootloader firmware file then power on in Oled appears cubes (see picture).
This means that my screen work and the fault lies somewhere else.
What could be the problem.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 28, 2016, 10:41:34 am
Maybe you are using wrong firmware.

Program it with "softwarefrontUS_Firmware.XdistPIC32_StandaloneproductionUS_Firmware.X.production.hex" as provided in the "rar". Don't recompile it.

The cubes shows that you are in "bootloader" mode, so it is normal. It stays there if no firmware is uploaded with bootloader.

...and, look at datasheet of your display if it wants 9 ot 12V and change the feedback resistors if needed. My blue display wants 9V and my Yellow display wants 12V.
Title: Re: Really universal soldering controller
Post by: overheater on April 28, 2016, 12:03:22 pm
Hello Sparky,

thank you for your quick answer. Please help me again with the reason for this high voltage. Behind the bridge rectifier I  would expect a voltage about 37 volts if the transformer - and sure I will take one - has 26 volts with no load.  Or are there inductance spike when switching off?
Where is the mistake I make?
Title: Re: Really universal soldering controller
Post by: sparkybg on April 28, 2016, 12:30:47 pm
Where exactly is "behind the bridge"? Pay attention - there is not a filter capacitor directly behind the bridge, so the voltage there should be half sinusoide with 5V plateau.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 28, 2016, 03:33:48 pm
[quote author="protons"]Sparybg, Iwanushka thanks for help, now i get 12V for Oled VCC.
Anyway program PIC32 firmware - standalone and turning on the station nothing on the screen.
When I programs PIC32 with bootloader firmware file then power on in Oled appears cubes (see picture).
This means that my screen work and the fault lies somewhere else.
What could be the problem.[/quote]

Hi,

could you post here or pm me with a link to the oled you bought?
Title: Re: Really universal soldering controller
Post by: sparkybg on April 28, 2016, 08:09:08 pm
[quote author="Iwanushka"]

Hi,

could you post here or pm me with a link to the oled you bought?[/quote]

http://www.texim-europe.com/product/WEO ... N00000-WSR (http://www.texim-europe.com/product/WEO012864DBPP3N00000-WSR)
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 28, 2016, 08:17:11 pm
[quote author="sparkybg"]
http://www.texim-europe.com/product/WEO ... N00000-WSR (http://www.texim-europe.com/product/WEO012864DBPP3N00000-WSR)[/quote]

This one is out of stock
Title: Re: Really universal soldering controller
Post by: sparkybg on April 28, 2016, 09:10:19 pm
[quote author="Iwanushka"][quote author="sparkybg"]
http://www.texim-europe.com/product/WEO ... N00000-WSR (http://www.texim-europe.com/product/WEO012864DBPP3N00000-WSR)[/quote]

This one is out of stock[/quote]

They were not in stock when I bought them. We ordered around 70pcs, if I remember well and they arrived a month or so after we paid for them.

Any 128x64 OLED with SSD1306 will work. Ebay is another source, but mostly they are made by different manufacturers and with considerably shorter lifespan.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 28, 2016, 10:32:50 pm
[quote author="sparkybg"][quote author="Iwanushka"][quote author="sparkybg"]
http://www.texim-europe.com/product/WEO ... N00000-WSR (http://www.texim-europe.com/product/WEO012864DBPP3N00000-WSR)[/quote]

This one is out of stock[/quote]

They were not in stock when I bought them. We ordered around 70pcs, if I remember well and they arrived a month or so after we paid for them.

Any 128x64 OLED with SSD1306 will work. Ebay is another source, but mostly they are made by different manufacturers and with considerably shorter lifespan.[/quote]

Sparkybg,

I've bought this one http://www.ebay.com/itm/0-96-I2C-IIC-SP ... Swv0tVeD0N (http://www.ebay.com/itm/0-96-I2C-IIC-SPI-Serial-128X64-White-OLED-LCD-LED-Display-Module-for-Arduino-/201428440360?hash=item2ee6121528:g:MOYAAOSwv0tVeD0N)

It comes with I2C, I hope they did not butcher the controller and it has SPI interface, so it would be handy to have ebay link with known to work OLED just in case :)

Note: assembled OLEDs on ebay are 1/2 price of OLED screen itself...
Title: Re: Really universal soldering controller
Post by: afedorov on April 28, 2016, 10:55:35 pm
[quote author="Iwanushka"]Note: assembled OLEDs on ebay are 1/2 price of OLED screen itself...[/quote]
I'm using the same approach. Hope mine will work. The bad thing is the quality and absence of any documentation to display itself.
BTW what are the symptoms of low VCC to the display - is it dim, low contrast or information isn't visible at all?
Title: Re: Really universal soldering controller
Post by: MadBekon on April 28, 2016, 11:05:08 pm
I used OLED from aliexpress.
Works just fine. Good brightness and contrast. 4 USD.
Just too small.
2 inch would be nicer.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 28, 2016, 11:32:23 pm
[quote author="MadBekon"]I used OLED from aliexpress.
Works just fine. Good brightness and contrast. 4 USD.
Just too small.
2 inch would be nicer.[/quote]

Later on I'm planning to hook up 4.3" LCD to this thing :)
Title: Re: Really universal soldering controller
Post by: sparkybg on April 28, 2016, 11:32:40 pm
Sure. Here it is:
http://www.ebay.com/itm/0-96-128x64-OLE ... 0751769678 (http://www.ebay.com/itm/0-96-128x64-OLED-Display-SSD1306-White-Color-/130751769678)

and another one:
http://www.ebay.com/itm/0-96-inch-30-Pi ... xyE-dRyW3N (http://www.ebay.com/itm/0-96-inch-30-Pins-128x64-OLED-LED-LCD-Display-Module-White-/151197646369?hash=item233414fe21:g:awkAAOxyE-dRyW3N)

Aliexpress:
http://www.aliexpress.com/item/0-96-inc ... .81.dZyiAK (http://www.aliexpress.com/item/0-96-inch-30PIN-8Bit-Blue-OLED-Display-Screen-SSD1306-Drive-IC-128-64-SPI-I2C/32554788444.html?spm=2114.40010508.4.81.dZyiAK)

Most of these are made by Univision, and the model is UG-2864HSWEG01 - datasheet is available - just search for it in google.
For example: https://cdn-shop.adafruit.com/datasheet ... SWEG01.pdf (https://cdn-shop.adafruit.com/datasheets/UG-2864HSWEG01.pdf)

I don't remember the seller I bought my first one from. But it was eBay, and it was white, and it required 9V instead of 12. And it was sold as a pair, for around USD10.

There are 2 inch displays with SSD1306, but you will have to make another PCB for it - the pinout spacing is different.
Title: Re: Really universal soldering controller
Post by: overheater on April 28, 2016, 11:37:22 pm
[quote author="sparkybg"]Where exactly is "behind the bridge"? [/quote]

Hi,

directly behind the bridge, lets say at the TVS1-Diode.

If I have 230V AC I get 26V TrueRms after the transformer  (without load) that are about 73V AC PkPk Sinus. After the rectifier I get round 36V (half sinus with 100Hz)

If there are 10 % over voltage (253V) it reads 29V after the transformer, 79V PkPk and 39V  (100Hz)

Quote
so the voltage there should be half sinusoide with 5V plateau.

In the moment I do not know, what you mean with 5V Plateau?
Title: Re: Really universal soldering controller
Post by: Wolfram on April 28, 2016, 11:38:24 pm
[quote author="MadBekon"]I used OLED from aliexpress.
Works just fine. Good brightness and contrast. 4 USD.
Just too small.
2 inch would be nicer.[/quote]
http://https://www.youtube.com/watch?v=maHOO12lgTg
Title: Re: Really universal soldering controller
Post by: sparkybg on April 28, 2016, 11:41:25 pm
[quote author="Iwanushka"]
I've bought this one http://www.ebay.com/itm/0-96-I2C-IIC-SP ... Swv0tVeD0N (http://www.ebay.com/itm/0-96-I2C-IIC-SPI-Serial-128X64-White-OLED-LCD-LED-Display-Module-for-Arduino-/201428440360?hash=item2ee6121528:g:MOYAAOSwv0tVeD0N)
[/quote]

It will be OK. Univision display with SSD1306 has SPI for sure.
Title: Re: Really universal soldering controller
Post by: overheater on April 28, 2016, 11:44:55 pm
I measured this values at the Indel transformer 2x12V 150VA and it is possible to send photos.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 28, 2016, 11:51:42 pm
[quote author="overheater"]
Hi,
directly behind the bridge, lets say at the TVS1-Diode.
If I have 230V AC I get 26V TrueRms after the transformer  (without load) that are about 73V AC PkPk Sinus. After the rectifier I get round 36V (half sinus with 100Hz)
If there are 10 % over voltage (253V) it reads 29V after the transformer, 79V PkPk and 39V  (100Hz)
[/quote]
It should be like that. Again - there is not a filter capacitor behind the bridge, so you must have half sinus there.

[quote author="overheater"]
In the moment I do not know, what you mean with 5V Plateau?[/quote]

Excise my english. There should be around 5V valley, not plateau.

It should be more or less like this, without load on the controller - just the valley should be a bit higher:
[attachment=0]

From what you wrote, your PCB looks OK in this respect.
Title: Re: Really universal soldering controller
Post by: overheater on April 28, 2016, 11:57:59 pm
Ok - thank you. But when we get a max. voltage about 40 Volts here, why 75 volts for the FET?
Title: Re: Really universal soldering controller
Post by: sparkybg on April 29, 2016, 12:31:22 am
[quote author="overheater"]Ok - thank you. But when we get a max. voltage about 40 Volts here, why 75 volts for the FET?[/quote]

Because 24V nominal means 34V peak. When transformer has no load on it, it can easily go up to 10% and even more, so it becomes 37. Now, put another 20% for mains variations, and you get 45V. Put some possible peaks here and there, and you get 50 volts. The TVS is 60V, and the transistors are 75 - you have to have some safety margin.
Title: Re: Really universal soldering controller
Post by: overheater on April 29, 2016, 02:59:48 am
Ok Sparky,

thank you for your patience!

Quote
you have to have some safety margin.

It's good to know that this is the reason......and not some other technical  causes I didn't understand.

The only problem is, to order two single Fets from Mouser, Farnell, etc.  I have a order for Reichelt - thats the reason, I ask for the two Fets in the beginning. But it seems that they don't have anything with higher voltages in the needed package.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 29, 2016, 11:51:29 am
[quote author="overheater"]Ok Sparky,

thank you for your patience!

Quote
you have to have some safety margin.

It's good to know that this is the reason......and not some other technical  causes I didn't understand.

The only problem is, to order two single Fets from Mouser, Farnell, etc.  I have a order for Reichelt - thats the reason, I ask for the two Fets in the beginning. But it seems that they don't have anything with higher voltages in the needed package.[/quote]

TME has AUIRFR3607, IPD12CN10NGATMA1. Shipping to Bulgaria is 7EUR, no matter what the price of the order is.

Don't you have another distributor? I also like buying pars from a local one, but they rarely have everything I need in my projects. I also have local representatives of Farnell, Mouser, Digikey. It is a matter of one week to order anything from these. In Deutchland must be even easier I think.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 29, 2016, 07:06:03 pm
Sparkybg,

Which TVS you would recommend? Had a few 1.5KE68A so used them, but maybe better to use 1.5KE62A or 1.5KE56A

http://lt.farnell.com/webapp/wcs/stores ... reId=10167 (http://lt.farnell.com/webapp/wcs/stores/servlet/ProductDisplay?catalogId=15001&langId=370&urlRequestType=Base&partNumber=9885102&storeId=10167)

http://lt.farnell.com/stmicroelectronic ... dp/9801162 (http://lt.farnell.com/stmicroelectronics/1-5ke62a/diode-tvs-62v-1500w/dp/9801162)

http://lt.farnell.com/stmicroelectronic ... dp/9885099 (http://lt.farnell.com/stmicroelectronics/1-5ke56a/diode-tvs-56v-1-5kw/dp/9885099)
Title: Re: Really universal soldering controller
Post by: sparkybg on April 29, 2016, 07:26:01 pm
If your MOSFETs are 80V, any of these is OK. However, I would use 62 or 56.
Title: Re: Really universal soldering controller
Post by: Iwanushka on April 29, 2016, 07:43:35 pm
[quote author="sparkybg"]If your MOSFETs are 80V, any of these is OK. However, I would use 62 or 56.[/quote]

I think FETs are 75V, at the moment plan is to run it from LAB psu until I get cores to make transformer for it.
Title: Re: Really universal soldering controller
Post by: dumitruv on April 30, 2016, 02:03:27 pm
[quote author="sparkybg"][quote author="dumitruv"]I used LM2674-3.3V instead of LM2675 with 220uH and it works well. I just found it in my monkey box and I decided to give it a try and it seem to work well.

Sparky,
Is there a reason behind using a 1A IC instead of a 500mA one? It is 2$ cheaper.[/quote]

I didn't had an estimate of the final current consumption, so I decided to use 1A version. And it gets a little warm after a hour or so. So I suspect the 0.5A version will get a bit warmer. I don't like a warm parts on my devices. If you look at the power mosfets and the shunt resistor, they are pretty overspecified also. In fact the warmest parts are the rectifier diodes when there's a heavy load on C245 tips. Maybe around 50-55 degrees Celsius. But his happens when I submerge the tip in a pot of cold isopropyl alcohol. This measn full 140 watts for 10 seconds or so...


...and I bought these from a local distributor. 2674 is 1.74USD and 2675 is 2.14USD, so the difference here is only 0.4USD, and if I buy 5pcs, the difference becomes 0.3USD.

Moreover, on farnell's site 2675 is 2.86EUR and 2674 is 3.29EUR - the 1A part is cheaper than 0.5A part.

So it seems it is a reseller-dependant issue.[/quote]

AT Digikey 2674 is CAD 4.12 vs CAD 6.1 2675 ( 2.95 vs 4.37 in USD). What a rip-off...2 X compared to your local distributor...plus 13% tax. I wonder what mark-up these guys have. And I bet your distributor makes profit too. Some times I wonder if this is sucker's land.

Anyway, I measured the current on 3.3V and it is around 90 to 93mA. And 2674 is as cold as a dead raccoon after 10 min.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 30, 2016, 02:09:49 pm
Measure it after you put all the parts together. The display itself consumes more than 93mA. My 2675 gets a little warm after some time. Maybe around 40 degrees Celsius.
Title: Re: Really universal soldering controller
Post by: dumitruv on April 30, 2016, 03:56:26 pm
[quote author="sparkybg"]Measure it after you put all the parts together. The display itself consumes more than 93mA. My 2675 gets a little warm after some time. Maybe around 40 degrees Celsius.[/quote]

I did, I measured in the wire between back and front board with a T15 at 300C.
Title: Re: Really universal soldering controller
Post by: overheater on May 02, 2016, 02:12:55 pm
Hello,

so, the next one is soldered .... but unfortunately not working.

I have succeeded in flashing the Pic - so told the MPLAB.
All voltages (3,3 / -0,6 / 12 / Vref 3,000V) are present, the crystal clocks at 8 Mhz but no reaction at all. It seems that the processor is not running.

I connected an iron for testing - no reaction at all....

The complete station without iron takes 34 mA - when pushing a button 41mA from a labor-PSU. There is no change when testing with the transformer.

The  sources of Q14 and Q16 are on 3V3 the gates nearly too. Looks like the CPU likes darkness - but why?

Any idea where the search should begin?

[attachment=0]

Any tip, help, suggestion, what ever is welcome

best regards
Klaus
Title: Re: Really universal soldering controller
Post by: overheater on May 02, 2016, 02:19:17 pm
Oh, I put in a new Q14 and forgot to clean it - this is why it looks a little bit strange there......
Title: Re: Really universal soldering controller
Post by: sparkybg on May 03, 2016, 09:33:36 am
Remove Q20 and D17. These are used when a buzzer with integrated generator is used.

Then, program it with the bootloader HEX ("frontUS_BootLoader.XdistPIC32productionUS_BootLoader.X.production.hex") and tell me what happens.

Also, make a photo of the back of the board and post it here.
Title: Re: Really universal soldering controller
Post by: overheater on May 03, 2016, 11:19:38 am
Hello Sparky,

thank you for your help.

After removing of Q20 and D17 I have a constant beep when power on.

After flashing I'm in bootloader-mode (you told in a few posts ago) with the "running" squares. So the Oled works! The speaker is quiet.

Photo follows.....
Title: Re: Really universal soldering controller
Post by: overheater on May 03, 2016, 02:06:42 pm
Hello Sparky,

here the photo from the back of the board:
[attachment=0]
Title: Re: Really universal soldering controller
Post by: protons on May 03, 2016, 02:25:31 pm
Hi,
have the same situation what have "overheater":
I have succeeded in flashing the Pic - so told the MPLAB.
All voltages (3,3 / -0,6 / 12 / Vref 3,000V) are present, the crystal clocks at 8 Mhz but no reaction at all. It seems that the processor is not running.


what can be wrong in programming?
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 03, 2016, 04:15:58 pm
Got the assembled OLED from china, any ideas how OLED is attached to the PCB and easy way to remove it? I'm thinking to heat it from the PCB side and hope it will fall off, just no idea if they used some glue or double sided tape and at what places, long story short no idea what temp to use on my hot air.
Title: Re: Really universal soldering controller
Post by: Sjaak on May 03, 2016, 04:38:09 pm
[quote author="Iwanushka"]Got the assembled OLED from china, any ideas how OLED is attached to the PCB and easy way to remove it? I'm thinking to heat it from the PCB side and hope it will fall off, just no idea if they used some glue or double sided tape and at what places, long story short no idea what temp to use on my hot air.[/quote]

Set the temp to 350 degrees C and airflow to 30% of you r hotair gun. Circle around the soldered connection and it goes off pretty quick. The OLED should be ok to reuse. AFAIK no glue is used on assembly of those boards.

Done many protoboards with the same OLED :)
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 03, 2016, 04:43:24 pm
[quote author="Sjaak"][quote author="Iwanushka"]Got the assembled OLED from china, any ideas how OLED is attached to the PCB and easy way to remove it? I'm thinking to heat it from the PCB side and hope it will fall off, just no idea if they used some glue or double sided tape and at what places, long story short no idea what temp to use on my hot air.[/quote]

Set the temp to 350 degrees C and airflow to 30% of you r hotair gun. Circle around the soldered connection and it goes off pretty quick. The OLED should be ok to reuse. AFAIK no glue is used on assembly of those boards.

Done many protoboards with the same OLED :)[/quote]

Strange, my OLED is fixed to the PCB in some way...
Title: Re: Really universal soldering controller
Post by: Sjaak on May 03, 2016, 05:03:07 pm
[quote author="Iwanushka"][quote author="Sjaak"][quote author="Iwanushka"]Got the assembled OLED from china, any ideas how OLED is attached to the PCB and easy way to remove it? I'm thinking to heat it from the PCB side and hope it will fall off, just no idea if they used some glue or double sided tape and at what places, long story short no idea what temp to use on my hot air.[/quote]

Set the temp to 350 degrees C and airflow to 30% of you r hotair gun. Circle around the soldered connection and it goes off pretty quick. The OLED should be ok to reuse. AFAIK no glue is used on assembly of those boards.

Done many protoboards with the same OLED :)[/quote]

Strange, my OLED is fixed to the PCB in some way...[/quote]

two sided tape to keep the glass down? should be easy come off with some solvents.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 03, 2016, 06:33:35 pm
This will be tough...

Constant beep on power-on means that it cannot complete the initialization. I will make some changes to the firmware in order to show where exactly the problem is.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 03, 2016, 07:00:49 pm
OK, try to upload the new firmware and tell me what number it shows on the screen.
Also, remove Q15 and Q17!
Title: Re: Really universal soldering controller
Post by: overheater on May 03, 2016, 07:38:38 pm
Hello Sparky,

its 13
Title: Re: Really universal soldering controller
Post by: overheater on May 03, 2016, 08:38:04 pm
Hello Sparky,

your spontaneous reaction is outstanding!

I had removed Q15 and Q17 already this morning, just to test whether they can be missing or they must be missing.

As you see, no problem to flash the firmware and the displayed number is 13 - with a urgently beep in the background.

Please tell me that it isn't hopeless...... ;-)

with best regards
Klaus
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 03, 2016, 09:41:18 pm
sparkybg,

OLED schematic states C76 is 1nF, but in BOM C76 is 100pF, which one is correct value?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 03, 2016, 09:50:31 pm
[quote author="overheater"]Hello Sparky,

your spontaneous reaction is outstanding!

I had removed Q15 and Q17 already this morning, just to test whether they can be missing or they must be missing.

As you see, no problem to flash the firmware and the displayed number is 13 - with a urgently beep in the background.

Please tell me that it isn't hopeless...... ;-)

with best regards
Klaus[/quote]

You have I2C problem.

Please upload the new firmware (I've just upload a new one) and tell me the number again. I've added additional diagnostic steps for I2C.
Title: Re: Really universal soldering controller
Post by: protons on May 03, 2016, 10:01:57 pm
I also have Nr.13, what mean I2C problem, i need change some part on main board or  is programing problem
Title: Re: Really universal soldering controller
Post by: sparkybg on May 03, 2016, 10:03:19 pm
[quote author="Iwanushka"]sparkybg,

OLED schematic states C76 is 1nF, but in BOM C76 is 100pF, which one is correct value?[/quote]

For FAN5331 100p must be enough.

I tried several other chips in place of FAN5331, so the 1n was a capacitor for one of the other chips I've tried.

Anyway, now it is 100p on the schematics also. Thanks for mentioning it.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 03, 2016, 10:04:00 pm
[quote author="protons"]I also have Nr.13, what mean I2C problem, i need change some part on main board or  is programing problem[/quote]

Try it again and tell me the new number. I've uploaded a newer firmware 5 minutes ago.
Title: Re: Really universal soldering controller
Post by: overheater on May 03, 2016, 10:06:12 pm
Hello Sparky,

so, after downloading and flashing new it is 13 again!  (I did it two times because I didn't trust)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 03, 2016, 10:44:10 pm
[quote author="overheater"]Hello Sparky,

so, after downloading and flashing new it is 13 again!  (I did it two times because I didn't trust)[/quote]

OK then... It cannot turn on the I2C of the MCU.

You have a problem with I2C bus. It is either a short circuit to ground or to 3.3V somewhere, or a device on the bus does not behave as expected.

Take a good look at U8, U10, U11, U15, R27, R28, and the traces of the I2C bus. From my personal experience, the easiest part to fry while soldering it is the offset DAC (U11), then the gain pot (U15), then the current source pots(U10), and finally the EEPROM(U8). The DAC is the smallest one, with many small terminals, and in very small package. I fried one myself on one of the previous versions of this controller, but in the I2C bus it behaved properly - only the output was malfunctioning.

Also, before anything other, measure the VCC around any of these chips. There must not be any considerable voltage drop there.
Title: Re: Really universal soldering controller
Post by: overheater on May 03, 2016, 11:27:37 pm
Hi Sparky,

:-)))  it works! You were right!

R27 and R28 were in the wrong position (90° turned ( the silkscreen is a little tricky there - and if you don't look at the layout....))

I like to bet that protons has the same problem.

Great thing this self-debugging of the hardware.

But now - please let me have a closer look at this very nice part of engineering!
and many thanks for all!!!

best regards from Ruhrpott (Germany)

Klaus
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 03, 2016, 11:30:54 pm
[quote author="overheater"]Hi Sparky,

:-)))  it works! You were right!

R27 and R28 were in the wrong position (90° turned ( the silkscreen is a little tricky there - and if you don't look at the layout....))

I like to bet that protons has the same problem.

Great thing this self-debugging of the hardware.

But now - please let me have a closer look at this very nice part of engineering!
and many thanks for all!!!

best regards from Ruhrpott (Germany)

Klaus[/quote]

Can you please post high-quality photo of the front board, so everyone will know how it should look :)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 03, 2016, 11:41:53 pm
[quote author="Iwanushka"]
Can you please post high-quality photo of the front board, so everyone will know how it should look :)[/quote]

There's a picture in the first post:
(http://http://dangerousprototypes.com/forum/download/file.php?id=11712&mode=view)

You can view it bigger if you go to the first post and click on it.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 03, 2016, 11:52:19 pm
[quote author="sparkybg"][quote author="Iwanushka"]
Can you please post high-quality photo of the front board, so everyone will know how it should look :)[/quote]

There's a picture in the first post:

You can view it bigger if you go to the first post and click on it.[/quote]

Note for others: use WEB Browser to zoom the photo (quality will be really good, you can see where A/K goes for each diode, Windows Photo Viewer destroys the quality on zoom, you can't see a squat pixels only...
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 04, 2016, 12:00:51 am
sparkybg,

I have an idea, to help everyone to assemble all parts correctly we could use SMTAssitant software (http://www.alciom.com/en/downloads/free-downloads.html (http://www.alciom.com/en/downloads/free-downloads.html)) but for this you would need to generate pick & place files with Altium, could you share P&P files?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 04, 2016, 12:10:28 am
[quote author="Iwanushka"]sparkybg,

I have an idea, to help everyone to assemble all parts correctly we could use SMTAssitant software (http://www.alciom.com/en/downloads/free-downloads.html (http://www.alciom.com/en/downloads/free-downloads.html)) but for this you would need to generate pick & place files with Altium, could you share P&P files?[/quote]

Sure. Here it is.
[attachment=0]
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 04, 2016, 12:24:10 am
[quote author="sparkybg"][quote author="Iwanushka"]sparkybg,

I have an idea, to help everyone to assemble all parts correctly we could use SMTAssitant software (http://www.alciom.com/en/downloads/free-downloads.html (http://www.alciom.com/en/downloads/free-downloads.html)) but for this you would need to generate pick & place files with Altium, could you share P&P files?[/quote]

Sure. Here it is.
[attachment=0][/quote]

Thank you!
I will post instructions, how to set it up, just need find some free time between work and all that physiotherapy stuff.
Title: Re: Really universal soldering controller
Post by: razoramd on May 04, 2016, 12:52:10 am
If anybody have a spare boards to sell, please let me know. Thank you!
Title: Re: Really universal soldering controller
Post by: MadBekon on May 04, 2016, 05:12:51 pm
Hello Sparkybg,
Finally i assembled everything using JBC T245.
My last problem is, I get an temperature offset around 20-30 deg, comparing to termocouple measurement on the tip.
What can cause offset, is it wrong setting on potentiometer inside?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 04, 2016, 05:53:47 pm
[quote author="MadBekon"]Hello Sparkybg,
Finally i assembled everything using JBC T245.
My last problem is, I get an temperature offset around 20-30 deg, comparing to termocouple measurement on the tip.
What can cause offset, is it wrong setting on potentiometer inside?[/quote]

Did you made the calibration? What room  temperature the controller is displaying in the calibration menu?

...and, don't read the temperature with thermocouple. It loads the tip and cannot give good precision especially on smaller tips. The most precise way is to use 63/37 solder (183 degrees Celsius, eutectic) or pure lead (327.5 degrees Celsius, eutectic). Put small quantity on a well cleaned tip and look when it melts and solidifies. Do this for all the tips you are mostly using. +/-10 degrees deviation between different tips is normal. I've calculated the coefficients for all the irons I have this way, and it is as precise as it can be. The only method for better precision is to put the tip in a thermostatic oven, but again there will be a deviation from a real world, because there is always a gradient between the sensor and the tip's surface.

Also, leave the controller powered for half an hour or so, before doing any of these procedures.


P.S.: UPS! The new firmware crashes on calibration. I will see what causes this.

P.S.: Go to calibration menu only with unconnected iron for now.
Title: Re: Really universal soldering controller
Post by: MadBekon on May 04, 2016, 07:09:34 pm
Yes I did calibrate. Room temp is 25. And this is what is shown when i take out a tip from handle.
Maybe you are right with thermocouple, but I actually do feel that temp is lower that it should, comparing to settings i use at original JBC station.
Title: Re: Really universal soldering controller
Post by: overheater on May 04, 2016, 07:27:00 pm
Hello Sparky,

now my station is working. Calibration-menu was working this morning without iron.

This all is with DC. If I power it over the transformer,  there comes a 21 on the screen, then for one second the destination temperature and then "power lost" and it is booting endless.

Maybe this has something to do with this:
What I saw while powering with DC is a symbol for switch left from the "power-meter" coming up as a flash every few seconds.

Is it possible that it has to do with my very bad sinus in the AC-net:
[attachment=1]

after the rectifier it looks like this:
[attachment=0]

where shall I measure or look for other details?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 04, 2016, 07:28:49 pm
[quote author="MadBekon"]Yes I did calibrate. Room temp is 25. And this is what is shown when i take out a tip from handle.
Maybe you are right with thermocouple, but I actually do feel that temp is lower that it should, comparing to settings i use at original JBC station.[/quote]

Try it with 63/37 solder. This is the only way to be sure what the real temperature of the tip is.

Checked it again on my controller with C245 with 63/37. It melts exactly at 183 degrees.
Title: Re: Really universal soldering controller
Post by: overheater on May 04, 2016, 07:42:57 pm
Just a moment , Sparky - I think I found the mistake......
Title: Re: Really universal soldering controller
Post by: sparkybg on May 04, 2016, 07:47:44 pm
[quote author="overheater"]Hello Sparky,

now my station is working. Calibration-menu was working this morning without iron.

This all is with DC. If I power it over the transformer,  there comes a 21 on the screen, then for one second the destination temperature and then "power lost" and it is booting endless.

Maybe this has something to do with this:
What I saw while powering with DC is a symbol for switch left from the "power-meter" coming up as a flash every few seconds.

Is it possible that it has to do with my very bad sinus in the AC-net:
[attachment=1]

after the rectifier it looks like this:
[attachment=0]

where shall I measure or look for other details?[/quote]

Flashing symbol is normal. It tries to detect if there's a heater attached once per 4-5 seconds.

Showing 21 for a second or so is normal when DC power is used. It is testing the power on step 21 and decides if it is DC or AC. If it shows it on AC power for more than 0.1-0.2 seconds maybe there is a problem with comparator circuit.

1. Take oscillogram of Vin on J8-1. it should be the same as after the rectifiers.
2. Take oscillogram on VINT on one side of C60. It shoud be with flat tops around 3.2V max.
3. Take oscillogram on one side of R47. It should be the same as that on J8-1.
4. Take oscillogram on other side or R47. It again shoud look the same as Vin (J8-1), but with lower amplitude.
Title: Re: Really universal soldering controller
Post by: sebior on May 04, 2016, 09:44:20 pm
Hi, sparkybg. I have a problem with calibration. I soldered 10 ohm resistor between  SENSEA  and Vout1- and adjust the calibration trimmer. But there is almost no reaction. The ADC: and R: change their values just a bit. Here is a few measurements:

 U18. Pin 1,2,3 = 0 V. Pin 4 = -0.68 V. Pin 5,6,7 = 0 V. Pin 8 = 3.28 V
 
 U13. Pin 1,2,3 = 0 V. Pin 4 = -0.68 V. Pin 5,6,7 = 0 V. Pin 8 = 3.28 V

 U16. pin 1 = short pulses about 3 volts. Pin 2,3,4 = 0 V. Pin 5 = -0,68 V. Pin 6,7,8,9,10 = 0 V. Pin 11 = 3,25 V. Pin 12,13,14,15 = 0 V. Pin 16 = 3,28 V. Pin 17,18,19 = 20 V. Pin 20 = 3,25 V.

Please help me localise the problem.

P.S. I apologise for my poor google english.

regards
Title: Re: Really universal soldering controller
Post by: sparkybg on May 04, 2016, 10:39:39 pm
Remove the resistor and measure what current flows between SENSEA and Vout1-. It should be around 383uA. It if is not, you have a problem with current source (U10-9 should be around Vcc-0.625V, U12A, Q21, Q22, D19).

If it is 383uA, remove the resistor and the ADC should be 1023. It it is not, you have a problem on the signal path from SenseA to the MCU (either short circuit to ground or defective chip). Measure the voltage on U15-5 - if it is a little below 3.3V, the problem is with U15, U17, U11 or around them. If it is close to GND, the problem is U16, U18, U13A or around them somewhere.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 05, 2016, 12:00:58 am
I've uploaded a new firmware:
- Calibration menu does not crash when iron is attached
- Several bugfixes on iron detection.
Title: Re: Really universal soldering controller
Post by: overheater on May 05, 2016, 12:54:29 am
Since 19:15 yesterday evening it behaves like the solder-station I had seen in the video in the beginning.

It works with AC like a charm. All I can test and try is working as it was intended to.

Double thumbs up for Sparky!

At least I had three times the same mistake: the wrong position of two components 90° turned. I misunderstood the silkscreen.

My recommendation: take a photo or a placement-print for control during soldering.

I will tell you which parts it were in a next post

regards
Klaus
Title: Re: Really universal soldering controller
Post by: sparkybg on May 05, 2016, 11:46:49 am
Sebior, excuse me but I made a little mistake in the explanation - you should have a sort spikes on U15-5 (50 ot 100 per second) with the given voltage, not a constant voltage. The same pulses should be present at the MCU's ADC input.
Title: Re: Really universal soldering controller
Post by: MadBekon on May 05, 2016, 12:31:05 pm
I did a test. Connected to DC power supply, set 21V DC.
When the heating is fully on, station shows 78W, and DC power supply show consumption around 150W.
Any idea why is that so?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 05, 2016, 01:59:30 pm
[quote author="MadBekon"]I did a test. Connected to DC power supply, set 21V DC.
When the heating is fully on, station shows 78W, and DC power supply show consumption around 150W.
Any idea why is that so?[/quote]

150W is the peak consumption of single mains period. Mains period is emulated when on DC supply, so it powers on the iron every time the indicator shows. Perhaps your meter shows this. Put a shunt and make oscillogram of the consumption. You will see.

What iron are you using? JBC C245?
Title: Re: Really universal soldering controller
Post by: MadBekon on May 05, 2016, 02:53:30 pm
I use C245, big 30mm flat one.
I put it to a glass of water to force full power, so the reading below are constantly seen.

After placing RMS fluke in series I get a 6.4A of current while constant load, Voltage around 20V, so total power for sure should be more that 70W shown on screen.
Oh and I'm connected behind bridge, so no loss on rectifing diodes.

Cartrigde connected directly to the 21V DC drains 7.6A, showing around 160W consumption.

[attachment=2]
[attachment=1]
[attachment=0]
Title: Re: Really universal soldering controller
Post by: afedorov on May 05, 2016, 05:03:42 pm
MadBekon, do you have a histogram to IR image? just curious what actual temperatures there are.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 05, 2016, 08:02:53 pm
[quote author="MadBekon"]I use C245, big 30mm flat one.
I put it to a glass of water to force full power, so the reading below are constantly seen.

After placing RMS fluke in series I get a 6.4A of current while constant load, Voltage around 20V, so total power for sure should be more that 70W shown on screen.
Oh and I'm connected behind bridge, so no loss on rectifing diodes.

Cartrigde connected directly to the 21V DC drains 7.6A, showing around 160W consumption.
[/quote]

Hmmm, what is the resistence of Rs1, R37, R38, R42 and R48?

Is it showing the same 70W while AC powered?
Title: Re: Really universal soldering controller
Post by: sebior on May 05, 2016, 10:38:48 pm
[quote author="sparkybg"]Sebior, excuse me but I made a little mistake in the explanation - you should have a sort spikes on U15-5 (50 ot 100 per second) with the given voltage, not a constant voltage. The same pulses should be present at the MCU's ADC input.[/quote]
 

Thank you for explanation. I solved the problem. It was my fail. I got that problem because programmed firmware with PicKit2 with modified PK2DeviceFile.dat file.  I reflashed MCU with pic32prog.exe utility and it working fine.
Title: Re: Really universal soldering controller
Post by: overheater on May 05, 2016, 11:05:12 pm
Hello,
I have no problem but an idea for operating the station:
during the first power up of my station I wanted to minimize the risk of overheating the iron and pull the temperature down. So I pushed the left button and was surprised that the temperature went higher.

Will say, I normally expect the down button on the left side (like the volume down on every TV remote), also because I have a few devices that have the down on the left side.

So my idea is to make these two buttons changeable with a additional  menu-item.

The first question goes to Sparky, if you would expand the menu with this item if there are some people interested in?
And the second question goes to all: are there some people who would like the up-button on the right side?
Title: Re: Really universal soldering controller
Post by: dumitruv on May 06, 2016, 01:08:22 am
[quote author="overheater"]Hello,
I have no problem but an idea for operating the station:
during the first power up of my station I wanted to minimize the risk of overheating the iron and pull the temperature down. So I pushed the left button and was surprised that the temperature went higher.

Will say, I normally expect the down button on the left side (like the volume down on every TV remote), also because I have a few devices that have the down on the left side.

So my idea is to make these two buttons changeable with a additional  menu-item.

The first question goes to Sparky, if you would expand the menu with this item if there are some people interested in?
And the second question goes to all: are there some people who would like the up-button on the right side?[/quote]

Swap B1 and B3 in the software (PIC32MX534F064H.h), recompile and you should get exactly that. This feature is preference/box dependent and for Sparky's box wouldn't work.
Title: Re: Really universal soldering controller
Post by: overheater on May 06, 2016, 01:50:27 am
Thank you  dumitruv,

that would be a solution - if I find this in the code and the recompiling works flawless. (unfortunately I'm not the freak in programming - my thing is hardware, layouts and mechanic)

Quote
This feature is preference/box dependent and for Sparky's box wouldn't work.

In that point I'm with you - thats the reason why I suggested a menu - item to change it. Then you could change it  how you like.
But surely I understand: I like the button on the right side, the next one likes it on the left and the third one wants the middle button on the side..... Then we have 100 new menu-items.

regards
Title: Re: Really universal soldering controller
Post by: overheater on May 06, 2016, 02:22:25 am
Hello,

another question: how do I setup or start the PC-software and make a connection to the soldering station? I didn't find it in the complete tread, or I had "tomatoes on the eyes" - we say in Germany. So, if there is a place, please put a link or a date when it was posted.

thank you
Klaus
Title: Re: Really universal soldering controller
Post by: sparkybg on May 06, 2016, 02:37:42 am
You will have to compile it. And for this, you will have to download Visual Studio 2015 Community edition. I will upload compiled version soon.
Title: Re: Really universal soldering controller
Post by: MRBadGuy on May 06, 2016, 08:37:51 am
Guys i have a dumbass question for you.
Im beginner in radio-electronics stuff; & Im willing to ask you this :
What i must to solder before of all on the board ?
Im scared to blow -up my mcu by ESD,so which order for soldering of components i need to following ?
Thanks :)
Title: Re: Really universal soldering controller
Post by: MadBekon on May 06, 2016, 09:56:14 am
[quote author="sparkybg"][quote author="MadBekon"]I use C245, big 30mm flat one.
I put it to a glass of water to force full power, so the reading below are constantly seen.

After placing RMS fluke in series I get a 6.4A of current while constant load, Voltage around 20V, so total power for sure should be more that 70W shown on screen.
Oh and I'm connected behind bridge, so no loss on rectifing diodes.

Cartrigde connected directly to the 21V DC drains 7.6A, showing around 160W consumption.
[/quote]

Hmmm, what is the resistence of Rs1, R37, R38, R42 and R48?

Is it showing the same 70W while AC powered?[/quote]

Hi Sparkybg,
Rs1 0.03, R37,R42 - 1.5K, R38,48 - 47K all 0.1% Just confirmed it again and checked for shorts, seems OK.
On AC it shows a bit more, around 80W on full power (dipped in glass of water)

@afedorov, While normal soldering those go maybe warm. If you dip a tip into glass of water, they go pretty fast to around 80degree as far as I remember. Don't have histogram for this one, maybe later will do some more stess tests.

Also I did some termocouple / tip testing :

[attachment=1]
[attachment=0]

Oh, and +1 from me to make swap buttons functionality. I have buttons in vertical, and it feels bit funny when i have to press up to go down in menu. Sure I can compile it myself, but I'm sure there is more people facing this issue, maybe it's worth putting it in official.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 06, 2016, 12:33:40 pm
Measure the VSHUNT voltage (on C59 or on U5-12) while on full power. Also, measure the Vref voltage on C42, C43, C44.

The shunt resistane and the current amplifier resistors are correct so when tip current is 6A it should give around 0.564V on VSHUNT.

Also, you are using huge tip that has pretty large thermal losses and gradient between the sensor and tip's "tip". Use more "common" and smaller tip, for example C245-939 or C245-102. These large tips will always be cooler.

I can easily correct the coefficients for it, but when you use smaller tips they will be hotter than the temperature of the display.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 06, 2016, 10:44:03 pm
[quote author="MRBadGuy"]Guys i have a dumbass question for you.
Im beginner in radio-electronics stuff; & Im willing to ask you this :
What i must to solder before of all on the board ?
Im scared to blow -up my mcu by ESD,so which order for soldering of components i need to following ?
Thanks :)[/quote]

Usually I am soldering the MCU first, then the filter capacitors around it. Then - it depends on component placement.
Title: Re: Really universal soldering controller
Post by: MRBadGuy on May 06, 2016, 11:44:31 pm
bullshit and junk ,please delete this my post.
Thanks.
Title: Re: Really universal soldering controller
Post by: MadBekon on May 06, 2016, 11:50:00 pm
It's not sooooo fragile. No worries. Just don't wear wool, or anything that causes you get charges, and will be fine.
Title: Re: Really universal soldering controller
Post by: MRBadGuy on May 06, 2016, 11:55:49 pm
junk ,delete this .
Title: Re: Really universal soldering controller
Post by: tto4ka on May 08, 2016, 11:40:31 am
Hi guys!
I have received the PCB, and full sets a component (all inclusive including all sockets) for assembly, there are also aluminum cases (cases are ready to assembly, in them all openings on the CNC machine are cut through), transformers 24v/5a and sockets on cases. Also there are completely assembled devices. For business inquiries write in PM
Title: Re: Really universal soldering controller
Post by: mitch99 on May 08, 2016, 09:00:27 pm
Hello
sparkybg thank you for a good project.
will be exploring the topic.
Title: Re: Really universal soldering controller
Post by: mitch99 on May 09, 2016, 07:47:18 am
hi Sparkybg

Prompt please connector for soldering iron that you use this GX16-8.
Thank you
Title: Re: Really universal soldering controller
Post by: MadBekon on May 09, 2016, 09:19:09 am
I believe it's this one:
http://www.tme.eu/gb/details/fc684208/m ... ors/cliff/ (http://www.tme.eu/gb/details/fc684208/microphone-connectors/cliff/)
Title: Re: Really universal soldering controller
Post by: overheater on May 09, 2016, 10:22:04 am
or this one:

http://www.reichelt.de/B-608/3/index.ht ... nbaubuchse (http://www.reichelt.de/B-608/3/index.html?&ACTION=3&LA=446&ARTICLE=4550&artnr=B+608&SEARCH=mikrofon+einbaubuchse)

look at the prices.....
Title: Re: Really universal soldering controller
Post by: mitch99 on May 09, 2016, 11:26:39 am
Thanks for the answers.
Title: Re: Really universal soldering controller
Post by: tto4ka-old on May 09, 2016, 12:39:13 pm
Hi Guys
Have hacked the account and have removed all my messages :)
There are PCB and a set a full set a component for assembly, cases and sockets, transformers 24v/5a and also assembled ready controllers.
For business inquiries write in PM. A request to those who wrote to write once again!
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 09, 2016, 09:37:50 pm
sparkybg,

maybe you want to update OLED schematic/BOM to make it easier for other guys, I suggest the following divider for FAN5331
R66 - 30k 0.1% (much easier to select divider resistors than with 27k)

R68 for 9V OLED -> 4k7 which gives Vout 9.08V

R68 for 12V OLED -> 3k4 which gives Vout 12.08V
Title: Re: Really universal soldering controller
Post by: sparkybg on May 09, 2016, 10:08:25 pm
[quote author="Iwanushka"]sparkybg,

maybe you want to update OLED schematic/BOM to make it easier for other guys, I suggest the following divider for FAN5331
R66 - 30k 0.1% (much easier to select divider resistors than with 27k)

R68 for 9V OLED -> 4k7 which gives Vout 9.08V

R68 for 12V OLED -> 3k4 which gives Vout 12.08V[/quote]

The resistors are selected in order to minimize the BOM rows. There is no need for them to be 0.1% there, but, if you look at the BOM, 27K 0.1% are used in other parts of the project.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 09, 2016, 10:21:08 pm
[quote author="tto4ka"]
For business inquiries write in PM. A request to those who wrote to write once again![/quote]

It is stated at least in 2 posts, and I will write it again:

THIS PROJECT IS FREE ONLY FOR NON-COMMERCIAL PURPOSES!!! THIS MEANS YOU CAN DO WHATEVER YOU WANT WITH IT AS LONG AS YOU ARE NOT MAKING ANY PROFIT OUT OF IT!!!

So, if you ordered these parts to be helpful to others in this thread, and if you are selling them at the same (or close enough, say 10% higher in order to justify the time you spent on this) price you bough them - be my guest. But nothing more.
Title: Re: Really universal soldering controller
Post by: overheater on May 09, 2016, 11:47:23 pm
Hello ,

I soldered the connectors to the JBC-Irons I have - C245 and C210.  It is not so easy to put in the (207) ID resistors because they easily can make a not wanted connection to the inside of the connector when mounted.

So I took 1206 straight between the solder terminals, just for testing - but with qualms.

So my question, if someone has some experiences with these resistors in SMD. I fear that they could break due to the force while plugging in or out .....

Sparky, please tell us your recommendation - you must have a good bunch of connectors......
Title: Re: Really universal soldering controller
Post by: MRBadGuy on May 10, 2016, 12:20:49 am
[quote author="overheater"]Hello ,
I soldered the connectors to the JBC-Irons I have - C245 and C210.  It is not so easy to put in the (207) ID resistors because they easily can make a not wanted connection to the inside of the connector when mounted.
[/quote]
post a pics about it ,pls
Title: Re: Really universal soldering controller
Post by: sparkybg on May 10, 2016, 12:33:30 am
[quote author="overheater"]
Sparky, please tell us your recommendation - you must have a good bunch of connectors......[/quote]

I am using the smallest (I think 1/8 watt) trough-hole resistors. These are smaller than 1206 SMD and have ready to solder terminals. I never had any problems so far. They even fit between connector terminals.
Title: Re: Really universal soldering controller
Post by: overheater on May 10, 2016, 12:50:56 am
Oh, excuse me, I made a photo, but forget to load it....

[attachment=0]

but the light is not so good.

Yes, Sparky, I had the idea to use them after realizing that the 207 are a little bit big. I will try to get  some of these....

Or - the SMD 1206 are strong enough. Maybe someone used them too?
Title: Re: Really universal soldering controller
Post by: overheater on May 10, 2016, 12:54:18 am
Or, give the 1206 some help with hot glue. I think that will work - but it is not the "fine" way.....
Title: Re: Really universal soldering controller
Post by: ppsati on May 10, 2016, 01:41:29 am
Hi,sparkybg.
It will be possible to use this OLED display?

1.3" SPI Serial 128X64 OLED LCD
 
High resolution: 128 * 64
Viewing angle:> 160 °
Supports many control chip: Fully compatible with Arduino, 51 Series, MSP430 Series, STM32 / 2, CSR IC, etc.
Ultra-low power consumption: full screen lit 0.08W
Voltage: 3V ~ 5V DC
Working Temperature: -30ºC  ~ 70ºC
Module Size: 35.4mm x 33.5mm
I2C/IIC Interface, need 2 IO only.
Driver IC: Sh1106
[attachment=0]
Display link: http://www.ebay.com/itm/1-3-SPI-Serial- ... SwxvxW775w (http://www.ebay.com/itm/1-3-SPI-Serial-128X64-OLED-LCD-Display-Screen-Module-For-Arduino-UNO-R3-51-/172141505278?hash=item28146eeafe:g:G20AAOSwxvxW775w)

Datasheet IC: Sh1106 link: http://www.displayfuture.com/Display/da ... SH1106.pdf (http://www.displayfuture.com/Display/datasheet/controller/SH1106.pdf)
This link is much better...

Best Regards,
Title: Re: Really universal soldering controller
Post by: sparkybg on May 10, 2016, 09:07:01 am
[quote author="ppsati"]Hi,sparkybg.
It will be possible to use this OLED display?
[/quote]

You may try, but I am sceptical about it. It has different resolution. You will have to at least change the init routine, even if the controller and pins are compatible with ssd1306, which I don't know.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 10, 2016, 09:08:49 am
[quote author="overheater"]Or, give the 1206 some help with hot glue. I think that will work - but it is not the "fine" way.....[/quote]

Hot glue will give you nothing. The problem is that the resistors are not flexible. And the hot glue will not make them flexible.
Title: Re: Really universal soldering controller
Post by: Sjaak on May 10, 2016, 11:45:36 am
I removed some posts in this topic. We don't discrimate overhere nor do assumptions about people based on regions.

I choose to let the post here of tto4ka. I see it as a service he bought stuff and assembled the kit for other who can't do it.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 10, 2016, 12:02:56 pm
[quote author="Sjaak"]I removed some posts in this topic. We don't discrimate overhere nor do assumptions about people based on regions.

I choose to let the post here of tto4ka. I see it as a service he bought stuff and assembled the kit for other who can't do it.[/quote]

He talks about business inquiries. This is pretty far from my definition of "support".

I will gladly encourage anyone to help others build this project more easily, but as I see it, this is not a case.
In fact, if he just asked for permission prior doing this, with clear enough conditions and prices, I would probably grant it. But the way he done it I take as a dishonor of my work and will to share.

If you intend letting other's make business from my project without my permission, then I will simply stop supporting it. The choice is yours.
Title: Re: Really universal soldering controller
Post by: Sjaak on May 10, 2016, 12:32:14 pm
[quote author="sparkybg"]
He talks about business inquiries. This is pretty far from my definition of "support".

I will gladly encourage anyone to help others build this project more easily, but as I see it, this is not a case.
In fact, if he just asked for permission prior doing this, with clear enough conditions and prices, I would probably grant it. But the way he done it I take as a dishonor of my work and will to share.

If you intend letting other's make business from my project without my permission, then I will simply stop supporting it. The choice is yours.[/quote]

It is not my intend.. All I say things aren't black an white. From the post I see he boughts parts and offers that he can send that to a fellow forummember. Perhaps he is only charging a 10% for that, and for what I read from you that is ok with you..
Title: Re: Really universal soldering controller
Post by: sebior on May 10, 2016, 12:33:50 pm
Sparkybg. What diameter of copper wire should be sufficient for jbc t245 cartridges? I'm going to make tool by myself.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 10, 2016, 01:17:00 pm
[quote author="Sjaak"]...perhaps he is...[/quote]

...and perhaps not. :) Do you know it for sure?

In either case, a required way to act is to ask the author first even if you make 0.0001% profit. And the problem is - he has not done this.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 10, 2016, 01:18:05 pm
[quote author="sebior"]Sparkybg. What diameter of copper wire should be sufficient for jbc t245 cartridges? I'm going to make tool by myself.[/quote]
I don't know. I Never measured it, but I think it is under 1 square millimeter.
Title: Re: Really universal soldering controller
Post by: afedorov on May 10, 2016, 05:00:24 pm
[quote author="sebior"]Sparkybg. What diameter of copper wire should be sufficient for jbc t245 cartridges? I'm going to make tool by myself.[/quote]
On the page 28 MadBekon reported dimensions of original cable.
Title: Re: Really universal soldering controller
Post by: Wolfram on May 11, 2016, 02:25:15 am
pls can the admin of this thread ,delete all my posts ,because i've asked a lot of bullshit ,which makes this thread polluted .
Thanks
PS :
(http://http://i.imgur.com/ipAxGE3.png)
Title: Re: Really universal soldering controller
Post by: Sjaak on May 11, 2016, 10:19:53 am
[quote author="Wolfram"]pls can the admin of this thread ,delete all my posts ,because i've asked a lot of bullshit ,which makes this thread polluted .
[/quote]

That would brake the whole thread, as answers to your question will stay there. If you really want to delete your stuff you got the option to edit/remove the posts you made yourself. (edit button).
Title: Re: Really universal soldering controller
Post by: MadBekon on May 11, 2016, 04:19:52 pm
I really don't like what i happening in here. People posting offers messing up this topic.

Yes i did ordered and excess number of boards, and yes I did offer the excess in here, but I made it to keep the cost low, not for profit. I really don't like the fact, that some one gets more boards from me, and then puts them on sale in this topic with higher price. This is just sick.

Sparkybg, did fantastic job building this project and if he says you can't make profit out of it, you can't. End of story.
Title: Re: Really universal soldering controller
Post by: Sjaak on May 11, 2016, 08:57:18 pm
[quote author="MadBekon"]I really don't like what i happening in here. People posting offers messing up this topic.

Yes i did ordered and excess number of boards, and yes I did offer the excess in here, but I made it to keep the cost low, not for profit. I really don't like the fact, that some one gets more boards from me, and then puts them on sale in this topic with higher price. This is just sick.

Sparkybg, did fantastic job building this project and if he says you can't make profit out of it, you can't. End of story.[/quote]

[quote author="Wolfram"]PS :
[img][/quote]

As far as I can tell is 14 USD approximately the same as 12 EUR (the price you are offering the PCBs) so I don't see much 'extra' profit in there.

If you are referring to another post or user I missed please tell me and I'll look into the matter.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 12, 2016, 07:19:54 pm
Guys,

Can someone share a link or part number for correct usb connector (best would be from tme.eu or mouser.com because I will be ordering parts from them), farnell had only one vertical usb connector and guess what footprint is wrong...

Thank you!
Title: Re: Really universal soldering controller
Post by: afedorov on May 12, 2016, 08:25:41 pm
I've bought an Wurth Electronics 651005136421 and it fits nice but not tight, though its row spacing is 1.8 mm instead of 2.2 mm in the footprint. It's the only difference.
http://www.digikey.com/product-search/e ... 1005136421 (http://www.digikey.com/product-search/en?keywords=651005136421)
I think mounting holes are made intentionally bigger than should be to accommodate slight differences between connectors.
Title: Re: Really universal soldering controller
Post by: afedorov on May 12, 2016, 09:25:28 pm
I'am going to flash the controller and have a question about powering. Do I need to connect power from back board to flash the firmware or my pickit3 clone will source it through ICSP?

It's ALIVE! )
Title: Re: Really universal soldering controller
Post by: sparkybg on May 12, 2016, 10:29:54 pm
[quote author="afedorov"]
I think mounting holes are made intentionally bigger than should be to accommodate slight differences between connectors.[/quote]

Exactly!

[quote author="afedorov"]I'am going to flash the controller and have a question about powering. Do I need to connect power from back board to flash the firmware or my pickit3 clone will source it through ICSP?

It's ALIVE! )[/quote]

Yes, you have to. PicKit3 can source upto 30mA, if I remember well.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 12, 2016, 11:55:48 pm
[quote author="afedorov"]I've bought an Wurth Electronics 651005136421 and it fits nice but not tight, though its row spacing is 1.8 mm instead of 2.2 mm in the footprint. It's the only difference.
http://www.digikey.com/product-search/e ... 1005136421 (http://www.digikey.com/product-search/en?keywords=651005136421)
I think mounting holes are made intentionally bigger than should be to accommodate slight differences between connectors.[/quote]

Thank you, just checked my Farnell order, and stupid me ordered microusb not miniusb connector :D
Title: Re: Really universal soldering controller
Post by: afedorov on May 13, 2016, 12:36:58 am
[quote author="sparkybg"]Yes, you have to. PicKit3 can source upto 30mA, if I remember well.[/quote]
Thanks for clarifying!
I saw this number in the manual, so I thought that having two sources on one line is a bad thing, and decided to ask.
But it turns out that power output from pickit has to be enabled explicitly in IPE, when it needed.

Another question. Does it make sense to put a multi-turn Rc2?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 13, 2016, 01:18:39 am
[quote author="afedorov"]
Another question. Does it make sense to put a multi-turn Rc2?[/quote]

No.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 14, 2016, 02:30:18 am
Hello sparkybg,

Almost finished assembling the station and I have a few questions:
1. At what events buzzer turns on? I'm using this buzzer (should be the one from BOM by mouser part number):
    http://http://eu.mouser.com/Search/ProductDetail.aspx?R=PB-1221PQvirtualkey53950000virtualkey539-PB1221PQ
    A) I've tried to run system with nothing connected - no sound
    B) with calibration resistor connected - no sound
    C) with Hakko FX8801 ID resistors (I get Sensor Open Error) - no sound
2. How stable is ADC reading for calibration resistor, last digit is floating like insane here?

3. I still haven't received connectors for my Irons, could you tell me how to change FX8801 profile so it would work with K type thermocouple (somewhere I have clone of hakko 907 iron that has K type thermocouple instead of PTC), want to check if Input and Output stage is working before I plugin something expensive :D

Thank You!
Title: Re: Really universal soldering controller
Post by: Wolfram on May 14, 2016, 03:16:22 am
delete
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 14, 2016, 03:17:52 am
sparybg,

Also when station boots I see 21 in top left corner for 1 second before main sceen shows up, is this normal?
Title: Re: Really universal soldering controller
Post by: Wolfram on May 14, 2016, 03:24:42 am
exscusme ,but im really tired of this panel control in this forum .
can someone explain me how i can remove my posts here ?
Thanks :)
Title: Re: Really universal soldering controller
Post by: afedorov on May 14, 2016, 04:19:40 am
Iwanushka,
may be you've soldered Q20 and D17 which are for buzzer with generator.
21 is displayed at the stage of power type detection - DC or AC and it takes some time on DC.
Station beeps on boot, on entering menu or you may force it to beep via PC software.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 14, 2016, 09:31:27 am
[quote author="Iwanushka"]sparybg,

Also when station boots I see 21 in top left corner for 1 second before main sceen shows up, is this normal?[/quote]

It is normal when powered with DC. On AC it shows for considerably less time.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 14, 2016, 09:33:05 am
[quote author="Iwanushka"]sparybg,

Also when station boots I see 21 in top left corner for 1 second before main sceen shows up, is this normal?[/quote]

It is normal when powered from DC. On AC it shows for considerably less time.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 14, 2016, 09:33:31 am
[quote author="Iwanushka"]sparybg,

Also when station boots I see 21 in top left corner for 1 second before main sceen shows up, is this normal?[/quote]

It is normal when powered from DC. On AC it shows for considerably less time.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 14, 2016, 04:27:20 pm
Guys,

Removed Q20/D17 now Buzzer beeps on boot and when I enter menu, youtube suggest that it should beep while pressing any off the buttons, but mine doesn't do that. Also my buzzer is somewhat strange usually buzzers w/o generators beep constantly when connected to power, but mine produces low clicking noises...

Edit: profile for chinese irons with separate K type thermocouple should be like this if I'm right:
China 907 (clone, with Separate with K type Thermocouple Sensor):
- Outer shell, Thermocouple negative and heater negative connected to EARTH, Vout1- and SENSEB
- Heater positive connected to Vout1+
- Thermocouple positive connected to SENSEA
- 100R between ID and Vout1-
- 150R between ID and Vout2-
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 14, 2016, 04:53:04 pm
[quote author="Wolfram"]
Hi there iwanushka ,pls can you post the foto of your unisolder station?
Thanks[/quote]

It looks the same like all other photos, don't have a case just bare PCBs with bunch of cables on a table.
Title: Re: Really universal soldering controller
Post by: afedorov on May 14, 2016, 05:31:47 pm
[quote author="Iwanushka"]usually buzzers w/o generators beep constantly when connected to power, but mine produces low clicking noises...[/quote]
It's oppositely, buzzer with generators do beep on DC, that's generator in it for. Q20/C57/R32 forms a low-pass filter, allowing using both types of buzzers without modifying firmware. On the other hand with simple buzzer C57 AC-couple square wave and R32 limits the current.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 14, 2016, 06:37:36 pm
Guys,

One more question, how do I change channel in iron profile, e.g I want to connect hakko fx8801 iron to second channel - vout2?
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 15, 2016, 02:16:34 am
sparkybg,

I've connected my china 907 clone, with Separate K type Thermocouple Sensor like this:
- Thermocouple negative connected to Vout1- and SENSEB
- Heater negative connected to Vout1-
- Heater positive connected to Vout1+
- Thermocouple positive connected to SENSEA
- 100R between ID and Vout1-
- 150R between ID and Vout2-

Station acts like this:
1. when Iron starts to heat I see 24C (room temp)->30->200C->511C this happens in a split second, basically when Iron temp is 40C maybe less (I can hold tip in my hand just fine it's warm) I get 511C on display, it uses K type thermocouple which is like 47uV/C, looks like firmware thinks that 1C = 4uV what is going on here.

2. Iron is always taking 33W shown by display (my PSU shows 1.6A), voltage is around 23.3V after all diodes. is there power limit set to 33W or is something horribly wrong with the controller, also it should show around 38W not 33W.

3. controller shows current temp 511C, if I set temp below 256C controller turns on power to heater, if I set temp to 256C or more heater is off, looks like there is overflow issue somewhere.

I will see if I can recompile the software and disable heater checking so I can see sensor readings w/o enabling heater and hook up thermocouple to known temperature(s).
Title: Re: Really universal soldering controller
Post by: sparkybg on May 15, 2016, 10:14:17 am
This is the only iron that is not tested, so it might be a profile error. Connect the FX8801 and see if it works OK, then you will know  if it is a profile mistake or hardware problem.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 15, 2016, 10:22:16 am
[quote author="Iwanushka"]usually buzzers w/o generators beep constantly when connected to power, but mine produces low clicking noises...[/quote]

There are buzzers with generator and without generator. The firmware is made to use buzzer without generator. Buzzers without generator will not beep when connected to power. They need AC voltage to beep. Only buzzers with generator will beep constantly when connected to power.

[quote author="afedorov"]Q20/C57/R32 forms a low-pass filter, allowing using both types of buzzers without modifying firmware.[/quote]
No. The firmware works only with generatorless buzzers for now. You should not connect Q20 and D17.

C57 is just for AC coupling, and R32 limits the current. That's it.

I just made the PCB ready for buzzer with generator also. Changing the firmware is easy, but changing the PCB is not. :) It is the same with 7-segment indicators.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 15, 2016, 02:15:38 pm
[quote author="sparkybg"]This is the only iron that is not tested, so it might be a profile error. Connect the FX8801 and see if it works OK, then you will know  if it is a profile mistake or hardware problem.[/quote]

Sparkybg,

Hakko FX-8801 iron works okay!
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 16, 2016, 10:02:26 pm
sparkybg,

china 907 clone in firmware has these coefficients:
                {                          //TPoly (TC Type K)
                    0,                      //c0
                    2.508355e-2,            //c1
                    7.860106e-8,            //c2
                  -2.503131e-10,          //c3
                    8.315270e-14,          //c4
                  -1.228034e-17,          //c5
                    9.804036e-22,          //c6
                  -4.413030e-26,          //c7
                    1.057734e-30,          //c8
                  -1.052755e-35            //c9
                },

Google says correct coefficients should be:
0
2.508355e+1
7.860106e-2
-2.503131e-1
8.31527e-2
-1.228034e-2
9.804036e-4
-4.41303e-5
1.057734e-6
-1.052755e-8
Title: Re: Really universal soldering controller
Post by: sparkybg on May 16, 2016, 11:59:05 pm
[quote author="Iwanushka"]sparkybg,

china 907 clone in firmware has these coefficients:
                {                          //TPoly (TC Type K)
                    0,                      //c0
                    2.508355e-2,            //c1
                    7.860106e-8,            //c2
                  -2.503131e-10,          //c3
                    8.315270e-14,          //c4
                  -1.228034e-17,          //c5
                    9.804036e-22,          //c6
                  -4.413030e-26,          //c7
                    1.057734e-30,          //c8
                  -1.052755e-35            //c9
                },

Google says correct coefficients should be:
0
2.508355e+1
7.860106e-2
-2.503131e-1
8.31527e-2
-1.228034e-2
9.804036e-4
-4.41303e-5
1.057734e-6
-1.052755e-8[/quote]

Try them. I cannot - I don't have chinese 907 with thermocouple right now to try. I've got the coefficient from here:
https://www.omega.com/temperature/Z/pdf/z198-201.pdf (https://www.omega.com/temperature/Z/pdf/z198-201.pdf) I don't know why the exponents are different.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 17, 2016, 12:04:10 am
[quote author="sparkybg"]

Try them. I cannot - I don't have chinese 907 with thermocouple right now to try. I've got the coefficient from here:
https://www.omega.com/temperature/Z/pdf/z198-201.pdf (https://www.omega.com/temperature/Z/pdf/z198-201.pdf) I don't know why the exponents are different.[/quote]

Tried them it's better now, but still there is some strange problem I set temp to 150C, now display shows 24C->27-29C (29C on display feels like 60C) and then magic begins: controllers loops between 50C->~70C->150C->170C and again back to beginning with 50C on display, so heater is always on (melts 63/37 solder just fine), looks like overflow issue somewhere.

Edit1: my coefficients are for temps from 0C to 500C. used this link (http://http://srdata.nist.gov/its90/type_k/kcoefficients_inverse.html)
Edit2: my JBC T245 will arrive in a week or so (still haven't completed selecting parts for the order), I hope there is just profile issue and not EMI/EMC noise on ADC....

Edit3: is there a way to connect TC directly to senseB and senseA without connecting it to Vout1- or Vout2-?, want to try running TC completely separate from the header, maybe there is some voltage injected to from heater or just bunch of noise...
Title: Re: Really universal soldering controller
Post by: sparkybg on May 17, 2016, 12:20:38 am
It is not a noise, unless if hardware problem is present, but if FX8801 works OK, then the hardware must be OK too.

This is the only iron with so much coefficients in the profile. I suspect the problem is in the polynomial calculating routine. I will have to get a 907 with thermocouple and debug that section. For now, you can leave c0=0, c1=24.20 and c2 to c9 = 0. It should work this way.

One end of the thermocouple must be connected to Vout-. The input is fully differential, but every differential amplifier has common mode voltage range and this one is not an exception.
Title: Re: Really universal soldering controller
Post by: Wolfram on May 17, 2016, 04:53:40 pm
if i will donate to sparkybg1 some cash ,maybe something like 50 euros ,can sparkybg1 do the encoder in the next version ?
i know that this does not make any kind of improvements,BUT IT'S COOL :D
I also knows that this project at begin was made only for the self of sparkybg1 ,but this project is something which every one dreams to get  ;)
You know what's i mean .
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 17, 2016, 08:24:19 pm
[quote author="Wolfram"]if i will donate to sparkybg1 some cash ,maybe something like 50 euros ,can sparkybg1 do the encoder in the next version ?
i know that this does not make any kind of improvements,BUT IT'S COOL :D
I also knows that this project at begin was made only for the self of sparkybg1 ,but this project is something which every one dreams to get  ;)
You know what's i mean .[/quote]

I will be adding rotary encoder support later on (need to find free time for this) it will be using I/O of 3 buttons that we have right now, or maybe I will hook it up via I2C/SPI so we will have 3 buttons + encoder.

Conclusion there is no need to make new PCBs

Best Regards,
Mantas
Title: Re: Really universal soldering controller
Post by: ppsati on May 18, 2016, 12:18:58 am
Hi,Sparkybg.
I have a MiniPro programmer with ICSP / ISP port, I can use it instead of PICkit3?
And it gives to replace the PICkit3 how can I use it?
You have knowledge of it?
sorry for so many questions ...
Title: Re: Really universal soldering controller
Post by: sparkybg on May 18, 2016, 11:17:34 am
I don't know anything about this programmer. I've always used PicKit3 for all microchip products.
Title: Re: Really universal soldering controller
Post by: ppsati on May 18, 2016, 02:29:01 pm
Thank´s, Sparkybg.

Someone here in the Forum is aware of this programmer and how do I use it instead of PICkit3.
Regards, from Portugal.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 18, 2016, 05:49:36 pm
[quote author="ppsati"]Thank´s, Sparkybg.

Someone here in the Forum is aware of this programmer and how do I use it instead of PICkit3.
Regards, from Portugal.[/quote]

Hi,

Just get Pickit3 from ebay for 13USD...checked google, but the one that looks like in your photo does not support PIC32
Title: Re: Really universal soldering controller
Post by: Evgeny1 on May 20, 2016, 11:08:39 am
Good afternoon.
Tell me where to get the firmware .hex?  in the archive no hex file
and how to flash it pickit3
Title: Re: Really universal soldering controller
Post by: sparkybg on May 20, 2016, 11:26:57 am
[quote author="Evgeny1"]...in the archive no hex file...[/quote]

Yes, there is:
Quote
UniSolder52_Software.zipfrontUS_Firmware.XdistPIC32_StandaloneproductionUS_Firmware.X.production.hex
Title: Re: Really universal soldering controller
Post by: Evgeny1 on May 20, 2016, 11:32:45 am
Thank you
Title: Re: Really universal soldering controller
Post by: dan4ik on May 22, 2016, 10:34:20 am
Hi guys,
Can anyone explain how can I check what voltage the display needs? I bought on ebay this one - UG-2864HSWEG01, checking datasheet one shows 9V? another one 12V. I asked seller but he hasn't answered yet. Also reading this tread Sparkybg wrote that he has some displays and blue display wants 9V and his Yellow one wants 12V. I bought blue one.
One more question about firmware. I understood from the tread that I should flash standalone hex not bootloader. In that case will it be possible to update firmware through USB in future?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 22, 2016, 11:10:20 am
[quote author="dan4ik"]Hi guys,
Can anyone explain how can I check what voltage the display needs? I bought on ebay this one - UG-2864HSWEG01, checking datasheet one shows 9V? another one 12V.
[/quote]
9V!
[quote author="dan4ik"]
One more question about firmware. I understood from the tread that I should flash standalone hex not bootloader. In that case will it be possible to update firmware through USB in future?[/quote]

No, it won't be possible.
Title: Re: Really universal soldering controller
Post by: dan4ik on May 22, 2016, 12:08:55 pm
[quote author="sparkybg"]//////
9V!
//////

No, it won't be possible.[/quote]
Hi Sparkybg, thank you for the answer. Your project is great. I'm on the way to finish the assembly if it will work I'll be very happy ))))) because it's my first big project. Before that I assembled only easy electronic projects.
in that case for what then usb is needed?
One more stupid question can I check back board without connecting it to front one? What boards points need to be checked for to be sure that back board works well? I finished back board but waiting for some components and programmer for front one. I'm afraid of that if there are some problems on back it would burn components on front board.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 22, 2016, 02:16:57 pm
Hi dan4ik,

Check J3 connector if you have 3v3 output and -0,5-0,6V out, check +12V rail near U2 it should be below 15V.
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 22, 2016, 10:40:38 pm
[quote author="sparkybg"]It is not a noise, unless if hardware problem is present, but if FX8801 works OK, then the hardware must be OK too.

This is the only iron with so much coefficients in the profile. I suspect the problem is in the polynomial calculating routine. I will have to get a 907 with thermocouple and debug that section. For now, you can leave c0=0, c1=24.20 and c2 to c9 = 0. It should work this way.

One end of the thermocouple must be connected to Vout-. The input is fully differential, but every differential amplifier has common mode voltage range and this one is not an exception.[/quote]

Hi sparkybg,

It's alive now, looks like there is an issue with polynomial calculating routine.

Can you help me edit profile, so it uses second channel, and how do I connect the sensor/heater on second channel, want to make sure that all FETs are working.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 23, 2016, 12:57:05 am
[quote author="Iwanushka"]
Can you help me edit profile, so it uses second channel, and how do I connect the sensor/heater on second channel, want to make sure that all FETs are working.[/quote]

You cannot. The firmware works with iron on channel1 or channel1 and channel2. It will not work with iron on channel2 only.
Title: Re: Really universal soldering controller
Post by: dan4ik on May 23, 2016, 09:44:12 pm
[quote author="Iwanushka"]Hi dan4ik,

Check J3 connector if you have 3v3 output and -0,5-0,6V out, check +12V rail near U2 it should be below 15V.[/quote]

Hi Iwanushka, Thanks for the answer.
I've measured. At pin 6 of U2 I have 13,91V. At J3 connector I have -0,5 and 4,99V As I think is it more than needed or is it OK?
Title: Re: Really universal soldering controller
Post by: Iwanushka on May 23, 2016, 10:21:34 pm
[quote author="dan4ik"][quote author="Iwanushka"]Hi dan4ik,

Check J3 connector if you have 3v3 output and -0,5-0,6V out, check +12V rail near U2 it should be below 15V.[/quote]

Hi Iwanushka, Thanks for the answer.
I've measured. At pin 6 of U2 I have 13,91V. At J3 connector I have -0,5 and 4,99V As I think is it more than needed or is it OK?[/quote]

Hi dan4ik,

output from LM2675 should be 3.3V not 5V, what resistor values you used for R3 & R4?
All other rails look okay.
Title: Re: Really universal soldering controller
Post by: dan4ik on May 24, 2016, 09:12:52 am
[quote author="Iwanushka"]
Hi dan4ik,

output from LM2675 should be 3.3V not 5V, what resistor values you used for R3 & R4?
All other rails look okay.[/quote]

Hi, I used according BOM and schematic. R3-4k7 R4 - 1k5
Title: Re: Really universal soldering controller
Post by: SZ64 on May 24, 2016, 10:00:26 am
[quote author="dan4ik"]

Hi, I used according BOM and schematic. R3-4k7 R4 - 1k5[/quote]


instead 1K5 (R4) should be 2K7 and then the voltage is exactly 3.316V ;)

Vout=1.21 x (1+4700/2700)=3.316...
Title: Re: Really universal soldering controller
Post by: dan4ik on May 24, 2016, 06:19:39 pm
[quote author="SZ64"]
instead 1K5 (R4) should be 2K7 and then the voltage is exactly 3.316V ;)

Vout=1.21 x (1+4700/2700)=3.316...[/quote]
Hi SZ64, I did as you wrote now I have 3,3V.

P.S. Thanks to all for help
Title: Re: Really universal soldering controller
Post by: ppsati on May 26, 2016, 01:29:46 am
Hi,sparkybg.
I need a little help here.
I am having troubles programming the Pic if i put the US_BootLoader.X the display stay this way.
[attachment=3]screen-19.16.49[25.05.2016].png[/attachment]
[attachment=2]screen-19.17.24[25.05.2016].png[/attachment]
[attachment=4]screen-00.11.43[26.05.2016].png[/attachment]
when programming the Pic with PIC32_Standalone, I get only the number 13 on the display corner.
[attachment=1]screen-00.37.34[26.05.2016].png[/attachment]
[attachment=0]screen-00.30.25[26.05.2016].png[/attachment]
I think I'm doing all right

Can you help me.

Regards,
Title: Re: Really universal soldering controller
Post by: sparkybg on May 26, 2016, 01:40:46 am
You don't have a problem with programming but a hardware problem with I2C bus. As a start, check it's pull-up resistors.

The photo is too small to see if all the parts are in place and with the right orientation.
Title: Re: Really universal soldering controller
Post by: ppsati on May 26, 2016, 01:47:07 am
[quote author="sparkybg"]You don't have a problem with programming but a hardware problem with I2C bus. As a start, check it's pull-up resistors.

The photo is too small to see if all the parts are in place and with the right orientation.[/quote]

Thank you for answering so fast, i need to see tlhe I2C pull up resitor of the display?
Title: Re: Really universal soldering controller
Post by: ppsati on May 26, 2016, 01:57:29 am
Sparkybg.
I send another picture with better quality.
[attachment=0]screen-00.55.39[26.05.2016].jpeg[/attachment]
Regards, from Portugal.
Title: Re: Really universal soldering controller
Post by: overheater on May 26, 2016, 02:01:06 am
Turn R27 and R28  90° and ths problem is gone - I made the same mistake ....... The silkscreen is a little bit tricky there.
Title: Re: Really universal soldering controller
Post by: overheater on May 26, 2016, 02:06:08 am
and do the same with resistor R63 and R65 - they are wrong too. again it is a misunderstanding the silkscreen.
Title: Re: Really universal soldering controller
Post by: ppsati on May 26, 2016, 02:16:38 am
[quote author="overheater"]Turn R27 and R28  90° and ths problem is gone - I made the same mistake ....... The silkscreen is a little bit tricky there.[/quote]
Hi, overheater.
In the middle of so many pieces, I dont noticed that the R27, R28, R63 and R65 are in a wrong position, already correct and everything is 100%
Thank you so much.

Best Regards from Portugal.
Title: Re: Really universal soldering controller
Post by: overheater on May 26, 2016, 02:30:10 am
Hello ppsati,

Quote
I dont noticed that the R27 and R28 are in a wrong position

as I told - I made the same mistake - and there are two other places, where one can misunderstand the silkscreen:

R65 - R63  and C60 - R46 - you are wrong at R65 and the last two are correct on your board

best way is: to take the 3D photo in post 1 and compare.....

again: thumbs up for sparky! It isn't easy to find a good position for the markings for the parts - and its well done for nearly all of the parts......

best regards from Germany
Klaus
Title: Re: Really universal soldering controller
Post by: ppsati on May 26, 2016, 02:45:33 am
[quote author="overheater"]


again: thumbs up for sparky!..
 
best regards from Germany
Klaus[/quote]

Thank you, Klaus, for your big help.

Sparky did a great job and a great design, shows that he is a great man , a very big thank you for Sparky.

Best Regards, from Portugal.
Paulo.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 26, 2016, 09:00:44 am
ppsati, remove Q20 and D17 from the PCB.
Title: Re: Really universal soldering controller
Post by: Sjaak on May 26, 2016, 10:17:01 am
Did some cleaning of this topic...

Please keep it technical and be kind to others.

Edit: removed again some posts.. Selling surplus PCBs/parts is ok, but use the PM system or ebay or marktplaats for that
Title: Re: Really universal soldering controller
Post by: Evgeny1 on May 26, 2016, 06:10:50 pm
Good afternoon!
Filled firmware, it worked with a soldering iron T12. (Display with an inscription T15)
There are a few questions:
1-is it possible to connect the solder thermocouple from lukeu 852D?  http://http://www.payalniki.ru/i/o/57d5310138c9787904338bd0f7ee316b.jpg
2-in speaker does not emit any sounds, how to enable it?
3-what signal you need to apply for withdrawal of sleep? (Circuit with a photocell on pic12f615 I'm not going, I can do without it?)
4 where to get the software for the PC for the USB connection?

Thank you.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 26, 2016, 07:07:26 pm
[quote author="Evgeny1"]
1-is it possible to connect the solder thermocouple from lukeu 852D? 
[/quote]
Yes. Use Chinese 907 profile, read some posts behind - set all coefficient to 0 except c1, which must be around 24.1
[quote author="Evgeny1"]
2-in speaker does not emit any sounds, how to enable it?
[/quote]
Remove Q20 and D17 and you will start to hear it.

[quote author="Evgeny1"]
3-what signal you need to apply for withdrawal of sleep? (Circuit with a photocell on pic12f615 I'm not going, I can do without it?)
[/quote]
Without sensor in the stand, any button use clears the sleep timer. Once it goes to sleep, you must restart it. All this can be adjusted from the settings menu.

[quote author="Evgeny1"]
4 where to get the software for the PC for the USB connection?
[/quote]
The PC software is in the software package as Visual Studio 2015 solution, but it is at very early stage of development and has limited use.

Thank you.[/quote]
Title: Re: Really universal soldering controller
Post by: Evgeny1 on May 27, 2016, 08:18:40 am
Quote
Yes. Use Chinese 907 profile, read some posts behind - set all coefficient to 0 except c1, which must be around 24.1
what? where the coefficient in this menu do not exist. How to change this?

Quote
Remove Q20 and D17 and you will start to hear it.
Still no sound.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 27, 2016, 08:48:59 am
[quote author="Evgeny1"]
what? where the coefficient in this menu do not exist. How to change this?
[/quote]
The coefficients are in the firmware. You will have to change them there and recompile the firmware.

Quote
Still no sound.
Maybe you are using wrong type of buzzer. I don't know. Do you have oscilloscope? If yes, measure the voltage on the wire that goes to the speaker.
Title: Re: Really universal soldering controller
Post by: Evgeny1 on May 27, 2016, 04:22:57 pm
Pardon me!
It was a bad speaker.
Put another and working.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 27, 2016, 11:02:47 pm
[quote author="tto4ka"]Hi Spakybg
Prompt please where to look.
 On the display number 21, then 45 and everything on it stops[/quote]

After printing 45 it tries to load paramaters from the EEPROM. Probably you have a problem with one of the I2C devices.
Title: Re: Really universal soldering controller
Post by: protonoob on May 30, 2016, 12:35:14 pm
has somebody found a decent pcb prototyper to send assembled and tested pcbs if so please mention their contact info
thanks
Title: Re: Really universal soldering controller
Post by: dumitruv on May 30, 2016, 12:41:35 pm
http://www.pcbway.com/ (http://www.pcbway.com/)

I've got PCBs from them, they offer assemblies as well but I'm not sure about the price.
Title: Re: Really universal soldering controller
Post by: DinikS on May 30, 2016, 01:28:13 pm
Hi guys,
The question how to flash microcontroller by pickit 2?  Could somebody tell me how and which programm is used for flashing? My old version version of MLAB supports pickit2 but not support microcontroller, the last version supports microcontroller but not support pickit 2.
Title: Re: Really universal soldering controller
Post by: sebior on May 31, 2016, 10:32:49 am
[quote author="DinikS"]Hi guys,
The question how to flash microcontroller by pickit 2?  Could somebody tell me how and which programm is used for flashing? My old version version of MLAB supports pickit2 but not support microcontroller, the last version supports microcontroller but not support pickit 2.[/quote]

I used pic32prog utility. It works fine with my PicKit 2 chinese clone.
Title: Re: Really universal soldering controller
Post by: DinikS on May 31, 2016, 10:40:38 am
[quote author="sebior"]
I used pic32prog utility. It works fine with my PicKit 2 chinese clone.[/quote]
Hi sebior, thank you! If it's possible could you please PM me short mannual how to use this program?
Title: Re: Really universal soldering controller
Post by: protonoob on June 01, 2016, 08:16:26 am
Supplier reported that their was missing part #s in BOM, i am very new to this and took a look but couldnt find which were missing
Has anybody had this issue from an assembler
Title: Re: Really universal soldering controller
Post by: afedorov on June 01, 2016, 03:37:42 pm
[quote author="protonoob"]Supplier reported that their was missing part #s in BOM, i am very new to this and took a look but couldnt find which were missing
Has anybody had this issue from an assembler[/quote]
Original BOM is not specific. You have to choose exact parts you wanted in the project and provide specific BOM to assembling fab.
Also, it covers all PCB variations, you should remove superfluous parts from the final BOM.
Title: Re: Really universal soldering controller
Post by: protonoob on June 02, 2016, 11:10:42 am
[quote author="afedorov"][quote author="protonoob"]Supplier reported that their was missing part #s in BOM, i am very new to this and took a look but couldnt find which were missing
Has anybody had this issue from an assembler[/quote]
Original BOM is not specific. You have to choose exact parts you wanted in the project and provide specific BOM to assembling fab.
Also, it covers all PCB variations, you should remove superfluous parts from the final BOM.[/quote]

Thanks for the information, i was definitely not aware of that

This is beyond my scope of understanding at the moment is there anybody who is willing to help me get everything i need to have a pcb assembler and of course i would be more than willing to donate via paypal for time
Title: Re: Really universal soldering controller
Post by: sebior on June 04, 2016, 08:25:38 pm
Hi sparkybg. I have made  DIY handpiece for JBC c245 cartriges and it working properly. But while a cartrige is half inserted its core terminal may connecting to Vout1+ and at the same time outer shell connected to EARTH. In other words Vout1+ connected to EARTH through the cartrige. And the question is can it cause any damage if I will change cartriges on the fly?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 04, 2016, 11:27:55 pm
No, it will not make any damage. You can change the tips freely, no matter if the controller is powered or not. The controller may show "short circuit" or "open heater" or "open sensor" for some seconds at most, but nothing more. At least I think so. :)

You cannot damage the controller no matter what you do with Earth, Vout+/- and SENSEA/B. The only way you can damage the controller (more specifically the MCU in it) is to make a short circuit between the ID pin and one of the Vout+ pins, but this is very unlikely to happen because it will not put a power to Vout+ without proper ID resistors on ID to Vout-.
Title: Re: Really universal soldering controller
Post by: DinikS on June 04, 2016, 11:33:37 pm
Hi guys,
Could somebody explain me how I can check front and oled board separately? I assembled the unit but the screen is black, nothing happens when switched on. It was switched on without soldering iron. My PSU just shows 40 mA of consumption. What pads should be measured on the both boards to be sure that boards work as they should work?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 04, 2016, 11:50:08 pm
[quote author="DinikS"]Hi guys,
Could somebody explain me how I can check front and oled board separately? I assembled the unit but the screen is black, nothing happens when switched on. It was switched on without soldering iron. My PSU just shows 40 mA of consumption. What pads should be measured on the both boards to be sure that boards work as they should work?[/quote]

Did it programmed OK?
Title: Re: Really universal soldering controller
Post by: DinikS on June 04, 2016, 11:55:38 pm
[quote author="sparkybg"]
Did it programmed OK?[/quote]
I think yes. At least pic32prog utility writes that all things done succsesfully.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 04, 2016, 11:59:08 pm
Post a photo of the front board please.
Title: Re: Really universal soldering controller
Post by: sebior on June 05, 2016, 12:08:49 am
[quote author="sparkybg"]No, it will not make any damage. You can change the tips freely, no matter if the controller is powered or not. The controller may show "short circuit" or "open heater" or "open sensor" for some seconds at most, but nothing more. At least I think so. :)

You cannot damage the controller no matter what you do with Earth, Vout+/- and SENSEA/B. The only way you can damage the controller (more specifically the MCU in it) is to make a short circuit between the ID pin and one of the Vout+ pins, but this is very unlikely to happen because it will not put a power to Vout+ without proper ID resistors on ID to Vout-.[/quote]
 
Thank you very much for explanation, Sparkybg.
Title: Re: Really universal soldering controller
Post by: DinikS on June 05, 2016, 12:17:53 am
[quote author="sparkybg"]Post a photo of the front board please.[/quote]
Here it is.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 05, 2016, 01:25:26 am
:)

1. Remove Q20, D17, Q17, R29. You should start hearing a beep when you power up the controller.
2. Make solder jumpers in the middle of U9 like on this photo:
(http://http://dangerousprototypes.com/forum/download/file.php?id=11930&mode=view)

3. Make solder jumpers on the back of the front pcb. like on this photo:
(http://http://dangerousprototypes.com/forum/download/file.php?id=11917&mode=view)

The display will start showing something when you do these things.
Title: Re: Really universal soldering controller
Post by: randomone on June 05, 2016, 03:28:21 am
Can I ask who (if anyone) has a PCB set currently for sale for V5.2 ?

Cam.
Title: Re: Really universal soldering controller
Post by: DinikS on June 05, 2016, 07:51:35 am
Hi Sparkybg,
Thank you for the answer.
All things you were listed were implemented in my board.
Regarding U9 it's not good visible on my the picture but I used 0R.
Q20 and D17 were installed because I use buzzer with integrated generator. I haven't inductive one.
On the other side of board all jumpers are soldered as on the picture you shown.
Regarding Q17 and Q15 yesterday I tried with and without them the result is the same.
So why I asked in the tread how I can check boards separetely. I have problem somewhere but can't find where it is.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 05, 2016, 11:04:39 am
Try porgramming it with the bootloader hex - not the firmware for bootloader, but the bootloader itself (US_BootLoader.X.production.hex). If it still does'n show anything try measuring the vortages on the 0R resistors with oscilloscope - if the SPI clock and data are active, then the MCU is working and the problem is in display PCB. If not, then the CPU is not running.

Get a buzzer without generator if you can. I don't know if this firmware will work with buzzer with generator. Then if you hear a beep on powering, then the MCU is operational.

Because the 0R resistors are pretty small - better remove them and make a solder jumpers - you may have a problem with some of them eventually.
Title: Re: Really universal soldering controller
Post by: DinikS on June 05, 2016, 02:41:25 pm
[quote author="sparkybg"]Try porgramming it with the bootloader hex - not the firmware for bootloader, but the bootloader itself (US_BootLoader.X.production.hex). If it still does'n show anything try measuring the vortages on the 0R resistors with oscilloscope - if the SPI clock and data are active, then the MCU is working and the problem is in display PCB. If not, then the CPU is not running.

Get a buzzer without generator if you can. I don't know if this firmware will work with buzzer with generator. Then if you hear a beep on powering, then the MCU is operational.

Because the 0R resistors are pretty small - better remove them and make a solder jumpers - you may have a problem with some of them eventually.[/quote]
Hi Sparkybg again, thanks for answering my questions
Tomorrow I will try to reflash microcontroller and check with oscilloscope. All my things are at work. The question is when I flashed the controller last time only chip and header PD1 were soldered but now I need to connect back board and power it. Can this extra power breaks the programmer or there shouldn't be any problem? Sorry for my stupid question I never deal with Microship I always worked with Atmel chips.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 05, 2016, 10:52:19 pm
PicKit3 has an option if it should power the device. But there should not be any problem, because it also detects if the device is powered up.

The only problem that can be present is if you use SMPS for powering the controller - sometimes there will be ground loops, and the programmer sometimes don't even detect the device, and sometimes gives several other errors while programming. The best way is to use USB isolator for programmer, but I don't have one yet so I had to retry and attach/detach the programmer several times in order to program it.
Title: Re: Really universal soldering controller
Post by: DinikS on June 06, 2016, 10:31:15 am
Hi Sparkybg,
I reflashed microcontroller. The result is the same - black screen. I removed OR, made solder jumpers and measured these pins by oscilloscope. There are some impulses on pads. But I don't know how much voltages should be there?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 06, 2016, 11:09:59 am
Did you replaced the buzzer with generatorless one? Do you hear a beep on power up when flashed with standalone HEX? If you are still using your old buzzer, measure the voltage on Q17's gate - you should have several (2-3) Khz square wave there on power up - this is the beep signal.

If you don't hear a beep and you don't have this signal, them the MCU is not running. If you hear beep or have this signal, then the MCU is running and the problem must be in the display PCB.
Title: Re: Really universal soldering controller
Post by: DinikS on June 06, 2016, 02:33:52 pm
[quote author="sparkybg"]Did you replaced the buzzer with generatorless one? Do you hear a beep on power up when flashed with standalone HEX? If you are still using your old buzzer, measure the voltage on Q17's gate - you should have several (2-3) Khz square wave there on power up - this is the beep signal.

If you don't hear a beep and you don't have this signal, them the MCU is not running. If you hear beep or have this signal, then the MCU is running and the problem must be in the display PCB.[/quote]
I found one buzzer without generator and have quiet beep sound when power up. Quiet because operating voltage of found buzzer is 4-6V
So it's sorted out that MCU is running. Is it possible to check oled somehow?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 06, 2016, 02:45:02 pm
[quote author="DinikS"][quote author="sparkybg"]Did you replaced the buzzer with generatorless one? Do you hear a beep on power up when flashed with standalone HEX? If you are still using your old buzzer, measure the voltage on Q17's gate - you should have several (2-3) Khz square wave there on power up - this is the beep signal.

If you don't hear a beep and you don't have this signal, them the MCU is not running. If you hear beep or have this signal, then the MCU is running and the problem must be in the display PCB.[/quote]
I found one buzzer without generator and have quiet beep sound when power up. Quiet because operating voltage of found buzzer is 4-6V
So it's sorted out that MCU is running. Is it possible to check oled somehow?[/quote]

Check the input and output voltages. I don't know what more can be tested there. If the voltages are OK, then maybe the display itself is defective.
Title: Re: Really universal soldering controller
Post by: DinikS on June 06, 2016, 03:08:39 pm
[quote author="sparkybg"]
Check the input and output voltages. I don't know what more can be tested there. If the voltages are OK, then maybe the display itself is defective.[/quote]
How much the input voltage should be?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 06, 2016, 03:21:52 pm
OLEDVDD and OLEDVCCIN both should be around 3.3V.
Title: Re: Really universal soldering controller
Post by: DinikS on June 06, 2016, 07:28:31 pm
[quote author="sparkybg"]OLEDVDD and OLEDVCCIN both should be around 3.3V.[/quote]
I've measured OLEDVCCIN - 3,3V OLEDVDD - voltage is missing.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 06, 2016, 08:08:45 pm
[quote author="DinikS"][quote author="sparkybg"]OLEDVDD and OLEDVCCIN both should be around 3.3V.[/quote]
I've measured OLEDVCCIN - 3,3V OLEDVDD - voltage is missing.[/quote]

You have a problem with Q14 or the connection between Q14's gate and MCU pin 45.
Title: Re: Really universal soldering controller
Post by: DinikS on June 06, 2016, 08:23:06 pm
[quote author="sparkybg"]You have a problem with Q14 or the connection between Q14's gate and MCU pin 45.[/quote]
Q14 source - 3,3V, gate -3,2V transistor is not broken I've checked it why it's not oppening I don't know
Title: Re: Really universal soldering controller
Post by: sparkybg on June 06, 2016, 10:37:12 pm
Then you have a problem with SPI bus, or the controller cannot detect the OLED board.

SDO-SDI must be connected with each other on the OLED's board. The MCU checks this in order to detect if OLED is present. Then it  turns on the VDD to the OLED using Q14, and after a while if turns on the VCCIN using Q16, and turns on the CS, reset, and SPI.

So you definitely have a problem with one of these things. Check ALL of your connections from the MCU to the OLED board for continuity and short circuits, and all the connections of Q14 and Q16.
Title: Re: Really universal soldering controller
Post by: DinikS on June 07, 2016, 11:39:12 am
[quote author="sparkybg"]Then you have a problem with SPI bus, or the controller cannot detect the OLED board.

SDO-SDI must be connected with each other on the OLED's board. The MCU checks this in order to detect if OLED is present. Then it  turns on the VDD to the OLED using Q14, and after a while if turns on the VCCIN using Q16, and turns on the CS, reset, and SPI.

So you definitely have a problem with one of these things. Check ALL of your connections from the MCU to the OLED board for continuity and short circuits, and all the connections of Q14 and Q16.[/quote]
Hi Sparkybg, thank you. I will check all you listed and be back with result.
Title: Re: Really universal soldering controller
Post by: tto4ka on June 07, 2016, 06:48:41 pm
Hi Sparky
I have a question concerning a butloader.
I am flash a butloader, then flash firmware, everything is OK. I can't understand how then to update firmware how to stop loading at a stage of a butloader that he was ready to accept new firmware
All I have understood :) Thanks :)
Title: Re: Really universal soldering controller
Post by: TheCircuiteer on June 08, 2016, 01:55:41 pm
I'm having a little trouble finding the right parts on mouser. I don't suppose anybody has a BOM from mouser or digikey with part # from their order I can use? Sorry, I'm a bit new to sourcing parts.
Title: Re: Really universal soldering controller
Post by: DinikS on June 08, 2016, 07:54:22 pm
[quote author="sparkybg"]Then you have a problem with SPI bus, or the controller cannot detect the OLED board.

SDO-SDI must be connected with each other on the OLED's board. The MCU checks this in order to detect if OLED is present. Then it  turns on the VDD to the OLED using Q14, and after a while if turns on the VCCIN using Q16, and turns on the CS, reset, and SPI.

So you definitely have a problem with one of these things. Check ALL of your connections from the MCU to the OLED board for continuity and short circuits, and all the connections of Q14 and Q16.[/quote]
The problem has been found. There was short circuit under the display flat cable on oled board. OLEDVDD was shorted on ground. So thank to all of you guys who were helping me.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 09, 2016, 09:00:03 am
[quote author="tto4ka"]Hi Sparky
I have a question concerning a butloader.
I am flash a butloader, then flash firmware, everything is OK. I can't understand how then to update firmware how to stop loading at a stage of a butloader that he was ready to accept new firmware
All I have understood :) Thanks :)[/quote]

As I already wrote, the PC software is at very early stage of development, and I don't know when I will be able to update it, so for the moment flash the microcontroller with "standalone" hex, not the bootloader one.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 09, 2016, 09:01:26 am
[quote author="TheCircuiteer"]I'm having a little trouble finding the right parts on mouser. I don't suppose anybody has a BOM from mouser or digikey with part # from their order I can use? Sorry, I'm a bit new to sourcing parts.[/quote]

The BOM is BOM and nothing more. It is not a "Mouser BOM" or "Farnell BOM". What problems do you have with Mouser?
Title: Re: Really universal soldering controller
Post by: Sjaak on June 09, 2016, 09:28:37 am
[quote author="sparkybg"][quote author="TheCircuiteer"]I'm having a little trouble finding the right parts on mouser. I don't suppose anybody has a BOM from mouser or digikey with part # from their order I can use? Sorry, I'm a bit new to sourcing parts.[/quote]

The BOM is BOM and nothing more. It is not a "Mouser BOM" or "Farnell BOM". What problems do you have with Mouser?[/quote]

MOuser (digikey too?) has a method to export/share a BOM with their sku's/partnumbers. That will make it convieniant for others. Kinda like dangerousprototypes does here: http://dangerousprototypes.com/docs/Shopping_carts (http://dangerousprototypes.com/docs/Shopping_carts)
Title: Re: Really universal soldering controller
Post by: tto4ka on June 09, 2016, 09:31:18 am
[quote author="sparkybg"]
As I already wrote, the PC software is at very early stage of development, and I don't know when I will be able to update it, so for the moment flash the microcontroller with "standalone" hex, not the bootloader one.[/quote]
Sparky thanks I understood, everything works, though with errors :), I want to add a few PC software at least to a stage that it is possible to select a firmware file and to eliminate the main errors which appear at present :)
Title: Re: Really universal soldering controller
Post by: sparkybg on June 09, 2016, 11:04:51 am
[quote author="tto4ka"][quote author="sparkybg"]
As I already wrote, the PC software is at very early stage of development, and I don't know when I will be able to update it, so for the moment flash the microcontroller with "standalone" hex, not the bootloader one.[/quote]
Sparky thanks I understood, everything works, though with errors :), I want to add a few PC software at least to a stage that it is possible to select a firmware file and to eliminate the main errors which appear at present :)[/quote]

What errors?
Title: Re: Really universal soldering controller
Post by: tto4ka on June 09, 2016, 02:06:43 pm
I didn't look yet, just in the course of operation the application stops.
Prompt Sparky that such RLE TEST
until added dialog boxes for opening of files, without them very much it isn't convenient :)))
Title: Re: Really universal soldering controller
Post by: DinikS on June 10, 2016, 11:40:12 pm
Hi Sparkybg, I connected C210 the temperature was set 350C. it's not stable it always jumps up and down between +- 346 and 357 and never stabilizes. Where is the problem?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 11, 2016, 12:05:23 am
[quote author="DinikS"]Hi Sparkybg, I connected C210 the temperature was set 350C. it's not stable it always jumps up and down between +- 346 and 357 and never stabilizes. Where is the problem?[/quote]

There is not a problem. C210 has so small thermal mass and so small resistance that even one mains period of 24V AC is able to heat it a few degrees up. Peak electrical power of these tips is almost 300W at 24V.

If you are using only these tips, try using lower voltage power source - they will "jump" less, because the peak power will be lower.
Title: Re: Really universal soldering controller
Post by: DinikS on June 11, 2016, 12:07:45 pm
[quote author="sparkybg"]
There is not a problem. C210 has so small thermal mass and so small resistance that even one mains period of 24V AC is able to heat it a few degrees up. Peak electrical power of these tips is almost 300W at 24V.

If you are using only these tips, try using lower voltage power source - they will "jump" less, because the peak power will be lower.[/quote]
Yes, I tried to power it up by 12V the jumping is lower +- 2-3 degrees up and down.
I'm going to use both C210 and C245 and first one will be used more frequently than the second one. So I should accept "jumping", shouldn't I?
Title: Re: Really universal soldering controller
Post by: DinikS on June 11, 2016, 07:06:21 pm
T245 was connected and it works very stable, thetemperature tolerance is +-5-7C
Thank you Sparkybg for nice project.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 11, 2016, 08:48:07 pm
[quote author="DinikS"]
Yes, I tried to power it up by 12V the jumping is lower +- 2-3 degrees up and down.
I'm going to use both C210 and C245 and first one will be used more frequently than the second one. So I should accept "jumping", shouldn't I?[/quote]

Everything is normal. You will have to live with it. In fact, the real jumps on the top of the tip is far less than what is displayed. I am working with C210, Microtweezers (2 tips, similar to C210), C245, and HAKKO T12 for a long time without any problems so far.

These tips are just so tiny and with very low resistance - the method I am using for control cannot control them better. It is the physics I cannot change.
Title: Re: Really universal soldering controller
Post by: wailer on June 12, 2016, 11:37:53 am
Greetings to all
  I renew my request:
Some forum user can provide a co kit components for this fantastic project?
Thank you
Title: Re: Really universal soldering controller
Post by: tto4ka on June 12, 2016, 05:30:45 pm
Hi Sparky
Concerning mistakes in the application, Pressing of button jump to application and jump to bootloader causes crash application :)
Title: Re: Really universal soldering controller
Post by: sparkybg on June 12, 2016, 08:48:20 pm
[quote author="tto4ka"]Hi Sparky
Concerning mistakes in the application, Pressing of button jump to application and jump to bootloader causes crash application :)[/quote]

I know about this.
Title: Re: Really universal soldering controller
Post by: tto4ka on June 12, 2016, 09:39:48 pm
Well just you asked about mistakes I and called them :)))) I understand because of what they but I don't understand yet as it is correct to eliminate them :)
Title: Re: Really universal soldering controller
Post by: sparkybg on June 12, 2016, 10:43:38 pm
[quote author="tto4ka"]Well just you asked about mistakes I and called them :)))) I understand because of what they but I don't understand yet as it is correct to eliminate them :)[/quote]

I meant mistakes in the firmware.

It will be hard to eliminate PC software errors, because there's many thing you must rewrite in the code.
Title: Re: Really universal soldering controller
Post by: atmicandr on June 14, 2016, 07:48:40 am
Still such question: insertions for PIC12 and PIC32 microcontrollers under a soldering iron on the T12/T15 base in open access? If yes, can you tell me that where here to find them in a subject?
Title: Re: Really universal soldering controller
Post by: jry on June 15, 2016, 01:06:52 pm
[quote author="sparkybg"]There is not a problem. C210 has so small thermal mass and so small resistance that even one mains period of 24V AC is able to heat it a few degrees up. Peak electrical power of these tips is almost 300W at 24V.[/quote]

I didn't study your code, but wouldn't it be possible to shutdown MOSFET in the calculated time and don't wait for whole mains period? I plan to examine this option in my JBC controller. Maybe with some simple MOSFET power dissipation model, so we can fall back to whole period switching to lower MOSFET temperature.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 15, 2016, 01:42:03 pm
[quote author="jry"][quote author="sparkybg"]There is not a problem. C210 has so small thermal mass and so small resistance that even one mains period of 24V AC is able to heat it a few degrees up. Peak electrical power of these tips is almost 300W at 24V.[/quote]

I didn't study your code, but wouldn't it be possible to shutdown MOSFET in the calculated time and don't wait for whole mains period? I plan to examine this option in my JBC controller. Maybe with some simple MOSFET power dissipation model, so we can fall back to whole period switching to lower MOSFET temperature.[/quote]

Yes, it is possible, and yes, it will create transformer noise and other (visible and invisible) problems. I've tried it. ;)

Whole period zero current switching is not because MOSFET dissipation and temperature. MOSFET switching losses at 100Hz are next to nothing, no matter when you switch them on and off.
Title: Re: Really universal soldering controller
Post by: jry on June 15, 2016, 02:57:16 pm
OK, so not a good path. What about half-cycle switching (I mean 100Hz in Europe), is it viable?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 15, 2016, 03:12:43 pm
[quote author="jry"]OK, so not a good path. What about half-cycle switching (I mean 100Hz in Europe), is it viable?[/quote]

This is extremely nasty for transformer. You must take equal amount of energy from it in both half periods, or it will not be very pleased - will start to hum and get considerably warmer. It also may saturate blow your fuses (depending on construction and safety margins).
Title: Re: Really universal soldering controller
Post by: jry on June 15, 2016, 03:55:40 pm
I understand, thank you for saving my time with these dead ends.
Title: Re: Really universal soldering controller
Post by: tto4ka on June 15, 2016, 11:05:13 pm
My Case for UniSolder :)
Title: Re: Really universal soldering controller
Post by: wailer on June 19, 2016, 04:28:00 pm
Congratulations
A really nice job
Title: Re: Really universal soldering controller
Post by: Evgeny1 on June 27, 2016, 01:17:17 am
I finally completed the station
Title: Re: Really universal soldering controller
Post by: DinikS on June 27, 2016, 09:00:41 am
[quote author="Evgeny1"]I finally completed the station[/quote]
It's nice.
Evgeny1, I'm not sure but check U10 I see short between 13 and 14 pins.
Title: Re: Really universal soldering controller
Post by: Evgeny1 on June 27, 2016, 09:28:44 am
Yes, the way it should be, according to the scheme they are connected
Title: Re: Really universal soldering controller
Post by: DinikS on June 27, 2016, 12:11:33 pm
[quote author="Evgeny1"]Yes, the way it should be, according to the scheme they are connected[/quote]
I've not followed schematic just seen this. It's OK if so ))))
Title: Re: Really universal soldering controller
Post by: sparkybg on June 27, 2016, 09:31:55 pm
U10 is OK.

Transparent box looks pretty fancy. :)
Title: Re: Really universal soldering controller
Post by: wailer on June 29, 2016, 05:49:23 pm
Did you use a switching power supply with 24V output, instead of the transformer?
Title: Re: Really universal soldering controller
Post by: wailer on June 29, 2016, 05:51:18 pm
And the handpiece is homemade .... Congratulations
Title: Re: Really universal soldering controller
Post by: Evgeny1 on June 29, 2016, 07:44:31 pm
[quote author="wailer"]Did you use a switching power supply with 24V output, instead of the transformer?[/quote]

27V
Title: Re: Really universal soldering controller
Post by: MadBekon on June 29, 2016, 10:02:30 pm
For those that are going to solder this project, basic helper, helping find elements on PCB.
BOM is related on elements I used, is not exactly the same as original BOM.
This is just to help locating components on the boards.

Hope this will be usefull...
PS. Please don't browse the code. I'm totally not a JS / HTML programmer.
Code is not optimal or well organized. But should work.

Also available here: http://serwer1392854.home.pl/unisolder/ (http://serwer1392854.home.pl/unisolder/)
[attachment=0]
Title: Re: Really universal soldering controller
Post by: Iwanushka on July 01, 2016, 04:48:56 pm
MadBekon,

Thank you for this tool, will come in handy
Title: Re: Really universal soldering controller
Post by: MadBekon on July 01, 2016, 09:03:36 pm
Can U please explain me what is this part of circuit doing?
[attachment=0]
I soldered another set of boards. First powered up with DC, working fine, then powered up with AC, it powered up.
I swiched off, then switched on and from that time, seems that Vin is not doing through Q1. I have 1V on pin 3 of Q1.
Title: Re: Really universal soldering controller
Post by: sparkybg on July 01, 2016, 09:32:34 pm
I've already explained this. This makes a valley of about 5-6V between the half periods of the transformer's secondary rectified voltage. Otherwise the voltage penetrates through MOSFET's drain-source capacitance and the temperature reading of series thermocouple becomes erratic.
Title: Re: Really universal soldering controller
Post by: MadBekon on July 01, 2016, 10:20:44 pm
I see, so then it's nothing related with cutting off Q1.
It's strange that it could have been damaged, there was even no load connected yet.
Title: Re: Really universal soldering controller
Post by: Iwanushka on July 08, 2016, 01:09:07 am
sparkybg,

Hi, just finished assembling another set and something is wrong with calibration, connected 10R resistor when i turn pot all they way counter clockwise R goes to ~1020 when I turn it all the way clockwise it goes up to 1400, looks like something is wrong with the divider, where do I start checking?

Looks like random issue, might be cold joint somewhere.

Also regarding OLED brightness does it work? on all 3 sets that setting does nothing.


Also which JBC tweezers are supported in the firmware, cant find model number anywhere?
Title: Re: Really universal soldering controller
Post by: tto4ka on July 11, 2016, 11:31:54 am
[quote author="Iwanushka"]sparkybg,

Hi, just finished assembling another set and something is wrong with calibration, connected 10R resistor when i turn pot all they way counter clockwise R goes to ~1020 when I turn it all the way clockwise it goes up to 1400, looks like something is wrong with the divider, where do I start checking?

[/quote]

in my opinion a problem in U13 U18.
Possibly bad soldering
Title: Re: Really universal soldering controller
Post by: afedorov on July 11, 2016, 07:06:59 pm
It could be any IC in the path (IMO, especially I2C pot and DAC), also Vref, assuming all passives are OK. If working PCB set is available, one can just compare voltages along the signal path.
On my board and display adjusting brightness also seems doing nothing, I presume it might be for 7seg LED display.
Title: Re: Really universal soldering controller
Post by: sparkybg on July 11, 2016, 08:54:24 pm
For now brightness does nothing on OLED.

About calibration - double check all the resistors in divider. I suspect it is a bad resistor somewhere.
Title: Re: Really universal soldering controller
Post by: Iwanushka on July 12, 2016, 09:26:13 pm
Guys, how about JBC tweezers? I'm looking at PA120 (c120 tips) model, is it supported in current firmware? I'm a bit busy (actually a bit behind the schedule...err quite a lot actually)  so would be nice to get tweezers that work of out the box
Title: Re: Really universal soldering controller
Post by: overheater on July 12, 2016, 10:35:53 pm
Yes - tweezers..... I'm searching too.

But I decided to build them in diy - out of two tips from the c210-014.

@ sparky: would these two tips work with the "JBC-Tweezers-profile"?

The connection of these tips is easy to do - a special 3,5mm socket for earphones and a single socket for one pin of a  6C33 Tube will do. (If someone is interested, I will post more information about this)

[attachment=0]

Has someone build the mechanics for such tweezers? and like to tell - how?

Also any idea (if it will work or not) for building is welcome.
Title: Re: Really universal soldering controller
Post by: sparkybg on July 12, 2016, 10:50:51 pm
Yes, it will work with tweezers profile as long as you connect them in the same way.

...but I am skeptical about the 3.5mm earphone jack. The peak current there is more than 12A on 24V DC and more than 16A on 24V AC.
Title: Re: Really universal soldering controller
Post by: overheater on July 12, 2016, 11:44:36 pm
Thank you Sparky!

and off course you are right with your objection to the earphone jack.

but there is a solder-tip from Weller with 40W and afaik up to 55W which has a build-in 3,5mm (headphone plug) connector and there are hundreds of Diy - stations that uses these jacks for connections.....

http://www.reichelt.de/WELLER-RT-4/3/in ... =weller+rt (http://www.reichelt.de/WELLER-RT-4/3/index.html?&ACTION=3&LA=446&ARTICLE=63437&artnr=WELLER+RT+4&SEARCH=weller+rt)

I own one too. I have no problems and I never heard about problems about the jacks.

And if you have a look at the Chinese Hakko T12 connectors in the irons....... I opened a Hakko-clone solder iron and a headphone jack - the headphone jack looks more solid.
Title: Re: Really universal soldering controller
Post by: sparkybg on July 13, 2016, 12:07:33 am
Weller has much bigger resistance and much smaller peak current. ;)

Hakko T12/T15' resistance is between 8 and 9 ohms - they have 70W peak power at 24V,  C210's resistance is as low as 1.7 ohms, and the peak power at 24V is more than 320W.
Title: Re: Really universal soldering controller
Post by: mrjoda on August 04, 2016, 06:57:32 pm
i want to buy one set of pcbs on this project. Only from inside EU. VAT and customs are bit..s

send me PM or email please

thanks
Title: Re: Really universal soldering controller
Post by: Bilal on August 04, 2016, 10:01:11 pm
Hello
I also want to buy a pcb if it is avalible for this project
please.
I live in eu Germany

Thnaks a lot

Bilal
send a pw or email me
Title: Re: Really universal soldering controller
Post by: Bilal on August 05, 2016, 12:14:44 am
Sorry i have a question about this great project.
what is in the gerber file -> the sensor board ?
I must order it also ?
Or the solder is working also and it is just a option ?

Thanks

Bilal
Title: Re: Really universal soldering controller
Post by: Bilal on August 05, 2016, 02:53:52 am
In the Bom List
(wich i can not import to farnel why ???)

is the C4 Polarized Capacitor (Radial), size is market with TH10x12.5 ->
so this means width 10mm and high 12.5mm ? or the width is 10mm and the soldering pins are 12.5mm wide ?

so for an example at farnel i can take this for C4 capacitor ???  EEE1CA471AP
pls google it i am a new user 24hours spamm block Website link ;(

thanks

Bilal
Title: Re: Really universal soldering controller
Post by: Bilal on August 05, 2016, 02:59:03 am
for this capacitors it means uf not u allright ?
sorry but dont wanna order 2 times ;)

C14, C15, C19   10u 25V   Comet   3   1206   Capacitor   

bom-list -- line 7 -- comment

thx
Bilal
Title: Re: Really universal soldering controller
Post by: sparkybg on August 05, 2016, 09:23:42 am
10x12.5 is 10mm body diameter and 12.5mm body height. Pin spacing is a standart one for this body, in this case 5mm.

C14, C15 and C19 are 10uF 24V SMD 1206 ceramic capacitors. Preferably X7R.
10u means 10 microfarads, 10p means 10 picofarads, 10n means 10 nanofarads.

Sensor board is optioal. It is for the iron holder, and tells the controller to go to lower temperature when the iron is the holder.
Title: Re: Really universal soldering controller
Post by: Bilal on August 05, 2016, 04:42:59 pm
thans a lot Sparky, you are great
Title: Re: Really universal soldering controller
Post by: Bilal on August 05, 2016, 06:52:22 pm
the capacitors where is no voltage description in the BOM
like the 0603 packs in the lines of BOM list
-10
-12
-13
-15
is it ok to get 100v types or also 50v ?

and how is it about the diodes? how much volt i have to choose?
is it enought to get 50v Types or must it be 100v ?

Thanks

Bilal
Title: Re: Really universal soldering controller
Post by: sparkybg on August 05, 2016, 10:47:57 pm
[quote author="Bilal"]the capacitors where is no voltage description in the BOM
like the 0603 packs in the lines of BOM list
-10
-12
-13
-15
is it ok to get 100v types or also 50v ?
[/quote]
Use X7R. 50V is better than 100V

[quote author="Bilal"]
and how is it about the diodes? how much volt i have to choose?
is it enought to get 50v Types or must it be 100v ?[/quote]

Some diodes are critical, so use the exact types, stated in the BOM.
Title: Re: Really universal soldering controller
Post by: Bilal on August 09, 2016, 11:35:36 am
Thanks Speky

this means for all the capacitors it will be possible to get 50V types ?
I mean norrmally without any induction the board is running on 24V max ???
Allright or i see anything wron on my side of view.

Thanks

Bilal

p.s. i will see maybe i will later load the Farnell list up to tis tread for other people to collect the Items faster and as best as possible.

Thanks
Title: Re: Really universal soldering controller
Post by: sparkybg on August 09, 2016, 01:08:38 pm
If a voltage is explicitly stated in the BOM/schematics, you must use that voltage or higher. If the voltage is not stated in the BOM/schematics, you can use any voltage. C0G is best (these are available for up to around 1nF), X7R is prefered, then X5R,  then Y5V( which I do not recommend).
Title: Re: Really universal soldering controller
Post by: wailer on August 18, 2016, 07:46:49 pm
Finally I can post my Unisolder.
That, thanks to the tireless collaboration of "tto4ka" It works perfectly.
An infinite thanks to the work of "SPARKYBG"

Only problem, I would like it to work the SLEEP function.
I used the same box JBC how to do?
Title: Re: Really universal soldering controller
Post by: sparkybg on August 18, 2016, 09:40:29 pm
You must either make a sensor board, or use a switch for a sleep function to work.
Title: Re: Really universal soldering controller
Post by: wailer on August 19, 2016, 06:48:05 am
Could you give some more news more?
What type of sensor or where to connect the 'switch?
Title: Re: Really universal soldering controller
Post by: sparkybg on August 19, 2016, 09:29:45 am
Sensor board PCB and schematics is in the files in the first post. It connects to RJ11 connector of the back board. You can use simple switch instead if you want, of make your own sensor board.

Taking the "SLEEP" signal line to GND means that the iron is in the stand.
Title: Re: Really universal soldering controller
Post by: wailer on August 19, 2016, 01:19:45 pm
Available as always .... Thanks.
I try to solve
Title: Re: Really universal soldering controller
Post by: randomone on August 21, 2016, 09:36:25 pm
Is this project moddable to deliver the 250watts needed for the likes of the JBC C470 ?
Title: Re: Really universal soldering controller
Post by: sparkybg on August 21, 2016, 09:44:45 pm
It needs pretty big redesign of power stage (diodes and MOSFETs) in order to do this. It can drive it with no modifications, but it will be limited to 24V 6A.
Title: Re: Really universal soldering controller
Post by: randomone on August 21, 2016, 09:50:39 pm
Redesign as in different schematic ? or just better rated diodes and MOSFETs ?
Title: Re: Really universal soldering controller
Post by: sparkybg on August 21, 2016, 10:11:54 pm
Better diodes and heatsink for diodes and MOSFETs.

...and change of current limit in the software.
Title: Re: Really universal soldering controller
Post by: randomone on August 21, 2016, 10:21:03 pm
OK, so maybe not a neat change on the current PCB but possible as a hack ?
If I pick some possible replacement components can I get your opinion ?
Title: Re: Really universal soldering controller
Post by: sparkybg on August 21, 2016, 10:29:19 pm
You need 20A TO220 Schottky diodes and TO220 MOSFETs with similar or better Rdson than these in the project, all mounted on insulated heatsink.
Title: Re: Really universal soldering controller
Post by: randomone on August 21, 2016, 11:55:31 pm
What if it is possible to find MOSFETs with half the Rdson ?
Title: Re: Really universal soldering controller
Post by: sparkybg on August 22, 2016, 12:20:42 am
The lower, the better. But don't go too far. In fact, only the P mosfets are getting warm on heavy load. The N mosfet's will be OK for upto 20A and more.

There are IR thermal camera pictures some pages back in the thread. You can see clearly which parts need cooling.
Title: Re: Really universal soldering controller
Post by: randomone on August 22, 2016, 12:27:07 am
I was thinking of finding MOSFETS in the same package (TO252) but with half the resistance, and avoiding going to TO220 and heatsinks.
Title: Re: Really universal soldering controller
Post by: sparkybg on August 22, 2016, 12:33:00 am
[quote author="randomone"]I was thinking of finding MOSFETS in the same package (TO252) but with half the resistance, and avoiding going to TO220 and heatsinks.[/quote]

Good luck with P channel ones. ;)

And the diodes will still need cooling.
Title: Re: Really universal soldering controller
Post by: randomone on August 22, 2016, 12:40:17 am
I did wonder if that would be the answer :)

Any advice for installing the diodes and FETs on flying leads, say around 100mm ?
Title: Re: Really universal soldering controller
Post by: sparkybg on August 22, 2016, 02:00:45 am
[quote author="randomone"]
Any advice for installing the diodes and FETs on flying leads, say around 100mm ?[/quote]

I hate "solutions" like this. And I don't think it will work. Far better solution will be to bolt them to the controller's case, if is is a metal one. But you will have to make a PCB redesign anyway.
Title: Re: Really universal soldering controller
Post by: randomone on August 22, 2016, 02:27:31 am
It wasn't going to be a solution, more a temporary fix. As you say a PCB redesign is best.
Title: Re: Really universal soldering controller
Post by: klaus11 on August 23, 2016, 01:09:09 pm
Hello new here, I look for a set PCB. Original sparky, someone has one for me ...
Title: Re: Really universal soldering controller
Post by: Matlkatzi on August 31, 2016, 01:36:46 pm
Hi Sprakybg!


First of all many thanks for posting this nice project!
In the past have also built a solder-desolder station for driving an Weller WSP80, DXV80 with PT20 sensor and an older ERSA with seperate Thermocouple sensor.
Now i was reading your schematic, and i have a question concerning reading the thermocouple sensor.

In case of configuration TC in series with heater for example JBC Microtweezers the Sense input A
Is connected to Vout+.
See attached file

How you meassure the thermocouple voltage (U thermocouple) ?
Is it right that in this case you switch Q10 on and measure (with high impedance input) between Sense A and SGND trough Q10 und RS1?

Does Q10 und RS1 influence the measuring?


Thanks in advance for your reply.

Matlkatzi
Title: Re: Really universal soldering controller
Post by: sparkybg on August 31, 2016, 02:02:40 pm
Yes, I am measuring the voltage between SGND and Vout1/2+.

There are no significant flowing currents there while I take measurements other than MOSFET's gate leakages (nano-pico amperes), the shunt resistor is with very low resistance, the N-MOSFET too, the P MOSFET has very high off resistance. I haven't noticed any influences, and I cannot see any mechanism for influences to exist.

The thermocouple's resistance in series with heater is under 2-3 ohms on C210, but even if it was higher, say 200-500 ohms, I still cannot see how the measurements will be influenced by Q10 and the shunt resistor.

For example:
- for 1 degree Celsius influence, you need delta of 2 on the ADC, which is  0.00586V (3/512).
- With a gain of 650 (the gain for C210 and mictotweezers was around this value if I remember well), you must have 9uV influence on the input of the amplifier
- With Q10 and shunt combined resistance of 0.0083ohms, you need a little more than 1mA flowing current through them to produce 9uV on the amplifier's input.

This 1mA current is nowhere to be found while P MOSFET is off unless I put it there intentionally with current sources, but I am using just 30uA current from current sources while measuring TC voltage. And these 20uA are compensated in the firmware for the TC+heater resistance.
Title: Re: Really universal soldering controller
Post by: Matlkatzi on August 31, 2016, 02:28:11 pm
Thank your very much for your quick reply.
Now its clear for me.
Congrats for your very smart design.

Matlkatzi
Title: Re: Really universal soldering controller
Post by: tchleb on September 05, 2016, 09:35:31 pm
Hello,

can i use the teriodal transformer?
This transformator have a duty cycle (ED = Einschaltdauer) about 40%
This means for 4 Minutes the full 120VA can be supply, after this the transformer need some time too cool down.

Is supplied Voltage ok?
Title: Re: Really universal soldering controller
Post by: sparkybg on September 16, 2016, 02:14:28 pm
Yes, you can.
Title: Re: Really universal soldering controller
Post by: DinikS on September 24, 2016, 09:43:05 pm
[quote author="sparkybg"]Taking the "SLEEP" signal line to GND means that the iron is in the stand.[/quote]

hello sparkybg, if I understood you right there is no need to assembly sensor board it needs just only one wire "sleep" (J5 connector) being connected to the iron stand, and when the iron is being put on stand as it has GND on its body the station will switch sleep mode on? or I'm not right? Could you please comment this? Thanks
Title: Re: Really universal soldering controller
Post by: sparkybg on September 24, 2016, 11:05:38 pm
[quote author="DinikS"][quote author="sparkybg"]Taking the "SLEEP" signal line to GND means that the iron is in the stand.[/quote]

hello sparkybg, if I understood you right there is no need to assembly sensor board it needs just only one wire "sleep" (J5 connector) being connected to the iron stand, and when the iron is being put on stand as it has GND on its body the station will switch sleep mode on? or I'm not right? Could you please comment this? Thanks[/quote]

No. Az I mentioned earlyer, GND and EARTH are different things, and the outer shell of the iron isn't always connected at all.

On the back RJ connector, you have 3.3V and GND. You must connect the SLEEP wire to GND on it. The SLEEP wire has pull-up to 3.3V, so a simple switch is OK. I made it optical, because it was easier for me to do. An it hasn't any moving parts, so it is very reliable.
Title: Re: Really universal soldering controller
Post by: DinikS on September 24, 2016, 11:14:28 pm
[quote author="sparkybg"]
No. Az I mentioned earlyer, GND and EARTH are different things, and the outer shell of the iron isn't always connected at all.

On the back RJ connector, you have 3.3V and GND. You must connect the SLEEP wire to GND on it. The SLEEP wire has pull-up to 3.3V, so a simple switch is OK. I made it optical, because it was easier for me to do. An it hasn't any moving parts, so it is very reliable.[/quote]
Oh I see! Thank you for explanation.
Title: Re: Really universal soldering controller
Post by: wailer on September 28, 2016, 06:13:39 pm
Mythical Sparkypg,
 I've been using with great satisfaction your project, and I have to thank you for your selfless work.
I have a question.
From the menu I put him to sleep time (10 minutes). And 'possible to insert in a soft "beep" warning that starts the sleep period?
Thanks again
Title: Re: Really universal soldering controller
Post by: sparkybg on September 28, 2016, 06:48:03 pm
[quote author="wailer"]
From the menu I put him to sleep time (10 minutes). And 'possible to insert in a soft "beep" warning that starts the sleep period?
Thanks again[/quote]

Firmware needs to be updated for this. And I don't know when I will have the time to update it.
Title: Re: Really universal soldering controller
Post by: Evgeny1 on September 29, 2016, 01:28:03 pm
Sometimes the right sleep during soldering!
It would be nice to do not fall asleep at a time when there is an active pumping of heat from the tip.
Sorry for my english
Title: Re: Really universal soldering controller
Post by: sparkybg on September 30, 2016, 11:05:08 am
[quote author="Evgeny1"]Sometimes the right sleep during soldering!
It would be nice to do not fall asleep at a time when there is an active pumping of heat from the tip.
Sorry for my english[/quote]

This is extremely unreliable, especially when made universal. Even with 2 different tips on the same system (for example small and big C245 tip). That's why there's so many systems for this - acoustic, capacitive and so on. Optical sensor in the iron's stand is much more reliable, universal, cheap and easy to do solution. Works rock-solid on my stands.
Title: Re: Really universal soldering controller
Post by: Evgeny1 on October 02, 2016, 09:09:47 pm
:(
Title: Re: Really universal soldering controller
Post by: Circuiteromalaguito on October 03, 2016, 02:27:55 pm
[quote author="sparkybg"][quote author="wailer"]
From the menu I put him to sleep time (10 minutes). And 'possible to insert in a soft "beep" warning that starts the sleep period?
Thanks again[/quote]

Firmware needs to be updated for this. And I don't know when I will have the time to update it.[/quote]

Is the firmware somewhat hardware independent? Using the same MCU family, but in a similar way to Mikrocontroller.net (http://http://www.mikrocontroller.net/)'s transistortester (http://https://github.com/svn2github/transistortester)?

Can it be made Affero GPL v3 or greater then? It would be nice if it's used by more projects, so there could be a bigger community behind it :D

Thanks a lot for your project!
Title: Re: Really universal soldering controller
Post by: sparkybg on October 03, 2016, 02:34:45 pm
[quote author="Circuiteromalaguito"]...[/quote]

As I already mentioned several times, the project will stay the way it is. PERIOD! Please stop asking the same thing again and again.
Title: Re: Really universal soldering controller
Post by: Railjumper on October 08, 2016, 12:09:19 am
Hello Guy's, Hi Sparky,
first of all i have to thank Sparky for that gorgeous project! Thumbs Up! Yesterday i have soldered the bords, everything works fine. For testing i've soldered two oled boards with two different displays but each one is indicated as UG-2864HSWEG01.After the first test both displays doesn't work as expected. The first display is showing the correct screen but it is unreadable, the second one is flickering. What could be the cause? i have messured the pins(P2 Pin 1 and GND) on oled board, but i've never messured more than 3.5V, 3.3V on OLEDVCCIN. I think the FAN5331 does not work. Who has a tip? Thanks
Here are the Pics:
Sorry Guys, i can't post the pictures. I must wait 24h(new account)
Title: Re: Really universal soldering controller
Post by: sparkybg on October 08, 2016, 12:19:44 am
Send the pictures of front and back of OLED board to sparky@omegatim.com. Then I will be able to comment.
Title: Re: Really universal soldering controller
Post by: Railjumper on October 08, 2016, 01:38:19 am
Hi Sparky, pictures are on it's way. Thanks
Title: Re: Really universal soldering controller
Post by: sladoledko on October 17, 2016, 09:40:35 am
Hi  , could i have one of  universal soldering circuit board .  or to buy finished pcb with all elements.
and i am from Bulgaria, in last for shipping:).
Regards
Title: Re: Really universal soldering controller
Post by: stazis on October 20, 2016, 10:53:46 pm
Hello,
I want to buy a PCB if it is available for this project.
Please contact me.
Thank you!
Title: Re: Really universal soldering controller
Post by: wailer on October 24, 2016, 05:22:49 pm
How to thank sparkybg?
He worked for free for an ambitious and difficult project.
THANK YOU THANK YOU THANK YOU: SPARKYBG.
You're an exceptional person
Title: Re: Really universal soldering controller
Post by: randomone on October 26, 2016, 03:08:31 am
Has anyone got any sensor pcbs spare ? I'm after 4 or 5 of them.

Cam.
Title: Re: Really universal soldering controller
Post by: stazis on November 02, 2016, 08:41:33 pm
Hi,

I have a question. It is possible to use the Weller WMRP iron with this soldering controller?
Like this one: http://uk.farnell.com/weller/wmrp/solde ... dp/1120571 (http://uk.farnell.com/weller/wmrp/soldering-iron-40w-12v-no-tip/dp/1120571)

If yes, where can I find the thermal coefficients for this iron in order to adapt the firmware?
Title: Re: Really universal soldering controller
Post by: michib on November 23, 2016, 10:22:49 pm
Hi everyone,
I have some PCBs left. If anyone is interested in Germany or EU please pm me.

Michael

!!! No more PCBs left !!!
Dez 13
 Michael
Title: Re: Really universal soldering controller
Post by: BadAd84 on December 15, 2016, 09:33:52 pm
[quote author="sparkybg"]first post[/quote]

Hi,

Do you have the files for the replacement back panel for the BK2000+ enclosure, like you had for your older controller (as posted here: viewtopic.php?f=56&t=5264&p=58589#p58595 (http://dangerousprototypes.com/forum/viewtopic.php?f=56&t=5264&p=58589#p58595))?

Thanks
Title: Re: Really universal soldering controller
Post by: svilens on December 23, 2016, 06:53:56 pm
[quote author="randomone"]Has anyone got any sensor pcbs spare ? I'm after 4 or 5 of them.

Cam.[/quote]

I am going to order 10 or 20pcs.
If you're interested I could send some.
Title: Re: Really universal soldering controller
Post by: BadAd84 on December 25, 2016, 12:46:48 am
Chinese Hakko 907
- Outer shell (green wire), PTC negative (blue wire) and heater negative (white wire) connected together to EARTH and Vout1-
- Heater positive (black wire) connected to Vout1+
- PTC positive (red wire) connected to SENSEA
- 100ohm between ID and Vout1-
- 150ohm between ID and Vout2-

The first post has an updated firmware, as the Chinese Hakko 907 profile didnt work correctly. However, it now works with sparky's update.

Your wire colours may vary.
Title: Re: Really universal soldering controller
Post by: Evgeny1 on December 26, 2016, 09:53:44 pm
Via USB you can reflash?
Title: Re: Really universal soldering controller
Post by: sparkybg on December 26, 2016, 11:06:07 pm
[quote author="Evgeny1"]Via USB you can reflash?[/quote]

Yes you can, but the PC software looks for the HEX file in a specific location on the disk for the moment, and I don't know when I will have the time to finish it.
Title: Re: Really universal soldering controller
Post by: BadAd84 on December 27, 2016, 11:12:12 pm
I was intending to strip out the flashing functions into a more streamlined app - its only vb.net.

Would make flashing and testing changes easier - until you get time to finish the app.
Title: Re: Really universal soldering controller
Post by: johnconnor on December 28, 2016, 11:58:27 pm
Good night all.
I am new to the forum, but I have been following this project for a long time, and I already have my unisolder mounted and running .....
Now I want to modify some things of the software
However I have a problem when modifying the software.

I'm working with mplab ide v3.45 and xc32 v1.34.
I open the original sparkybg´s project (US_firmware.x), and without touching anything I build project and put it in pic32mx with mplab program device utility.
In appearance it makes everything right and the unisolder works, but when I connect an iron, the temperature on the display change continuously with absurds values (21,50,32,105,80,200,78 .....) until the iron is heated so much that "open sensor".

Mplab ide when build says:
C:  program files (x86)  microchip  xc32  v1.34  bin  bin  ../../ lib / gcc / pic32mx / 4.5.2 /../../../../ pic32mx /include/peripheral/adc10.h:396:4: warning: #warning "Warning: configport argument for OpenADC10 only works for Port B."
"C:  Program Files (x86)  Microchip  xc32  v1.34  bin  xc32-gcc.exe" -g -xc -c -mprocessor = 32MX564F128H -ffunction-sections -fno-schedule-insns -fno-schedule -insns2 -D_SUPPRESS_PLIB_WARNING -MMD -MF build / PIC32_NoOptimization / production / main.od -o build / PIC32_NoOptimization / production / main.o main.c -DXPRJ_PIC32_NoOptimization = PIC32_NoOptimization
"C:  Program Files (x86)  Microchip  xc32  v1.34  bin  xc32-gcc.exe" -g -xc -c -mprocessor = 32MX564F128H -ffunction-sections -fno-schedule-insns -fno-schedule -insns2 -D_SUPPRESS_PLIB_WARNING -MMD -MF build / PIC32_NoOptimization / production / isr.od -o build / PIC32_NoOptimization / production / isr.o isr.c -DXPRJ_PIC32_NoOptimization = PIC32_NoOptimization
In File included from c:  program files (x86)  microchip  xc32  v1.34  bin  bin  ../../ lib / gcc / pic32mx / 4.5.2 /../../../ ../pic32mx/include/plib.h:49:06,


I suspect the problem is the openADC10 ...¿¿¿¿ ????
I have spent a lot of time trying to solve this problem but I can not find the solution.
Can someone help me?

Thanx.
Title: Re: Really universal soldering controller
Post by: sparkybg on December 29, 2016, 01:15:43 am
I am compiling it with 1.33 and no such warnings are present. Please try XC32 1.33 and let me know. Also, please try the compiled and uploaded HEX and let me know if there is a problem also.

What iron are you connecting to the controller?

P.S. Also, try to compile the project for PIC32MX534F064, not ..564F128, with full optimizations.
Title: Re: Really universal soldering controller
Post by: johnconnor on December 29, 2016, 10:08:17 pm
If I put the original .hex, unisolder working OK.
I  uninstall mplab ide and xc32 v1.34 and reinstall mplab ide and xc v1.33 and now ¡¡¡¡¡¡¡¡I can compile!!!!!!! ..... it works fine .....:)

[quote author="sparkybg"]What iron are you connecting to the controller?[/quote]
I am connecting jbc microtwezzers ....

another question.
If I give a small value (for example 50) to the offset in the profile of the microtwezzers, I could get that the screen does not appear at times "open sensor" when I put the set at 450ºC ...

Thank you.
Title: Re: Really universal soldering controller
Post by: sparkybg on December 29, 2016, 11:05:30 pm
[quote author="johnconnor"]
If I give a small value (for example 50) to the offset in the profile of the microtwezzers, I could get that the screen does not appear at times "open sensor" when I put the set at 450ºC ...
[/quote]

It gives you an "open sensor" because these iron tips are producing pretty large spikes on the reading, and sometimes the reading goes out of range, which is how the controller detects when there is open sensor.

Both hardware gain and offset can be used to correct this behavior. If you are using offset to correct it, make sure the controller works normally at both 150ºC and 450ºC.
Title: Re: Really universal soldering controller
Post by: JJAnderson on December 30, 2016, 03:01:48 pm
Hello Forum

Thank you Sparkybg for the tremondous work you have put into this project and for making it open to others. I've just ordered a batch of PCB's from HQPCB in China. First time I've ordered PCB's so no idea what the company is like or the quality I will receive. Fingers crossed. I've ordered 25 copies of the full PCB. And only 10 of the sensor PCB. The cost for 25 just about the same as it was for 10 so thought I might as well get spares. Happy to pass them on to anyone in the United Kingdom for £5 each (Full PCB set no sensor board).
Probably be a couple of weeks before they appear?

Big component list and RS Components quantities mean I could buy a solder station for the cost of components alone, but not so much fun and I'll have enough spare's to last a lifetime.

Jim
Title: Re: Really universal soldering controller
Post by: baltersice on December 31, 2016, 01:29:29 am
Awesome project!
Happy new year! Can only get better, right?
Title: Re: Really universal soldering controller
Post by: JJAnderson on January 08, 2017, 11:43:41 pm
Does anyone know how best to incorporate desoldering option?

I saw a section in the thread where Sparky shows two different pumps he has used. As it stands I don't see that the station has been designed with desoldering in mind as the socket doesn't seem to incorporate pins for switching on the vaccum and I don't think the firmware supports it? Maybe I have missed something?

Another thing that someone might be able to help me with?
I was looking through the iron.c and iron.h files.

If I want to add an iron to the list presumably I have to change the value of the array in the line:

const t_IronPars Irons[8] //change to 9 for one additional iron?

Then copy and paste one of the other irons to the end of the list and edit it to suit my iron?
 
I don't understand where the hex number 0x1213 in the second line of the code below comes from? Or how the ID resistors tie in with selecting the iron from the list? I assume that two reads are taken on the ADC one with vout1- pulled low then another with vout2- pulled low?

I have a Pace TD100 pencil which I already have a soldering station for but was interested in adding it for the new series of compatible heater elements which can deliver 120W if you use the new Pace WJS station. I was sort of hoping I can connect my existing TD100 pencil to the Unisolder with a new profile for the higher wattage elements?

I'm not sure if the pencil is exactly the same, Pace states:

 "WJS 100 uses inexpensive (about $12 US) Gold Series Tip Heater Cartridges that deliver 120 watts of pure, high performance power! These gold ended tip-heater cartridges are uniquely engineered to deliver maximum heat through-put to the work and increase productivity while allowing you to solder at safer, lower temperatures—even with lead-free solder. The WJS 100 comes standard with a special anniversary edition of PACE’s renowned TD-100 Tip-Heater Cartridge Soldering Iron"

I'd of imagined that some things would require a beef up to cope with the additional current?

{
        0,
        0x1213,
        "HAKKO FX8801            ",
        {//-----------------------------------------------------------------------------------------
            {
                2,                          //Type
                {
                    0,                      //HChannel
                    5,                      //SChannel
                    1,                      //CBandA
                    1,                      //CBandB
                },                         
                205,                        //CurrentA
                0,                          //CurrentB
                0,                          //HRCompCurrent
                13,                        //Gain
                331,                        //Offset
                {                          //TPoly
                    -165.5,                //c0
                    3.98513793,            //c1
                    0,                      //c2
                    0,                      //c3
                    0,                      //c4
                    0,                      //c5
                    0,                      //c6
                    0,                      //c7
                    0,                      //c8
                    0                      //c9
                },
                0,                          //WSLength
                20,                        //PID_DGain
                (UINT16)(0.4 * 32768),      //PID_KP
                (UINT16)(0.02 * 32768),    //PID_KI
                14,                        //PID_OVSGain
                65,                        //PID_PMax
                65                          //PID_PNom
            },
            {0}
        }
    },
Title: Re: Really universal soldering controller
Post by: sparkybg on January 09, 2017, 12:31:16 am
[quote author="JJAnderson"]
I saw a section in the thread where Sparky shows two different pumps he has used.
[/quote]
I have only one pump, and it comes with it's own controller.

[quote author="JJAnderson"]
 As it stands I don't see that the station has been designed with desoldering in mind as the socket doesn't seem to incorporate pins for switching on the vaccum and I don't think the firmware supports it? Maybe I have missed something?
[/quote]
For the moment the controller does not have an option to control desoldering pump.

[quote author="JJAnderson"]
If I want to add an iron to the list presumably I have to change the value of the array in the line:

const t_IronPars Irons[8] //change to 9 for one additional iron?

Then copy and paste one of the other irons to the end of the list and edit it to suit my iron?
[/quote]
Yes, exactly.

[quote author="JJAnderson"]
I don't understand where the hex number 0x1213 in the second line of the code below comes from? Or how the ID resistors tie in with selecting the iron from the list?
[/quote]
Look at the "resid.xlsx" file in the firmware archive.

[quote author="JJAnderson"]
 I assume that two reads are taken on the ADC one with vout1- pulled low then another with vout2- pulled low?
[/quote]
Yes.

[quote author="JJAnderson"]
I have a Pace TD100 pencil which I already have a soldering station for but was interested in adding it for the new series of compatible heater elements which can deliver 120W if you use the new Pace WJS station. I was sort of hoping I can connect my existing TD100 pencil to the Unisolder with a new profile for the higher wattage elements?

I'm not sure if the pencil is exactly the same, Pace states:
[/quote]
Copy Hakko T12/T15 profile as the base for your experiments. PACE TD100 has the same TC voltage and connections, so you will only have to play with the PID coefficients, which will look like JBC C245's coefficients. You will have to change PID_PMax and PID_PNom to 120.

[quote author="JJAnderson"]
I'd of imagined that some things would require a beef up to cope with the additional current?
[/quote]
The controller has a software protection at 6 Amps, which is around 132W at 24V input (-2 diode drops). Even if the resistance of the tip is lower (for example, C210's resistance is under 2 ohms) the controller will limit the current to 6A average, and the power to PMax of the profile.
Title: Re: Really universal soldering controller
Post by: JJAnderson on January 09, 2017, 10:08:33 am
Hello Sparkybg,

Thanks for taking the time to answer my questions.

I had looked at the resistor ID spreadsheet before but couldn't see where the hex value for the iron came from. Feel pretty stupid now that I see it.

Hex ID  = (resistor value HexID on vout2-) followed by (resistor value HexID on vout1-)

Ok at least I know where to start with adding my own irons now.

Where I enquired about parts being beefed up for the 120W elements on the TD100 I meant the pencil itself. I'm unsure if there are any differences?

Is there any value in using the PC software at present? I have had Visual Studio installed on my PC before. Quite a large installation of software which I didn't really need or know how to use. It also kept flagging up incomplete components on boot of my laptop so I uninstalled it. If PC communication is not required can the USB isolator be ommited. I have ordered two and will use for my first build but they were one of the more expencive items for further builds if not being used.

Eagerly awaiting my PCB's from China should be in this week. Most of the components here and the rest expected before the end of the week. Is it wrong to be excited? :)
Title: Re: Really universal soldering controller
Post by: sparkybg on January 09, 2017, 10:24:28 am
You will be able to make firmware upgrades with the PC... somewhere in the future... eventually.

Also, my intentions were to be able to add and edit the iron profiles from the PC software.

...but I don't know when and if I will have enough spare time for this.
Title: Re: Really universal soldering controller
Post by: JJAnderson on January 09, 2017, 11:09:45 pm
I tried to add two new iron profiles but received build errors when I tried to compile.

I've only done simple microcontroller programming and never in C so I'm probably missing something simple.

Changed the array value to ten, copied and pasted the Hakko irons to the end of the ERSA iron, pretty sure the braketing was OK.

Changed the text string and the hex ID, copied and pasted the JBC245 PID parameters to one of my new iron profiles.

When I tried to build it showed exclamation marks all the way down the left hand side of the two new iron parameters.
I should have noted down what the fault listed but it was a pointer to the iron.h file and a constant integer value.

So I deleted the two new irons and just modified the Hakko T15 and Chinese Hakko iron parameters to suit my irons.

Now builds without errors and hopefully have no issues with programming the PIC?

[quote author="sparkybg"]You will be able to make firmware upgrades with the PC... somewhere in the future... eventually.

Also, my intentions were to be able to add and edit the iron profiles from the PC software.

...but I don't know when and if I will have enough spare time for this.[/quote]

I understand, between the design and support you have given to the project you've obviously already put in a mass of time and effort.

Thanks Jim
Title: Re: Really universal soldering controller
Post by: sparkybg on January 10, 2017, 12:13:50 am
I am pretty sure it was a bracketing/syntax problem.
Title: Re: Really universal soldering controller
Post by: baltersice on January 15, 2017, 12:38:27 pm
I made a 250W controller for the JBC C470 tips. 43.5 * thermocouple mV seems to work perfectly for those too.
http://https://www.youtube.com/watch?v=GYIiOkr6x9o
Title: Re: Really universal soldering controller
Post by: Gabesz103 on January 15, 2017, 09:31:18 pm
Hello,

Iam Gabor from Hungary.

I would like to buy 2pcs set from unisolder 5.2 PCB.
As somebody can send me? Please send me offer..
Title: Re: Really universal soldering controller
Post by: JJAnderson on January 17, 2017, 09:47:56 am
Two boards on their way Gabor. I have 15 spare if anyone requires one use PM to keep the thread clear.
Just waiting for a few components to finish my boards.
For someone who's not done a great deal of SMD soldering this has been a real pleasure to build. Nice selection of packages to practice on.
Title: Re: Really universal soldering controller
Post by: Aigor on January 18, 2017, 12:07:30 am
Hi, maybe a dumb question, what purpose for sensor board that i saw in gerber file?
I saw several realization, but i didn't see any sensor bord in, i'm becoming blind O.o ?
Title: Re: Really universal soldering controller
Post by: JJAnderson on January 20, 2017, 05:22:58 pm
The sensor PCB is basically a photo interuptor for mounting in the iron stand. It will sense that the iron is in the stand for placing the iron into standby. The all in one PCB that I posted to you doesn"t include the sensor PCB. I'm not sure how usefull it is without the stand which it was designed to fit? I am trying to make a stand to accomodate the sensor PCB for a JBC 245 that I have ordered. But for the stands that I already own the sensor PCB would be quite difficult to incorporate. Be interesting to see how others have managed to integrate it into their stands?
Title: Re: Really universal soldering controller
Post by: JJAnderson on January 23, 2017, 11:51:16 pm
Hi Sparky,

I don't suppose you have connections for Pace TD100?

There are four wires in the handle as follows:

Green to heater shell
White goes to one end of a cold junction thermocouple bead in the handle - Unused by controller?
Blue goes to the other end of the cold junction thermocouple and one side of the heater
Red to other end of heater

Do I just connect as per the Hakko T12 and forget about the cold junction?

Thanks
Jim
Title: Re: Really universal soldering controller
Post by: afedorov on January 25, 2017, 09:56:17 pm
[quote author="JJAnderson"]Be interesting to see how others have managed to integrate it into their stands?[/quote]
Sensor board is simple relative to controller, I believe it's easier to redesign and make a new PCB that fits perfectly the particular stand than do a mechanic job to incorporate Sparky's sensor PCB.
Title: Re: Really universal soldering controller
Post by: sparkybg on January 25, 2017, 11:35:35 pm
[quote author="JJAnderson"]Hi Sparky,

I don't suppose you have connections for Pace TD100?

There are four wires in the handle as follows:

Green to heater shell
White goes to one end of a cold junction thermocouple bead in the handle - Unused by controller?
Blue goes to the other end of the cold junction thermocouple and one side of the heater
Red to other end of heater

Do I just connect as per the Hakko T12 and forget about the cold junction?

Thanks
Jim[/quote]

Yes, use T12's connections. You may have to play a little with the PID coefficients, but TD100 gives the same TC voltage as Т12 does.
Title: Re: Really universal soldering controller
Post by: JJAnderson on January 25, 2017, 11:39:32 pm
Nice job, what stand did you make it to fit? That's pretty much what I thought myself, stand will dictate in most cases.
Title: Re: Really universal soldering controller
Post by: sparkybg on January 26, 2017, 12:11:01 am
It is made for this exact stand:
http://www.circuitspecialists.eu/solder ... el-holder/ (http://www.circuitspecialists.eu/soldering/accessories-spares/all-accessories/csi-2630-spare-soldering-iron-stand-with-solder-reel-holder/)

I've uploaded the firmware again. This one positively works on my controller. Upload the "standalone" version and let me know what happens. The "with bootloader" version works on my controller for sure.
Title: Re: Really universal soldering controller
Post by: afedorov on January 26, 2017, 12:34:46 am
[quote author="JJAnderson"]what stand did you make it to fit?[/quote]
Since initially I didn't have any stand, I've decided to try making my own, which resembles original JBC T245 stand.
Title: Re: Really universal soldering controller
Post by: JJAnderson on January 26, 2017, 01:34:02 am
Thank you Sparky.

New firmware did the trick. Now have JBC245 and Pace TD100 working. TD100 needs a bit a calibration but JBC seems spot on with 63/37 solder.

Cheers
Title: Re: Really universal soldering controller
Post by: JJAnderson on January 27, 2017, 08:57:45 pm
Hi Sparky,

I am trying to modify the iron parameters to suit my Pace TD100. Before doing any major alterations I tried only editing the text string for the Hakko T15 iron to "Pace TD-100 Standard    " (24 characters) When I build and program the PIC the new text is displayed, when I plug my iron in. But back to iron temperature being erratic then reading room temperature while still heating the iron at full power.
To get the Unisolder to function correctly I have to program the hex file directly from the download. I had initially had problems with this, where the Pickit3 would report no target device. I found that if I disconnect the front panel and select the option to power the target from the Pickit3. I can program the pre-built hex file which works fine.

When I try to build the PIC32_Standalone I get lots of errors relating to XC32 being the free version and requiring a licence for this option.

When I build the PIC32_NoOptomizations. I get no build error and the PIC programs but still with erratic temperature.

Could it be that the optimazations are required for proper operation of the controller?

If this is the case it would mean I need a licenced version before I can modify to suit my Irons?

I will uninstall XC32 1.33 and install 1.32 to see if it makes any difference.

I also noticed that when I open the project for a start it specifies a PIC32MX534F064H and that one of the source code files is PIC32MX534F064H.c The Micro that I have is the one in the BOM which is a PIC32MX534F128H. I'm guessing that the difference is just memory?

Thanks Jim
Title: Re: Really universal soldering controller
Post by: sparkybg on January 27, 2017, 09:08:39 pm
Yes, the difference is just memory. I have the smaller chip in my controller.

I am compiling with 1.33. When I compile it with "no optimisations" the memory in my controller is too low for it to fit.

For the programming - you may try to use USB isolator. I am also getting errors from time to time when programming with PicKit3.

P.S.: "No optimization" version is only for debugging disassembled code. I've never tested it.
Title: Re: Really universal soldering controller
Post by: JJAnderson on January 27, 2017, 09:55:27 pm
I just uninstalled V1.33 and installed V1.32 tried to build both the NoOptimizations and the Standalone. The Standalone version flags the same warnings about the free version. Neither of the two function correctly after programming the device.

Are you using the free version of XC32 V1.33?

If so it must be something I am doing wrong.

From your software download. I take the Project Front US_Firmware and drop it into the folder  C:MTTTLS2101US_Firmware.X
I open MPLAB IDE
Open Project [Navigate to the above project]
In the Projects Tab I select the Project [US_Firmware]
Right click on the project and set as main project
Right click on the project and go to Properties
I select the device as PIC32MX564F128H
Choose the Pickit3 as the hardware tool
I select XC32 V1.32 as the compiler
In the categories pane I select the Pickit3 and select the power options
Select power the target from Pickit3 [yes]
OK
On the main window I select clean and build
Then make and program the main project.

Programs fine but as reported, temperature problem comes back.

Programming the HEX file direct from the download works perfectly, just doesn't give me the ability to adapt irons.

I'm either doing something stupid or the difference is in the optimizations?
Title: Re: Really universal soldering controller
Post by: Evgeny1 on January 31, 2017, 07:22:28 pm
What controls the current setting in the calibration menu?
Title: Re: Really universal soldering controller
Post by: sparkybg on January 31, 2017, 07:36:51 pm
You can change it with +/- buttons if you want.
Title: Re: Really universal soldering controller
Post by: Evgeny1 on January 31, 2017, 07:46:44 pm
and what are the benefits?
I change, but there is no difference
Title: Re: Really universal soldering controller
Post by: sparkybg on January 31, 2017, 08:10:51 pm
There should not be difference. When 10 ohm resistor is connected, only the current and ADC changes. The firmware calculates the resistance of calibration resistor based on settings.

Also there is not any benefit changing it. The only function of calibration menu is to calibrate the amplifiers gain. When set to 128, the current sources have the best accuracy, because it is exactly at the mid scale of the digital pots that controls them. At the same time, gain setting of 128 also has the best accuraccy, because it is at the mid scale of the gain setting digital pot. And when ADC's value is near the mid scale, the ADC is at it's best accuracy, and with 10ohm resistance it should be 490. In fact the ideal calibration resistor would be 10.449 ohm. Then with current pot set to 128 and gain pot set to 128, the ADC value would be 512.
Title: Re: Really universal soldering controller
Post by: Evgeny1 on January 31, 2017, 08:13:05 pm
Thank you
Title: Re: Really universal soldering controller
Post by: puzzle on February 21, 2017, 01:55:20 pm
Hello to everybody!
New to the forum, and I like to congratulate the author of this incredible project!!!
Me and my friend would very much like to build this and we are missing crucial part  :D the boards :D 
Does anyone here have 2 spare board sets? I'm located in Europe, Bulgaria.

Thank you in advance
Title: Re: Really universal soldering controller
Post by: protonoob on February 22, 2017, 12:42:01 pm
Hello,

I am looking to get some pcbs made with sensors, i dont quite understand the file list as apparently there are different configurations

If somebody can perhaps skype with me and help me get this sorted i can pay you via paypal for your time

I was going to hire a local pcb engineer to help but would rather put money into this great community
Title: Re: Really universal soldering controller
Post by: zed65 on February 22, 2017, 10:18:02 pm
Ok, first of all thanks sparky for a great project!

I've now finished the project and it finally works.
Thought I would share some of my experience when building this.

1. Place all the components in right angle (90 degrees) especially R46, C60, R65, R63. Be careful, double check (I didn't) :)
2. You can NOT program the PIC via the PicKit2/3 standalone programming software. You have to put the programmer into
MPLab mode in the standalone software then program it via MPLab. (took me quite some time and chips to figure out).
3. If you (like me) burn your 74HC02D, don't replace it with a CD4001B, they are not fully pin compatible :)
4. Bridge correct jumpers to the LCD (look at photos).
5. If you are going to change something in the software you need the right compiler: XC32 v1.33 and you also need to do
optimization "s", so it will not compile with the Free version of MPLab X.

And last, if it doesn't work, check for bad solderjoints again and again.

/Alex
Title: Re: Really universal soldering controller
Post by: puzzle on February 23, 2017, 08:54:35 am
Hello again,
now the 24h spam filter limit has passed I can finally add the word "to buy" in my posts:) Man, was it a pain registering 6 times to figure that out :D
So does anyone have 1 or 2 spare sets of boards to sell to us?

Have a nice day
Title: Re: Really universal soldering controller
Post by: zed65 on February 24, 2017, 07:08:55 pm
Here are a picture of my Unisolder 5.2

[attachment=0]
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 01, 2017, 08:18:53 am
I still have spare boards. £6 each plus £4 for European postage. Can fit two boards in one envelope if needed. Use PM to contact me.

The last time I used my Unisolder I have a feeling it overheated the iron when it went to sleep. Wasn't using a stand with standby function and iron left unused in the stand for a good period of time. JBC 245 tip blue and seemed very hot. Station displayed Zzzz...

First time it's been left unused for any length of time makes me a little nervous. Anyone else have this happen?
Title: Re: Really universal soldering controller
Post by: sparkybg on March 01, 2017, 09:48:23 am
No one else reported such problem and I cannot reproduce it either. I am using C245 on a daily basis.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 01, 2017, 09:00:51 pm
Latest - Weller WMRT. Needs slight hardware modification, but works like a charm:
http://https://www.youtube.com/watch?v=eHNJuQEw6XU&feature=youtu.be
Title: Re: Really universal soldering controller
Post by: Iwanushka on March 01, 2017, 09:05:42 pm
Hello sparkybg,

Could you post schematic for these changes?
Title: Re: Really universal soldering controller
Post by: sparkybg on March 01, 2017, 09:50:50 pm
The schematic is the same. two power supply traces on the boars are cut, and two wires are installed. I will post them when I got the time for it. It is a small modification.
Title: Re: Really universal soldering controller
Post by: electronics on March 02, 2017, 08:51:59 pm
Hello sparkybg,

I have some questions about your UniSolder 52:

Which program you used to create the PCB layout and which you used for programming the microcontroller ?
Which program could open the PCB layout gerber files ( .gbl, .gbo, .gbp, .gbs, .gd1, .gg1, .gko, .gtl, .gto, .gtp, .gts)    ?
Do you know, if the JBC DR 5600 desoldering iron or the AOYUE  desoldering iron for e.g. the AOYUE Int474A++ desoldering station is compatible to the UniSolder?
Title: Re: Really universal soldering controller
Post by: sparkybg on March 02, 2017, 09:56:55 pm
I am using MPLAB X+PicKit3 for programming. Gerber files can be opened with most PCB design software. For example http://www.viewplot.com/ (http://www.viewplot.com/)

I cannot publish the design files because they are not made with free software.

Any soldering iron with thermocouple or resistive sensor can be driven, given the heater's resistance is higher than 0.8 ohm. This does not mean that you can drive it straight away - you will have to make profiles for your irons and recompile the firmware.
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 02, 2017, 11:02:43 pm
[quote author="electronics"]Hello sparkybg,

Do you know, if the JBC DR 5600 desoldering iron or the AOYUE  desoldering iron for e.g. the AOYUE Int474A++ desoldering station is compatible to the UniSolder?[/quote]

Yes JBC DR5600 works perfectly. Though it's performance isn't stellar. No fault of the unisolder and may be improved with a better vacuum pump. Unisolder wont control the pump/venturi though. For that you need your own controls. I bought an old Weller DS 801 stripped the soldering iron controller and replaced it with the Unisolder. Works perfectly, just wish the DR5600 nozzles sealed against the heater body better, loose a lot of suction though the lack of sealing.

[quote author="sparkybg"]No one else reported such problem and I cannot reproduce it either. I am using C245 on a daily basis.[/quote]
 
I can confirm the same thing happened with JBC DR5600. Left on in the stand. Picked up the iron and tip was blue. Controller in Zzzz... Switched off the controller then back on, temperature 512 deg C. Sleep temp set to 150 deg C. It is like to cotroller just stops regulating the temperature when it enters Zzzz... I think the only thing stopping it heat is the ADC going over range, somehow it is losing the setpoint.

I did have a look at the source code but I'm not proficeint enough at coding to fathom it out. The furthest I got was the case statement that generates the Zzzz.. text by the value of CMode. Can the stand by function be disabled? The shut back temperature works fine when I use the holder with the PCB in it just haven't finished manufacturing a base for it yet.

Otherwise I'm enjoying the controller thank you.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 02, 2017, 11:11:01 pm
I will check the source code again....
Title: Re: Really universal soldering controller
Post by: sparkybg on March 03, 2017, 02:27:44 am
I've just reproduced it. It does it only with C245. I will correct it after I find where the problem is.
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 03, 2017, 07:59:59 am
[quote author="sparkybg"]I've just reproduced it. It does it only with C245. I will correct it after I find where the problem is.[/quote]

Hi Sparky, My DR5600 is just a copy of the C245 iron profile with the power rating reduced. Thanks for looking into it.
Title: Re: Really universal soldering controller
Post by: Cr0oK on March 03, 2017, 12:26:49 pm
Hi JJAnderson I would be interested in your experience with the DR5600. Can you share the wiring??
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 03, 2017, 05:13:26 pm
[quote author="Cr0oK"]Hi JJAnderson I would be interested in your experience with the DR5600. Can you share the wiring??[/quote]

Wiring is the same as JBC245 you have two additional wires for the switch which you can use to operate your pump or valve. On the Weller station which I used had a drive transistor for the pump motor already so the switch is just providing base current. I don't think you'd want to switch much more than that by the switch on the iron. Means you need an additional pair of pins on all of your plugs ans sockets.

Iron profile is the same as JBC245 with modified power.

Code: [Select]
{
        0,
        0x1412,
        "JBC DR5600              ",
        {
            {
                1,                          //Type
                {
                    0,                      //HChannel
                    7,                      //SChannel
                    1,                      //CBandA
                    1,                      //CBandB
                },
                0,                          //CurrentA
                10,                        //CurrentB
                0,                          //HRCompCurrent
                87,                        //Gain
                0,                          //Offset
                {                          //TPoly
                    0,                      //c0
                    43.5,                  //c1
                    0,                      //c2
                    0,                      //c3
                    0,                      //c4
                    0,                      //c5
                    0,                      //c6
                    0,                      //c7
                    0,                      //c8
                    0                      //c9
                },
                1,                          //WSLength
                11,                        //PID_DGain
                (UINT16)(0.3 * 32768),      //PID_KP
                (UINT16)(0.003 * 32768),    //PID_KI
                10,                        //PID_OVSGain
                75,                        //PID_PMax
                130                        //PID_PNom
            },
            {0}
        }
    },

Outer shell (green wire) connected to GND and SENSEB
Heater positive(red wire) connected to Vout1- and SENSEA
Heater negative(blue wire) connected to Vout1+
820R between ID and Vout1+
1K2 between ID and Vout2+
Can't remeber the colours of the switch wires, whatever is left, think they were yellow and black? Also check I can't remember if any of those two wires were initially connected to the heater shell inside the iron. Easy enough for you to measure between shell and both of those wires. If it is you'd need to remove the link so you have a completely volt free switch contact or be aware of it for interfacing with your vaccum circuit.

The desolding iron performance isn't as good as I hoped. I have a Pace SX80 which is probably better but prone to blocking the nozzle. Haven't had that problem with the DR5600. I haven't tried using the Pace vacuum pump with the DR5600. might be worth a try. The Weller pump is much more quiet but I'd rather have suction than worry about noise. The next one I do I'm going to try a venturi to see if I can get a bit more suck out of the DR5600?
Title: Re: Really universal soldering controller
Post by: sparkybg on March 03, 2017, 10:02:52 pm
Spotted it! It was a bug in the PID.c file. A stupid mistake, VERY hard to find.

I've uploaded the latest firmware in the first post. It is mandatory for everyone to download it. It affects all irons, if the current  temperature of the iron is above 256 degrees Celsius at the moment the controller goes to sleep.
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 04, 2017, 12:07:34 am
[quote author="sparkybg"]Spotted it! It was a bug in the PID.c file. A stupid mistake, VERY hard to find.
[/quote]

Thank you Sparky. Compared the files and can see it would have been easy to miss -

Much appreciated :)
Title: Re: Really universal soldering controller
Post by: electronics on March 05, 2017, 12:12:12 am
Hello JJAnderson,

Do you use the original JBC stand for the DR 5600 desoldering iron or do you use another stand ?
How long does it take to heat up the hole desoldering iron with the unisolder (desoldering nozzle and the pipe of the heating elemet up to the solder containe) and not only the desoldering nozzel ?
Title: Re: Really universal soldering controller
Post by: electronics on March 05, 2017, 12:25:51 am
Hello sparkybg,

Is it possible to use the CSI 2630 Soldering Iron Stand for the JBC T245 and T210 soldering Irons ?
In which range are the sleep time and sleep temperatur adjustable ?

Thank you very much for your help!
Title: Re: Really universal soldering controller
Post by: sparkybg on March 05, 2017, 12:40:38 am
There are connector on the back pcb for the stand, containing +3.3V, GND and SLEEP (active low with 3k pull up) signal. As long as you make the stand to provide this signal, you can use it.

There is immediate holder temperature setting (150-450 degrees), then after 0-240 seconds it goes to "sleep" mode (150-450 degrees), and then, after 0-240 minutes, it goes to "stand-by" mode, displaying "ZZZ.. .  .", and you will have to restart it in order to use it again.
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 05, 2017, 11:23:13 am
[quote author="electronics"]Hello JJAnderson,

Do you use the original JBC stand for the DR 5600 desoldering iron or do you use another stand ?
How long does it take to heat up the hole desoldering iron with the unisolder (desoldering nozzle and the pipe of the heating elemet up to the solder containe) and not only the desoldering nozzel ?[/quote]

Yes I do have the original stand but haven't connected it to the controller as of yet. To be honest I was a little wary of connecting the mains earth referenced iron sheath to control ground at any point other than the iron? For the same reason I am unsure weather the stand chassis should be connected to control ground, mains earth or left floating?

Heating of the joint is not something you could put a time on, too variable depending on copper mass, number of layers, lead free or no. Heating of the iron from cold to 350 deg C is between 45 and 50 seconds. I did try it with sleep function in homemade stand but the re-heat time from even 200 deg C is a bit of a pain, not unworkable but does mean you have to wait for about 10-15 seconds for the iron to achieve heat.
Normally speaking I turn on the desolding iron remove all of the items I want to extract then turn it off. I'm just an electrician with an electronics hobby. I see the new JBC desoldering iron is specified as having max power of 160W and looks to be the same. But any reference I could find for the DR5600 shows max heater as 75W. Maybe I could drive the element harder? The Unisolder certainly has the capacity, it is currently being limited by software at 75W. Heat loss during joint heating and vacuum use is not an issue though. Very large heater mass and element is certainly capable of maintaining the heat.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 05, 2017, 02:58:40 pm
Stand must be left floating for jbc instruments.
Title: Re: Really universal soldering controller
Post by: chefgeek on March 06, 2017, 12:52:28 am
Does anyone have a kit for this iron?  Or assembled PCBs?  If not, how do I tell how big each PCB is?  I wanted to place an order with seed fusion pcb but it says the max pcb size is 100x100cm so I wasn't sure if the _full gerber would fit in 100x100cm.
Title: Re: Really universal soldering controller
Post by: zed65 on March 06, 2017, 06:16:41 pm
Note, the largest panel seed can do is 100x100 cm (1x1 meter).
Unisolder fits into that I can assure you :)
Title: Re: Really universal soldering controller
Post by: sparkybg on March 06, 2017, 06:41:57 pm
UniSolder52_full is 144mm X 87mm.
Title: Re: Really universal soldering controller
Post by: chefgeek on March 07, 2017, 09:16:00 pm
[quote author="sparkybg"]UniSolder52_full is 144mm X 87mm.[/quote]

Thanks everyone for the info.  How did you figure out the size from the gerber?
Title: Re: Really universal soldering controller
Post by: chefgeek on March 07, 2017, 10:48:26 pm
What case are you putting this in?
Title: Re: Really universal soldering controller
Post by: sparkybg on March 07, 2017, 11:38:26 pm
[quote author="chefgeek"]How did you figure out the size from the gerber?[/quote]

I am not looking at gerbers, but they also can be used. Open them in decent gerber viewer and it will be able to tell the dimensions. For example http://www.gerber-viewer.com/ (http://www.gerber-viewer.com/)

[quote author="chefgeek"]What case are you putting this in?[/quote]

This is answered on the third page. ;)
Title: Re: Really universal soldering controller
Post by: sparkybg on March 08, 2017, 03:07:35 pm
[quote author="JJAnderson"]Hi Sparky,

I don't suppose you have connections for Pace TD100?

There are four wires in the handle as follows:

Green to heater shell
White goes to one end of a cold junction thermocouple bead in the handle - Unused by controller?
Blue goes to the other end of the cold junction thermocouple and one side of the heater
Red to other end of heater

Do I just connect as per the Hakko T12 and forget about the cold junction?

Thanks
Jim[/quote]

Do you have any idea what is the value of cold junction thermistor of TD100? I've just ordered a TD100 handpiece, but it will take a while to arrive. So far I cannot find any information regarding this.
Title: Re: Really universal soldering controller
Post by: Iwanushka on March 10, 2017, 01:41:05 am
Sparkybg where can I buy Pace T-100 hand piece?
Title: Re: Really universal soldering controller
Post by: sparkybg on March 10, 2017, 09:35:10 am
farnell
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 10, 2017, 01:47:07 pm
Quote
Do you have any idea what is the value of cold junction thermistor of TD100? I've just ordered a TD100 handpiece, but it will take a while to arrive. So far I cannot find any information regarding this.

I will have a look at it later tonight

Just checked it and the NTC thermistor bead is red with a gold top. Resistance measures about 2k2 at 25 deg C.

Hope it helps
Title: Re: Really universal soldering controller
Post by: aion on March 13, 2017, 11:17:34 pm
[quote author="JJAnderson"]I still have spare boards. £6 each plus £4 for European postage. Can fit two boards in one envelope if needed. Use PM to contact me.

The last time I used my Unisolder I have a feeling it overheated the iron when it went to sleep. Wasn't using a stand with standby function and iron left unused in the stand for a good period of time. JBC 245 tip blue and seemed very hot. Station displayed Zzzz...

First time it's been left unused for any length of time makes me a little nervous. Anyone else have this happen?[/quote]

If you still have any spares, please check your PM.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 14, 2017, 08:55:23 am
[quote author="JJAnderson"]
Quote
Do you have any idea what is the value of cold junction thermistor of TD100? I've just ordered a TD100 handpiece, but it will take a while to arrive. So far I cannot find any information regarding this.

I will have a look at it later tonight

Just checked it and the NTC thermistor bead is red with a gold top. Resistance measures about 2k2 at 25 deg C.

Hope it helps[/quote]

Don't bother. It is a standard 2k NTC.
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 15, 2017, 08:28:40 am
Quote
Don't bother. It is a standard 2k NTC.

I'm not sure what you mean by "don't bother" I did look and posted up what I found? Maybe not enough information?

So now that you know what the thermister is do you plan to incorporate it somehow?
Title: Re: Really universal soldering controller
Post by: sparkybg on March 15, 2017, 10:32:05 am
[quote author="JJAnderson"]
Quote
Don't bother. It is a standard 2k NTC.

I'm not sure what you mean by "don't bother" I did look and posted up what I found? Maybe not enough information?

So now that you know what the thermister is do you plan to incorporate it somehow?[/quote]

Oh! I've missed this somehow. Sorry.

I will see what I can do. But according to my measurements, it show 2.0K at 25 degrees, not 2.2. I will try to find a datasheet...

It seems to be this one:
http://uk.farnell.com/vishay/ntcle100e3 ... dp/1187025 (http://uk.farnell.com/vishay/ntcle100e3222jb0/thermistor-ntc-2k2-5-radial/dp/1187025)

I will have to disassemble mine and see if the coloring is the same. Red+gold means 2.2K 5% according to the datasheet.
Title: Re: Really universal soldering controller
Post by: TilmanBaumann on March 15, 2017, 10:37:46 am
I'm in the process of building up the BOM at Digikey. It's pretty horrendous, to be honest.
I guess it could be better with farnell, but they don't do business with end customers in Germany. :(

I wonder, has anyone built a complete BOM which he could share. At some kind of shop that sells in Europe.

Ideally, I would hope somebody would make a kit. I don't mind soldering this board, but some of the parts are surprisingly exotic and I'm no purchasing expert. (Inductors for example. I think only size and impedance matters, but I'm no expert)
Title: Re: Really universal soldering controller
Post by: sparkybg on March 15, 2017, 10:46:58 am
Most parts are available form Mouser also.

I am very surprised that there's a problem with Farnell in Germany, considering the fact that I can buy form them either directly or using local representative in Bulgaria. Both as a company or as a private person. This is strange.

The inductors on the back board is available from at least 2 major manufacturers, Coilcraft for example, and also from several chinese ones. And yes - only the impedance and indictance matters. I am using Coilcraft 3D bodies for them, so they are pretty common inductors.

The small inductor on the display board is alsо from Coilcraft and is available both from Mouser and Farnell. It must be a high frequency one - the booster can be up to 2.5MHz, so high frequency parameters do matter.
Title: Re: Really universal soldering controller
Post by: TilmanBaumann on March 15, 2017, 11:52:57 am
Thanks for your reply.
Ah well, Farnell in Germany is special. Very much not the element14 type hacker friendly establishment. They are stuck in their ways and actively and quite rudely get rid of non-commercial customers.
I was always a happy customer with Farnell UK and I think they were happy with the level of compulsive impulse buys. :)
Anyway, they don't want me and I don't want to beg. Fuck them. :)

I have to spread my BOM a little I suspect. I can for example not find a single coilcraft product ad digikey. Which is a little crazy TBH.
Here is my list so far. Only capacitors, inductors, diodes and a few transistors so far.
http://www.digikey.de/short/32fnnf (http://www.digikey.de/short/32fnnf) (Amounts have generous padding so I can loose a few components)

Perhaps somebody here in the forum will step forward with a public shopping cart that actually makes sense. :)
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 15, 2017, 12:14:04 pm
Quote
I will have to disassemble mine and see if the coloring is the same. Red+gold means 2.2K 5% according to the datasheet

That was the datasheet I looked at. The measurement was a little up and down but 2k2 seemed to tie in with the Vishay datasheet colour code.

I have attached my parts list numbers mainly from RS Components. Some from Farnell and Mouser as well Not very organized either. I had also started to use a colour index as to which board the components were fitted to but didn't complete. Might be of help?
Title: Re: Really universal soldering controller
Post by: sparkybg on March 15, 2017, 12:17:34 pm
[quote author="TilmanBaumann"]
...Here is my list so far....[/quote]
You don't need DS1, DS2, DS3, U9, and Ra-Rd. Thiese are for 7-segment version, and only OLED version is available.

1N4007 diodes are in wrong package. You need SMD parts

Also, don't use Y5V capacitors. Forget about all ceramic capacitors that starts with "Y". Use only X5R and X7R.

You will have to unsolder the display from adafruit PCB. You need bare display. I bought my first one from eBay:
http://www.ebay.com/sch/i.html?_from=R4 ... =100&rt=nc (http://www.ebay.com/sch/i.html?_from=R40&_sacat=0&_sop=15&_nkw=0.96+oled&_pgn=3&_skc=100&rt=nc)

It must look like this:
http://www.ebay.com/itm/0-96in-128X64-W ... SwxEpYxfAW (http://www.ebay.com/itm/0-96in-128X64-White-OLED-LCD-LED-Display-12864-0-96-SSD1306-Stable-for-Arduino-/332152952699?hash=item4d55dbd77b:g:O68AAOSwxEpYxfAW)
Title: Re: Really universal soldering controller
Post by: TilmanBaumann on March 15, 2017, 03:16:15 pm
Thanks Sparkybg. Those are exactly the details I need. :)
Thanks also to JJAnderson. This list will help identify the right components. I can't buy with RS though. The minimal order quantity pushes the BOM price over 300 EUR. For that kind of money, I could go straight to JBC and buy the most expensive option. :)
Not that I expect to pay a whole lot than a professional solder station. Universal is the selling point here for sure.

SZ64 contacted me directly, he will sell me most of the semiconductors and inductors and shunt resistor. That will help a lot.

Does anyone have a board in EU? OSHPark is throwing a error 500 right now...
Title: Re: Really universal soldering controller
Post by: sparkybg on March 15, 2017, 04:04:40 pm
BOM per unit, bought from Farnell+local electronics distributor is around 80EUR, if I remember well. The PCBs made in china come at around 5-10EUR per set. So the total cost should be around 90-100EUR max.

I am nobody, living in a small country that some people even don't know where is, and buying components as a private person for single units. I don't know why your calculation is so different. Mouser, Farnell, TME, Digikey and local distributors are my sources for components.

I'll try to make a BOM from my prespective tonight. 300EUR is INSANE price.
Title: Re: Really universal soldering controller
Post by: TilmanBaumann on March 15, 2017, 04:33:43 pm
Don't worry. That is probably specific for RS-Components and their very high minimal order values. (often 50 or 100 parts, some even 200)
I would share the list, but RS does not have this feature. But with those prices there is no point really.
Don't worry. I have no intention to go with that. :)

But generally, it would be really great for the project to have a few links to shopping lists on various parts suppliers like farnell and a few others. Or have the part numbers in the excel sheet.

PS: SZ64 will actually sell me the complete list of parts. So I'm good.

PPS: I was a little surprised that I can not find the bare OLED anywhere. Seems a little excessive to buy a full kit including display driver and then rip the screen out.
Title: Re: Really universal soldering controller
Post by: SZ64 on March 15, 2017, 05:03:38 pm
@Tilman: Here I bought;)

AliExpress
White:
https://www.aliexpress.com/item/0-96-in ... c47a5acbbf (https://www.aliexpress.com/item/0-96-inch-128X64-White-OLED-Display-12864-LCD-Screen-Board-0-96-SSD1306-Passive-Matrix/32780178211.html?spm=2114.01010208.3.120.WkxsyS&ws_ab_test=searchweb0_0,searchweb201602_1_10065_10068_433_434_10136_10137_10138_10060_10062_10056_10140_10055_10054_128_301_10059_10099_10103_10102_10096_10052_10053_10050_10107_10051_10106_10084_10083_10119_10080_10082_10081_10110_10111_10112_10113_10114_10037_10033_10078_10079_10077_10073_10070_10122_10123_10120_10126_10124-10120,searchweb201603_1,afswitch_1_afChannel,ppcSwitch_7,single_sort_0_default&btsid=e42f8c0e-ac4e-4afc-9c63-92a3568f6513&algo_expid=99a5f9b1-e634-453a-baa5-00c47a5acbbf-12&algo_pvid=99a5f9b1-e634-453a-baa5-00c47a5acbbf)

Blue:
https://www.aliexpress.com/item/0-96-in ... 8a8e2ce380 (https://www.aliexpress.com/item/0-96-inch-128X64-Blue-OLED-Display-12864-LCD-Screen-Board-0-96-SSD1306-Passive-Matrix/32780216407.html?spm=2114.01010208.3.102.RZfeBF&ws_ab_test=searchweb0_0,searchweb201602_1_10065_10068_433_434_10136_10137_10138_10060_10062_10056_10140_10055_10054_128_301_10059_10099_10103_10102_10096_10052_10053_10050_10107_10051_10106_10084_10083_10119_10080_10082_10081_10110_10111_10112_10113_10114_10037_10033_10078_10079_10077_10073_10070_10122_10123_10120_10126_10124-10120,searchweb201603_1,afswitch_1_afChannel,ppcSwitch_7,single_sort_0_default&btsid=b469a1aa-5dbc-4ff6-8366-b9a36e69556d&algo_expid=565374e0-20ac-4cd5-8f8a-758a8e2ce380-11&algo_pvid=565374e0-20ac-4cd5-8f8a-758a8e2ce380)

@eBay:

http://www.ebay.at/itm/0-96in-128X64-OL ... iMUO_Vv6_w (http://www.ebay.at/itm/0-96in-128X64-OLED-LCD-LED-Display-12864-0-96-SSD1306-for-Arduino-3-Colors-/371775254815?var=&hash=item568f88311f:m:mCOhz8D2ddbr6iMUO_Vv6_w)
http://www.ebay.at/itm/0-96in-OLED-LCD- ... 7-XoDj7tng (http://www.ebay.at/itm/0-96in-OLED-LCD-LED-Display-12864-0-96-SSD1306-128X64-for-Arduino-3-Colors-/131985558639?var=&hash=item1ebaf3cc6f:m:mQbi5QrduK9XL7-XoDj7tng)
http://www.ebay.at/itm/SSD1306-0-96-128 ... bpZuM13-Cg (http://www.ebay.at/itm/SSD1306-0-96-128X64-OLED-LCD-LED-Display-12864-0-96in-for-Arduino-3-Colors-/252635319603?var=&hash=item3ad23d0d33:m:m5btvZwcR0gLBbpZuM13-Cg)
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 15, 2017, 07:37:09 pm
Yeah I did pay about £200 for parts to build the unisolder. From those components I have enough parts to build five of them though. Two for bench at home, one for battery site use. Not got that far yet and no harm in having a couple of spares :) Good soldering practice and enjoyable project with nice useful tool at the end. Spare components hopefully be of use for next project. Who am I kidding, be a completely different BOM. Doesn't matter how many components you have, never the right ones.

I have spare PCB's £6 for all in one PCB £4 postage to EU and £0.5 for Paypal fee PM me for If you need one.
Title: Re: Really universal soldering controller
Post by: afedorov on March 18, 2017, 05:40:51 pm
[quote author="TilmanBaumann"]
Ah well, Farnell in Germany is special. Very much not the element14 type hacker friendly establishment. They are stuck in their ways and actively and quite rudely get rid of non-commercial customers.[/quote]
Sounds familiar to me!
Was trying to buy at Digikey, but they've said I buying too many of positions, and they conclude it's a commercial order, which is have to be placed by a company. I've tried to argue, but they didn't even answer. Screw them!
I've found a local agent which is provide access to a several major distributors for a reasonable charge, and consolidate all my parts in one package.
Got all my components from both digikey and farnell without any unnecessary questions.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 21, 2017, 11:58:19 pm
Here's what you must modify to use the controller for Wellert WMRT how tweezers (future support for Weller WMRT will also require this). Cut the power trace around the third button (red lines) and make the connections shown:
[attachment=0]

I will upload the new firmware with added Weller WMRT and PACE TD100 (both black and yellow) profiles soon.

Also, you will be able to upload the firmware with PC software using the bootloader and the USB connection. It will be ready in a week or so.

I will upload and updated GERBERS for a new PCB revision with these modifications. The not needed 7-segment parts will be also removed in the new revision, both from the PCB and the schematic. It will be fully hardware compatible with the current revision.
Title: Re: Really universal soldering controller
Post by: TwinSpark on March 22, 2017, 12:12:09 am
Hi,
I want to buy RS because I have an account at work but I have problems with the digital potentiometers, the SUD50P10 and the MCP6V28-E / SN. Questions:
Can I mount the 10K potentiometers?
Can I mount the MCP6V26-E / SN?
I can not find anything similar to the SUD50P10 ... (100v drain voltage, 20v gate voltage, 136w, 40A ...) Any ideas?

Thank you very much, greetings.
TwinSpark
Title: Re: Really universal soldering controller
Post by: sparkybg on March 22, 2017, 12:27:26 am
You can use MCP6V01/03/06/08/26/28.

For the pots, you canot use 10K. Only 50K and 100K can be used.

I don't know what else can be used instead of SUD50P10. The resistance is the most important parameter. You can use 80V part, and make sure it is not a low voltage gate variant (it must be a good old 10V rated power P-MOSFET).
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 22, 2017, 08:01:12 am
Quote
I will upload the new firmware with added Weller WMRT and PACE TD100 (both black and yellow) profiles soon.

Are you using the cold juction in the TD-100 handpeice? Do you have switchable profile between black and yellow heaters?

Quote
Also, you will be able to upload the firmware with PC software using the bootloader and the USB connection. It will be ready in a week or so.

That will be great :)

The best open source soldering station gets even more universal.
Title: Re: Really universal soldering controller
Post by: sparkybg on March 22, 2017, 09:45:09 am
[quote author="JJAnderson"]Are you using the cold juction in the TD-100 handpeice? Do you have switchable profile between black and yellow heaters? [/quote]

Soon... It needs some firmware updates.
Title: Re: Really universal soldering controller
Post by: unhollyone on March 22, 2017, 06:04:19 pm
Hi. First of all thank you for an amazing project.  i have an idea for an improvement. to be able to use the dual tool feature with 2 different irons, this will need some PCB modifications and a firmware upgrade. the idea is to add another iron sensor to control the sleep/wake of the iron that is picked up and in addition to lock the second iron and that it is left on the second stand. this could be done with a multiplexer to switch between the sensors when both irons are in the stands (use a ironactivated variable). same thing to do with the iron id. sense and iron voltage could be switched with relays. so when you pick up the iron 1, activate the heater/s relay/s and temp sense of iron 1 and lock the iron2 and only unlock when iron 1 is put into his stand. when i'll have more time (first to finish my unisolder hahahah) i'll try adding a tft with touch control and make an ui like jbc dde, dme, nase with all the solder irons
Title: Re: Really universal soldering controller
Post by: valerionew on March 23, 2017, 03:06:00 am
Does someone have a spare board (in europe)?
I've not finished yet to read the entire discussion, so I'm sorry if someone already posted an easy answer to my question :)
Title: Re: Really universal soldering controller
Post by: unhollyone on March 23, 2017, 10:05:51 am
[quote author="valerionew"]Does sameone have a spare board (in europe)?
I've not finished yet to read the entire discussion, so I'm sorry if someone already posted an easy answer to my question :)[/quote]

There is a guy from Rusia Seling on ebay.. realy good price also...Also he sells the components that go with the board (like 105€ shipping included for PCB+parts) I tried to build my own bom on farnel Spain, and with a few parts missing and came around 80€.. so I think it is worth the price he is asking
Title: Re: Really universal soldering controller
Post by: carpin on March 23, 2017, 09:04:23 pm
[quote author="JJAnderson"]
Quote
That will be great :)

The best open source soldering station gets even more universal.
[/quote]
I agree with you :)
Title: Re: Really universal soldering controller
Post by: carpin on March 23, 2017, 09:10:18 pm
And I still didn't find the force, to build the "soldering workhorse station", maybe next month :)
Thanks Sparky
Title: Re: Really universal soldering controller
Post by: valerionew on March 24, 2017, 03:35:39 am
[quote author="unhollyone"]
There is a guy from Rusia Seling on ebay.. [/quote]

Awesome, thanks! :)

EDIT: Just another question (i can't neither search for "power" nor "current" in the topic). If i want to use a 24Vac transformer, how many VA will I need?
Title: Re: Really universal soldering controller
Post by: JJAnderson on March 24, 2017, 08:26:43 am
Quote
Just another question (i can't neither search for "power" nor "current" in the topic). If i want to use a 24Vac transformer, how many VA will I need?

120VA transformer is recomended Controller output current is limited to 6A
Title: Re: Really universal soldering controller
Post by: sparkybg on March 24, 2017, 10:10:51 am
[quote author="JJAnderson"]

120VA transformer is recomended Controller output current is limited to 6A[/quote]

120VA Toroidal transformer. There are some pretty nasty non-toroidals out there, having HUGE leakage inductance, and this matters, despite the fact that I have done everything possible in the firmware to handle most of them.
Title: Re: Really universal soldering controller
Post by: stazis on March 24, 2017, 10:34:11 am
Here is a picture on my UniSolder 5.2. Thank you sparkybg for this great project!

[attachment=0]
Title: Re: Really universal soldering controller
Post by: TilmanBaumann on March 24, 2017, 10:40:12 am
@Sparkybg Oh, I got the same BlackJack station as you. I just assumed you re-used the built in transformer.
Is that node the case? I still might need to go shopping then...
Title: Re: Really universal soldering controller
Post by: sparkybg on March 24, 2017, 10:48:05 am
[quote author="TilmanBaumann"]@Sparkybg Oh, I got the same BlackJack station as you. I just assumed you re-used the built in transformer.
Is that node the case? I still might need to go shopping then...[/quote]

No, I am not using the original transformer. It is one of these nasty ones I mentioned.

I am using this, if I remember well:
http://www.tme.eu/bg/details/tst120w_24 ... tst120003/ (http://www.tme.eu/bg/details/tst120w_24v/toroidni-transformatori/indel/tst120003/)
Title: Re: Really universal soldering controller
Post by: loopingz on March 24, 2017, 11:08:30 am
Anyone with the material to sell or to group buy? Thanks
Title: Re: Really universal soldering controller
Post by: valerionew on March 24, 2017, 11:17:32 am
[quote author="loopingz"]Anyone with the material to sell or to group buy? Thanks[/quote]

I asked just in the previous page...
There is a seller on eBay who sells the enteire kit (except for the transformer I think).
Anyway where are you based?
Title: Re: Really universal soldering controller
Post by: loopingz on March 24, 2017, 11:45:02 am
Hum sorry it looks like I posted too fast.
I am in Europe.
And by the way thanks sparkybg for the project.
Title: Re: Really universal soldering controller
Post by: mwalker on March 28, 2017, 03:07:09 pm
Thanks @sparkybg, this project looks awesome, although I still have a lot of reading to do, 59 pages!
Title: Re: Really universal soldering controller
Post by: sparkybg on April 04, 2017, 12:19:48 am
A new PC software and front firmware is uploaded to the first post.

The PC Software is now entirely in C#, the front end is rewritten. Now you can program only the bootloader, and then use the software for firmware updates using the USB connection. The PC software also does not crash anymore when device is unplugged and plugged in the USB or turned on/off, and automatically switches to bootloader and back when uploading new firmware. Also, a legend with checkboxes is added for every data that is displayed on the graph, so you can switch it on or off. There is still pretty much work to be done on it, but at least it is much more functional now.
Added to the firmware are Pace TD100 Black and Weller WMRT profiles, some work is done on several other places. Now the firmware handles better some irons, where there was initial overshoot when heating for the first time or changing the target temperature.
Title: Re: Really universal soldering controller
Post by: projector42 on April 04, 2017, 01:32:36 pm
what type of sensors/heaters are in these tweezers ?
https://ru.aliexpress.com/item/orginal- ... 31537.html (https://ru.aliexpress.com/item/orginal-AOYUE-950-electric-tweezers-IC-soldering-station-Hot-Tweezer-for-BGA-SMD-repairing-T001/32657031537.html)
Title: Re: Really universal soldering controller
Post by: sparkybg on April 04, 2017, 01:47:31 pm
I don't know. These tweezers are HUGE, and absolute crap! I have them in my drawers somewhere, buried very, very deep...
Title: Re: Really universal soldering controller
Post by: carpin on April 05, 2017, 04:38:55 am
[quote author="sparkybg"]A new PC software and front firmware is uploaded to the first post.
[/quote]

Thank You
Title: Re: Really universal soldering controller
Post by: DinikS on April 05, 2017, 08:06:38 pm
[quote author="sparkybg"]A new PC software and front firmware is uploaded to the first post.

The PC Software is now entirely in C#, the front end is rewritten. ///////.[/quote]
Hi sparkybg, thank you for your project! Could you please shortly explain how to upgrade firmware using PC soft. I suppose Visual Studio needed. Does Visual Studio 2017 suit well?
Title: Re: Really universal soldering controller
Post by: sparkybg on April 06, 2017, 01:02:46 am
1. Upload bootloader to the controller with whatever tool you are using.
2. Turn on the controller, connect it to your PC using USB, eventually wait for the drivers to be installed, open and run the solution in "PC" section of the software with Visual Studio 2015 or later, hit the "Update firmware" button, and select the HEX you want to upload.
Title: Re: Really universal soldering controller
Post by: NECHTO on April 07, 2017, 12:33:29 pm
Hello dear sparkybg!
Many thanks to you for this project!
  You took my brain - I threw all another matters :)
(I had an idea to make that that similar and I thought what cannot be that someone did not think up it yet and began to look for. I found your project and... SUPER!)
Title: Re: Really universal soldering controller
Post by: NECHTO on April 07, 2017, 12:41:53 pm
In your BOM file is position 85 - U15 = MCP4561T-503E/MS. after the numbers 4561 present the letter "T" there is a fundamental difference ? If you use MCP4561-503E/MS (MCP4561 without the letter "T"). I tried to find information and all the specs on this chip (on the manufacturer's website) appears marking MCP4561-503E/MS. What do you think - explain please. Thank you very much!
Title: Re: Really universal soldering controller
Post by: sparkybg on April 07, 2017, 12:52:37 pm
The parts with "T" are the same. "T" means "Tape and Reel", which is how the chips are packed

It is written at the end of the datasheet, on page 99:
http://ww1.microchip.com/downloads/en/D ... 22107B.pdf (http://ww1.microchip.com/downloads/en/DeviceDoc/22107B.pdf)
Title: Re: Really universal soldering controller
Post by: NECHTO on April 07, 2017, 01:05:01 pm
Thank You very much for the quick reply! (Yes I am a fool - just went back through 77 pages).
Title: Re: Really universal soldering controller
Post by: DinikS on April 08, 2017, 09:40:01 pm
[quote author="sparkybg"]1. Upload bootloader to the controller with whatever tool you are using.
2. Turn on the controller, connect it to your PC using USB, eventually wait for the drivers to be installed, open and run the solution in "PC" section of the software with Visual Studio 2015 or later, hit the "Update firmware" button, and select the HEX you want to upload.[/quote]
Hi sparkybg, I did as you said but the problem occured. It started to flash firmware the screen on soldering station became dark and now it doesn't work even not defined by PC. I guess it was uploaded not right firmware and bootloader was corrupted. Is it possible?
And now I think I have to flash bootloader again by pickit. What do you think?
Title: Re: Really universal soldering controller
Post by: sparkybg on April 08, 2017, 11:28:11 pm
Push the "+" and "-" buttons and hold them pushed while turning on the controller. If bootloader is OK, it should enter bootloader mode and the screen will show a row of black and white squares moving to the left.

Does it show these?
Title: Re: Really universal soldering controller
Post by: DinikS on April 09, 2017, 09:22:15 am
[quote author="sparkybg"]
Does it show these?[/quote]
Hi sparkybg, Yes it enter into bootloader mode. Bootloader is OK, but again during flashing the screen become dark, and helps only your method to enter into bootloader mode again.
I try to flash this firmware frontUS_Firmware.XdistPIC32_with_bootloaderproductionUS_Firmware.X.production.hex
Is it right?
Title: Re: Really universal soldering controller
Post by: sparkybg on April 09, 2017, 11:26:47 am
Did you used the exact HEX files from the uploaded archive, or did you recompiled them?

I've just tried them - uploaded the bootloader to my controller with PICKit3, and the uploaded the firmware with PC software - everything works.
Title: Re: Really universal soldering controller
Post by: DinikS on April 09, 2017, 11:56:39 am
[quote author="sparkybg"]Did you used the exact HEX files from the uploaded archive, or did you recompiled them?
[/quote]
I used HEX from uploaded archive from the first page of this tread.
Also I have the eror when start the software. But after pushing the OK button the soft starts well. 
May be this is the reason I can't flash new firmware?
Unfortunately it's my fist experience to use Visual Studio :-(
Title: Re: Really universal soldering controller
Post by: DinikS on April 09, 2017, 01:10:13 pm
Now I won the error which occurs in Visual Studio. It was not correct settings at the startup settings. Now no any errors in Visual Studio but the result is the same - dark screen when the firmware is choosen.
Can it be because the old bootloader is flashed into the chip.
Title: Re: Really universal soldering controller
Post by: DinikS on April 09, 2017, 01:23:47 pm
Updated:
I don't know what happened but finally I succeeded to flash soldering station with new firmware. Some bugs :-) I didn't change any settings in Visual Studio just try again and again to flash.
sparkybg how do you think is it needed to calibrate station after new firmware is flashed into the station?
Title: Re: Really universal soldering controller
Post by: DinikS on April 09, 2017, 01:59:01 pm
[quote author="DinikS"]
sparkybg how do you think is it needed to calibrate station after new firmware is flashed into the station?[/quote]
New problem - the station shows 30C on display but the soldering tip C245 burns and become red. Sparky could you please advice where is the problem?
Title: Re: Really universal soldering controller
Post by: sparkybg on April 09, 2017, 03:12:16 pm
Was it working in the past, or you are just completed your controller?
Title: Re: Really universal soldering controller
Post by: DinikS on April 09, 2017, 03:28:41 pm
[quote author="sparkybg"]Was it working in the past, or you are just completed your controller?[/quote]
I finished it a half year ago and it worked perfectly before updating firmware.
Title: Re: Really universal soldering controller
Post by: sparkybg on April 09, 2017, 03:47:57 pm
Try to upload standalone firmware the old way and see if it works. Maybe it is a boot loader issue, but it still works on my controller. Strange....
Title: Re: Really universal soldering controller
Post by: DinikS on April 09, 2017, 04:08:58 pm
[quote author="sparkybg"]Try to upload standalone firmware the old way and see if it works. Maybe it is a boot loader issue, but it still works on my controller. Strange....[/quote]
The problem is I haven't my own pickit, before I need to buy it. :-(
Now I use the old bootloader. I think the issue date of soft something like June-July last year.
A question - is it necessary for this firmware to make PCB upgrade shown by you some pages earlier. Or this is not affect to the firmware?
I mean this upgrade
Title: Re: Really universal soldering controller
Post by: sparkybg on April 09, 2017, 04:53:26 pm
The modification is only for Weller WMRT. The firmware is compatible to all versions of the hardware. I suspect issue with boot loader. Maybe something is wrong with programming speed.
Title: Re: Really universal soldering controller
Post by: DinikS on April 09, 2017, 05:09:07 pm
Thank you Sparkybg for help. I will buy or may be find pickit and try to flash and be back with result

Updated:
Just ordered pickit3 on ebay. The worst thing - need wait some time :-(
Title: Re: Really universal soldering controller
Post by: SZ64 on April 09, 2017, 06:48:14 pm
[quote author="sparkybg"]

I've just tried them - uploaded the bootloader to my controller with PICKit3, and the uploaded the firmware with PC software - everything works.[/quote]


I have also tested (recompiled hex) and everything works perfectly ;-)
Title: Re: Really universal soldering controller
Post by: sparkybg on April 09, 2017, 08:15:39 pm
[quote author="SZ64"]I have also tested (recompiled hex) and everything works perfectly ;-)[/quote]

Thank you.

Anyone else?
Title: Re: Really universal soldering controller
Post by: dumitruv on April 11, 2017, 05:17:10 am
I tried it too.I haven't seen a significant improvement in stability with Hakko T15, I haven't tried it with 906. I also have the same temperature offset so I'll have to alter C1 again. The bootloader works well though.
Title: Re: Really universal soldering controller
Post by: valerionew on April 11, 2017, 06:48:55 pm
Does anybody have a clue about the T245 connector's name? Can i buy it from TME?
Title: Re: Really universal soldering controller
Post by: afedorov on April 11, 2017, 08:28:54 pm
[quote author="valerionew"]Does anybody have a clue about the T245 connector's name? Can i buy it from TME?[/quote]
Iwanushka stated that receptacle is Hirose RPC1-12RB-6P(71)
viewtopic.php?f=56&t=7218&p=63873&hilit=hirose#p63873 (http://dangerousprototypes.com/forum/viewtopic.php?f=56&t=7218&p=63873&hilit=hirose#p63873)
digikey suggests mating plug Hirose RPC1-12P-6S(71)
Title: Re: Really universal soldering controller
Post by: afedorov on April 11, 2017, 08:33:36 pm
[quote author="DinikS"]
It started to flash firmware the screen on soldering station became dark and now it doesn't work even not defined by PC.
[/quote]
The same thing. Tried several times with no change. But then decided to flash (by PC software) firmware with integrated bootloader and it flashes just fine (two times).
Title: Re: Really universal soldering controller
Post by: sparkybg on April 11, 2017, 11:05:14 pm
Of course it will be this way!

"Standalone" HEX is meant to be used ONLY when flashed directly with PICKit3 ot ICD, or something similar.

When PC software and USB is used, you must upload the "with_bootloader" HEX. It is not with integrated bootloader, but meant to be flashed using the bootloader and PC software!
Title: Re: Really universal soldering controller
Post by: afedorov on April 12, 2017, 05:26:54 pm
Oh, I thought it has a bootloader in it and as bootloader is already flashed there is no point to reflash it.
Thanks, sparkybg, to clear this out for me!
Title: Re: Really universal soldering controller
Post by: mesodumb on April 14, 2017, 07:08:46 am
Hello all.

Im looking to build this project asap. Tired of my sub-par stations that promise features and functionality that somehow disappear. Cant say how many tips ive burned due to failed sleep/shutdown timers. I considered the hakko 951, but it felt limited by comparrison to this project and im too frugal to buy the big boy units @500+++.

 I do have a business account with digikey and mouser,  so i can order as needed. However,  i prefer to buy overstock from someone within the community...plus, admittedly, sourcing parts from multiple vendors is a bit of a pain in the butt. 

If anyone has full kits (preferably un-assembled; its not as fun if you dont actually put it together) then i would like to buy.

Bare minimum, i need a board  or two and supply of the harder to aquire parts due to lower qty and/or usa based dist availability.  I looled at having a run of boards made via chinese manufacturer, but unless i wanted to buy 100 it did not seem worth it. Definitely dont need 100 plus boards. Side note... Amazing that their better pricing started with 15 units. However, difference in price between 15 and 100 was so marginal that it would be silly not to buy the biggest bang per buck.

Thats all my ranting for tonight. I look forward to the project and discussing it as i progress.
Title: Re: Really universal soldering controller
Post by: valerionew on April 17, 2017, 06:34:14 pm
Hi everyone,

First of all, sorry if some details are missing: i wrote this message before, then i pressed "Submit" and i was taken to a login page. Once i logged, my message has disappeard. So i'm re-writing it and i might miss something.

I'm making my BOM with all the parts from TME, with all the links, the minimum quantities, the prices etc.
I really need to buy all or most components from there. I can share it, if someone needs it.

Therefore, i need to change some parts with others.

These are the parts that i want to use insted of the original BOM ones. Maybe sparkybg or someone who knows the design can tell if them would be adequate or not.

SB5100 instead of SR580 (has an higher maximum voltage)

BAT46W instead of BAT46WH (little bit lower forward current: 150mA instead of 250mA, little bit higher Vf)

SK310SMA instead of SS310A (practically the same part from a different manifacturer)

GF1M instead of 1N4007 (i can't find a smd version of the 1n4007. GF1M is also 1kV 1A)

BAV23A insted of MMBD1505A (this is an hard match. they are both in the same configuration, but: BAV23A has 250V instead of 200V reverse voltage and an higher current rate, this should not be a problem. The reverse current is 100nA @ 200V instead of 10nA @ 180V. The forward voltage is similar)

SK34SMA instead of SS34A (the SS34A is listed as Controlled Avalanche Power Diode, the SK as Schottky Barrier Rectifier Diode, but all the other parameters are very similar)

NZT605 instead of FZT605 (very similar charateristics. the NZT605 has a lower V(br)ceo: 110V instead of 140V. Seems compatible, from a different manifacturer)

SPD15P10PL instead of SUD50P10 (similar ratings, the SPD15P10PL is rated for an higher current)

PSMN025-100D instead of IPD053N08N3 (not quite sure of this match. The PSMN025-100D has 47A current instead of 90A)

Now we get to the hard part, the ICs matching.

LM4120 instead of REF3030 (this is an hard match as before. the LM4120 is a STO23-5, the REF3030 a SOT23-3. the two extra pins can be left disconnected and the shared pins match. Nevertheless, the LM4120 has a maximum current of 5mA instead of 25mA and a dropout voltage of 100mV instead of 1mV. The precision is the same. Is it suitable?)

LM4041AIM3-1.2 instead of LM4041CIM3-1.2 (the substitute one seems better performing in terms of precision, i dont really know which other parameters i need to compare)

I havent found any 1:1 substitute for the LM2675M-3.3. There is the LM2671-3.3 which has 500mA instead of 1A of current. is it suitable or i need the full amp?

I can't find the MCP4651-503E/ST and MCP4561T-503E/MS 50k digital potentiometers, but i've found the MCP4561T-103 and MCP4651T-103 10kohm counterparts. Are they ok?

I can't find the HOLDER connector. Maybe i can look for a different connector with the same pin pitch.

I still can't find the ADG734, the MCP6V28-E/SN, the shunt resistor, the buzzer and the oled display.
For the buzzer it seems hard to find 12mm diameter buzzers with a 6.5mm pin spacing. I can only find ones with 7.6mm spacing. Maybe i can just put a connector or solder two wires.

I also ecnountered some problems with the BOM:

A potentiometer is a THT part, but in the discussion i've found that it is an SMD part, 3364X. It really needs to be updated :D
In the BOM there are some 3V zener and some 3.0V ones. 3V±2% would do the job?

Sorry for the many questions but i really need to get my modifications reviewed by someone who knows the design and has more experience than me.
I hope i can give my contribution to the project soon :)


EDIT:
[quote author="mesodumb"]
 I do have a business account with digikey and mouser,  so i can order as needed. However,  i prefer to buy overstock from someone within the community...plus, admittedly, sourcing parts from multiple vendors is a bit of a pain in the butt. [/quote]

I'll have almost certanly some surplus passives. I'm planning to place the parts order within a month. If you are interested, let me know. Where are you based?
Title: Re: Really universal soldering controller
Post by: sparkybg on April 17, 2017, 08:27:56 pm
[quote author="valerionew"]
SB5100 instead of SR580 (has an higher maximum voltage)
[/quote]
It is OK, however, higher voltage parts tend to have larger forward voltage and might warm up a bit more.

[quote author="valerionew"]
BAT46W instead of BAT46WH (little bit lower forward current: 150mA instead of 250mA, little bit higher Vf)
[/quote]
It is OK.
[quote author="valerionew"]
SK310SMA instead of SS310A (practically the same part from a different manifacturer)
[/quote]
It is OK.

[quote author="valerionew"]
GF1M instead of 1N4007 (i can't find a smd version of the 1n4007. GF1M is also 1kV 1A)
[/quote]
OK.
[quote author="valerionew"]
BAV23A insted of MMBD1505A (this is an hard match. they are both in the same configuration, but: BAV23A has 250V instead of 200V reverse voltage and an higher current rate, this should not be a problem. The reverse current is 100nA @ 200V instead of 10nA @ 180V. The forward voltage is similar)
[/quote]
Not OK. You need low reverse leakage diode there, and BAV23A is not specified. LL4148CA is tested OK, however, some manufacturers do sell a schottky instead for 4148, which is definitely NOT OK.

[quote author="valerionew"]
SK34SMA instead of SS34A (the SS34A is listed as Controlled Avalanche Power Diode, the SK as Schottky Barrier Rectifier Diode, but all the other parameters are very similar)
[/quote]
OK.

[quote author="valerionew"]
NZT605 instead of FZT605 (very similar charateristics. the NZT605 has a lower V(br)ceo: 110V instead of 140V. Seems compatible, from a different manifacturer)
[/quote]
Looks OK. Everything with more than 80V rating must be OK.

[quote author="valerionew"]
SPD15P10PL instead of SUD50P10 (similar ratings, the SPD15P10PL is rated for an higher current)
[/quote]
Definitely NOT OK! SPD15P10PL has 0.200ohm resistance and SUD50P10 has 0.043ohm - this is 5 times difference.

[quote author="valerionew"]
PSMN025-100D instead of IPD053N08N3 (not quite sure of this match. The PSMN025-100D has 47A current instead of 90A)
[/quote]
Same thing - you are trying to replace 0.005ohm part with 0.020 ohm part. It will not overheat, but on the lower MOSFETS the resistance is also important for another reasons. Don't compare amperavge rating but Rds-on, when substituting.

[quote author="valerionew"]
LM4120 instead of REF3030 (this is an hard match as before. the LM4120 is a STO23-5, the REF3030 a SOT23-3. the two extra pins can be left disconnected and the shared pins match. Nevertheless, the LM4120 has a maximum current of 5mA instead of 25mA and a dropout voltage of 100mV instead of 1mV. The precision is the same. Is it suitable?)
[/quote]
There are two parts, connected to this reference voltage - the MCU's ADC reference, and the offset DAC. I don't know how much current they consume - you will have to find out yourself. 3.0V 0.1% is the most important rating but I am a bit skeptical about the proposed substitute.

[quote author="valerionew"]
LM4041AIM3-1.2 instead of LM4041CIM3-1.2 (the substitute one seems better performing in terms of precision, i dont really know which other parameters i need to compare)
[/quote]
"A" part is OK. In fact, I am using A part on my controller.

[quote author="valerionew"]
I havent found any 1:1 substitute for the LM2675M-3.3. There is the LM2671-3.3 which has 500mA instead of 1A of current. is it suitable or i need the full amp?
[/quote]
I don't know if 500mA part is OK - you will have to find out yourself. You can substitute it with LM2675-ADJ and put a feedback resistors - there is a place for them on the PCB. When 3.3V part  is used, the top resistor is replaced with solder sumper.

[quote author="valerionew"]
I can't find the MCP4651-503E/ST and MCP4561T-503E/MS 50k digital potentiometers, but i've found the MCP4561T-103 and MCP4651T-103 10kohm counterparts. Are they ok?
[/quote]
10K parts are not OK. 100K (104) parts must be OK.

[quote author="valerionew"]
I can't find the HOLDER connector. Maybe i can look for a different connector with the same pin pitch.
[/quote]
It is a common RJ11 telephone cable connector, and I do have at least 2 alternatives in my drawer. There are MANY manufacturers making this part. Just look at their footprint drawing in the datasheet to find a compatible one.

[quote author="valerionew"]
I still can't find the ADG734
[/quote]
You will have to. It has no alternative. It is available in Farnell, Digikey and Mouser.

[quote author="valerionew"]
 the MCP6V28-E/SN
[/quote]
I think I wrote this many times already, but again - MCP6V01, MCP6V03, MCP6V06, MCP6V08, MCP6V26, MCP6V28 are all switable.
For the 2 opamp parts - MCP6V02, MCP6V07, MCP6V27 are compatible.
Again, these are available from Farnell, Mouser and Digikey.

[quote author="valerionew"]
, the shunt resistor
[/quote]
No alternative. It must be in the same package, so you will have to find 0.003 or 0.004ohm shunt in the same package. Of you look at the front PCB schematic, there is a table with differences when 0.003 and 0.004ohm parts are needed.
These are again available form Farnell and Mouser. I am not sure about Digikey.

[quote author="valerionew"]
 the buzzer
[/quote]
This is the simplest buzzer ever made. Tons of compatible parts exist.

[quote author="valerionew"]
 and the oled display.
[/quote]
You can buy it from eBay. You need SSD1306 128x64 OLED display. Look some posts back - there's even links to the ebay sales.
Be sure to adjust the OLED boost regulator's voltage divider - some displays are 9V, and some are 12V. They will not fail immediately, but I am not sure about long term reliability.

[quote author="valerionew"]
I also ecnountered some problems with the BOM:
A potentiometer is a THT part, but in the discussion i've found that it is an SMD part, 3364X. It really needs to be updated :D
[/quote]
It will be corrected...

[quote author="valerionew"]
In the BOM there are some 3V zener and some 3.0V ones. 3V±2% would do the job?
[/quote]
Ordinary 3V Zeners are OK.
Title: Re: Really universal soldering controller
Post by: valerionew on April 17, 2017, 11:26:28 pm
[quote author="sparkybg"]
Not OK. You need low reverse leakage diode there, and BAV23A is not specified. LL4148CA is tested OK, however, some manufacturers do sell a schottky instead for 4148, which is definitely NOT OK.
[/quote]
Ok, seems a difficult part. I'll source from somewhere else

[quote author="sparkybg"]
Definitely NOT OK! SPD15P10PL has 0.200ohm resistance and SUD50P10 has 0.043ohm - this is 5 times difference.
[/quote]
So i'll go for a AOD409 instead of SUD50P10 (less than 40mΩ Rdson, but only -60V. Shouldn't be a problem, right? On tme there are no better options)

[quote author="sparkybg"]
Same thing - you are trying to replace 0.005ohm part with 0.020 ohm part. It will not overheat, but on the lower MOSFETS the resistance is also important for another reasons. Don't compare amperavge rating but Rds-on, when substituting.
[/quote]
So there's the new part that I've chosen
IPD031N06L3 instead of IPD053N08N3 (0.31mohm rdson, also 60V maximum)

[quote author="sparkybg"]
There are two parts, connected to this reference voltage - the MCU's ADC reference, and the offset DAC. I don't know how much current they consume - you will have to find out yourself. 3.0V 0.1% is the most important rating but I am a bit skeptical about the proposed substitute.
[/quote]
I'm skeptical too, but it's worth a try...

[quote author="sparkybg"]
You can substitute it with LM2675-ADJ and put a feedback resistors - there is a place for them on the PCB.
[/quote]
Cool design feature! I'll try both!

[quote author="sparkybg"]
10K parts are not OK. 100K (104) parts must be OK.
[/quote]
To be sourced somewhere else! :) Maybe i can make a small order to another supplier

[quote author="sparkybg"]
It is a common RJ11 telephone cable connector
[/quote]
I was misled by a picture of the board i was looking to quicker identify the components, and by v in the bom. No problem, i'll get one of these

[quote author="sparkybg"]
You will have to. It has no alternative.
[/quote]
I'll put it in my tiny order from another supplier :D

[quote author="sparkybg"]
I think I wrote this many times already, but again - MCP6V01, MCP6V03, MCP6V06, MCP6V08, MCP6V26, MCP6V28 are all switable.
For the 2 opamp parts - MCP6V02, MCP6V07, MCP6V27 are compatible.
Again, these are available from Farnell, Mouser and Digikey.[/quote]
I'm sorry, i haven't looked deep enough in the thread. Also the 10k/50k/100k potentiometer thing was already mentioned. My bad...

[quote author="sparkybg"]
you will have to find 0.003 or 0.004ohm shunt in the same package
[/quote]
Tiny tiny order :P

[quote author="sparkybg"]
You can buy it from eBay. You need SSD1306 128x64 OLED display. Look some posts back - there's even links to the ebay sales.
Be sure to adjust the OLED boost regulator's voltage divider - some displays are 9V, and some are 12V. They will not fail immediately, but I am not sure about long term reliability.
[/quote]
Allright, i've found it on tme. Same interface and pinout, i assume that the ribbon would be also the same dimensions. REX012864DWPP3N0 (http://http://www.tme.eu/gb/details/rex012864dwpp3n0/graphical-oled-displays/raystar-optronics/rex012864dwpp3n00000/)

[quote author="sparkybg"]
It will be corrected...
[/quote]
It was just a reminder, no offense :D


By the way, thank you so much for your reply!
Title: Re: Really universal soldering controller
Post by: sparkybg on April 18, 2017, 12:11:23 am
60V parts may or may not work. It depends on your transformer's leakage inductance. 24*1.414*1.2 (transformer when idle)*265(max mains voltage)/230(nominal mains voltage) = 46 volts DC max. But when transformer leakage inductance is large enough, there can be peaks that exceed 60V (the TVS voltage). I had this experience with the transformer from the station I am using enclosure from - nasty chinese non-toroidal one, heating up pretty much even when idle. There were peaks that the TVS limited and no parts were damaged. That's why the TVS is there.

I've taken some precautions (3-rd capacitor on the back board, zero current switch-off of heater) in order to avoid peaks even on nasty transformer with big leakage inductance, but I am using 80-100V parts and I don't know if 60V will work reliably. But that's me - I have a nasty habit of being too conservative when making things.

So, make some measurements of the voltage after the diodes if you have an oscilloscope. There should not be any peaks close to 60V there. You can use 55V instead of 60V TVS, just to be sure your MOSFET-s are safe, despite the fact that they are also working as big zeners when their voltage rating is exceeded. However, I don't know if something else can be damaged and how the controller will perform if there are peaks.

The display looks OK. Bear in mind that white one has 20000 hours life and yellow one has 50000 hours. Also, the white one is 12V, and the yellow one is 9V. The yellow looks more fancy, IMHO. :)
Title: Re: Really universal soldering controller
Post by: valerionew on April 18, 2017, 02:02:02 am
[quote author="sparkybg"]60V parts may or may not work. It depends on your transformer's leakage inductance. 24*1.414*1.2 (transformer when idle)*265(max mains voltage)/230(nominal mains voltage) = 46 volts DC max. But when transformer leakage inductance is large enough, there can be peaks that exceed 60V (the TVS voltage). I had this experience with the transformer from the station I am using enclosure from - nasty chinese non-toroidal one, heating up pretty much even when idle. There were peaks that the TVS limited and no parts were damaged. That's why the TVS is there.

I've taken some precautions (3-rd capacitor on the back board, zero current switch-off of heater) in order to avoid peaks even on nasty transformer with big leakage inductance, but I am using 80-100V parts and I don't know if 60V will work reliably. But that's me - I have a nasty habit of being too conservative when making things.

So, make some measurements of the voltage after the diodes if you have an oscilloscope. There should not be any peaks close to 60V there. You can use 55V instead of 60V TVS, just to be sure your MOSFET-s are safe, despite the fact that they are also working as big zeners when their voltage rating is exceeded. However, I don't know if something else can be damaged and how the controller will perform if there are peaks.
[/quote]
I didn't expected that at all. Anyway i'm planning to use a decent toroidal transformer, also from tme here (http://http://www.tme.eu/gb/details/tst120w_24v/toroidal-transformers/indel/tst120003/). By the way i have also some questions about the transformer connection. What's happening with J1 and J7? What's doing J7 there?

[quote author="sparkybg"]
The display looks OK. Bear in mind that white one has 20000 hours life and yellow one has 50000 hours. Also, the white one is 12V, and the yellow one is 9V. The yellow looks more fancy, IMHO. :)[/quote]
It also seems that no SSD1306 display at all is currently in stock... I'll wait..
Title: Re: Really universal soldering controller
Post by: sparkybg on April 18, 2017, 09:15:42 am
[quote author="valerionew"]
I didn't expected that at all.
[/quote]
Me neither. That's one of the reasons the version of the controller moved from 5.0 to 5.2.

[quote author="valerionew"]
questions about the transformer connection. What's happening with J1 and J7? What's doing J7 there?
[/quote]
J7 is for DC power supply - it avoids one diode drop, J1 is for AC and is using all 4 rectifiers.

[quote author="sparkybg"]
The display looks OK. Bear in mind that white one has 20000 hours life and yellow one has 50000 hours. Also, the white one is 12V, and the yellow one is 9V. The yellow looks more fancy, IMHO. :)[/quote]

[quote author="valerionew"]
It also seems that no SSD1306 display at all is currently in stock... I'll wait..[/quote]

As I said, there are displays on eBay you can buy if you don't want to wait. Although these are with considerably shorter life than TME ones.
Title: Re: Really universal soldering controller
Post by: valerionew on April 19, 2017, 11:11:21 am
[quote author="sparkybg"]

J7 is for DC power supply - it avoids one diode drop, J1 is for AC and is using all 4 rectifiers.[/quote]
Ah i see, it's possibile to use DC. I think i'm going with AC.

Anyway i'm reviewing my BOM now and I am going to use a 56V transil, so no worries for the MOSFETs :)
Title: Re: Really universal soldering controller
Post by: sparkybg on April 19, 2017, 11:22:09 am
[quote author="valerionew"]I think i'm going with AC.[/quote]

Mains toroidal transformer is the best possible power source for this controller. For many reasons.
Title: Re: Really universal soldering controller
Post by: SZ64 on April 22, 2017, 02:27:11 pm
[quote author="sparkybg"][quote author="valerionew"]

[quote author="valerionew"]
LM4120 instead of REF3030 (this is an hard match as before. the LM4120 is a STO23-5, the REF3030 a SOT23-3. the two extra pins can be left disconnected and the shared pins match. Nevertheless, the LM4120 has a maximum current of 5mA instead of 25mA and a dropout voltage of 100mV instead of 1mV. The precision is the same. Is it suitable?)
[/quote]

[quote author="sparkybg"]
There are two parts, connected to this reference voltage - the MCU's ADC reference, and the offset DAC. I don't know how much current they consume - you will have to find out yourself. 3.0V 0.1% is the most important rating but I am a bit skeptical about the proposed substitute.
[/quote][/quote][/quote]


I have tested (curiosity) and result is: 262.26 μA.

As a replacement for REF3030 (only in this case) you can take the following ICs:  MAX6010AEUR, MAX6063AEUR, ISL21010CFH330Z
Title: Re: Really universal soldering controller
Post by: puzzle on April 24, 2017, 04:25:05 pm
Hi to everybody,
I'm almost done with soldering - still waiting one IC and the transformer and I'll be able to try it out for the first time :D
I have a few lame questions, if someone could explain - sorry for that but electronics is more of a hobby of mine and some things I can't do or understand by myself...
For now my questions are regarding the display board:
It seems like my display is 9v (it is this one https://www.aliexpress.com/item/1pcs-0- ... 0.0.dYYx9q (https://www.aliexpress.com/item/1pcs-0-96-inch-OLED-Display-LCD-module-with-128x64-Resolution-and-blue-on-black-SPI/1430628386.html?spm=2114.13010608.0.0.dYYx9q)  )
So, back in one of the pages I have read that I need to change R66 to 30k and R68 to 4.7k.
In the schematics R66 is 0.1% tolerance - Is it critical or can I solder a 1% resistor?
Other option was to leave R66 as is, and only change R68 to 4.3k, and voltage will be 8.95V. - How much will be the voltage if I place a 4.7k resistance instead?
I really do not want to make another order and pay for shipment again just for few resistors.

And another question - In the schematics, for C71 is given 10uF at 16V, but in the BOM it's 10uF at 25V. I have placed the 25V version but it would be nice to know were is the truth, since you have to order separate value and have to buy at least 10 of them.
And just for clarification if I'm right - we do NOT solder Q15, Q17, Q20 and D17 - correct?

Edit: I just remembered to ask if the station will go to sleep if I send the "sleep" signal to a metal soldering iron holder?
I understood that you have to send "sleep" to "GND" and since the iron itself is grounded, would that suffice or there is separate "GND". And if there are separate ground lines is it a problem if they connect together? - as would be when the iron is in the holder.

Thank you very much, SparkyBG for your time and great project!

Regards
Title: Re: Really universal soldering controller
Post by: sparkybg on April 24, 2017, 07:16:08 pm
0.1% is not critical. I've used this in order for BOM to be with fewer lines. 1% standard resistors are OK of the OLED board.

There is a equation in the datasheet of the chip how the resistors are calculated. There are many combinations both for 12V and 9V.

About C71 - when the OLED is 9V, 16V capacitor is OK, but when the OLED is 12V, 16V capacitor is a bit close to it's limit, and because it is a X5R/X7R ceramic capacitor, it's capacitance will fall when driven near the limit.

So, if it is in the same package, better order 25V - it will be OK both for front PCB and OLED PCB, no matter what voltage the OLED wants.
Title: Re: Really universal soldering controller
Post by: puzzle on April 24, 2017, 07:45:38 pm
Thank you for the fast reply!
Now I understood how it is calculated, so for my scenario if I change only R68 to 4.7k the voltage would be 8.3V - perfectly in specs of the display :D
I understood about the cap, also - thank you for the explanation! I already have a 25V one soldered so no need to change it :)

Greetings from Bourgas :D
Title: Re: Really universal soldering controller
Post by: SecurityCze on April 25, 2017, 01:35:38 pm
Hello everyone,
I'm curious if anybody has some PCBs left, or even components. Let's be honest, it is really frustrating searching all the necessary components.
So, if somebody has something left. I can certainly set free this parts from slavery :)
Title: Re: Really universal soldering controller
Post by: Q11 on April 27, 2017, 05:28:30 pm
Hello,
I finished my Unisolder today. I calibrated it, connected my ERSA RT80 to it. It shows up as ERSA RT80 but it constantly says "SENSOR OPEN". I checked wiring four times, and except that my soldering iron has a red instead a pink wire it is correctly wired. What am I doing wrong?
Title: Re: Really universal soldering controller
Post by: sparkybg on April 27, 2017, 06:45:32 pm
1. Measure heater's resistance and tell me what it is, and the wires it is on.
2. Check continuity between front PCB SENSEA and SENSEB and your iron connector's SENSEA and SENSEB.
Title: Re: Really universal soldering controller
Post by: Q11 on April 27, 2017, 07:25:17 pm
Thank you for answering. I measured the following resistances:
Black-Red: infinity Ohms
Black-White: 2.3 Ohms
Red-White: infinity Ohms
So I guess that Black-White is the heater, isn't it?

Without Iron Plugged in and Soldering Station off: Resistance between SENSEA and SENSEB is 111 kOhms
Without Iron Plugged in and Soldering Station on: Resistance between SENSEA and SENSEB is 4.8k - 6.1k Ohms

With Iron plugged in and Soldering Station off: Resistance between SENSEA and SENSEB is 2.3 Ohms
With Iron plugged in and Soldering Station on: Resistance between SENSEA and SENSEB is 60-70 Ohms
Title: Re: Really universal soldering controller
Post by: sparkybg on April 27, 2017, 07:57:06 pm
Yes, black-white is heater, red is outer body. Your iron connections are OK.

1. Measure the continuity between SENSEA signal on the front PCB and SENSEA on the iron's connector without iron connected
2. Measure the continuity between SENSEB signal on the front PCB and SEBSEB on the iron's connector without iron connected
3. Measure the resistance between SENSEA and SENSEB on the front PCB with iron connected without powering up the controller.
Title: Re: Really universal soldering controller
Post by: ScotY808 on April 27, 2017, 09:43:27 pm
Hello all!

I am a new member here and just finished reading through all 62 pages of this thread!  Wow, thank you sparkybg for sharing this project...it sounds amazing and I would like to put one together.  However, I am a total newbie and it sounds a little challenging.  The soldering should be okay, it's sourcing the proper parts and programming the chip that will be hard for me. 

I'm curious to know what the general consensus is...should I make an attempt or no?  Are PCBs (or preferably completed boards) available in the US, or anyone willing to ship to the US?  Advise greatly appreciated.

Thanks once again!

Scot
Title: Re: Really universal soldering controller
Post by: sparkybg on April 27, 2017, 11:13:29 pm
[quote author="mesodumb"]Hello all.

Im looking to build this project asap. Tired of my sub-par stations that promise features and functionality that somehow disappear. Cant say how many tips ive burned due to failed sleep/shutdown timers. I considered the hakko 951, but it felt limited by comparrison to this project and im too frugal to buy the big boy units @500+++.

 I do have a business account with digikey and mouser,  so i can order as needed. However,  i prefer to buy overstock from someone within the community...plus, admittedly, sourcing parts from multiple vendors is a bit of a pain in the butt. 

If anyone has full kits (preferably un-assembled; its not as fun if you dont actually put it together) then i would like to buy.

Bare minimum, i need a board  or two and supply of the harder to aquire parts due to lower qty and/or usa based dist availability.  I looled at having a run of boards made via chinese manufacturer, but unless i wanted to buy 100 it did not seem worth it. Definitely dont need 100 plus boards. Side note... Amazing that their better pricing started with 15 units. However, difference in price between 15 and 100 was so marginal that it would be silly not to buy the biggest bang per buck.

Thats all my ranting for tonight. I look forward to the project and discussing it as i progress.[/quote]

It is a bit problematic to me to send items outside EU. You can order a PCBs from itead or seed (around 20USD fot 5 PCBs if I remember right).

[quote author="ScotY808"]Hello all!

I am a new member here and just finished reading through all 62 pages of this thread!  Wow, thank you sparkybg for sharing this project...it sounds amazing and I would like to put one together.  However, I am a total newbie and it sounds a little challenging.  The soldering should be okay, it's sourcing the proper parts and programming the chip that will be hard for me. 

I'm curious to know what the general consensus is...should I make an attempt or no?  Are PCBs (or preferably completed boards) available in the US, or anyone willing to ship to the US?  Advise greatly appreciated.

Thanks once again!

Scot[/quote]

If you can solder pars with 0.5mm pin spacing - go for it. You can cooperate with mesodump for parts ordering and PCBs.

I don't think you will have any problem ordering all the parts from US. They are all US made parts and nothing is too exotic I think.
Title: Re: Really universal soldering controller
Post by: dumitruv on April 28, 2017, 04:23:11 am
I still have couple of boards except for the sensor which I didn't order and I live in Canada.
Title: Re: Really universal soldering controller
Post by: ScotY808 on April 28, 2017, 08:41:12 am
Thanks, Sparkybg...I think I will give it a shot!

Dumitruv,
If I can figure out how to PM you, I am interested in buying one off you. That would be great!
Title: Re: Really universal soldering controller
Post by: Q11 on April 28, 2017, 03:14:22 pm
Hello, thanks for your help. I found one faulty component and will replace it. I will let you know when I solved this problem.
Title: Re: Really universal soldering controller
Post by: puzzle on April 29, 2017, 06:25:18 pm
:D It's alive guys :D
Hello everybody, my controller is finally done and it started almost without hiccups. I'm happy as a fly at honey :D
So I discovered that no mater what, you must first program the bootloader, then standalone... the version that says "with bootloader" did not work for me.
Now I have to see my calibration because I have 300C on dysplay but 60/40 solder melts like in his first stages of melting - regular termocouple says 240C - I will try the methods Sparky sayed, planning to use lead fishing weights for the tests , don't have any 63/37 solder.

And still have not sorted out the grounds but with baby steps... :D

I want to say only that if you make everything as described here and you have ordered the parts as in BOM you will have fully functional soldering station immediately after flashing the PIC!


Several times people asked for pictures and frankly I needed them too.  There are places that you can't see due to components in the way in all pictures I found here or the net overall.
So I made a few and will post them - note that they are made before mounting all components and some parts you do not need to solder at all.

[attachment=4]
At front board, make sure the correct orientation of R27, R28, R63, R65.
Also When using an OLED display you do NOT solder parts - U9, Q15, Q17
And depending on Speaker you may not need also to solder Q20 and D17
[attachment=3]

[attachment=2]

[attachment=1]
In this picture R68 is different(4.7k) as in BOM(3k) as my display is 9v!
With R68 changed the voltage is 8.3V- perfectly in specs of this particular display - http://https://www.aliexpress.com/item/1pcs-0-96-inch-OLED-Display-LCD-module-with-128x64-Resolution-and-blue-on-black-SPI/1430628386.html?spm=2114.13010608.0.0.dYYx9q.
Make sure you do NOT have shorts on display cable!


Images are reduced, if anyone needs full size 2,5x bigger I can send it.

Thank you Sparkybg for the great project!!! I had much fun building it :D

Greetings from Bourgas, Bulgaria

P.S. I have lost many hours searching the parts in different stores here is my BOM file with all the links inside!
[attachment=0]
Title: Re: Really universal soldering controller
Post by: sparkybg on April 29, 2017, 10:45:32 pm
[quote author="puzzle"]
So I discovered that no mater what, you must first program the bootloader, then standalone... the version that says "with bootloader" did not work for me.
[/quote]
You must flash the bootloader with PicKit3 or whatever you want, then connect the controller to your PC with USB, and then use the PC software to program the "...with bootloader" hex. I've build 3 controllers already and I didn't detected any programming bugs so far.

[quote author="puzzle"]
Now I have to see my calibration because I have 300C on dysplay but 60/40 solder melts like in his first stages of melting - regular termocouple says 240C - I will try the methods Sparky sayed, planning to use lead fishing weights for the tests , don't have any 63/37 solder.
[/quote]
60/40's melting temperature is close enough to 183 degrees Celsius. You can also buy 63/37 solder from http://www.comet.bg (http://www.comet.bg) and several other places in Bulgaria. It is available in almost any electronics shop here.

About pure Lead - I bought 0.3mm pure lead wire from local online fishing shop, but I don't remember the name of the shop - you will have toi find it yourself. Fishing weights are not guaranteed to be pure lead. Another source for guaranteed pure lead may be a company selling laboratory chemicals and reactives. You can also buy pure Zink from there.

[quote author="puzzle"]
P.S. I have lost many hours searching the parts in different stores here is my BOM file with all the links inside!
[/quote]
Every single part is available from Comet. Some from their local warehouse, some from Farnell, which they represent in Bulgaria They have a section in their site for Farnell parts. I am buying 99.9% of my parts (not for this project alone, but for all my projects) from them. Any part that Farnell has is 3 days away from you, and there aren't any additional costs for shipping except local Econt or Speedy cost, around 4-5EUR.
Title: Re: Really universal soldering controller
Post by: TheCircuiteer on April 30, 2017, 01:47:10 am
When I flash US_Bootloader.X.production, the controller can be detected through usb by my computer, but there's no beep. When I flash the US_Firmware.X.production standalone, i get a constant beep. In both cases, nothing shows up on the lcd. trying to update the firmware while bootloader is flashed through the pc software seems to do something, as the verify for the bootloader fails, but nothing happpens on the lcd then either. holding - and + while starting with bootloader gives nothing.
Title: Re: Really universal soldering controller
Post by: puzzle on April 30, 2017, 05:07:18 pm
You are right, comet/farnell is the fastest and maybe best way to buy parts!

Well links are in my BOM so everybody can choose how to obtain what he needs...also many parts can be delivered to local shops without much extra cost and no excess parts .

Me and a friend bought almost all parts from comet/farnell - but some are sold in quantities that are more than we need - as a hobbyist who builds various small projects I don't see myself using 5 digital potentiometers or 20 capacitors 0805 all same capacitance...  anyway,  we used TME for the others.  Mouser wanted 20Eur for delivery so we left it out.

I'm  learning electronics by myself on the fly, by trial and error... so my fist controller programming was on this project and from what I've read on this forum I need bootloader to be flashed, so first tried the firmware "with bootloader "- got nothing, blanc screen, no sounds, nothing...there's whole story behind me, trying to make Pickit3 to recognize the chip :D...anyway, so, there was nothing after several  tries. Then flashed the "bootloader" and voila, some lines appeared on the screen, then I flashed "with bootloader" - nothing again, then repeated "bootloader" after that "standalone" version and everything was as it should!  I remember flashing one time over PC(don't remember exactly if I had flashed "bootloader" previous to that) but got blanc screen again so I repeated previous steps and now its working... used so many words just to say that problems I had are my fault and I want to thank you for explaining  how it is properly done! Now I can guide my friend, also hobbyist making same project - we combined orders  because of the excess parts you have to buy...

It would be very helpful  if you have time to explain to me the Ground planes a little bit. Many parts I understand but I'm missing the part as from were to take "Earth" for the soldering iron?
...I'm using AC toroidal transformer...
As you say :
"1. HAKKO T12:
- Outer shell, and heater negative (middle) terminal connected together to Vout1- and EARTH..."
or
"3. JBC C245:
- Outer shell (green wire) connected to EARTH and..."
I tried to connect it to "Gnd" on J5(on Back board) as it appeared to be connected with J7, pin 1(which still not sure if I have to connect to mains "earth"), so in this trial J7, pin 1 was connected to mains "earth"(in our 2 wire electrical system in my building it is connected to Neutral of the mains). At first everything appeared to be working normally until I tried if the "sleep" function would work that way :D well :D maybe, but while I was trying touching "sleep" signal wire(at J5 pin 6) with various parts of the iron tip something got wrong and the Iron tip(C245 iron) got red glowing in a matter of a second... I saw controller rising the temperature(80..100...) and looked the iron which was already red hot. So it looks like this is not the proper way to connect things :D but I gave up the trials because this iron belongs to my friend(brand new, first run on this controller) and I don't want to trash it. I will continue when my Chinese t12 arrives.
On another side when J7, pin 1 is not connected to mains "earth"(again in my case it would be same as mains neutral) and Irons "Earth" not connected at all, I have some voltage in the irons cable - it is detected by non contact voltage meter, and the back of your hand, felt as when touching non grounded appliance which has voltage on outer shell... it disappears as soon I connect mains "earth" to J7, pin 1. So maybe it has to be connected... or the voltage is induced buy the transformer as wires are everywhere.

You are  probably right about the lead, I'll rather buy 63/37 solder.

Please excuse my long post, I'm trying to explain at my best so you can deduce if it is an user error(most probably :D) or maybe I have shorted something - despite my probing for an hour, searching for shorts, before powering everything...
Thank you for your time!!!
Title: Re: Really universal soldering controller
Post by: puzzle on April 30, 2017, 05:10:35 pm
@TheCircuiteer: are you using MPLab to flash the bootloader?
At first I tried different way and there were always an error not recognizing the chip - in MPLab everything went fine!
Title: Re: Really universal soldering controller
Post by: TheCircuiteer on April 30, 2017, 05:13:33 pm
Yes, mplab and pickit 3. bootloader flashes and verifies fine, just no beep or lines on screen.
Title: Re: Really universal soldering controller
Post by: puzzle on April 30, 2017, 05:25:17 pm
@TheCircuiteer: To me this happened when I tried to import the ".lib" file... then I proceeded this way:
In MPLab 8.92, chose the PickIt3, and made sure it recognizes the chip! ...Oh, I made this with powered controller! I did not succeed when PickIt3 powered the chip!
Then got to File>Import... and chose the latest firmware(04.04.2017) only bootloader.hex. and pressed program.
It goes fast and immediately after that i had  wiggling lines on the screen.

Then I programmed the standalone hex, but you may try as Sparky said true the PC.

Well If you made it all- powering the board then flashing with standalone and still have nothing then I'm not of help to you, sorry!

P.S. Forgot to ask if you have soldered Q15, Q17, Q20 and D17 to the front board? If Yes probably you have to remove them.
Title: Re: Really universal soldering controller
Post by: TheCircuiteer on April 30, 2017, 07:15:03 pm
@puzzle Like I said above, it detects te pic fine, and with the bootloader flashed, I can plug it into usb and the pc detects it, and shows it as Unisolder Soldering Station, but I don't get a beep when power is applied, or anything on the lcd. When I try to upload software through the pc software, it seems to attempt something, but fails, unless I'm not waiting long enough. When the pc software is running, before I upload the main firmware, is anything supposed to show on the graphs?
Title: Re: Really universal soldering controller
Post by: puzzle on April 30, 2017, 11:12:10 pm
@TheCircuiteer: Immediately after I flashed bootloader.hex I had some lines wigle true the lcd - like pulse motor power on oscilloscope, only not freeze framed but running.
From what I've read here, most mistakes are those components I wrote before and some resistors and capacitors soldered 90 degrees wrong... then on my lcd board was a short because at first I've soldered it backwards, and that was my first suspicion when I had problems flashing but at some point I flashed just bootloader.hex and the lines appeared. Sorry I can't help much.
Title: Re: Really universal soldering controller
Post by: puzzle on May 01, 2017, 09:19:19 am
@TheCircuiteer:
Just tried flashing again and I have black screen!
Steps were: Program bootloader with Pickit3, then connect to PC and sing software "update firmware" tried "with bootloader" and everything is black, no sound, no waves nothing... will try aggain

edit:
Test 2:
1. Connecting Pickit3 to PC and to 5 pin header on front board,
2.Powering the "soldering station" - I have the Iron connected but no heater in it.
3. Opening MPLab, and selecting programmer to Pickit3 - it has connected and found the chip, loaded correct firmware for pic32mx.
4. I chose "Import..." and browsed to the "US_BootLoader.X.production.hex" and select "OPEN"
5. I select "Program" - it goes very fast true: " Programming... Programming/Verify complete" - And I IMIDEATELY have wiggling lines on the screen.
Now I will try to flash it true PC:
1. I remove Pickit3 from the board - not sure if I have to switch it off, but previously I did not and got nothing so now I will switch the board off.
2 Connecting USB cable to "Soldering station" - I use the cable of the programmer.
3. Open software -  "UniSolder.exe"
4. Switch the station on - I have wiggling lines on screen, no sounds, nothing on software or on the PC indicates that I have switched something
5. I press "Update firmware"  and browse to the "US firmwareX > PIC32 with bootloader> "US_Firmware.X.production.hex" - I press "Open" - after 5-7 seconds I heard beep  and now the station looks fine - it shows my iron and "Heater open" as it should.
So the only difference from my previous attempt was that I shut the station down this time. But still after flashing "bootloader" I had dose lines!
Title: Re: Really universal soldering controller
Post by: sparkybg on May 01, 2017, 09:43:09 am
[quote author="puzzle"]@TheCircuiteer: To me this happened when I tried to import the ".lib" file... then I proceeded this way:
In MPLab 8.92, chose the PickIt3, and made sure it recognizes the chip! ...Oh, I made this with powered controller! I did not succeed when PickIt3 powered the chip!
Then got to File>Import... and chose the latest firmware(04.04.2017) only bootloader.hex. and pressed program.
It goes fast and immediately after that i had  wiggling lines on the screen.

Then I programmed the standalone hex, but you may try as Sparky said true the PC.

Well If you made it all- powering the board then flashing with standalone and still have nothing then I'm not of help to you, sorry!

P.S. Forgot to ask if you have soldered Q15, Q17, Q20 and D17 to the front board? If Yes probably you have to remove them.[/quote]

The bootloader sole purpose is to be able to flash "..with_bootloader" hex with the PC software, using the USB port. Only the bootloader hex is flashed with PicKit3. For all other fhashing, the PC Unisolder software is used, and you must choose "_with bootloader" hex file.

What you have done is to overwrite the bootloader with standalone hex. You will not be able to use the bootloader, because you don't have a bootloader after flashing "_standalone" hex.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 01, 2017, 09:59:38 am
[quote author="puzzle"]
At first everything appeared to be working normally until I tried if the "sleep" function would work that way :D well :D maybe, but while I was trying touching "sleep" signal wire(at J5 pin 6) with various parts of the iron tip something got wrong and the Iron tip(C245 iron) got red glowing in a matter of a second...[/quote]

You should NOT touch any wire of the board with soldering iron, connected on the board! in the sleep connector there are 3 signals = +3.3V, SLEEP and GND. When you connect SLEEP to GND, the controller interpret it as if the soldering iron is in the stand. When you connect SLEEP to +3.3V, the controller interprets is as if the iron is out of the stand. You must connect SLEEP signal ONLY to GND or 3.3V signals ON THE SAME CONNECTOR!

The stand itself, if metallic, SHOULD NOT be connected to anything, especially when C245 is used.

The only connection of EARTH to somethiing else is in the iron's connector, and it should be there and nowhere else. Different soldering irons have different EARTH connections which are explained in the first post. Same iron tips have outer shell connected to one of the power terminals (C245, C210, JBC Microtweezers), and if you are working with these, dont assume enything but connect it as it is written on the first post. For example, I am reading the thermocouple on C245 tips using the outer shell. When you connect this outer shell to GND (like you did when you touched the sleep signal) with it, the thermocouple signal goes away, and the temperature goes up.

If yu want to use the sleep function, you must either make the optical sensor from the project, or make something that does the same thing, for example putting a simple switch that connects SLEEP to GND when you get the iron out of the stand.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 01, 2017, 10:05:24 am
[quote author="puzzle"]
So the only difference from my previous attempt was that I shut the station down this time. But still after flashing "bootloader" I had dose lines![/quote]

The BIG difference from you previous attempt is the now you have a bootloader in the device and you don't have to open your device every time a new firmware is out, but only connect it to you PC's USB port and use the Unisolder PC software to flash it.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 01, 2017, 10:06:46 am
[quote author="TheCircuiteer"]@puzzle Like I said above, it detects te pic fine, and with the bootloader flashed, I can plug it into usb and the pc detects it, and shows it as Unisolder Soldering Station, but I don't get a beep when power is applied, or anything on the lcd. When I try to upload software through the pc software, it seems to attempt something, but fails, unless I'm not waiting long enough. When the pc software is running, before I upload the main firmware, is anything supposed to show on the graphs?[/quote]

You have a malfunction on your boards. Please upload a photo of 2 sides of front PCB, and 2 sides of your OLED board, and I will be able to comment.
Title: Re: Really universal soldering controller
Post by: puzzle on May 01, 2017, 10:32:39 am
@Sparkybg
OK, I've got it! I will make a switch or not use it at all - at the rate it heats up it is irrelevant if it uses sleep or not.
Thank you very very much!!!
I really do not want to waste more of  your time answering my stupid questions, so please tell me were to connect pin 8(Earth) of your connector pictured at first page(do I really have to connect it to mains earth? or it is a place on the board for it that I've missed) Were did you connect it?
And lastly you are using AC transformer - do you have connected to something  pin1 at J7?
Once again I'm sorry for my many stupid questions!
Title: Re: Really universal soldering controller
Post by: sparkybg on May 01, 2017, 10:46:20 am
[quote author="puzzle"]@Sparkybg
at the rate it heats up it is irrelevant if it uses sleep or not.
[/quote]
It is not irrelevant. When the soldering tip stays at 350 degrees (I am using this temperature 99% of the time), it builds up an oxide layer on the solder that's on the tip. When the tip stays in the holder with 200-250 degrees, it does not build that oxide layer. Also, the tip's life is extended this way.

[quote author="puzzle"]
I really do not want to waste more of  your time answering my stupid questions, so please tell me were to connect pin 8(Earth) of your connector pictured at first page(do I really have to connect it to mains earth? or it is a place on the board for it that I've missed) Were did you connect it?
[/quote]
No, there is not a place on the boards for EARTH connection, because this connection is tip dependant, and the boards don't need it at all. If you want your tips EARTH-ed, you must connect it. If you don't - don't connect it or connect it using, say, 2-5 megaohm resistor. Again - the only place that EARTH is connected to someting is in the iron's connector, as shown in the first post. Nowhere else!

[quote author="puzzle"]
And lastly you are using AC transformer - do you have connected to something  pin1 at J7?
[/quote]
 2 pages above:
[quote author="sparkybg"]
J7 is for DC power supply - it avoids one diode drop, J1 is for AC and is using all 4 rectifiers.
[/quote]

DO NOT connect anything to J7, when using mains transformer as a power source.
Title: Re: Really universal soldering controller
Post by: puzzle on May 01, 2017, 11:05:15 am
Quote
It is not irrelevant. When the soldering tip stays at 350 degrees (I am using this temperature 99% of the time), it builds up an oxide layer on the solder that's on the tip. When the tip stays in the holder with 200-250 degrees, it does not build that oxide layer. Also, the tip's life is extended this way.

Yes, I meant I can switch it off when not in use...  it is better to have sleep  and my plans are to make a switch or rid switch or something, will see -

Quote
No, there is not a place on the boards for EARTH connection, because this connection is tip dependant, and the boards don't need it at all. If you want your tips EARTH-ed, you must connect it. If you don't - don't connect it or connect it using, say, 2-5 megaohm resistor. Again - the only place that EARTH is connected to someting is in the iron's connector, as shown in the first post. Nowhere else!

Thank you, and...

Quote
DO NOT connect anything to J7, when using mains transformer as a power source.

...Thank you very much!!!

Greetings
Title: Re: Really universal soldering controller
Post by: TheCircuiteer on May 02, 2017, 12:05:17 am
@sparkybg

Here are the pictures of the front board and lcd.
https://imgur.com/a/RKLaW (https://imgur.com/a/RKLaW)
After I took the picture I tried the board again with q16 removed, no change. I didn't reflash after removal, if that makes a difference. At this point I feel like I'm doing something stupid or simple wrong.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 02, 2017, 12:19:52 am
R27 and R28 are rotated 90 degrees. Look at the pictures on the previous page. Also look for other errors there. After everything is the same as on the pictures, we will discuss further.

But anyway - after you flash the bootloader, you should see something on the screen. Check the voltages of the OLED and the voltages on the front PCB.
Title: Re: Really universal soldering controller
Post by: puzzle on May 02, 2017, 09:18:59 am
Hi, again :D
Sparky I have a question on sensor board...
Is C24 tantalum, size C capacitor at 10v?
And can I make the 3.3v connection as shown in the snip in red... or do you have 2 excess sensor boards for sale?
If I don't find boards I will try make them, I would use double sided board but will try to make all the connections only on one side...or it's not a problem to use single side? For first time board making I'm not sure how to make the vias.
[attachment=0]
Title: Re: Really universal soldering controller
Post by: sparkybg on May 02, 2017, 09:45:12 am
Yes, it is tantalum size C.

There is no critical layout on the sensor board, so it can be made even on a prototype board.
Title: Re: Really universal soldering controller
Post by: puzzle on May 02, 2017, 09:56:27 am
Thank you very much!!!
Title: Re: Really universal soldering controller
Post by: TheCircuiteer on May 02, 2017, 03:28:54 pm
@sparkybg

Wow, yeah I figured it was something stupid. Screen is working now, and I get a beep at startup as i should. screen shows 21, then 45. I'm guessing that's a debug code?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 02, 2017, 03:36:49 pm
Are you using DC power? Then 21 for around half second is OK. When AC power is used it shows it just briefly, maybe for 1/10 of a second. In this step the controller detects if it is powered with AC or DC, and the frequency of AC, if used.

45 means I2C or EEPROM failure. Maybe something is still wrong with I2C bus or there is malfunctioning device on the I2C bus. Tell me tha exact part number of the DAC you used - it's address is factory written and there are parts with many addresses. If it is with wrong address, the MCU waits for it to respond and  will stay at step 45.

At step 45 of the initialization it sends the commands to DAC and 2 pots, then it tries to load what is saved in the EEPROM. These are all four I2C devices, so it may be any of them. I haven't figured out yet how to make it more specific - it is a bit problematic from programming point of view.

Does it stay on 45 or just shows it for a moment and then starts normally?
Title: Re: Really universal soldering controller
Post by: TheCircuiteer on May 02, 2017, 09:41:45 pm
Stays there. I'll go over the i2c once I get home. And yes, as of right now its on DC power.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 02, 2017, 10:07:19 pm
[quote author="TheCircuiteer"]Stays there. I'll go over the i2c once I get home. And yes, as of right now its on DC power.[/quote]

Also check the exact DAC part number you bought.
Title: Re: Really universal soldering controller
Post by: seeker on May 03, 2017, 10:45:02 pm
@Sparkybg, I've just spent one week reading all of these posts on this topic. And I'd like to thank you for your amazing work on designing, implementing, programming, debugging and wonderous support you are giving to this project.

For above mentioned reasons i'm also going to try to build this project.

Kr, Miika / Seeker
Title: Re: Really universal soldering controller
Post by: TheCircuiteer on May 05, 2017, 04:33:29 pm
@sparkybg, found the problem after I got out the magnifiers. Pin 8 on u8 wasn't connected. Got the main screen now, thanks for your patience man.

*edit

trying to do the calibration now, and its always zero, with or without resistor. poking around u15 pin 5 reads ~ -320mv. Reading back, that would be problems with U16 ,18 or 13?
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 08, 2017, 09:56:43 pm
Hello Sparkybg,

I am starting on my order from Mouser and some questions. 

C24, C25, etc. specifies 100nf but there is not voltage specification on the BOM.  Please tell me what voltage to choose.  Actually, there are numerous caps with no voltage spec.  If there is none, what to choose?

For SMD caps, I am choosing X7R which I believe is best?  Also, I am choosing best tolerance, sometimes it is 5% and other times it seems to be 10%.  Is this okay?

For C71, I can only find X5R...is this okay?

Is this okay for C23 and C47?
http://www.mouser.com/ProductDetail/AVX ... xfP0thw%3d (http://www.mouser.com/ProductDetail/AVX/TPSD227K010R0150/?qs=sGAEpiMZZMtZ1n0r9vR22WBN%252bThccN0vKuMjxfP0thw%3d)

Is this okay for D1, D2, D3, and D4?
http://www.mouser.com/ProductDetail/Dio ... 8dvA%3d%3d (http://www.mouser.com/ProductDetail/Diodes-Incorporated/SB580-T/?qs=sxN%252boM2fis%252bk2DUvtj8dvA%3d%3d)

I am planning to order all 1% resistors but you said in this thread that some must be 0.1% in the signal? path...or something like this.  I am a newbie to electronics and am not certain which these are.  Can you say?

Thank you!
Scot
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 08, 2017, 11:52:37 pm
I am starting to realize that ordering all this stuff is going to be a challenge for me.  If anyone happens to have a shopping list from Mouser, Digikey, or any other US supplier, it would be very helpful.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 09, 2017, 12:35:54 am
[quote author="ScotY808"]

C24, C25, etc. specifies 100nf but there is not voltage specification on the BOM.  Please tell me what voltage to choose.  Actually, there are numerous caps with no voltage spec.  If there is none, what to choose?
[/quote]
Whene there is no voltage spec, any cap in this package will do. When the voltage spec is important, it is specified.

[quote author="ScotY808"]
For SMD caps, I am choosing X7R which I believe is best?  Also, I am choosing best tolerance, sometimes it is 5% and other times it seems to be 10%.  Is this okay?[/quote]
Caps tolerance is not specified, and not important in this project.

[quote author="ScotY808"]
For C71, I can only find X5R...is this okay?
[/quote]
Just get the best possible part in this package. Nothing more.

[quote author="ScotY808"]
Is this okay for C23 and C47?
http://www.mouser.com/ProductDetail/AVX ... xfP0thw%3d (http://www.mouser.com/ProductDetail/AVX/TPSD227K010R0150/?qs=sGAEpiMZZMtZ1n0r9vR22WBN%252bThccN0vKuMjxfP0thw%3d)
[/quote]
Again, any tantalum/niobium capacitor in the same package and with the same voltage spec (if specified) will do. There's 3.3V on these, so 99.9% of tantalum capacitors in this package will be OK.

[quote author="ScotY808"]
Is this okay for D1, D2, D3, and D4?
http://www.mouser.com/ProductDetail/Dio ... 8dvA%3d%3d (http://www.mouser.com/ProductDetail/Diodes-Incorporated/SB580-T/?qs=sxN%252boM2fis%252bk2DUvtj8dvA%3d%3d)
[/quote]
Yes.

[quote author="ScotY808"]
I am planning to order all 1% resistors but you said in this thread that some must be 0.1% in the signal? path...or something like this.  I am a newbie to electronics and am not certain which these are.  Can you say?
[/quote]
Where it needs to be 0.1%, it is specified as 0.1% on the schematics and in the BOM. If the BOM says 0.1%, the use 0.1%. Use 1% in all other cases.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 09, 2017, 12:42:56 am
Thank you, Sparky. I will slowly work my way through the BOM. I apologize in advance as I know there will be many more questions.

I promise this as my humble contribution...once I finish my Mouser order, I will post it here so others like me (especially in the US), will be able to build your controller without too much trouble.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 09, 2017, 05:24:39 am
More component questions...for me, it's quite difficult to cross reference these parts.  I am sorry.

D5, D8, D10, D14, D15 schottky rectifier...what specifications do I look for?  Is this okay?
http://www.mouser.com/ProductDetail/Fai ... fdd6Oic%3d (http://www.mouser.com/ProductDetail/Fairchild-Semiconductor/MBR0530/?qs=sGAEpiMZZMtQ8nqTKtFS%2fEjIZ86Z177mq5NT%2fdd6Oic%3d)

D6, D7, D12 schottky rectifier...is this okay?
http://www.mouser.com/ProductDetail/STM ... 3zc5bl0%3d (http://www.mouser.com/ProductDetail/STMicroelectronics/STPS1L30A/?qs=sGAEpiMZZMtQ8nqTKtFS%2fM2amOy8Xbj2%2fJ4J3zc5bl0%3d)

D9, D11, D13...is this okay?
http://www.mouser.com/ProductDetail/Dio ... 4yIhNFM%3d (http://www.mouser.com/ProductDetail/Diodes-Incorporated/S1M-13-F/?qs=sGAEpiMZZMtbRapU8LlZD4HrL8li0POPzS3R4yIhNFM%3d)

D16, D17, D20, D21...is this okay?
http://www.mouser.com/ProductDetail/ON- ... NeYuKOD6TF (http://www.mouser.com/ProductDetail/ON-Semiconductor/BAW56LT1G/?qs=sGAEpiMZZMtqO%252bWUGLBzeHNeYuKOD6TF)

D18, D19...is this okay?
http://www.mouser.com/ProductDetail/Fai ... vHkJCxc%3d (http://www.mouser.com/ProductDetail/Fairchild-Semiconductor/MMBD1205/?qs=sGAEpiMZZMutXGli8Ay4kIcWkBCBEmdEqaOQvHkJCxc%3d)

D22...is this okay?
http://www.mouser.com/ProductDetail/Dio ... VnY7CxE%3d (http://www.mouser.com/ProductDetail/Diodes-Incorporated/B340A-13-F/?qs=sGAEpiMZZMtQ8nqTKtFS%2fLDoMakfJd%2f0jr6cVnY7CxE%3d)
Title: Re: Really universal soldering controller
Post by: seeker on May 09, 2017, 06:39:29 am
Hello there,

This is my version of mouser bom. please check it with maximum care, i haven't sourced any components before this project.
Only component what should be missing is oled screen and it's resistors.

If you have any notes or improvements to this bom please share it with others(me included) so there is no unneeded components on the list.

Some components have been selected based on current availability and others based on minimum order quantity.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 09, 2017, 06:51:44 pm
[quote author="ScotY808"]More component questions...for me, it's quite difficult to cross reference these parts.  I am sorry.

D5, D8, D10, D14, D15 schottky rectifier...what specifications do I look for?  Is this okay?
http://www.mouser.com/ProductDetail/Fai ... fdd6Oic%3d (http://www.mouser.com/ProductDetail/Fairchild-Semiconductor/MBR0530/?qs=sGAEpiMZZMtQ8nqTKtFS%2fEjIZ86Z177mq5NT%2fdd6Oic%3d)

D6, D7, D12 schottky rectifier...is this okay?
http://www.mouser.com/ProductDetail/STM ... 3zc5bl0%3d (http://www.mouser.com/ProductDetail/STMicroelectronics/STPS1L30A/?qs=sGAEpiMZZMtQ8nqTKtFS%2fM2amOy8Xbj2%2fJ4J3zc5bl0%3d)

D9, D11, D13...is this okay?
http://www.mouser.com/ProductDetail/Dio ... 4yIhNFM%3d (http://www.mouser.com/ProductDetail/Diodes-Incorporated/S1M-13-F/?qs=sGAEpiMZZMtbRapU8LlZD4HrL8li0POPzS3R4yIhNFM%3d)

D16, D17, D20, D21...is this okay?
http://www.mouser.com/ProductDetail/ON- ... NeYuKOD6TF (http://www.mouser.com/ProductDetail/ON-Semiconductor/BAW56LT1G/?qs=sGAEpiMZZMtqO%252bWUGLBzeHNeYuKOD6TF)

D18, D19...is this okay?
http://www.mouser.com/ProductDetail/Fai ... vHkJCxc%3d (http://www.mouser.com/ProductDetail/Fairchild-Semiconductor/MMBD1205/?qs=sGAEpiMZZMutXGli8Ay4kIcWkBCBEmdEqaOQvHkJCxc%3d)

D22...is this okay?
http://www.mouser.com/ProductDetail/Dio ... VnY7CxE%3d (http://www.mouser.com/ProductDetail/Diodes-Incorporated/B340A-13-F/?qs=sGAEpiMZZMtQ8nqTKtFS%2fLDoMakfJd%2f0jr6cVnY7CxE%3d)[/quote]

1. Read page 61. Some of your questions are answered there.

2. For the remaining questions (after reading page 61 and removing questions that are answeretd there), PLEASE write the part number that you want to replace and the part number you want to replace it with in the thread, not just the designators. Also,direct links to the datasheets will help better than links to the site that sells them.

When written the way it is written now, I will have to open schematics and BOM, to look for the parts, to look for the datasheet, then to go to the mouser site, to look for the link to the datasheet, then read it. Make my work easier, and you will have my answers sooner. ;)
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 09, 2017, 08:38:23 pm
Okay, I understand...thank you.

SS310A...is this okay? SK310A-TP
Datasheet...http://www.mouser.com/ds/2/258/SK32A-SK310A(HSMA (http://www.mouser.com/ds/2/258/SK32A-SK310A(HSMA))-349734.pdf

BAV199...is this okay? BAV199,215
http://www.mouser.com/ds/2/302/BAV199-840428.pdf (http://www.mouser.com/ds/2/302/BAV199-840428.pdf)

SS34A...is this okay? SS34FA
http://www.mouser.com/ds/2/149/SS34FA-1012641.pdf (http://www.mouser.com/ds/2/149/SS34FA-1012641.pdf)

For the board connectors (header pins, 1x2x4.2, etc.) what type/series connector is this?  I'm having trouble searching for the correct parts.
Is this okay? http://www.mouser.com/ProductDetail/Mol ... ynl2UN4%3d (http://www.mouser.com/ProductDetail/Molex/39-29-9042/?qs=sGAEpiMZZMs%252bGHln7q6pm%252bS0pk2Wo0Xx9WR6ynl2UN4%3d)
http://www.mouser.com/ProductDetail/Mol ... fJDg%3d%3d (http://www.mouser.com/ProductDetail/Molex/44472-0251/?qs=%2fha2pyFadug5ymkdbAsdtcn0ksnd3rx6RfwLdcerGOczQu5xlMfJDg%3d%3d)
Datasheet is not useful here.  These are board lock type but must not be the correct type.
Title: Re: Really universal soldering controller
Post by: seeker on May 09, 2017, 09:15:43 pm
@ScotY808, please check my bom from mouser and see if there's anything you need
Title: Re: Really universal soldering controller
Post by: sparkybg on May 09, 2017, 09:50:53 pm
[quote author="ScotY808"]
SS310A...is this okay? SK310A-TP
Datasheet...http://www.mouser.com/ds/2/258/SK32A-SK310A(HSMA (http://www.mouser.com/ds/2/258/SK32A-SK310A(HSMA))-349734.pdf
[/quote]
It is OK.

[quote author="ScotY808"]
BAV199...is this okay? BAV199,215
http://www.mouser.com/ds/2/302/BAV199-840428.pdf (http://www.mouser.com/ds/2/302/BAV199-840428.pdf)
[/quote]
It is the same part. Low leakage and reverse voltage are the important specs.

[quote author="ScotY808"]
SS34A...is this okay? SS34FA
http://www.mouser.com/ds/2/149/SS34FA-1012641.pdf (http://www.mouser.com/ds/2/149/SS34FA-1012641.pdf)
[/quote]
OK

[quote author="ScotY808"]
For the board connectors (header pins, 1x2x4.2, etc.) what type/series connector is this?  I'm having trouble searching for the correct parts.
Is this okay? http://www.mouser.com/ProductDetail/Mol ... ynl2UN4%3d (http://www.mouser.com/ProductDetail/Molex/39-29-9042/?qs=sGAEpiMZZMs%252bGHln7q6pm%252bS0pk2Wo0Xx9WR6ynl2UN4%3d)
http://www.mouser.com/ProductDetail/Mol ... fJDg%3d%3d (http://www.mouser.com/ProductDetail/Molex/44472-0251/?qs=%2fha2pyFadug5ymkdbAsdtcn0ksnd3rx6RfwLdcerGOczQu5xlMfJDg%3d%3d)
Datasheet is not useful here.  These are board lock type but must not be the correct type.[/quote]

There are 2 porision 1 row and 2 position 2 row connectors in the project. "1x2x4.2" means "1 row, 2 positions, 4.2mm pitch", 2x2x4.2 means "2 rows, 2 positions, 4.2mm pitch".

The first link you gave is to 4 position, 2 row (8 pins total), and the second link is to 2 position, 2 row (4 pins total). Both have side "legs" that you don't need.

2 pin connectrors are 39-28-1023:
http://www.molex.com/pdm_docs/adobe3D/39-28-1023.pdf (http://www.molex.com/pdm_docs/adobe3D/39-28-1023.pdf)

4 pin coinnectors are 39-28-1043:
http://www.molex.com/pdm_docs/adobe3D/39-28-1043.pdf (http://www.molex.com/pdm_docs/adobe3D/39-28-1043.pdf)
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 09, 2017, 09:52:37 pm
Hello seeker,
Yes, thank you for posting it!  I was able to find one part using your BOM. I found some things that maybe are wrong though. 1N4007 is not SMD. The connectors I think are not for PCB mounting.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 09, 2017, 09:53:26 pm
Thank you, sparkybg!  I will continue on with the ordering process later today when I go home.
Title: Re: Really universal soldering controller
Post by: seeker on May 09, 2017, 10:05:36 pm
[quote author="ScotY808"]Hello seeker,
Yes, thank you for posting it!  I was able to find one part using your BOM. I found some things that maybe are wrong though. 1N4007 is not SMD. The connectors I think are not for PCB mounting.[/quote]

Like stated earlier, please post back your findings, I didn't understood that connectors should be smd, will look another ones another time.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 09, 2017, 10:09:42 pm
There are no SMD connectors in the project. All connectors are through-hole.
Title: Re: Really universal soldering controller
Post by: seeker on May 10, 2017, 07:06:27 am
[quote author="sparkybg"]There are no SMD connectors in the project. All connectors are through-hole.[/quote]

Thanks that saved a lot of my time

Edit: Has anybody else noticed that if i upload BOM to mouser it find whatever components it wants. And i even used mousers own product numbers so i really don't get why it finds what ever it wants to.

And after I select to buy from BOM, there's still some weird components, like capacitors happens to be extra costly diodes.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 10, 2017, 08:14:38 am
Hello seeker,

I can say that Mouser's search function is terrible. It does many strange things. I haven't made much progress today but will certainly share when I am finished. Quite a lot more to do though.

I should clarify what I said earlier. Your 1N4007 is not SMD but it needs to be. Your header connectors are for wire connections. They need to be for PCB mounting, through hole as sparky said.

I received my PCB set in the mail today. It is smaller than I imagined it would be!
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 10, 2017, 08:25:24 am
Sparkybg,
I know in your videos it shows you use a BK2000+ case. But I also saw mention in this thread that BK3000 also works the same?  Please see this link:
https://circuitspecialists.glopal.com/e ... ialists.eu (https://circuitspecialists.glopal.com/en-US/p-231/bk-3000lf-70w-blackjack-solderwerks-professional-digital-solder-station.html?utm_campaign=en_GB&utm_medium=pr&utm_source=www.circuitspecialists.eu)

It is BK3000LF with iron stand. Will this station work well and is the stand the one you use for the sensor?  The website does not say the model/part number for the stand but it looks like the one you posted earlier in this thread.

I must buy a soldering station to build this project because my iron is not small enough. I suppose I should just buy the correct one from the start.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 10, 2017, 09:39:55 am
I have both BK2000+ and BK3000LF, and I am using their enclosures. This is the stand for the sensor, yes. You will have to drill 2 holes for the PCB and 2 holes for the diode and receiver, but it is easy thing to do.

The back panel must also be replaced. I will give you the drawings when you are ready with everything else.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 11, 2017, 03:58:35 am
Thank you.  I am waiting for BK3000LF to come back in stock in the USA.  I am almost finished ordering page 1 of BOM! :-)  2 more pages to go.

Can you tell me what kind of header is RJ11V?  It says 8 pin header but on the back PCB, I see only 6 holes.  It is 2 rows of 3 pins, but the rows are offset.

LPS4018...is this okay?  Mouser 994-LPS4018-103MRB
http://www.mouser.com/ds/2/597/lps4018-270702.pdf (http://www.mouser.com/ds/2/597/lps4018-270702.pdf)

SUD50P10...is this okay?  Mouser 781-SUD50P10-43L-E3
http://www.mouser.com/ds/2/427/sud50p10-315714.pdf (http://www.mouser.com/ds/2/427/sud50p10-315714.pdf)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 11, 2017, 09:56:38 am
[quote author="ScotY808"]
Can you tell me what kind of header is RJ11V?  It says 8 pin header but on the back PCB, I see only 6 holes.  It is 2 rows of 3 pins, but the rows are offset.
[/quote]
6pin RJ11 vertical connector. 2 additional pins are the fixing pins.
https://www.google.bg/search?q=rj11+ver ... 96&bih=788 (https://www.google.bg/search?q=rj11+vertical&source=lnms&tbm=isch&sa=X&ved=0ahUKEwi407yMrufTAhXlDZoKHeK2AP8Q_AUIBigB&biw=1396&bih=788)

[quote author="ScotY808"]
LPS4018...is this okay?  Mouser 994-LPS4018-103MRB
http://www.mouser.com/ds/2/597/lps4018-270702.pdf (http://www.mouser.com/ds/2/597/lps4018-270702.pdf)
[/quote]
Yes.

[quote author="ScotY808"]
SUD50P10...is this okay?  Mouser 781-SUD50P10-43L-E3
http://www.mouser.com/ds/2/427/sud50p10-315714.pdf (http://www.mouser.com/ds/2/427/sud50p10-315714.pdf)[/quote]
Yes.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 11, 2017, 08:09:52 pm
RJ11...is this the correct part?  This one has 8 positions and 2 fixing pins.  I'm guessing it's not the right part.  Mouser 538-52018-8846
http://www.mouser.com/ds/2/276/520188846_sd-206567.pdf (http://www.mouser.com/ds/2/276/520188846_sd-206567.pdf)

I am not sure how to determine which speaker to use.  I recall reading that you need the type without generator but I don't know how to tell. 
Is this okay?  Mouser 665-AI1223TWT5V5R
http://www.mouser.com/ds/2/334/AI-1223- ... 532187.pdf (http://www.mouser.com/ds/2/334/AI-1223-TWT-5V-5-R-532187.pdf)

TVS1...is this okay?  Mouser 863-1.5KE68AG
I do not know if breakdown or clamping voltage is the 60v specification that you call for.
Datasheet is not available for this part but specs are here:
http://www.mouser.com/ProductDetail/Lit ... TjTuL0I%3d (http://www.mouser.com/ProductDetail/Littelfuse/15KE68AG/?qs=sGAEpiMZZMvxHShE6Whpu6Rssi0ON3OxztU6TjTuL0I%3d)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 11, 2017, 08:28:40 pm
[quote author="ScotY808"]RJ11...is this the correct part?  This one has 8 positions and 2 fixing pins.  I'm guessing it's not the right part.  Mouser 538-52018-8846
http://www.mouser.com/ds/2/276/520188846_sd-206567.pdf (http://www.mouser.com/ds/2/276/520188846_sd-206567.pdf)
[/quote]
This is RJ45. You need RJ11.

[quote author="ScotY808"]
I am not sure how to determine which speaker to use.  I recall reading that you need the type without generator but I don't know how to tell. 
Is this okay?  Mouser 665-AI1223TWT5V5R
http://www.mouser.com/ds/2/334/AI-1223- ... 532187.pdf (http://www.mouser.com/ds/2/334/AI-1223-TWT-5V-5-R-532187.pdf)
[/quote]
There are no special requrements to it but the case, the pin spacing, and NOT having an internal generator. It must be pure speaker needing AC on it's leads in order to work.

[quote author="ScotY808"]
TVS1...is this okay?  Mouser 863-1.5KE68AG
I do not know if breakdown or clamping voltage is the 60v specification that you call for.
Datasheet is not available for this part but specs are here:
http://www.mouser.com/ProductDetail/Lit ... TjTuL0I%3d (http://www.mouser.com/ProductDetail/Littelfuse/15KE68AG/?qs=sGAEpiMZZMvxHShE6Whpu6Rssi0ON3OxztU6TjTuL0I%3d)[/quote]

This is 68V. You need 60V or close to 60V.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 11, 2017, 08:47:58 pm
Edit: This one looks better.  Is this the correct part for MINIUSB-V?  Mouser 710-651005136421
Product page 
http://www.mouser.com/ProductDetail/Wur ... 2bPS9og%3d (http://www.mouser.com/ProductDetail/Wurth-Electronics/651005136421/?qs=sGAEpiMZZMulM8LPOQ%252bykyMnO5Xm8QqQtUX9o%252bPS9og%3d)
Datasheet
http://www.mouser.com/ds/2/445/651005136421-537802.pdf (http://www.mouser.com/ds/2/445/651005136421-537802.pdf)


HC49US 8Mhz crystal oscillator...is this okay?  Mouser 815-ABL-8-B2
Product page
http://www.mouser.com/ProductDetail/ABR ... hnO7jKU%3d (http://www.mouser.com/ProductDetail/ABRACON/ABL-8000MHZ-B2/?qs=sGAEpiMZZMsBj6bBr9Q9aUe%252bp9Tek3UMZwPYhnO7jKU%3d)
Datasheet
http://www.mouser.com/ds/2/3/ABL-10083.pdf (http://www.mouser.com/ds/2/3/ABL-10083.pdf)
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 11, 2017, 09:06:20 pm
How about this one for TVS1?  Mouser 863-1.5KE62ARL4G
http://www.mouser.com/ProductDetail/Lit ... RRL4z0k%3d (http://www.mouser.com/ProductDetail/Littelfuse/15KE62ARL4G/?qs=sGAEpiMZZMvxHShE6Whpu6Rssi0ON3OxkAloRRL4z0k%3d)
http://www.mouser.com/ds/2/240/Littelfu ... 098032.pdf (http://www.mouser.com/ds/2/240/Littelfuse_TVS_Diode_1N6267A_D_Datasheet.pdf-1098032.pdf)

This one looks like a speaker  Mouser 490-CEM-1206S
http://www.mouser.com/ProductDetail/CUI ... fMkQ%3d%3d (http://www.mouser.com/ProductDetail/CUI/CEM-1206S/?qs=sGAEpiMZZMtWZVZ%2fjgUYS2uwMNWqYSRM1MuCOnUXWi2tAFabArfMkQ%3d%3d)
http://www.mouser.com/ds/2/670/cem-1206s-515977.pdf (http://www.mouser.com/ds/2/670/cem-1206s-515977.pdf)

This looks okay for RJ11?  Mouser 523-RJE01-660-01
http://www.mouser.com/ProductDetail/Amp ... 2eLH0OQ%3d (http://www.mouser.com/ProductDetail/Amphenol-Commercial-Products/RJE01-660-01/?qs=sGAEpiMZZMvQhAhQbXdbBt6WycxQSKiVmVJH2eLH0OQ%3d)
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 11, 2017, 09:43:36 pm
My shopping cart is almost done!!!  Just need to clarify a few more items for when sparkybg has time to answer.  My total is about $125 USD so far.  I have ordered a few extra of the small items in case I drop them on the floor. :-)  I have chosen, as much as possible, in stock items.  I am not a good value shopper and am very inexperienced so I'm sure it could be less expensive.

I will post my shopping list with Mouser part numbers soon.  I don't want to post it now until I am fairly confident the information is accurate for others to use.

Another question...does the iron holder sensor have a separate BOM or are the parts already there?  I didn't notice any parts that seemed like they could be used to sense the presence of an iron.  Also, does anyone have a sensor PCB available for sale?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 12, 2017, 07:05:09 pm
[quote author="ScotY808"]How about this one for TVS1?  Mouser 863-1.5KE62ARL4G
http://www.mouser.com/ProductDetail/Lit ... RRL4z0k%3d (http://www.mouser.com/ProductDetail/Littelfuse/15KE62ARL4G/?qs=sGAEpiMZZMvxHShE6Whpu6Rssi0ON3OxkAloRRL4z0k%3d)
http://www.mouser.com/ds/2/240/Littelfu ... 098032.pdf (http://www.mouser.com/ds/2/240/Littelfuse_TVS_Diode_1N6267A_D_Datasheet.pdf-1098032.pdf)
[/quote]
OK

[quote author="ScotY808"]
This one looks like a speaker  Mouser 490-CEM-1206S
http://www.mouser.com/ProductDetail/CUI ... fMkQ%3d%3d (http://www.mouser.com/ProductDetail/CUI/CEM-1206S/?qs=sGAEpiMZZMtWZVZ%2fjgUYS2uwMNWqYSRM1MuCOnUXWi2tAFabArfMkQ%3d%3d)
http://www.mouser.com/ds/2/670/cem-1206s-515977.pdf (http://www.mouser.com/ds/2/670/cem-1206s-515977.pdf)
[/quote]
Looks OK.

[quote author="ScotY808"]
This looks okay for RJ11?  Mouser 523-RJE01-660-01
http://www.mouser.com/ProductDetail/Amp ... 2eLH0OQ%3d (http://www.mouser.com/ProductDetail/Amphenol-Commercial-Products/RJE01-660-01/?qs=sGAEpiMZZMvQhAhQbXdbBt6WycxQSKiVmVJH2eLH0OQ%3d)[/quote]
This is horizontal and you need vertical and it is clearly visible form the drawing.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 12, 2017, 07:40:01 pm
Darn!  Okay, this one looks better?  Mouser 649-69254-003LF
http://www.mouser.com/ProductDetail/Amp ... uhEWX8c%3d (http://www.mouser.com/ProductDetail/Amphenol-FCI/69254-003LF/?qs=sGAEpiMZZMvQhAhQbXdbBsMFtwC1IMPT1QbwuhEWX8c%3d)
http://www.mouser.com/ds/2/18/69254-942343.pdf (http://www.mouser.com/ds/2/18/69254-942343.pdf)

Thank you again, sparkybg, for all your assistance.  When you have time, could you look at my post above regarding the crystal oscillator and mini-USB?  Also, if you could tell me about sensor parts so I can order them, too?  I have read this entire thread 2 times (although sometimes I do not understand what reading) and I don't know where the parts list is for the sensor.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 12, 2017, 08:13:41 pm
[quote author="ScotY808"]Darn!  Okay, this one looks better?  Mouser 649-69254-003LF
http://www.mouser.com/ProductDetail/Amp ... uhEWX8c%3d (http://www.mouser.com/ProductDetail/Amphenol-FCI/69254-003LF/?qs=sGAEpiMZZMvQhAhQbXdbBsMFtwC1IMPT1QbwuhEWX8c%3d)
http://www.mouser.com/ds/2/18/69254-942343.pdf (http://www.mouser.com/ds/2/18/69254-942343.pdf)
[/quote]
Look for a part without side "things" if you are planning to use BK3000LF enclosure and my back panel for it.

Mini USB and crystal are OK.

For sensor parts, look at the schematic. These are not in the BOM.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 12, 2017, 08:25:06 pm
Thank you, sparkybg!  Okay, I will check the schematics and try to find a different RJ11 connector.

I just learned that the BK2000+ comes with an iron stand that looks like the same one you used. It's cheaper and in stock so am going to order one today. Does the BK2000+ also need a new back panel?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 12, 2017, 10:02:27 pm
Yes, it needs. The enclosures and the stands of 2000+ and 3000LF are the same.

Also, nothing inside is useful (even the transformer) and you must remove the tinted glass in front of the 7-segment indicator on the front panel.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 12, 2017, 10:51:27 pm
Thank you, sparkybg!  I have ordered the BK2000+ but have given up on the RJ11...I cannot find one any better. I will cut off the side things if need be.

I will post my Mouser shopping list in a couple of days. I am having trouble finding some power connectors (J1 and J2) and have to leave for business trip today.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 12, 2017, 11:34:04 pm
[quote author="ScotY808"]I am having trouble finding some power connectors (J1 and J2) and have to leave for business trip today.[/quote]

We already discussed this some posts ago and I provided the links for you.
viewtopic.php?f=56&t=7218&start=960#p66143 (http://dangerousprototypes.com/forum/viewtopic.php?f=56&t=7218&start=960#p66143)
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 13, 2017, 01:01:15 am
Yes, I know but I had some kind of problem. Maybe the part number didn't match up...I am not sure but will check when I get home when I can get on my computer. Thank you again for your assistance!
Title: Re: Really universal soldering controller
Post by: sparkybg on May 13, 2017, 10:28:05 am
What problem??? These are available from Farnell, Mouser, Digikey and almost any other electronics distributor. And this is when you look for Molex part. There are several other manufacturers of compatible connectors.

For example:
https://www.google.bg/search?q=39-28-10 ... e&ie=UTF-8 (https://www.google.bg/search?q=39-28-1023&oq=39-28-1023&aqs=chrome..69i57j6j69i59j69i60l2j69i61.639j0j7&sourceid=chrome&ie=UTF-8)
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 15, 2017, 07:22:33 am
I got confused about the different types, number of pins...and also about the mating connectors.  Mouser's descriptions sometimes are not very clear to me.  Thank you again for all your help. 

I have finally finished my order and will attach it to this post!  It lists the Mouser part numbers for all the items on the BOM.  I hope this will be helpful to someone but please check/confirm all items.  I have been as careful as I could be but I am not very knowledgeable about electronics and such.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 15, 2017, 07:19:34 pm
Is this a good choice for transformer?  Specifically, part number 1182P12.
http://www.mouser.com/ds/2/177/1182-736858.pdf (http://www.mouser.com/ds/2/177/1182-736858.pdf)
http://www.mouser.com/ProductDetail/Ham ... hKOg%3d%3d (http://www.mouser.com/ProductDetail/Hammond-Manufacturing/1182P12/?qs=sGAEpiMZZMvwUzoUXIIvySPCJQuQgm7b0k3qJXeSqxA%252bNv9WtDhKOg%3d%3d)
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 15, 2017, 10:50:36 pm
Just an FYI...for those who, like me, are not very knowledgeable about electronics, Digikey might be an easier place to order from.  I just placed my Mouser order but some parts were not in stock.  I found these missing parts on Digikey and the search and product info pages seem to me to be easier to deal with.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 15, 2017, 10:51:38 pm
Looks OK. Although, it is a bit expensive for my taste.

Look here:
http://www.tme.eu/gb/katalog/#id_catego ... 3A24750%3B (http://www.tme.eu/gb/katalog/#id_category=100028&search=toroidal&s_field=accuracy&s_order=DESC&visible_params=2%2C444%2C101%2C445%2C449%2C117%2C74%2C456%2C142%2C328%2C82%2C178%2C436&used_params=101%3A24624%2C24832%3B445%3A24838%3B449%3A24750%3B)

Some are 3 times cheaper. I am using INDEL brand. Around 15-18EUR from local seller.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 16, 2017, 12:36:15 am
That is quite a bit cheaper. However, I am in the USA and need 115v input. I do not know if that makes them more expensive?  Also, the one I posted above is 24v center tapped. Maybe that makes it more expensive?  I'll have to look around some more. What specifications are important?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 16, 2017, 01:06:48 am
[quote author="ScotY808"]What specifications are important?[/quote]

Toroidal, 24V secondary, 120VA.
Title: Re: Really universal soldering controller
Post by: chefgeek on May 16, 2017, 01:07:37 am
[quote author="sparkybg"]Looks OK. Although, it is a bit expensive for my taste.

Look here:
http://www.tme.eu/gb/katalog/#id_catego ... 3A24750%3B (http://www.tme.eu/gb/katalog/#id_category=100028&search=toroidal&s_field=accuracy&s_order=DESC&visible_params=2%2C444%2C101%2C445%2C449%2C117%2C74%2C456%2C142%2C328%2C82%2C178%2C436&used_params=101%3A24624%2C24832%3B445%3A24838%3B449%3A24750%3B)

Some are 3 times cheaper. I am using INDEL brand. Around 15-18EUR from local seller.[/quote]
Anyone have some links for USA?
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 16, 2017, 01:54:32 am
I've been searching and haven't found any toroidal transformers for a good price. Even the crappy looking Chinese ones on eBay are over $40 USD.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 16, 2017, 03:10:07 am
Is this the correct OLED?  I cannot find one that is not attached to PCB.
http://www.ebay.com/itm/391742247377 (http://www.ebay.com/itm/391742247377)?
Title: Re: Really universal soldering controller
Post by: dumitruv on May 16, 2017, 05:53:03 am
I found this one:
http://www.ebay.com/itm/0-96-128X64-128 ... SwmtJXWTAi (http://www.ebay.com/itm/0-96-128X64-12864-White-OLED-LED-COG-Display-Module-LCD-Screen-Panel-/222147099241?hash=item33b8ffba69:g:PgIAAOSwmtJXWTAi)

Also look at these USB connectors:
http://www.ebay.com/itm/5pcs-Mini-USB-F ... SwM4xXYaDp (http://www.ebay.com/itm/5pcs-Mini-USB-Female-5Pin-180-Socket-Connector-vertical-Legs-HW-MU-5F-23-/201604726385?hash=item2ef093fe71:g:9bkAAOSwM4xXYaDp)
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 16, 2017, 06:09:41 am
Thanks, dumitruv!  I am terrible at searching for stuff. That looks like a better one to get.

The only thing else I need is to get a transformer. Quite expensive and I suspect shipping will be high due to the weight.

I have all my parts on order.  Once the components arrive and I find some more free time, I can get to soldering.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 16, 2017, 10:19:27 am
[quote author="ScotY808"]Is this the correct OLED?  I cannot find one that is not attached to PCB.
http://www.ebay.com/itm/391742247377 (http://www.ebay.com/itm/391742247377)?[/quote]

Go to ebay and look for "ssd1306 0.96". You will see many not-attached displays. You don't need multicolor.

You will have to see what voltage it wants. It can be 9V or 12V and feedback resistors of the OLED PCB should be corrected accordingly.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 16, 2017, 07:34:24 pm
US Ebay does not show any when I search this. 

EDIT:  WRONG SIZE
I found some OLEDs on Aliexpress.  This is the only one I see so far that has part number so I search datasheet.  Does this one look okay?  I think it is 12v which is easier for me so I don't have to change resistors.
https://www.aliexpress.com/item/1pcs-1- ... 294248ab76 (https://www.aliexpress.com/item/1pcs-1-3-inch-OLED-Display-LCD-module-with-128x64-Resolution-and-white-on-black-SPI/1436446293.html?spm=2114.01010208.3.109.vCDo77&ws_ab_test=searchweb0_0,searchweb201602_3_10152_10065_10151_10130_10068_436_10136_10137_10157_10060_10138_10155_10062_10156_10154_10056_10055_10054_10059_100032_100033_100031_10099_10103_10102_10096_10147_10052_10053_10050_10107_10142_10051_10084_10083_10080_10082_10081_10178_10110_10111_10112_10113_10114_10181_10183_10182_10185_10078_10079_10073_10123,searchweb201603_2,ppcSwitch_3&btsid=a35f6a31-4c2a-4b03-be24-ba747a087f1c&algo_expid=5313143d-f594-4059-8245-3e294248ab76-14&algo_pvid=5313143d-f594-4059-8245-3e294248ab76)

http://pdf.masters.com.pl/WISECHIP/UG-2864KSWLG01.PDF (http://pdf.masters.com.pl/WISECHIP/UG-2864KSWLG01.PDF)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 16, 2017, 07:54:35 pm
This one is 1.3 inches, and I am using 0.96 inches. It may be compatible, but you will have to check if the pins are the same and the pin spacing is the same.
Title: Re: Really universal soldering controller
Post by: puzzle on May 17, 2017, 09:01:52 pm
@ScotY808:
Dude, this is the link for my display:
https://www.aliexpress.com/item/1pcs-0- ... 0.0.dYYx9q (https://www.aliexpress.com/item/1pcs-0-96-inch-OLED-Display-LCD-module-with-128x64-Resolution-and-blue-on-black-SPI/1430628386.html?spm=2114.13010608.0.0.dYYx9q)
And you need to replace just R68 to be 4.7k and your done!
It's a working combination
Title: Re: Really universal soldering controller
Post by: NECHTO on May 18, 2017, 10:07:54 am
Hello all :) What do you think about the possibility of installing this display
http://https://ru.aliexpress.com/item/3-0-inch-128X64Graphic-Dot-LCD-Modules-Gray-White-LCD-Handheld-device-display-FSTN-KS0107-KS0108/1210214420.html?spm=2114.13010608.0.0.0sQuBm

Displays the type KS0107/KS0108 or Equivalent 12864 display.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 18, 2017, 06:54:29 pm
[quote author="puzzle"]@ScotY808:
Dude, this is the link for my display:
https://www.aliexpress.com/item/1pcs-0- ... 0.0.dYYx9q (https://www.aliexpress.com/item/1pcs-0-96-inch-OLED-Display-LCD-module-with-128x64-Resolution-and-blue-on-black-SPI/1430628386.html?spm=2114.13010608.0.0.dYYx9q)
And you need to replace just R68 to be 4.7k and your done!
It's a working combination[/quote]

Thank you, puzzle. I think this must be the one to order. I have searched for some time now and most of them do not say part number and do not have voltage rating listed. The only one that says part number have been 9v displays.  I will order your part and try the 4.7k resistor.

BTW, anyone in the US, Mouser has been very slow to send my order. I also ordered Digi-Key at the same time and that order arrived to me much faster. As a newbie, I find Digi-Key easier to find/search parts, sometimes less expensive, and faster to ship. I am bummed that I spent so many hours choosing Mouser part numbers!
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 19, 2017, 05:13:38 am
Today I soldered on one component. :-) I got the microprocessor from Digi-Key so figured I'd start with that. My Mouser order is nowhere to be seen. They are terrible for service and I will avoid using them in the future.

While I am proficient at soldering, I have to say these parts are SMALL!  I used flux and solder wick and it looks good but I need some better magnification. I have just a cheap eye loupe. I need to find something better.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 19, 2017, 09:38:27 am
It is not that scary once you get used to it. Use small amount of solder on the iron, large amount of liquid flux (no-clean BGA flux is the best, IMHO), and solder wick to remove the excess solder. It is a bit harder with classical big soldering iron, but far from impossible. Your iron needs to be temperature controlled, at around 260-300 degrees celsius in order not to overheat the parts or PCB. I soldered my first chip (and many others) with 0.5mm spacing with huge 80 watt soldering iron without any problem. :)
Title: Re: Really universal soldering controller
Post by: SZ64 on May 19, 2017, 03:10:16 pm
Hi sparkybg,

How is the "GND" made between FRONT and OLED?
The U9 does not exist, I recognize that there is no common GND between FRONT and OLED or I have overlooked what?
Title: Re: Really universal soldering controller
Post by: puzzle on May 19, 2017, 04:14:58 pm
@ScotY808:
Yea, parts are small :D
I did not trust myself enough and used an aluminum radiator from old CPU to cover the small ICs while soldering! Still U11 is very very small and so fragile - I've bent one of the pins(more like melted) wile soldering so I was very surprised to see my controller working from the first run - no troubleshooting needed :D so just be more patient than me with this U11.

Best wishes to all
Title: Re: Really universal soldering controller
Post by: afedorov on May 19, 2017, 05:16:40 pm
[quote author="NECHTO"]Hello all :) What do you think about the possibility of installing this display[/quote]
At least you'll need to make a new PCB with appropriate power circuit for it and add support in firmware. If you're lucky you'll have enough free MCU pins for it (and MCU time to drive it).
What's the point to adapt this crusty old LCD? I saw on YT someone's managed to drive an LCD by Unisolder, but it was a modern COG one.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 19, 2017, 06:34:46 pm
I have a question about U19 which is the FAN5331. The component I ordered has 5 pins but there are 6 pins on the PCB of the OLED. Is this the correct part?
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 19, 2017, 06:41:32 pm
[quote author="sparkybg"][quote author="ScotY808"]Is this the correct OLED?  I cannot find one that is not attached to PCB.
http://www.ebay.com/itm/391742247377 (http://www.ebay.com/itm/391742247377)?[/quote]

Go to ebay and look for "ssd1306 0.96". You will see many not-attached displays. You don't need multicolor.

You will have to see what voltage it wants. It can be 9V or 12V and feedback resistors of the OLED PCB should be corrected accordingly.[/quote]

Hi sparkybg,
Puzzle says to change R68 to 4.7k for use with 9V OLED.  Is this the only resistor that needs to be changed?  I am too dumb to know what resistors are feedback resistors that you say.
Thank you!
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 19, 2017, 06:47:29 pm
This is my first ever SMD soldered part. I thought it would be difficult but I watch YouTube so I am an expert now! :-) Haha, joking!  I think actually passive components are harder because of the smaller size.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 19, 2017, 06:49:09 pm
[quote author="SZ64"]Hi sparkybg,

How is the "GND" made between FRONT and OLED?
The U9 does not exist, I recognize that there is no common GND between FRONT and OLED or I have overlooked what?[/quote]

You have overlooked that there are soldermask-free islands around some pins on the OLED connectors on the back of the front PCB. ;)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 19, 2017, 06:50:37 pm
[quote author="ScotY808"]
Hi sparkybg,
Puzzle says to change R68 to 4.7k for use with 9V OLED.  Is this the only resistor that needs to be changed?[/quote]

Yes.
Title: Re: Really universal soldering controller
Post by: SZ64 on May 20, 2017, 12:13:39 am
[quote author="sparkybg"]

You have overlooked that there are soldermask-free islands around some pins on the OLED connectors on the back of the front PCB. ;)[/quote]

Hi sparkybg,

Yes, that is it ... however, I must first come on the that this "island" has double function ;-)

In any case, with "without solder-bridging" the 0.96inch display has fully worked.
Problem is first dived with installation of a new 1.3inch display. The display could not reach the full contrast (it was completely in the lowest contrast area with slight flicker) and voltage at the OLEDVCC has varied between 5.52V and 9.30V depending on how much screen was filled.
So, no wonder the new 1.3 "OLED requires between 11.5V and 12.5V at the Vcc pin.
I have tried with the contrast 0x81,0xFF, -0xAF, -0x3F and DCOM 0xDB, 0x20, -0x00, -0x30 but no improvement.
I just wanted to replace the FAN5331 against LM2731 / LM2733 and with measurements I noticed something with the GND is not in order. That's why you asked how that is connected.

After your assistance I solved the "island" with the pin2 and now I have a 1.3inch display fully functional
together with all the right voltage.

I thank you very much for your help !
Title: Re: Really universal soldering controller
Post by: afedorov on May 20, 2017, 02:13:51 am
[quote author="ScotY808"]This is my first ever SMD soldered part.[/quote]
Looks good, but a little lack of solder. I would expect some dry joints.
Title: Re: Really universal soldering controller
Post by: puzzle on May 20, 2017, 07:13:08 am
[quote author="ScotY808"]I have a question about U19 which is the FAN5331. The component I ordered has 5 pins but there are 6 pins on the PCB of the OLED. Is this the correct part?[/quote]

Yes, mine was 5 pin too.
Title: Re: Really universal soldering controller
Post by: SZ64 on May 20, 2017, 12:35:49 pm
[quote author="puzzle"][quote author="ScotY808"]I have a question about U19 which is the FAN5331. The component I ordered has 5 pins but there are 6 pins on the PCB of the OLED. Is this the correct part?[/quote]

Yes, mine was 5 pin too.[/quote]


... and always remember that certain solder pads are for a different function ;-)
Title: Re: Really universal soldering controller
Post by: sparkybg on May 20, 2017, 07:24:17 pm
There are maybe 10 other booster chips that can be used instead of FAN5331, some of them having 6 pins. That's why there is 6 pin footprint on the PCB.
Title: Re: Really universal soldering controller
Post by: neddrag on May 21, 2017, 08:58:51 am
Hello!
Congratulations for the project!
Can you please tell something about transformer parameters?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 21, 2017, 05:20:06 pm
24V 120VA toroidal.
Title: Re: Really universal soldering controller
Post by: neddrag on May 21, 2017, 07:47:02 pm
Thank you!
Title: Re: Really universal soldering controller
Post by: Blackfinger on May 24, 2017, 03:25:31 pm
Hi every one

I'm new to this forum.

I have two questions that I hope someone in this forum will help to answer.

# 1 I have mad a Universal Solder 5.2 unit, and now I have to load the bootloader and the application into the
    device. Is there anyone who can help with a guide and what equipment I need to use for this ?

# 2 Do Universal Solder 5.2 support the following device:
      1. Hakko FM-2032-51 soldering handel ?
      2. JBC C105 Nano soldering device ?

Thanks for a nice project.

Bo
Title: Re: Really universal soldering controller
Post by: sparkybg on May 24, 2017, 08:03:55 pm
I am 99.999% sure it can drive them, but there are no profiles in the firmware for them for now.

If you live in EU, you can mail them to me, and I will be able to make profiles in a month or so and return them to you. This is how I made the profiles fot Weller WMRT, WSP80, ERSA RT80. I just cannot have any soldering iron in the world myself. ;)
Title: Re: Really universal soldering controller
Post by: Blackfinger on May 24, 2017, 10:26:27 pm
Thanks for your replay.

But before I send any thing, I need to find out how I program the PIC32 with the
bootloader and after that the program it selve.

Can anyone help with a guide, and info abouth what HW I need to buy ?

Thanks !

Bo
Title: Re: Really universal soldering controller
Post by: cbi7333 on May 24, 2017, 10:43:11 pm
Also new here, everything's ordered and just waiting for the postman to arrive.  I've reviewed most of the posts here and must say it's an impressive and interesting project..  Will surely be lots more fun than a 230V iron and dimmer :)  Thanks Sparky! 

@Blackfinger - I'm in EU and was also looking at the JBC 105. Am over budget at the moment but in a month or so could send one off for Sparky to work on a profile if you're from outside EU and not in a rush.

@Sparky - Have a couple 'newbie' questions I didn't seem to find answers for here.. First I saw that your station listed dual channel.. does that mean it can be used to drive two different soldering irons simultaneously or is it strictly for tweezers with two same heating elements sharing the same profile?  I really like the hotplug features you built in so guess two connectors and a switch would work well.  Second,  I looked at the BOM but did not see the panel connectors listed.  Is there some universal DIN type connector that works well with most irons or will I just have to cut the soldering iron wires and adapt to a connector?  Have a good source/part nr to recommend?

Apologies if any questions were answered before, the search function here is quite lacking..

Again Thanks!!
Title: Re: Really universal soldering controller
Post by: sparkybg on May 24, 2017, 11:36:41 pm
[quote author="Blackfinger"]Thanks for your replay.

But before I send any thing, I need to find out how I program the PIC32 with the
bootloader and after that the program it selve.

Can anyone help with a guide, and info abouth what HW I need to buy ?

Thanks !

Bo[/quote]

You need PicKit3 or any other tool that supports PIC32 for bootloader uploading, then you need to use Unisolder PC software to upload the "..._with_bootloader" firmware. In order to run Unisolder PC software you need Visual Studio 2015 installed.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 24, 2017, 11:46:18 pm
[quote author="cbi7333"]
@Sparky - Have a couple 'newbie' questions I didn't seem to find answers for here.. First I saw that your station listed dual channel.. does that mean it can be used to drive two different soldering irons simultaneously or is it strictly for tweezers with two same heating elements sharing the same profile?  I really like the hotplug features you built in so guess two connectors and a switch would work well.  Second,  I looked at the BOM but did not see the panel connectors listed.  Is there some universal DIN type connector that works well with most irons or will I just have to cut the soldering iron wires and adapt to a connector?  Have a good source/part nr to recommend?

Apologies if any questions were answered before, the search function here is quite lacking..

Again Thanks!![/quote]

The controller is made to control single instrument with one or two heaters. The heaters can be different (iron profile in the firmware has separate part for each heater), but they are always driven with the same temperature and in the same time.

There is not universal connector, sorry. So you will have to cut the wires as I did.
For example Amphenol C091 8pin connector is a good option.
There are a lot of others with similar size, including chinese ones. GX16-8 (ask Google) for example.
Title: Re: Really universal soldering controller
Post by: puzzle on May 25, 2017, 09:02:13 am
@Blackfinger:
After purchasing Pickit3 and installed MPLab, and being able to run Unisolder.exe - as Sparky described you do the following steps from page 63 on this topic...
1. Connecting Pickit3 to PC and to 5 pin header on front board,
2.Powering the "soldering station" - I have the Iron connected but no heater in it.
3. Opening MPLab, and selecting programmer to Pickit3 - it has connected and found the chip, loaded correct firmware for pic32mx.
4. I chose "Import..." and browsed to the "US_BootLoader.X.production.hex" and select "OPEN"
5. I select "Program" - it goes very fast true: " Programming... Programming/Verify complete" - And I IMIDEATELY have wiggling lines on the screen.
Now I will try to flash it true PC:
1. I remove Pickit3 from the board -  now I will switch the board(soldering station) off.
2 Connecting USB cable to "Soldering station" - I use the cable of the programmer.
3. Open software - "UniSolder.exe"
4. Switch the station on - I have wiggling lines on screen, no sounds, nothing on software or on the PC indicates that I have switched something
5. I press "Update firmware" and browse to the "US firmwareX > PIC32 with bootloader> "US_Firmware.X.production.hex" - I press "Open" - after 5-7 seconds I heard beep and now the station looks fine - it shows my iron and "Heater open" as it should.

This is how it programs the chip to be able to do following updates to the firmware true the PC, not needing to open your soldering station.

Greetings to all
Title: Re: Really universal soldering controller
Post by: Blackfinger on May 25, 2017, 09:34:51 am
Thanks!  Puzzle for this guide.
Title: Re: Really universal soldering controller
Post by: cbi7333 on May 25, 2017, 11:21:04 am
@Sparky - have been reading a lot regarding transformers you suggest.  Have no problem with ordering the toroidal but I do have a high quality 230 / 24 / 12 / 150VA transformer available that I got from a local manufacturer so am tempted...  The windings are layered on top of each other 230V inside 24V outside and not two separate, stacked windings. Full copper.  If you think it might be worth a try, what would be the negative symptoms to look for if it's not a good match?

[attachment=0]
Title: Re: Really universal soldering controller
Post by: sparkybg on May 25, 2017, 11:46:06 am
Temperature instability would be one of the possible causes.

You must connect an oscilloscope before the rectifiers and see what's going on when controller is powering the iron, and when it does not. When observing the secondary voltage before the rectifiers, there should not be any significant zero-cross time shift between neighboring periods when the iron is powered and when it is not.

The controller is highly dependent on zero cross point to read the temperature.

I made everything I can think of in order to eliminate the effect of the leakage inductance of non-toroidal transformers but I cannot guarantee it will work with any non-toroidal transformer. The one that I have tested it with was really nasty in this respect, and it still works, but as I said before - a toroidal transformer is the best power source for this controller. Leakage inductance is a nasty thing to deal with, sometimes with very hard to predict end effects.
Title: Re: Really universal soldering controller
Post by: cbi7333 on May 25, 2017, 12:37:47 pm
Thanks Sparky!  I'll order the toroidal and save this transformer for another project ;)  Am patiently awaiting the mailman and can pick up a toroidal locally.  I can always give it a curious try after I'm up and running just to see how it handles. 

An aside regarding plugs/sockets, found reported in another fora that HIROSE(HRS)  RPC1-12RB-6P may well be the socket to use with JBC 245 handles available at digikey.  Will order that also and report back if it fits to save cutting the handle wires.

Cheers!
Title: Re: Really universal soldering controller
Post by: sparkybg on May 25, 2017, 01:25:41 pm
JBC uses 7 pin, and my controller uses 8pin connector ;)
Title: Re: Really universal soldering controller
Post by: puzzle on May 25, 2017, 05:07:10 pm
@cbi7333:
This Hirose socket is the exact match for JBC 245 handle - I think I have it on by BOM published here on page 63 at the bottom of the list.
My friend bought it and we tested his brand new c245 iron on my controller without cutting off any wires, just disassembled it to see the wiring. The quality of the socket is exceptional and looks the same as the plug of the JBC handle!
My friend would use only this iron so the identification resistors are soldered to the Hirose's plug  and everything works as a charm.

I, on the other hand, bought 8 pin connector as Sparky's from page 1 here. Using it with a Chinese Hakko t12 handle - also working fine.

Edit: here is the link from my BOM:
https://store.comet.bg/CatalogueFarnell/Product/977100/ (https://store.comet.bg/CatalogueFarnell/Product/977100/)
Greetings
Title: Re: Really universal soldering controller
Post by: Blackfinger on May 25, 2017, 06:34:19 pm
@Puzzle

Could this be a Pickit3 programmer I can yse for the programmimg ?

https://www.aliexpress.com/wholesale?ca ... t=pickit+3 (https://www.aliexpress.com/wholesale?catId=0&initiative_id=SB_20170525083154&SearchText=pickit+3)
Title: Re: Really universal soldering controller
Post by: Raul on May 25, 2017, 07:53:14 pm
It's a great project.
I have a question about Goot Soldering Iron. Would it be possible to make Goot soldering iron work with your soldering controler?
I've read that resistance of temperature measuring part when tip is at 370C is 22R if it could help.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 25, 2017, 08:05:21 pm
[quote author="Raul"]It's a great project.
I have a question about Goot Soldering Iron. Would it be possible to make Goot soldering iron work with your soldering controler?
I've read that resistance of temperature measuring part when tip is at 370C is 22R if it could help.[/quote]

I am 99.999% sure it can drive it, but as I already said, you will have to mail it to me in order to make a profile for it. I suppose you are talking for RX80-GAS and RX-85GAS?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 25, 2017, 08:06:49 pm
[quote author="Blackfinger"]@Puzzle

Could this be a Pickit3 programmer I can yse for the programmimg ?

https://www.aliexpress.com/wholesale?ca ... t=pickit+3 (https://www.aliexpress.com/wholesale?catId=0&initiative_id=SB_20170525083154&SearchText=pickit+3)[/quote]

Yes, that's it. Although, I would buy it from eBay instead, from a seller with good reputation.
Title: Re: Really universal soldering controller
Post by: puzzle on May 25, 2017, 08:42:57 pm
@Blackfinger:
Yes, we bought our clone of Pickit3 from aliexpress also. It was some variation with cd which suppose to have some version of MPlab but i don't have a CD-rom on my PC and I downloaded v8.92 from the developer and it works fine... I have deleted the bookmark with the address- sorry!
But you can watch this:
https://www.youtube.com/watch?v=PqYY_nOIn5c (https://www.youtube.com/watch?v=PqYY_nOIn5c)
it explains some issues people are having with clones.
I did not experienced any so far.

Chears
Title: Re: Really universal soldering controller
Post by: Raul on May 25, 2017, 08:44:03 pm
[quote author="sparkybg"][quote author="Raul"]It's a great project.
I have a question about Goot Soldering Iron. Would it be possible to make Goot soldering iron work with your soldering controler?
I've read that resistance of temperature measuring part when tip is at 370C is 22R if it could help.[/quote]

I am 99.999% sure it can drive it, but as I already said, you will have to mail it to me in order to make a profile for it. I suppose you are talking for RX80-GAS and RX-85GAS?[/quote]
Yes, I thought about RX-80GAS.
So if it won't work from the start I would have to send iron to you?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 25, 2017, 09:44:44 pm
[quote author="Raul"]
So if it won't work from the start I would have to send iron to you?[/quote]

It won't work from the start. A specific profile for this exact iron is needed in the firmware.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 26, 2017, 08:26:06 am
Hello sparkybg,

I have slowly been making progress assembling the PCBs. Please see my picture. I am unsure about ZD3. I believe I have ordered the correct part from BOM. The size is the same in BOM for ZD1, ZD2, and ZD3 but the pads for ZD3 are much larger. Is this okay?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 26, 2017, 09:50:46 am
After you complete it, check if it warms up. If not, then it is OK, else you will have to put DO-214 zener there.
Title: Re: Really universal soldering controller
Post by: cbi7333 on May 26, 2017, 10:02:30 am
Hi again @all,

am doing my pre-build planning and reviewing the PIC programming / bootloader flashing etc that's involved.  I foresee some difficulties with this as I haven't owned a windows based computer in 20 years and have never worked with PIC...  Any OSX folks here that could help me figure out the easiest way to do these steps?  I see Pickit3 is 'supposed' to be workable with a mac but there seems to be little information googleable on and most is quite dated.  I'm hesitant to buy a clone that may not work the original for 80 bucks hoping to get good support...  I'd much rather buy and send a new iron like the JBC Nano to Sparky to add to the unisolder profiles.  Aside from that it'll probably be used once or maybe twice and end up as another expensive dustmonster in the garage.

Any good ideas?  I'm a PIC idiot.. this is my first project using it...

I looked at other arduino-pic and raspberry pi - pic based ideas like https://www.pedalpc.com/blog/posts/how- ... -pi-plus-2 (https://www.pedalpc.com/blog/posts/how-to-program-a-pic-microcontroller-using-a-raspberry-pi-or-orange-pi-plus-2)  but it seems the PIC32MX is incompatible...  aargh...

p.s. I really, really hate the search function here..  'bootloader' and 'PIC" a too common search terms for the server in a 70 page thread?  grrr... (and again apologies if this has already been addressed).
Title: Re: Really universal soldering controller
Post by: sparkybg on May 26, 2017, 10:09:18 am
Run windows virtual machine and do your work there. After you flash bootloader you will have to run the PC software anyway, which is again Windows software

P.S.: Most PicKit3 clones do work. Just buy it from a seller with 95%+ eBay reputation and everything will be OK. I have both original and clone and they both work flawlessly.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 26, 2017, 10:24:38 am
Thank you, sparkybg. Perhaps I will just order the correct size part since I need to order more things anyway.

I have been watching the YouTube video posted by puzzle. I am quite some time until I need it but would a Pickit2 be okay to use?  It seems many YouTube people prefer the Pickit2. And some say Pickit3 causes trouble.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 26, 2017, 11:07:31 am
I do have only PicKit3 and it programs everything that microchip manufactured ever (excluding Atmel chips). So I cannot comment anything on PicKit2.
Title: Re: Really universal soldering controller
Post by: cbi7333 on May 26, 2017, 11:29:57 am
[quote author="sparkybg"]Run windows virtual machine and do your work there. After you flash bootloader you will have to run the PC software anyway, which is again Windows software[/quote]

eeek :)  ok ordered the PicKit3.  I can get a friend to lend me his windows laptop so I don't have to buy a windows licence for VM  I doubt crossover for mac or wine would do it..
Title: Re: Really universal soldering controller
Post by: puzzle on May 26, 2017, 02:31:46 pm
@ScotY808: Hi!
As I said, did not experience any problems with the Pickit3 clone - from what I read and saw as videos- they are several specifics to it but all are covered in the video I posted. I don't think you should worry much for it, the clone was something like 12-15$ and for the money it is perfect.
And mainly the step by step guide in my post is exactly the steps I did and everything works great! So no worries there.

Hurray guys, I found the link for the programmer we bought :
https://www.aliexpress.com/item/PICKIT3 ... 697f&tpp=1 (https://www.aliexpress.com/item/PICKIT3-Programmer-PIC-ICD2-PICKit-2-PICKIT-3-Programming-Adapter-Universal-Programmer-Seat-FZ0508-Free-Shipping/1315482462.html?scm=1007.13338.71800.000000000000000&pvid=16b14f0b-ccfa-4545-82d4-ce29c607697f&tpp=1)
Title: Re: Really universal soldering controller
Post by: DinikS on May 26, 2017, 02:59:10 pm
Hi sparkybg, I have a question regarding IR receiver  used on sensor. Is it possible to use TSOP4838 instead of RPM7140?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 26, 2017, 03:39:27 pm
You will have to find out this yourself. It has to be with the same frequency, wavelength and the same AGC setting procedure. Look at the datasheets. I don't have enough time right now to do it.
Title: Re: Really universal soldering controller
Post by: Blackfinger on May 26, 2017, 10:36:06 pm
[quote author="puzzle"]@Blackfinger:
After purchasing Pickit3 and installed MPLab, and being able to run Unisolder.exe - as Sparky described you do the following steps from page 63 on this topic...
1. Connecting Pickit3 to PC and to 5 pin header on front board,
2.Powering the "soldering station" - I have the Iron connected but no heater in it.
3. Opening MPLab, and selecting programmer to Pickit3 - it has connected and found the chip, loaded correct firmware for pic32mx.
4. I chose "Import..." and browsed to the "US_BootLoader.X.production.hex" and select "OPEN"
5. I select "Program" - it goes very fast true: " Programming... Programming/Verify complete" - And I IMIDEATELY have wiggling lines on the screen.[/quote]

#1 How do you manage to make / finde the "US_BootLoader.X.production.hex" in the software packet ?
    Have you compile the program in MPLab ? 

#2 How do you wire the Pickit3 to the 5 pin header on frond board ?
    Do you have a wire connection diagram or description like Pickit3 Pin X --> Pin Y on 5 Pin Header on front board.

[quote author="puzzle"]
Now I will try to flash it true PC:
1. I remove Pickit3 from the board -  now I will switch the board(soldering station) off.
2 Connecting USB cable to "Soldering station" - I use the cable of the programmer.
3. Open software - "UniSolder.exe"
4. Switch the station on - I have wiggling lines on screen, no sounds, nothing on software or on the PC indicates that I have switched something
5. I press "Update firmware" and browse to the "US firmwareX > PIC32 with bootloader> "US_Firmware.X.production.hex" - I press "Open" - after 5-7 seconds I heard beep and now the station looks fine - it shows my iron and "Heater open" as it should.
[/quote]

#3 How do you manage to finde the "UniSolder.exe" in the software packet ?
    Have you also compiled this program with MPLab ? 

Thanks !!!
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 26, 2017, 10:49:20 pm
Sparkybg,
I have some problems. I had a solder bridge between C21 and R21 on the back board. I tried to remove it but had a lot of trouble. Now it looks like there is a trace that connects them. I struggle to read schematics so cannot figure this out. Please see picture.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 26, 2017, 10:52:22 pm
Also, can you tell me which side is R19 and R20?  Do they mount vertically or horizontally?
Title: Re: Really universal soldering controller
Post by: afedorov on May 26, 2017, 11:29:45 pm
[quote author="DinikS"]Hi sparkybg, I have a question regarding IR receiver  used on sensor. Is it possible to use TSOP4838 instead of RPM7140?[/quote]
Not all TSOPs really supports 3.3V supply, got TSOP4836 and it doesn't work, had to replace it by TSOP34840 which works well.
Title: Re: Really universal soldering controller
Post by: puzzle on May 26, 2017, 11:38:23 pm
@Blackfinger:
Quote
"#1 How do you manage to make / finde the "US_BootLoader.X.production.hex" in the software packet ?
Have you compile the program in MPLab ? " and
"#3 How do you manage to finde the "UniSolder.exe" in the software packet ?
Have you also compiled this program with MPLab ? "

              On the first page is an archive "...software" - in it there are 3 folders. "front" -for the front board(pic32mx).
      UniSolder52_SoftwarefrontUS_BootLoader.XdistPIC32production    - bootloader only - flashed first
UniSolder52_SoftwarefrontUS_Firmware.XdistPIC32_with_bootloaderproduction      - hex for flashing true USB - flashed second

Second is "PC" - there is the pc software.
          UniSolder52_SoftwarePCUniSolderbinRelease

And third is for the pic on the sensor board.
I did not compile anything, Sparky is very kind and provides every little detail for the project to be successful.


Quote
"#2 How do you wire the Pickit3 to the 5 pin header on frond board ?
Do you have a wire connection diagram or description like Pickit3 Pin X --> Pin Y on 5 Pin Header on front board."
    Well, on the 5pin header you surely have seen that one of the pins is square - there goes the arrow pin from the pickit3. Count it as pin 1 and from there is easy. Actually I did not use any cables, just pluged the programmer on to the heather - arrow to the square.



@ScotY808:

There ara pictures on page 63, it might be helpfull for the orientation of the components. If you need larger pictures I can send them to you!
C21, R21 are connected - I taught I bridged them too but found in the schematics it is meant to be that way.
R19 and R20 -horizontal

Greetings
Title: Re: Really universal soldering controller
Post by: SZ64 on May 27, 2017, 12:07:59 am
[quote author="DinikS"]Hi sparkybg, I have a question regarding IR receiver  used on sensor. Is it possible to use TSOP4838 instead of RPM7140?[/quote]

Hi DinikS,

• Instead of the RPM7140 (Carrier freq. 40.0kHz) (ROHM) can use TSOP4840 (Carrier freq. 40.0kHz) (VISHAY)
• Instead of the KM4457F3C (Kingbright) can use CQX48, TSKS5400S (VISHAY) or IRL80A (OSRAM)

All of these above replacement parts I tested and everything works fine ;)
Title: Re: Really universal soldering controller
Post by: chefgeek on May 27, 2017, 03:56:53 am
[quote author="cbi7333"][quote author="sparkybg"]Run windows virtual machine and do your work there. After you flash bootloader you will have to run the PC software anyway, which is again Windows software[/quote]

eeek :)  ok ordered the PicKit3.  I can get a friend to lend me his windows laptop so I don't have to buy a windows licence for VM  I doubt crossover for mac or wine would do it..[/quote]
you run an unactivated version of windows for free.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 27, 2017, 05:46:22 am
[quote author="puzzle"]
@ScotY808:

There ara pictures on page 63, it might be helpfull for the orientation of the components. If you need larger pictures I can send them to you!
C21, R21 are connected - I taught I bridged them too but found in the schematics it is meant to be that way.
R19 and R20 -horizontal

Greetings[/quote]

Thank you, puzzle...this is a relief!  I thought I damaged the PCB.

Thank you also for your pictures. I remember seeing them but could not find them in this huge thread. Now I have saved them on my computer so I can always see.

As I have said before, I am a newbie to this kind of thing. Before I thought the ICs and chips would be hardest to solder but I find the passive components are much harder!  They are so small and move around a lot. Does anyone know an inexpensive solution for magnification?  I use a cheap eye loupe but I cannot use it and solder at the same time.
Title: Re: Really universal soldering controller
Post by: puzzle on May 27, 2017, 08:38:17 am
@ScotY808:

I'm glad I can help.
I used a jewelers loupe but only to check the solder joints. To me, it was more helpful to watch several videos on SMD soldering were I understood  that a chisel tip is one of the keys, so I filed down my smallest cone tip, Just enough to make it appear like chisel and it was the best decision. The solder stayed at the flat side and was easier to manage on those small components.
Here are some of the videos I watched:
https://www.youtube.com/watch?v=vIT4ra6Mo0s (https://www.youtube.com/watch?v=vIT4ra6Mo0s)
https://www.youtube.com/watch?v=_6tpQE7ptqo (https://www.youtube.com/watch?v=_6tpQE7ptqo)
https://www.youtube.com/watch?v=QzoPxvIM2qE (https://www.youtube.com/watch?v=QzoPxvIM2qE)
https://www.youtube.com/watch?v=3NN7UGWYmBY (https://www.youtube.com/watch?v=3NN7UGWYmBY)

My loupe is made of 2 magnification glasses and you have 3 different magnifications - if you use one of the glasses you have 5x, if you use the other glass you have 10x, and if you use both you have 15x. It is an old jewelers loupe(some 20 years) and it can not be used to solder whit it but you can check the joints quite well on max magnification.
Also using a loupe at extended periods is detrimental for your eyes!

Cheers
Title: Re: Really universal soldering controller
Post by: SZ64 on May 27, 2017, 08:50:54 am
[quote author="puzzle"]
...
 Does anyone know an inexpensive solution for magnification?  I use a cheap eye loupe but I cannot use it and solder at the same time.[/quote]

I have used this ;)


Head-Wearing Elastic Band Magnifier with LED Illumination:
https://www.fasttech.com/products/1398900 (https://www.fasttech.com/products/1398900)
Title: Re: Really universal soldering controller
Post by: Blackfinger on May 27, 2017, 11:57:54 am
[quote author="puzzle"]@Blackfinger:
[quote author="Blackfinger"]"#1 How do you manage to make / finde the "US_BootLoader.X.production.hex" in the software packet ?
Have you compile the program in MPLab ? " and
"#3 How do you manage to finde the "UniSolder.exe" in the software packet ?
Have you also compiled this program with MPLab ? "[/quote]

              On the first page is an archive "...software" - in it there are 3 folders. "front" -for the front board(pic32mx).
      UniSolder52_SoftwarefrontUS_BootLoader.XdistPIC32production    - bootloader only - flashed first
UniSolder52_SoftwarefrontUS_Firmware.XdistPIC32_with_bootloaderproduction      - hex for flashing true USB - flashed second

Second is "PC" - there is the pc software.
          UniSolder52_SoftwarePCUniSolderbinRelease

And third is for the pic on the sensor board.
I did not compile anything, Sparky is very kind and provides every little detail for the project to be successful.[/quote]

Thanks ! Puzzle

I manage to finde alle the file with your help.

[quote author="Blackfinger"]"#2 How do you wire the Pickit3 to the 5 pin header on frond board ?
Do you have a wire connection diagram or description like Pickit3 Pin X --> Pin Y on 5 Pin Header on front board."[/quote]
 [quote author="puzzle"] Well, on the 5pin header you surely have seen that one of the pins is square - there goes the arrow pin from the pickit3. Count it as pin 1 and from there is easy. Actually I did not use any cables, just pluged the programmer on to the heather - arrow to the square.[/quote]

@Puzzle

If I've understood you correctly, the connection from PICkit3 to UniSolder 5.2 circuit board should be as shown in this picture?

Greetings
Title: Re: Really universal soldering controller
Post by: puzzle on May 27, 2017, 12:31:03 pm
@Blackfinger:
Glad to be able to help!

Quote
If I've understood you correctly, the connection from PICkit3 to UniSolder 5.2 circuit board should be as shown in this picture?

Yes, exsactly.

Greetings
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 27, 2017, 07:02:17 pm
Hello puzzle,

I am not finished soldering yet but could you post pictures of how the boards all connect together?  I am not sure how the 10 pin connector is wired together and also how the OLED board connects to the main board.

Thank you!
Title: Re: Really universal soldering controller
Post by: puzzle on May 27, 2017, 10:01:13 pm
@ScotY808:
I'm very sorry, but at this time I can't help. I have seasonal job and at this time of the year I'm in different city, and don't know when I'll go back. You could try find the pins looking at the schematics and probing with a Multimeter, as I did. Also my suggestion is to draw and label the findings. I did use my drawings allot wile wiring the soldering iron connectors.
If no one else replies to your request I will try to montage the posted here photos but will not guarantee it will be absolutely correct.
Never the less it will be better for you and your development in electronics if at least try to find them yourself.
Title: Re: Really universal soldering controller
Post by: DinikS on May 27, 2017, 10:42:09 pm
[quote author="afedorov"]
Not all TSOPs really supports 3.3V supply, got TSOP4836 and it doesn't work, had to replace it by TSOP34840 which works well.[/quote]

[quote author="SZ64"]
Hi DinikS,

• Instead of the RPM7140 (Carrier freq. 40.0kHz) (ROHM) can use TSOP4840 (Carrier freq. 40.0kHz) (VISHAY)
• Instead of the KM4457F3C (Kingbright) can use CQX48, TSKS5400S (VISHAY) or IRL80A (OSRAM)

All of these above replacement parts I tested and everything works fine ;)[/quote]

Hi guys, thanks for help. I've never worked with IR so I doubted with my choice.
SZ64 I've seen your message regarding the issue in the thread earlier and have already rebuild the sensor PCB for my holder but couldn't find any listed IR receiver in my city. So yesterday I had to order TSOP4840 from ebay.
Title: Re: Really universal soldering controller
Post by: afedorov on May 27, 2017, 10:50:59 pm
[quote author="ScotY808"]Hello puzzle,
I am not sure how the 10 pin connector is wired together and also how the OLED board connects to the main board.
[/quote]
Shrouded 10-pin receptacle and corresponding plug have a triangular mark for pin 1 on it. Flat cable usually have a red wire at one side (or all wires have a different color). On a PCB there is rectangular pad at connector's pin 1. Put it all together and you'll be fine.
OLED can be mounted using standard single row male 2.54mm headers. Flat flex cable of the screen should point to the top of the front board. Solder headers to the OLED board as flat as possible (pins should not protrude over PCB top face)
Title: Re: Really universal soldering controller
Post by: afedorov on May 27, 2017, 10:58:23 pm
2 DinikS
Place a bypass cap as close as possible to the IR receiver. Also, I recommend to implement additional RC filter on the power line, something like 10R and 4.7uF would be enough. IR receivers very susceptible to a power line noise.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 27, 2017, 11:46:28 pm
[quote author="afedorov"]
Place a bypass cap as close as possible to the IR receiver.
[/quote]
C2 must be close to IR reciever and C3 must be close to MCU. Also, the power line must be thicker, with tantalum capacitor  close to connector from which the power is coming.

[quote author="afedorov"]
 Also, I recommend to implement additional RC filter on the power line, something like 10R and 4.7uF would be enough. IR receivers very susceptible to a power line noise.[/quote]

Tantalum is higher than this.
10R won't hurt in this case (and won't help either), but I prefer inductor instead of resistor where filtering is mandatory.

I can say with high degree of confidence that no additional parts are needed for reliable work. I have 2 holders working side by side on my desk last 5-6 years, and are working on both 5V and 3.3V. I even had to shift the IR LED carrier frequency a bit in order to attenuate the signal, otherwise it managed to penetrate (I suspect reflections) even when some of my irons were in the holder. And in my room there was CFL, T8 Fluorescent, LED lighting, my computer monitor is nearby, my window is looking to the west, so sunlight penetrates easily, but nothing ever caused the holder sensors to stop working reliably.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 28, 2017, 12:16:42 am
Thank you for the pictures and explanation, afedorov!  Also, thank you, too puzzle. Like sparkybg, you have helped me very much!

Does anyone have sensor PCB for sale?
Title: Re: Really universal soldering controller
Post by: DinikS on May 28, 2017, 04:10:43 pm
[attachment=0]bottom_sensor_PCB.jpg[quote author="afedorov"]2 DinikS
Place a bypass cap as close as possible to the IR receiver. Also, I recommend to implement additional RC filter on the power line, something like 10R and 4.7uF would be enough. IR receivers very susceptible to a power line noise.[/quote]
[quote author="sparkybg"][quote author="afedorov"]
Place a bypass cap as close as possible to the IR receiver.
[/quote]
C2 must be close to IR reciever and C3 must be close to MCU. Also, the power line must be thicker, with tantalum capacitor  close to connector from which the power is coming.

Tantalum is higher than this.
10R won't hurt in this case (and won't help either), but I prefer inductor instead of resistor where filtering is mandatory.

.....[/quote]

Hi guys, thanks for support.

I redrew the PCB tried to take into account remarks. Pls see attached models
Title: Re: Really universal soldering controller
Post by: Blackfinger on May 28, 2017, 05:10:04 pm
Hi DinikS

What PCB drawing program are you using ?
Title: Re: Really universal soldering controller
Post by: DinikS on May 28, 2017, 05:28:44 pm
[quote author="Blackfinger"]Hi DinikS

What PCB drawing program are you using ?[/quote]
Hi Blackfinger, I'm using KiCad. It's not so flexible like Altium or Mentor but it's fully free. It's an open source software.
http://kicad-pcb.org/ (http://kicad-pcb.org/)
Title: Re: Really universal soldering controller
Post by: Blackfinger on May 30, 2017, 07:00:46 am
Hi,

Dos anyone what PCB drawing program there can be used for reading the gerber file to UniSolder 5.2 ?

Thanks !
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 30, 2017, 07:51:34 am
I am shopping for a toroidal transformer.  Because they are expensive where I live, I want to make sure I purchase the best one possible.  It seems most on Digikey are center tapped (I think so, but do not know) so, is it better to get 12v parallel/24v series OR 24v series/48v parallel?  Or does it not matter?  I do not understand this so if someone can explain, and perhaps show wiring diagram, it would be very helpful.  All I know if sparkbg says 24v 120VA toroidal but there are many choices which confuse me.

Thank you!

P.S. I have spent quite a few hours soldering parts and have finished the back board, except for big parts but those are easy.  Now I just have to solder all the SMD caps and resistors on front board...there are very many!  I sure hope I didn't make any mistakes.
Title: Re: Really universal soldering controller
Post by: afedorov on May 30, 2017, 04:06:03 pm
[quote author="Blackfinger"]Hi,
Dos anyone what PCB drawing program there can be used for reading the gerber file to UniSolder 5.2 ?
Thanks ![/quote]
I'm using ZofzPCB, it's free (at least for now). It have an excellent 3D view with the ability of measurements in various modes and many other goodness.
[quote author="DinikS"]
I redrew the PCB tried to take into account remarks. Pls see attached models
[/quote]
Now it's better )
[quote author="ScotY808"]is it better to get 12v parallel/24v series OR 24v series/48v parallel[/quote]
If you have to choose between those ones, 24V series connection is a better choice, because for a parallel connection windings have to be exactly the same, at best wounded by double wire, otherwise there be some loses due to windings non symmetry.
And bear in mind that winding connections (start/end) are matter. For series connection you have to connect end of one winding with the start of another, forming middle-point which should be isolated. Other two wires forms an output voltage.
If you don't know where the starts/ends of the windings, first of all determine wires of each winding - it should have near zero impedance. Then connect any two wires from different secondary windings and measure voltage on other two wires, if you get near 0v - just change wires of one winding.
For parallel connections it's basically opposite - start of two windings should be tied together, so as ends. After connecting two wires of different secondary windings, forming one output terminal, you should get 0v on other two wires, if so, tie this wires together and you'll get a second terminal. If not - again, change the wires of a single winding.
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 30, 2017, 06:51:20 pm
[quote author="DinikS"][quote author="Evgeny1"]I finally completed the station[/quote]
It's nice.
Evgeny1, I'm not sure but check U10 I see short between 13 and 14 pins.[/quote]

On page 47, there is this post.  In a later reply, sparkybg says it is okay. Must these pins be shorted together?
Title: Re: Really universal soldering controller
Post by: sparkybg on May 30, 2017, 07:02:27 pm
[quote author="ScotY808"]On page 47, there is this post.  In a later reply, sparkybg says it is okay. Must these pins be shorted together?[/quote]

Look in the schematics. The answer is there waiting for you to discover. ;)
Title: Re: Really universal soldering controller
Post by: afedorov on May 30, 2017, 08:57:08 pm
Just in curiosity tested eutectic Asahi Sn63Pb37 with C245945 - it changes phase exactly at transition 182-184°C. wow! :)
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 31, 2017, 03:56:24 am
[quote author="sparkybg"][quote author="ScotY808"]On page 47, there is this post.  In a later reply, sparkybg says it is okay. Must these pins be shorted together?[/quote]

Look in the schematics. The answer is there waiting for you to discover. ;)[/quote]

I am not so good at reading schematics but it looks like those 2 pins both are connected to 3.3v so it doesn't matter if they are bridged with solder?
Title: Re: Really universal soldering controller
Post by: ScotY808 on May 31, 2017, 08:16:33 am
Sparkybg,
Do you know how tall the push button switches need to be to fit the case you used?  I ordered some very short ones (not thinking) and they obviously will be too short.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 31, 2017, 08:58:57 am
[quote author="ScotY808"]Sparkybg,
Do you know how tall the push button switches need to be to fit the case you used?  I ordered some very short ones (not thinking) and they obviously will be too short.[/quote]

I am using 13mm, and I still need to solder them a little bit upwards from the PCB, maybe around a millimeter or so. It is better to get the enclosure before soldering them, because the middle button and the side buttons are with different heights.
Title: Re: Really universal soldering controller
Post by: cbi7333 on May 31, 2017, 04:51:34 pm
@Sparky - when you received your toroidal http://www.tme.eu/en/details/tst120w_24 ... tst120003/ (http://www.tme.eu/en/details/tst120w_24v/toroidal-transformers/indel/tst120003/)  did it include a mounting bracket?  If not, any suggestions where to get one or how you mounted it?  I didn't think about a bracket when I ordered it... = :/  I'll be mounting it flat in the case I will be using.

Thanks!
Title: Re: Really universal soldering controller
Post by: sparkybg on May 31, 2017, 07:19:56 pm
This came when I bought mine:
[attachment=0]ringkern-transformator-28v_300w[1].jpg[/attachment]

...but I bought it from a local dealer of INDEL, not from TME. I don't know if TME includes this.
Title: Re: Really universal soldering controller
Post by: DinikS on May 31, 2017, 07:47:41 pm
[quote author="cbi7333"]@Sparky - when you received your toroidal http://www.tme.eu/en/details/tst120w_24 ... tst120003/ (http://www.tme.eu/en/details/tst120w_24v/toroidal-transformers/indel/tst120003/)  did it include a mounting bracket?  If not, any suggestions where to get one or how you mounted it?  I didn't think about a bracket when I ordered it... = :/  I'll be mounting it flat in the case I will be using.

Thanks![/quote]
Hi, as a rule the trancformer includes a bracket but if not, let me give you a trick you can use draining grill for sinks. You can buy it in any hardware store like OBI or any other one in your city.
Title: Re: Really universal soldering controller
Post by: sparkybg on May 31, 2017, 07:56:02 pm
It won't fit the 120VA INDEL transformer. The transformer's center hole is too small.

...but simple 1mm round cut sheet metal with hole for the bolt in the center along with same size rubber sheets on top and on bottom of transformer will do the trick without any problems. I've done it many times.
Title: Re: Really universal soldering controller
Post by: cbi7333 on May 31, 2017, 08:52:07 pm
[quote author="puzzle"]@cbi7333:
This Hirose socket is the exact match for JBC 245 handle - I think I have it on by BOM published here on page 63 at the bottom of the list.
=========
Edit: here is the link from my BOM:
https://store.comet.bg/CatalogueFarnell/Product/977100/ (https://store.comet.bg/CatalogueFarnell/Product/977100/)
[/quote]

Puzzle,  doing a bit of research ran across https://www.eevblog.com/forum/projects/diy-jbc-nano/ (https://www.eevblog.com/forum/projects/diy-jbc-nano/)  seems the JBC nano handle/tweezers uses this... Binder 99-0996-102-05
www.farnell.com/datasheets/525884.pdf (http://www.farnell.com/datasheets/525884.pdf)

Along with the HIROSE(HRS)  RPC1-12P-6S(73) could make a nice adapter cable for a nano handle, maybe even the tweezers?

The panel version: BINDER  09 0998 00 05

Will try it out when the orders all come together down the road.  I'm thinking a JBC T245 and a nano handle would make a great combo for the unisolder, guess would need an on off on toggle and a relay or two to switch back and forth.  Looking at the tip sizes available I'm not seeing any great advantage with the T210 vs T245.  Thoughts from anyone that has used the T245 and nano?  As far as I can tell the T210 uses the same Hirose plug/socket as T245
Title: Re: Really universal soldering controller
Post by: cbi7333 on May 31, 2017, 08:55:51 pm
@ DinikS  -- now that is throwing in the kitchen sink !! :)
@ Sparky -- yes, should be easy to construct something similar.. thanks for the pic!
Title: Re: Really universal soldering controller
Post by: puzzle on May 31, 2017, 10:35:02 pm
@cbi7333:

We ordered our transformers from TME and it came both with metal plate and two rubbers.

I'm not very familiar with JBC's products. The Hirose plug was mentioned here somewhere in the pages. The JBC's C245 bought my friend for the sparky's controller and he did not wanted to cut the original cord so he ordered this Hirose plug.
I bought a Chinese "Hakko" t12. I was thinking however for the possibilities of mounting several plugs - if, for instance. I decide to borrow my friend's c245... I think it would be easy hack, not needing relays. A switch is maybe a good idea but there are too many wires. Easier way may be is to wire both plugs-or more if the sockets allow for the cables to fit in- and you just need to remember to have only one socket in use at any time... but I have tested very bad connection(mentioned in page 63) so being a newbie in electronics means my logic is not necessary correct! 
The reason I did not buy a Hirose sockets was I kinda decided to not spend 10$ on plugs for a 12$ iron.

I'm reading now the posts in the theme you're linking....

Quote
C245 iron is little bit bigger than regular pen, for general purposes, you can use very big tips or small smd (i have 0,5mm smallest, waiting for offs from TME and i want to 0,3mm). C210 is micro pen for micro tips (0,1mm smallest).

My understanding of the difference between the two - C245 have 0,3mm smallest tip. C210 have 0,1mm...also the wattage I know is different...any way, a JBC station have the possibility to drive several different tools , correct? If so I don't think they have several plugs for the different tool ...or I'm mistaking?
I'm not sure about the adapters...If you are sure you need these tools and willing to spend the money for the try I would suggest first to try if the tools can be plugged into the Hirose plug...or if you have a place where you can just test if the plug fits them. Or just order complete sets of Hirose plugs(male an females) and rewire them all. Those are really  hi quality plugs and rewiring is maybe the foremost easiest solution.

Cheers
Title: Re: Really universal soldering controller
Post by: sparkybg on May 31, 2017, 11:07:46 pm
I don't thing there is a job that cannot be done if you have T210 and T245. 210 is much more compact, compared to 245. MIcrotweezers are using the same tips as T210, just with different shape.

I can say with confidence that there is not a soldering job in the world that I cannot do with there 3 instruments. And still, in 99.99% of the time I am using T245.

I don't know how Nanotweezers and Nano handle compare with T210. Never had a chance to have both in my hand. But still, as I said some post ago, I can make a profiles for them if someone mail them to me for a month or so.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 01, 2017, 04:26:13 am
.
Title: Re: Really universal soldering controller
Post by: puzzle on June 01, 2017, 06:57:53 am
@ScotY808:
The transformer you linked is ok but the prices are...
I tried searching for USA shop on toroidal transformer and it is a difficult task - go figure... But I found a topic which may help you find a shop with somewhat normal prices - 50$ for a transformer, to me, are too much- in eu you can buy one for 15-20Euros.   
http://www.diyaudio.com/forums/solid-st ... onlne.html (http://www.diyaudio.com/forums/solid-state/35098-where-buy-toroidal-transformers-onlne.html)
It is true than they need to wind thicker wire for 110v but man common 50$?
It does not have to be electronics shop - general electric shops should sell them also...

The primary needs to be your local mains voltage- for example 110V. (Our is 220V)
Secondary - 24V - I don't think you need center tapped since you'r using only one voltage -24V. So single winded secondary will be  your choice.
Then for the output power you need 120VA which is 5A.

I hope you find a better priced one
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 01, 2017, 08:58:12 am
Thank you, puzzle. I found this site:
http://www.antekinc.com/as-2224-200va-24v-transformer/ (http://www.antekinc.com/as-2224-200va-24v-transformer/)
It's not clear to me, but they claim this transformer can be run on 110v or 220v. I don't understand how this can be true?  Anyway, I want to place my order because I need parts to finish the Unisolder so I am just going to pay the ridiculous price.
Title: Re: Really universal soldering controller
Post by: puzzle on June 01, 2017, 10:04:33 am
@ScotY808:
Yes it's possible - it has dual input - if you open its datasheet there is a diagram showing the cables and voltages.
It is a bit much, I think - it has dual 24v output - but the price is more like a normal one.
Paste here some shops from were you can shop and I'll look to see what they sell.
You need something like this:
https://store.comet.bg/en/Catalogue/Product/8450/ (https://store.comet.bg/en/Catalogue/Product/8450/)
http://www.tme.eu/en/details/tst120w_24 ... tst120003/ (http://www.tme.eu/en/details/tst120w_24v/toroidal-transformers/indel/tst120003/)

But the primary should be at your mains line Voltage - the ones I posted are 220V(Europe standart)
I tried searching in those shops for a 110V transformer but it seems they don't have one on 24v.

Cheers
Title: Re: Really universal soldering controller
Post by: sparkybg on June 01, 2017, 10:27:30 am
Scoty88,bear in mind that it is highly desirable to have the enclosure before you buy the transformer.

I will check the exact INDEL model I use, then you will be able to see it's dimensions and to compare to what is available to you. Outer diameter is a critical parameter if you plan to mount it in BlackJack soldering station enclosure.
Title: Re: Really universal soldering controller
Post by: cbi7333 on June 01, 2017, 03:37:55 pm
Here's the datasheet at TME for the toroidal I ordered  http://www.tme.eu/en/details/tst120w_24 ... tst120003/ (http://www.tme.eu/en/details/tst120w_24v/toroidal-transformers/indel/tst120003/) 

http://www.tme.eu/en/Document/1e8042756 ... 20-600.PDF (http://www.tme.eu/en/Document/1e8042756dec8ae4ae8d513471e5c4f0/TST20-600.PDF)

Looks like diameter is 105mm(4 9/64 inch) and height 40mm (1 37/64 inch) for what's listed as 120/TOR/01-01 

Sparky mentioned in an earlier post that his case dimensions are 130x110x95 mm so would be a tight squeeze for the 120VA I ordered but doable if his measurements are internal.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 02, 2017, 08:28:30 am
[quote author="puzzle"]@ScotY808:
Yes it's possible - it has dual input - if you open its datasheet there is a diagram showing the cables and voltages.
It is a bit much, I think - it has dual 24v output - but the price is more like a normal one.
Paste here some shops from were you can shop and I'll look to see what they sell.
You need something like this:
https://store.comet.bg/en/Catalogue/Product/8450/ (https://store.comet.bg/en/Catalogue/Product/8450/)
http://www.tme.eu/en/details/tst120w_24 ... tst120003/ (http://www.tme.eu/en/details/tst120w_24v/toroidal-transformers/indel/tst120003/)

But the primary should be at your mains line Voltage - the ones I posted are 220V(Europe standart)
I tried searching in those shops for a 110V transformer but it seems they don't have one on 24v.

Cheers[/quote]

Hi puzzle,
Thank you for your help!  I have ordered from mouser.com and digikey.com in the past.  I don't know too many other shops.  Antekinc.com looks like a good place to order toroidal transformers in the US.  I ordered the damned expensive one from Mouser already though.  I hope it fits my enclosure.

I accidentally soldered on R68 on the OLED board.  I was supposed to wait until I got my OLED before I did that.  The one I ordered is supposed to be the 9v version.  But now I wonder, how does one tell for sure if it's 9v or 12v?  Should I use the resistor for 9v one and try?  I am guessing if it's 12v OLED, it will then be very dim?
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 02, 2017, 08:30:39 am
[quote author="sparkybg"]Scoty88,bear in mind that it is highly desirable to have the enclosure before you buy the transformer.

I will check the exact INDEL model I use, then you will be able to see it's dimensions and to compare to what is available to you. Outer diameter is a critical parameter if you plan to mount it in BlackJack soldering station enclosure.[/quote]

Thank you for the warning, sparkybg.  The one I ordered says 95mm diameter.  I hope it fits but if not, I will have to change my plans.  Now, I just wait for my parts and do some reading again in this thread to learn about how to program the controller.
Title: Re: Really universal soldering controller
Post by: puzzle on June 02, 2017, 03:10:05 pm
@ScotY808:
Glad to be able to help.
Don't worry about R68... It forms something like a voltage divider with R66 so next you'll have to change R66 accordingly.
In the datasheet for your IC at U19, there is a simple formula to calculate both resistors for the desired voltage!
In my BOM file(on page 63), at the bottom there are 2 rows one is for that particular calculation for my particular IC - it is row132 - you change values for r1(column H) and r2(column I) and you will have the resulted voltage in column K. Search for a datasheet for the OLED from the place you ordered and check the voltages - my display was something like 3 to 9V.

Forgot to ask what value you have placed at R68?
about programming...from page 69
[quote author="puzzle"]@Blackfinger:
After purchasing Pickit3 and installed MPLab, and being able to run Unisolder.exe - as Sparky described you do the following steps from page 63 on this topic...
1. Connecting Pickit3 to PC and to 5 pin header on front board,
2.Powering the "soldering station" - I have the Iron connected but no heater in it.
3. Opening MPLab, and selecting programmer to Pickit3 - it has connected and found the chip, loaded correct firmware for pic32mx.
4. I chose "Import..." and browsed to the "US_BootLoader.X.production.hex" and select "OPEN"
5. I select "Program" - it goes very fast true: " Programming... Programming/Verify complete" - And I IMIDEATELY have wiggling lines on the screen.
Now I will try to flash it true PC:
1. I remove Pickit3 from the board -  now I will switch the board(soldering station) off.
2 Connecting USB cable to "Soldering station" - I use the cable of the programmer.
3. Open software - "UniSolder.exe"
4. Switch the station on - I have wiggling lines on screen, no sounds, nothing on software or on the PC indicates that I have switched something
5. I press "Update firmware" and browse to the "US firmwareX > PIC32 with bootloader> "US_Firmware.X.production.hex" - I press "Open" - after 5-7 seconds I heard beep and now the station looks fine - it shows my iron and "Heater open" as it should.

This is how it programs the chip to be able to do following updates to the firmware true the PC, not needing to open your soldering station.
[/quote]
Cheers
Title: Re: Really universal soldering controller
Post by: valerionew on June 02, 2017, 07:18:41 pm
Hi everyone
 
After a few pages i've made my order and received the parts. Yesterday i've started to solder the first passives on the board.
In the meantime, seeing that it's common for the author to repeat informations (such as compatibility in BOM), i started to gather all the usefull information from this thread.
I'm putting all the information here, on Github: https://github.com/5N44P/unisolder-notes (https://github.com/5N44P/unisolder-notes) in the README file.
My work is mainly intended for beginners who want to start to build their BOMs and the project.
If you want to contribute, do it by making a commit and a pull request. Also corrections via the forum are welcome!

I'm hoping that you will be pleased
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 02, 2017, 08:36:17 pm
[quote author="puzzle"]@ScotY808:
Glad to be able to help.
Don't worry about R68... It forms something like a voltage divider with R66 so next you'll have to change R66 accordingly.
In the datasheet for your IC at U19, there is a simple formula to calculate both resistors for the desired voltage!
In my BOM file(on page 63), at the bottom there are 2 rows one is for that particular calculation for my particular IC - it is row132 - you change values for r1(column H) and r2(column I) and you will have the resulted voltage in column K. Search for a datasheet for the OLED from the place you ordered and check the voltages - my display was something like 3 to 9V.

Forgot to ask what value you have placed at R68?
[/quote]

Hi puzzle,
I have used 3k resistor for R68.  I used all the specified resistors from sparkybg's BOM.  I have a feeling my OLED will not come with any specifications...usually how Chinese parts are.  I ordered a specifc OLED from Aliexpress and was told to use 4.7k resistor for R68 and it would work.  Sorry, I cannot remember who told me this here.  I will investigate your BOM for information.
Thank you, once again, for all your help!
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 02, 2017, 08:40:28 pm
I wanted to wait to order the JBC parts...in case my controller does not work.  But, because I now wait with nothing to do, perhaps I should just order them now.  I wanted to use T245 handle because it seems best for me and sparkybg recommends it. 

However, I am not sure what tip to order.  I cannot afford to order more than one tip.  I have bigger irons for other things (Weller 60 watt) and even bigger irons for even bigger cables and such.  The tip I think I should order would be for PCB projects such as the Unisolder.  What do you think I should get?  Maybe ~1mm point tip?  Or tiny flat point tip?

Thank you!
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 02, 2017, 09:50:31 pm
[quote author="puzzle"]
about programming...from page 69
[quote author="puzzle"]@Blackfinger:
After purchasing Pickit3 and installed MPLab, and being able to run Unisolder.exe - as Sparky described you do the following steps from page 63 on this topic...
1. Connecting Pickit3 to PC and to 5 pin header on front board,
2.Powering the "soldering station" - I have the Iron connected but no heater in it.
3. Opening MPLab, and selecting programmer to Pickit3 - it has connected and found the chip, loaded correct firmware for pic32mx.
4. I chose "Import..." and browsed to the "US_BootLoader.X.production.hex" and select "OPEN"
5. I select "Program" - it goes very fast true: " Programming... Programming/Verify complete" - And I IMIDEATELY have wiggling lines on the screen.
Now I will try to flash it true PC:
1. I remove Pickit3 from the board -  now I will switch the board(soldering station) off.
2 Connecting USB cable to "Soldering station" - I use the cable of the programmer.
3. Open software - "UniSolder.exe"
4. Switch the station on - I have wiggling lines on screen, no sounds, nothing on software or on the PC indicates that I have switched something
5. I press "Update firmware" and browse to the "US firmwareX > PIC32 with bootloader> "US_Firmware.X.production.hex" - I press "Open" - after 5-7 seconds I heard beep and now the station looks fine - it shows my iron and "Heater open" as it should.

This is how it programs the chip to be able to do following updates to the firmware true the PC, not needing to open your soldering station.
[/quote]
Cheers[/quote]

Puzzle,
I have found "UniSolder.exe" and when I click it, a window pops up briefly, but nothing happens.  Do I need some other program to make this work?  I remember reading you need Visual Studio 2015 or later to use something...I cannot find a link to download this for free.  Is it a paid program?  I am just trying it out now, I do not yet have all my components.
Title: Re: Really universal soldering controller
Post by: cbi7333 on June 02, 2017, 09:57:58 pm
[quote author="ScotY808"]
However, I am not sure what tip to order.  I cannot afford to order more than one tip.  I have bigger irons for other things (Weller 60 watt) and even bigger irons for even bigger cables and such.  The tip I think I should order would be for PCB projects such as the Unisolder.  What do you think I should get?  Maybe ~1mm point tip?  Or tiny flat point tip?
[/quote]

I'm sorta doing the same debate in my head.. I want it all and I want it now!  :)  but some will simply have to wait... considering the level of support here I'm not too worried about it not working.
http://www.jbctools.com/usuaris/moduls/ ... _eng11.pdf (http://www.jbctools.com/usuaris/moduls/arxius/1/31_1__31_1__catalogue_eng11.pdf) has a really good listing of tips at the bottom. 

I'm pretty much settled on the following two tip styles for the T245
[attachment=1] and [attachment=0]

Would also like to try the spoon type for drag soldering.. I'll start with either the normal or long chisel though and work from there.  Most likely the C245-844 which is the 20mm longer version extended chisel 1.8x0.8mm which is considerably smaller and thinner tip that my current one.  I'll get the C245-931 2.7mm spoon tip before I do another project where a good amount of drag soldering is involved.  I'll order the 245 in a couple of weeks/next paycheck and hopefully have enough left over to splurge and get the nano handle and tip to send to Sparky to add a new profile.  I ordered an assortment of what I hope are jbc compatible plugs and sockets, they should arrive Monday so will post some pics.  This will be my first JBC 'experience' so any helpful critique regarding my tip selection thoughts are welcome.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 02, 2017, 11:29:40 pm
I am using C245-064 tip most of the time, for smaller things. I also have C245-102 for larger things and C245-939 for even larger things. I also have C245-001, but I rarely use it.

Believe me, get yourself 064 and 102 tips and you will forget about your other irons, unless they are really-really big and powerful (200W and more).

Give me a link from where you bought the display and I will tell you the voltage.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 03, 2017, 12:37:53 am
Thank you for the recommendations.  I never would have thought to consider that type of tip.  Do the 064/102 tips hold solder in the "hoof?"

I ordered this OLED.  I think it is 9v model but am not sure.
https://www.aliexpress.com/item/1pcs-0- ... 0.0.WLBIot (https://www.aliexpress.com/item/1pcs-0-96-inch-OLED-Display-LCD-module-with-128x64-Resolution-and-blue-on-black-SPI/1430628386.html?spm=2114.13010608.0.0.WLBIot)
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 03, 2017, 12:57:31 am
I just ordered a T245-A and C245-064. I was tempted to order more tips but I think the 064 will be enough for me for now. $107 USD shipped...not too bad.
Title: Re: Really universal soldering controller
Post by: puzzle on June 03, 2017, 08:48:30 am
@ScotY808:
It may be me who recommended the display :D
Opened the link and it's like mine. So you will need to change R66 to be 18k and you will have 8.61V
Here is a link for its specs...
http://www.lcds-panel.com/products/UG-2 ... meter.html (http://www.lcds-panel.com/products/UG-2864HSWEG01_WiseChip_OLED_0.96-inch_128x64_parameter.html)

For the software - Yes, Sparky said it needs Visual Studio 2015... well the part you need come very often bundled in the installer for other software. I had it already wile installing something, don't know when it was installed.

Edit: Interesting, I don't have v2015 installed. I have 2005,2008 and 2010 and it worked...

Edit2: Found this link:
https://www.microsoft.com/en-pk/search/ ... orm=MSHOME (https://www.microsoft.com/en-pk/search/result.aspx?q=Microsoft+Visual+C%2B%2B&form=MSHOME)

Edit3: Found some info on combining the libraries into the EXE of the program so it wont depend on them:
https://stackoverflow.com/questions/350 ... applicatio (https://stackoverflow.com/questions/35097193/can-i-bundle-the-visual-studio-2015-c-redistributable-dlls-with-my-applicatio)

Greetings
Title: Re: Really universal soldering controller
Post by: sparkybg on June 03, 2017, 09:39:40 am
This is 9V panel. Here's the datasheet:
https://cdn-shop.adafruit.com/datasheet ... SWEG01.pdf (https://cdn-shop.adafruit.com/datasheets/UG-2864HSWEG01.pdf)
Title: Re: Really universal soldering controller
Post by: SZ64 on June 03, 2017, 12:14:03 pm
@all:
Who has opinion the 0.96" UG-2864HSWEG01 is too small (like me) he can take a 1.3" UG-2864KSWLG01 with integrated SSD1306 Contoller. The thing works perfectly without any further modification on sparkybg OLED board.
Title: Re: Really universal soldering controller
Post by: cbi7333 on June 03, 2017, 04:45:49 pm
@SZ64 - what about mounting the 1.3 inch display?  Have a picture of how you mounted it to your panel with Sparky's OLED board?
Thanks!
Title: Re: Really universal soldering controller
Post by: SZ64 on June 03, 2017, 07:26:55 pm
[quote author="cbi7333"]@SZ64 - what about mounting the 1.3 inch display?  Have a picture of how you mounted it to your panel with Sparky's OLED board?
Thanks![/quote]

Installation is very simple. Display is pin-to-pin compatible with the 0.96" ;-)
Vdd: 3.3V and Vcc: 12V
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 03, 2017, 07:31:56 pm
[quote author="sparkybg"]This is 9V panel. Here's the datasheet:
https://cdn-shop.adafruit.com/datasheet ... SWEG01.pdf (https://cdn-shop.adafruit.com/datasheets/UG-2864HSWEG01.pdf)[/quote]

Thank you, sparkybg and puzzle, too, for all the help!

I am struggling with the PC software and Visual Studio.  I have downloaded Visual Studio 2017 Community version.  I also installed the .NET desktop development.  I first tried without the .NET but when I tried to open a file within the software folder, it gave a .NET error (I forget what it said).  So, now with .NET, I can open the software folder and navigate to the Unisolder.exe file but nothing happens when I open it.  I will post a picture of what happens if I try to debug...a screen that looks like what must be the Unisolder program opens up.  I have no idea what I am doing but obviously something wrong.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 03, 2017, 07:34:33 pm
This is what opens when I choose debug for Unisolder.exe.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 03, 2017, 07:42:30 pm
[quote author="puzzle"]@ScotY808:
It may be me who recommended the display :D
Opened the link and it's like mine. So you will need to change R66 to be 18k and you will have 8.61V
Here is a link for its specs...
http://www.lcds-panel.com/products/UG-2 ... meter.html (http://www.lcds-panel.com/products/UG-2864HSWEG01_WiseChip_OLED_0.96-inch_128x64_parameter.html)
[/quote]

Hi puzzle,

Thank you for your information.  On page 63, you say to change R68 to 4.7k and it works for your display.  Should I also need to change R66 to 18k?  I do not have 18k resistor on hand.  I only have extras from the BOM items. 

EDIT:  Okay, I see J2 and J6 on the back board schematic.  For J6, I ASSUME the pin 1 is the one on the PCB that is square?  Please someone confirm this.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 03, 2017, 09:17:35 pm
Maybe I have figured it out? :-)
Please see my picture.
Red = Vout1+
Blue = Vout1-
Purple = Vout2-
Orange = Vout2+

Someone please check and tell me my mistake.

Thank you!
Title: Re: Really universal soldering controller
Post by: puzzle on June 03, 2017, 11:31:47 pm
@ScotY808:
I say to change only R68 to 4.7k and leave R66 as is(27k), but you have said  you placed a 3k on R68 so for the equation to be right now you need to place a 18k for R66 instead of 27k. Hope you understand...
One scenario R66=27k, R68=4.7k  =8.39V
Second scenario R66=18k, R68=3k  =8.61V
I remember asking Sparky if it is crucial for those R's to be 0.1% tolerance and he said it's OK to use 1%... I had a few 4.7k at 1% from the order we placed, that is the reason I recommended to change R68 - you wouldn't need to order again ... there are no 18k R's in the project's BOM, so you need to buy one or change the R68 instead.

Regarding J2 - I think you're wright.
Also looking at what's visible on the picture - check bottom 2 pins at U3 for short!

Cheers
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 04, 2017, 01:26:54 am
Thank you, puzzle. I have changed R68 to 4.7k...everything else is from the BOM. That is easier.  I had extra 4.7k resistor and it's easier to remove than R66.

You have a good eye!  I don't think it's a solder bridge though. I think it's lint or dust from cleaning off flux. I will double check all solder joints before I apply power.
Title: Re: Really universal soldering controller
Post by: dumitruv on June 04, 2017, 04:20:32 am
[quote author="SZ64"]@all:
Who has opinion the 0.96" UG-2864HSWEG01 is too small (like me) he can take a 1.3" UG-2864KSWLG01 with integrated SSD1306 Contoller. The thing works perfectly without any further modification on sparkybg OLED board.[/quote]

Hey SZ64,

Could you post a link? Where did you get it from?
Title: Re: Really universal soldering controller
Post by: SZ64 on June 04, 2017, 11:22:50 am
[quote author="dumitruv"]

Hey SZ64,

Could you post a link? Where did you get it from?[/quote]

Yes, I've tried all of these three Options ;)

1. eBay:
http://www.ebay.at/itm/302039904121?_tr ... EBIDX%3AIT (http://www.ebay.at/itm/302039904121?_trksid=p2060353.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT)

2. AliExpress:
https://www.aliexpress.com/item/1pcs-1- ... 0.0.ZOhLo6 (https://www.aliexpress.com/item/1pcs-1-3-inch-OLED-Display-LCD-module-with-128x64-Resolution-and-white-on-black-SPI/1436446293.html?spm=2114.13010308.0.0.ZOhLo6)

3. AliExpress: Even cheaper (3pcs set):
https://www.aliexpress.com/item/3pcs-1- ... 0.0.ZOhLo6 (https://www.aliexpress.com/item/3pcs-1-3-inch-OLED-Display-LCD-module-with-128x64-Resolution-white-on-black-SPI-Parallel/1437076732.html?spm=2114.13010308.0.0.ZOhLo6)
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 04, 2017, 08:38:42 pm
[quote author="ScotY808"]
I am struggling with the PC software and Visual Studio.  I have downloaded Visual Studio 2017 Community version.  I also installed the .NET desktop development.  I first tried without the .NET but when I tried to open a file within the software folder, it gave a .NET error (I forget what it said).  So, now with .NET, I can open the software folder and navigate to the Unisolder.exe file but nothing happens when I open it.  I will post a picture of what happens if I try to debug...a screen that looks like what must be the Unisolder program opens up.  I have no idea what I am doing but obviously something wrong.[/quote]

Okay, I am too dumb and give up with Visual Studio and PC software.  I have been reading once again this long thread, searching for knowledge...big challenge for me. :-)  I believe I do not need PC software, etc. to get Unisolder working, just need to program chip with Pickit3.

A couple of questions...can someone help?

1. When I program chip with Pickit3, do I need to apply power (24VAC) to PCB?
EDIT: my own answer found after searching for several hours...you must apply power to PCB to program chip.  Pickit3 does not supply enough power on it's own.

2. If I do not apply 24VAC, does chip use 3.3v power from Pickit3?  I believe this is so from reading the schematics.

Thank you!
Title: Re: Really universal soldering controller
Post by: dumitruv on June 04, 2017, 09:26:06 pm
[quote author="SZ64"][quote author="dumitruv"]

Hey SZ64,

Could you post a link? Where did you get it from?[/quote]

Yes, I've tried all of these three Options ;)

1. eBay:
http://www.ebay.at/itm/302039904121?_tr ... EBIDX%3AIT (http://www.ebay.at/itm/302039904121?_trksid=p2060353.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT)

2. AliExpress:
https://www.aliexpress.com/item/1pcs-1- ... 0.0.ZOhLo6 (https://www.aliexpress.com/item/1pcs-1-3-inch-OLED-Display-LCD-module-with-128x64-Resolution-and-white-on-black-SPI/1436446293.html?spm=2114.13010308.0.0.ZOhLo6)

3. AliExpress: Even cheaper (3pcs set):
https://www.aliexpress.com/item/3pcs-1- ... 0.0.ZOhLo6 (https://www.aliexpress.com/item/3pcs-1-3-inch-OLED-Display-LCD-module-with-128x64-Resolution-white-on-black-SPI-Parallel/1437076732.html?spm=2114.13010308.0.0.ZOhLo6)[/quote]

Thanks, you also could use an even bigger LCD with very little change to the software.
See this https://www.youtube.com/watch?v=maHOO12lgTg (https://www.youtube.com/watch?v=maHOO12lgTg)
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 04, 2017, 09:53:02 pm
Is this the correct orientation for J3 and J9?  Anyone know?

More questions...
1. If I do not install the USB and RJ11 port, will the board still work?
My own answer: I am pretty sure it will

2. I recall there is something to be shorted on the back? of the front board?  I cannot find where it says what to do.  Does anyone know?
Found it!  Sparkybg says to short pins of LED on back side of front board.  There are 3 pins that have solder pads that are easy to bridge.  So, solder at 3 places.
Title: Re: Really universal soldering controller
Post by: Blackfinger on June 05, 2017, 12:19:22 am
Hi all,

I have some questen to this projekt.

#1 If I want to use OLED as display, what components from the BOM do I not
need to buy and do I have to make some special work on the front board ?
Place some shorts on the board ?

#2 I have a 24Vdc switch mode power supply 2,5 A, can I use this power supply for the projekt?

#3 I can see some have used a 1,3 " OLED insted of the 0,93" OLED.
Can anyone explain all the change there have to be don if you use the 1,3 OLED ?

Thanks !
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 05, 2017, 03:54:02 am
[quote author="Blackfinger"]Hi all,

I have some questen to this projekt.

#1 If I want to use OLED as display, what components from the BOM do I not
need to buy and do I have to make some special work on the front board ?
Place some shorts on the board ?

#2 I have a 24Vdc switch mode power supply 2,5 A, can I use this power supply for the projekt?

#3 I can see some have used a 1,3 " OLED insted of the 0,93" OLED.
Can anyone explain all the change there have to be don if you use the 1,3 OLED ?

Thanks ![/quote]

I hate to answer questions because I am a newbie and don't know anything but since no one has answered you yet...

#1 - for OLED you do not need:
Ra, Rb, Rc, Rd, Re, Rf, Rg
Q15, Q17

You must make solder bridges on closely spaced pads in center of U9 (6 places) and also Ra-Rg (7 places).  On rear side of front board, there are 3 places to make solder bridges on the holes where LED displays would solder on.  You can see closely spaced pads next to 3 pins.

For buzzer, you should use generatorless buzzer (=speaker)
You need to not have Q20 and D17 installed - see page 40 of this thread

#2 - sparkybg said many times before SMPS can cause trouble.  Maximum output to iron is 24v and ~6amps so I think your power supply is too small anyway.

#3 - SZ64 just posted links to purchase larger OLED which he says can be used with no modifications to BOM.  See few posts above yours.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 05, 2017, 07:25:46 am
Attached is my updated Mouser BOM.  It is more correct than the one I posted previously.
Title: Re: Really universal soldering controller
Post by: Blackfinger on June 05, 2017, 07:55:21 am
Thanks ScotY808 for your fast replay !!!!!!!

I will buy a new and bigger power supply.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 05, 2017, 08:34:04 am
It is recommended by sparkybg to use 24v 120VA toroidal transformer.  He says switching power supply can cause problems.  That is all I know.  It would have been easier/cheaper for me to use PS but I followed his advice.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 05, 2017, 08:49:47 am
[quote author="Blackfinger"]
I will buy a new and bigger power supply.[/quote]

Buy a toroidal 24V 120VA transformer instead.
Title: Re: Really universal soldering controller
Post by: cbi7333 on June 05, 2017, 09:24:11 am
[quote author="ScotY808"]Is this the correct orientation for J3 and J9?  Anyone know?

[/quote]
Maybe use the pictures on page 1 as a guide?  I assume it's correct.  Your J3 looks ok, J9 also according to another photo posted earlier.

[attachment=2]

[attachment=0]

Also might want to double check the following areas just to make sure all is ok...
(left to right)
1. possible cold solder on this cap near Q7
2. Bridge near C21/R21?
3. U3 pin looks unsoldered
[attachment=1]

Might be just optical effects from the photo. 

Still waiting for the mailman from RU..  Reminds me of my old Heathkit days when everything was snailmail... those were fine kits and had a lot of fun with them.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 05, 2017, 09:47:55 am
Thank you, cbi7333.  I think that is a solder bridge on C21-R21. I forget and I am not home now but I did have a couple of bridged components that I could not fix. I think it might be okay because it's connected anyway, according to the schematics. I will double check all that you mention.

I could not tell from pics on first page about the orientation of J9. I just found the other pic you posted (blue PCB) but wanted to make sure it was correct. It is not common to see pics of the rear side of the boards. I'm assuming big problems if I get it wrong!  Sparkybg, can you say?
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 05, 2017, 10:07:57 am
[quote author="sparkybg"]
Remove Q20, D17, Q17, R29. You should start hearing a beep when you power up the controller.
[/quote]

This quote of sparkybg was from page 44. Is R29 not to be installed?  This is the first time I noticed it should not be used.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 05, 2017, 10:10:03 am
[quote author="ScotY808"]I could not tell from pics on first page about the orientation of J9. I just found the other pic you posted (blue PCB) but wanted to make sure it was correct. It is not common to see pics of the rear side of the boards. I'm assuming big problems if I get it wrong!  Sparkybg, can you say?[/quote]

I found on page 44 sparkybg referenced the picture of the blue PCB so I ASSUME the J9 connector is correct. Hopefully...
Title: Re: Really universal soldering controller
Post by: chefgeek on June 06, 2017, 12:02:19 am
Can someone tell me if either of these transformers would work?

I am in the US and using 115v input.  They are both 103x48 mm.

115V, 230V
Parallel 24V, Series 48V
Parallel 6.66A, Series 3.33A
https://www.digikey.com/product-detail/ ... ND/2090087 (https://www.digikey.com/product-detail/en/triad-magnetics/VPT48-3300/237-1349-ND/2090087)

115V, 230V
Parallel 12V, Series 24V
Parallel 13.34A, Series 6.67A
https://www.digikey.com/product-detail/ ... ND/2090084 (https://www.digikey.com/product-detail/en/triad-magnetics/VPT24-6670/237-1346-ND/2090084)
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 06, 2017, 12:41:46 am
I looked at those...I think either one will work. Which one is better?  I have no idea.
Title: Re: Really universal soldering controller
Post by: chefgeek on June 06, 2017, 12:45:19 am
Has anyone found a yellow blue (2 color) 1.3" OLED display?  I have found plenty of blue or yellow but the 2 color ones.
Title: Re: Really universal soldering controller
Post by: Toporkoff on June 06, 2017, 06:12:02 am
Hi.
I Have original station JBC CD-2BE with T245 & T210 handle but need JBC microtwizers so i build yours project. Unfortunately i steel wait for PicKit 3 from Aliexpress.

[attachment=0]

However i have some questions.
In first post c245 & c210,c120 have different pin connection to the station pins, it is correct?

[quote author="sparkybg"]
3. JBC C245:
 - Outer shell (green wire) connected to EARTH and SENSEB
 - Heater positive(red wire) connected to Vout1- and SENSEA
 - Heater negative(blue wire) connected to Vout1+
 - 150ohm between ID and Vout1-
 - 5.6k between ID and Vout2-

4. JBC C210:
 - Outer shell (green wire) connected to EARTH and SENSEB
 - Heater negative (middle terminal, blue wire) connected to Vout1-
 - Heater positive (smaller terminal, red wire) connected to Vout1+ and SENSEA
 - 3.0k between ID and Vout1-
 - 5.6k between ID and Vout2-

5. JBC Microtweezers:
 - Outer shell of both tips (green wire) connected to EARTH
 - Heater 1 negative (blue wire) connected to Vout1-
 - Heater 1 positive (red wire) connected to Vout1+ and SENSEA
 - Heater 2 negative (brown wire) connected to Vout2-
 - Heater 2 positive (yellow wire) connected to Vout2+ and SENSEB
 - 1.0k between ID and Vout1-

[/quote]

I draw the same pin connection in Paint & compare it with my original JBC plugs. I planed  use instrument with original plugs with both stations. Can you check my draw.

[attachment=1]

Thanks a lot for yours great job!
Title: Re: Really universal soldering controller
Post by: puzzle on June 06, 2017, 09:01:50 am
@Toporkoff:

My guess - it is the way to identify which iron is in the socket.
Sparky's way is resistors to identify irons.
You may use this controller only for the tweezers and use the JBC for the Irons or rewire and solder resistors in the plugs and use Sparky's controller for all.

edit: I have reread your question and now understand what you're asking - Sparky will respond, but  I think his diagrams are correct for the firmware to work.
Title: Re: Really universal soldering controller
Post by: puzzle on June 06, 2017, 09:13:31 am
I did not want to draw over the pictures but since it is needed, here they are (unedited pics are on page 63).
Those are my connections:
[attachment=3]
C21 and R21 are bridged when soldered - it is OK, they have to be connected.

[attachment=2]


[attachment=1]
I have soldered R29 - I did not see written it is not needed but I guess it is not critical if it is placed or not

[attachment=0]

Hope it helps  all newbees like me...

Sparky may comment if my drawings are correct but my station works so I think it is OK.
Cheers
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 06, 2017, 09:36:08 am
Thank you, puzzle...that is so much help!  I am getting close to applying power to the board and was worried about connections.

My transformer arrived today but it is too big to fit in enclosure. :-( Datasheet is wrong. I must find something else now but it is quite difficult to find a cheap box that is big enough yet not too big.
Do you think I can remote mount the OLED by using extensions on the 2x 5 pin headers?  If so, it might be easier to find a suitable box.

I also got Pickit3 in the mail. I will try to figure that thing out next.

I am still waiting for OLED. It is on slow boat from
China...haha!  Aliexpress is sure slow. eBay shippers are faster, I think.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 06, 2017, 10:28:40 am
[quote author="ScotY808"]This is what opens when I choose debug for Unisolder.exe.[/quote]

You must open ".sln" file, not the exe. Then click on "Run" button in the top toolbar, and that's it. If you connect the unisolder with uploaded bootloader, you will be able to use "update firmware" button - it will ask you for "HEX" file to upload, select "...with bootloader" hex and after it upload it, you will see a graph on your display.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 06, 2017, 10:35:34 am
[quote author="ScotY808"]

Okay, I am too dumb and give up with Visual Studio and PC software.  I have been reading once again this long thread, searching for knowledge...big challenge for me. :-)  I believe I do not need PC software, etc. to get Unisolder working, just need to program chip with Pickit3.
[/quote]

1. Download and install ".NET Framework 4.5.1"
2. Download and install "Visual studio 2015 Community edition"
3. Open the "unisolder.sln" with Visual studio
4. Click on "Run button"

That's it.

[quote author="ScotY808"]
A couple of questions...can someone help?

1. When I program chip with Pickit3, do I need to apply power (24VAC) to PCB?
EDIT: my own answer found after searching for several hours...you must apply power to PCB to program chip.  Pickit3 does not supply enough power on it's own.

2. If I do not apply 24VAC, does chip use 3.3v power from Pickit3?  I believe this is so from reading the schematics.
[/quote]

1. Yes.
2. No. The controller needs too much current and PicKit3 cannot handle this. Also, the PicKit3 needs a connection to the board power and GND in order to be able to see what voltage the board uses. That's why there are connections for these two lines.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 06, 2017, 10:43:27 am
[quote author="cbi7333"]
2. Bridge near C21/R21?
[/quote]

Both are connected to ground there. Bridge there is not a problem as soon as the bridge is connected also to GND.
Title: Re: Really universal soldering controller
Post by: Blackfinger on June 06, 2017, 10:46:58 am
Hi all.

Can anyone informe my what 8 PIN connector type there are used to connect to
the soldering handel ?

Some say it is a XS-12 standart, but I can just finde a 7 PIN not a 8 PIN ?

Thanks !
Title: Re: Really universal soldering controller
Post by: sparkybg on June 06, 2017, 11:18:24 am
[quote author="Toporkoff"]
However i have some questions.
In first post c245 & c210,c120 have different pin connection to the station pins, it is correct?
[/quote]

Yes, it is correct. I am using the best possible configuration for each instrument.

[quote author="Toporkoff"]
I draw the same pin connection in Paint & compare it with my original JBC plugs. I planed  use instrument with original plugs with both stations.
[/quote]
You won't be able to. Sorry. The connections are in the first post. You will have to make adapter cable for each instrument if you don't want cut the standart connector.

I cannot check your drawings - all of my instruments have been rewired a long time ago.

[quote author="puzzle"]@Toporkoff:
My guess - it is the way to identify which iron is in the socket.
[/quote]

Your guess is wrong. :) The controller is doing instrument identification only reading the resistance of two resistors in the connector.
Title: Re: Really universal soldering controller
Post by: puzzle on June 06, 2017, 02:17:58 pm
@sparkybg:
[quote author="sparkybg"][quote author="Toporkoff"]

[quote author="puzzle"]@Toporkoff:
My guess - it is the way to identify which iron is in the socket.
[/quote]

Your guess is wrong. :) The controller is doing instrument identification only reading the resistance of two resistors in the connector.[/quote][/quote]

That sentence was meant for the JBC's controller since there is an extra connection to the plugs on the drawing, but anyway... I'll learn when it's good to not interfere - sorry!


@ScotY808:

My controller is still without a box my friend uses it as is, boards and cables, and all :D
The prices are incredibly high for a box and I'm thinking of buying a sheet of Plexiglas  and building one myself.
I don't think it will be a problem to extend the connection of the display a little bit but I don't understand why you would need that - the front board would be mounted to one of the sides. Or you have something else in mind?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 06, 2017, 02:36:05 pm
[quote author="puzzle"]...I'll learn when it's good to not interfere - sorry![/quote]

Nothing to sorry about. :)

P.S: The JBC tools also have ID resistor in the connector.
Title: Re: Really universal soldering controller
Post by: puzzle on June 06, 2017, 02:49:18 pm
@sparkybg:
Ahaa, I did not see one when I have opened the plug on the T245 so this option never came in mind.

I have a question...
When I was programming my controller I used the unisolder.exe in the UniSolder52_SoftwarePCUniSolderbinRelease folder and it worked. Also I don't have Visual studio installed on my PC only the .net platform installed a long time ago.
Also when I had the controller already flashed and connected to PC - unisolder.exe showed everything I supposed it should show...all the lines going up, down when heating and so on.
Is it any particular reason to install visual studio and go the way you described instead of continue using Unisolder.exe form folder UniSolder52_SoftwarePCUniSolderbinRelease ?
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 06, 2017, 08:42:45 pm
Thank you, sparkybg for the information!  I am close to being able to power the board now but I do not yet have the OLED.  Sparkybg, can you please answer these questions?

1. Can I power it up and attempt to load the software without the OLED board connected?

2. Can I remote mount the OLED board and tactile switches?  (Answer for puzzle...the reason for my question) I am having trouble finding a good enclosure.  Most cheap ones are not tall enough to mount the PCBs.  If I can remote mount the OLED board and tactile switches, my options for enclosure become better.  I saw someone earlier in this thread that remote mount the switches...he used a fancy clear plastic enclosure, but he did not remote mount the OLED.

3. I have connected my transformer and it outputs about 26VAC.  I connected it to the back board and no smoke! :-)  I measure on J3 the correct voltages as in puzzle's pictures.  Is there anything I should check before connecting to the front board.  I'm a little scared. :-)
Title: Re: Really universal soldering controller
Post by: DinikS on June 06, 2017, 08:52:31 pm
[quote author="Blackfinger"]Hi all.

Can anyone informe my what 8 PIN connector type there are used to connect to
the soldering handel ?

Some say it is a XS-12 standart, but I can just finde a 7 PIN not a 8 PIN ?

Thanks ![/quote]

Hi, I use this one https://www.aliexpress.com/item/5Pcs-GX ... 77665f573f (https://www.aliexpress.com/item/5Pcs-GX16-8-Pin-Screw-Type-Electrical-Aviation-Plug-Socket-Connector-New/32758594514.html?spm=2114.01010208.3.2.xMxhtC&ws_ab_test=searchweb0_0,searchweb201602_4_10152_10065_10151_10068_5010017_10136_10137_10060_10138_10155_10062_437_10154_10056_10055_10054_10059_303_100031_10099_10103_10102_10096_10169_10052_10053_10142_10107_10050_10051_10084_10083_10119_10080_10082_10081_10110_519_10111_10112_10113_10114_10182_10078_10079_10073_5030019_10123_10120_10189_142-10050_10120,searchweb201603_13,ppcSwitch_3&btsid=ac0725d6-c807-4b83-b58d-ae07e0e26a2e&algo_expid=99b2b010-39bd-4167-adbb-9277665f573f-0&algo_pvid=99b2b010-39bd-4167-adbb-9277665f573f)
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 07, 2017, 03:11:54 am
Well, I have gotten brave and connected the front board. Still no smoke but am not able to program chip. Not sure of the reason. I have MPLab IDE v8.92 connected to Pickit3. I get error - "you must connect to a target device to use Pickit."

When I disconnect connector to J9, I measure 3.3v and -0.6v coming from the back board. But when I plug in connector to J9, I measure 0.02v and -0.7v when I probe the pins of J9 where it's soldered to the PCB. Something does not sound right.

EDIT: I found R27 and R28 mounted incorrectly!  I thought I was very careful assembling the board but apparently not enough. I have fixed them but the voltage readings are still the same as above.
Title: Re: Really universal soldering controller
Post by: puzzle on June 07, 2017, 08:18:07 am
@ScotY808:
You did not wait for Sparky to answer your questions! Remember that there is a time difference of around 7 hours between USA and Bulgaria!

I remember something Sparky mentioning that OLED board should be connected - I don't remember what it was exactly but remember saying to myself I must wait for the oled to power it. Patience is not my virtue also when it comes to this kind of things :D

Check again your board for shorts and for contact - almost all capacitors should sound continuity between one of their side and GND, but NOT sound on both sides. For those not beeping at all on GND find the nearest component they connect to and check them - you should not hear a beep on both sides of a cap for too long time.
Then you check your resistors - It should show resistance but it should not beep on his sides if its resistance is greater than the threshold of the multimeter for beeping continuity - that is how I found a shorted resistor on my board - then following the line found a short on OLED's cable.
You should spend as much time as you need to check all you components at least once.

And I just want to say - this was my experience with this fun project, I'm a newbee at electronics and for that always take my words with a grain of salt - it is very possible I'm wrong!

Edit: Post some pictures of the boards+ back side of the front board.
Cheers
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 07, 2017, 08:29:42 am
Pics of PCBs. Hopefully, sparkybg can help me. I have no idea where to start troubleshooting. I still do not have OLED.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 07, 2017, 09:02:28 am
Thank you, puzzle!  I have to go on a business trip tomorrow and had hoped to get the chip programmed so when I came back, hopefully my OLED would be here. I will try to check all components as you say and maybe sparkybg has also some good ideas of what might be wrong.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 07, 2017, 09:33:51 am
[quote author="puzzle"]
I have a question...
When I was programming my controller I used the unisolder.exe in the UniSolder52_SoftwarePCUniSolderbinRelease folder and it worked. Also I don't have Visual studio installed on my PC only the .net platform installed a long time ago.
Also when I had the controller already flashed and connected to PC - unisolder.exe showed everything I supposed it should show...all the lines going up, down when heating and so on.
Is it any particular reason to install visual studio and go the way you described instead of continue using Unisolder.exe form folder UniSolder52_SoftwarePCUniSolderbinRelease ?[/quote]

Yes it might work this way. Never tried it. I will try it tonight. It just wants .NET framework 4.5.1 to run.

I will make installable package when I have some time.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 07, 2017, 09:31:15 pm
Hello sparkybg,
Would you have any suggestions for my problems?  I have been checking the boards but have not yet noticed anything wrong. I hope it can be made to work.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 07, 2017, 10:31:11 pm
You have either wrong wiring between front and back boards, or short circuit to ground of the 3.3V line on the front board.

Show me the boards connected.

If you have a short circuit, start measuring the voltage on every filter capacitor on the 3.3v line on the front board. The closer you are to the short circuit, the smaller voltage you will measure. When you find the capacitor with the smallest voltage on it, look at the parts around it that have connection to 3.3V - the short circuit will be nearby, maybe even on the very capacitor you are measuring the voltage on.

About waiting for the OLED - some time ago the firmware was detecting if there was OLED or 7 segment connected and wouldn't start if the OLED was not connected. Now the firmware does not do this anymore, so It must start without it. However, I never tried it.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 08, 2017, 12:07:40 am
Hi sparkybg,

Thank you for your help. I have just left my home for a few days. I connected the J3 and J9 like puzzle shows in his pics on this page. Maybe I have made a mistake again. I will post pics when I return home.

I am sorry to ask this very stupid question but when you say to measure voltage on the filter caps, does black DVM probe go on J9 negative pin and red probe goes to capacitor?  Or is it one probe on each side of capacitor?

I have only very rudimentary understanding of electricity. :-(

Thank you, once again!
Title: Re: Really universal soldering controller
Post by: sparkybg on June 08, 2017, 01:10:50 am
Measure the voltage on the capacitor terminals. Measure all the capacitors on the front panel, post the results here, and maybe I will be able to tell you where to look.

...and again, post a picture the wires between the boards, while connected. It may be a wiring problem.
Title: Re: Really universal soldering controller
Post by: puzzle on June 08, 2017, 11:00:48 am
Would it be wrong to touch the board's components to see what is heating up and then to look and measure around it?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 08, 2017, 12:30:10 pm
Nothing heats up significantly on the front board, even when there's a short circuit. The 3.3V SMPS has limited output current and when there's a short circuit, the voltage is very low so it cannot heat anything, even if the current approaches 0.5A
Title: Re: Really universal soldering controller
Post by: dumitruv on June 09, 2017, 01:24:27 am
Maybe this helps with connections.
Title: Re: Really universal soldering controller
Post by: GuruMeditation on June 09, 2017, 01:35:00 am
Hi All,
  Many thanks to sparkybg for this project. Serious respect. I have ordered some pcbs and some oleds and am now going through the BOM and choosing suppliers.  I have had some trouble in finding exact matches for some of the parts.  If someone could check the following substitutions for me, I'd really appreciate it.

D6,D7,D12 - SS310A  -  Mouser  -  750-CDBA3100-G
D22 -  SS43A  -  Mouser  -  621-B340A-F
TVS1  -  60V  -  Farnell - 1458996

And for the transformer, I'm liking the "INDEL TST120/003 Transformer: toroidal; 120VA; 230VAC; 24V; 5A; 1.3kg; Leads: cables." from TME.

My aim is to power a Hakko copy T12 to start with.  As soon as I know what I'm doing I will be looking to help add support for an original FM2032-51 micro soldering iron from Hakko.

I'd also like hot tweezers but the good ones are out of my budget.  I've seen sparkybg mention that he has a set of the Ayoue tweezers buried in a draw somewhere because they were too big.  Can anyone tell me if that's a problem with the tips of the tweezers, the body or both ?

Many thanks in advance.
Title: Re: Really universal soldering controller
Post by: dumitruv on June 09, 2017, 02:48:39 am
[quote author="GuruMeditation"]Hi All,
  If someone could check the following substitutions for me, I'd really appreciate it.

D6,D7,D12 - SS310A  -  Mouser  -  750-CDBA3100-G
D22 -  SS43A  -  Mouser  -  621-B340A-F
TVS1  -  60V  -  Farnell - 1458996

My aim is to power a Hakko copy T12 to start with.  As soon as I know what I'm doing I will be looking to help add support for an original FM2032-51 micro soldering iron from Hakko.

[/quote]

D6,D7,D12 - SS310A  -  Check Farnell SK310A
D22 -  SS34A  -  Check Farnell SS34A
TVS1  -  60V  -  Farnell - 1458996 Clamping voltage is 10.5V, too low.

I power mine with a 19V DC supply from an old laptop and it works well and it doesn't need a TVS. I know, Sparky's going to jump, toroidal transformer is the best, I won't dispute that. My main problem is the case. I don't want to buy a BK2000, it wouldn't be economical anymore. I'm still looking.
Title: Re: Really universal soldering controller
Post by: GuruMeditation on June 09, 2017, 02:58:20 am
[quote author="dumitruv"]

-- Snip ---
D6,D7,D12 - SS310A  -  Check Farnell SK310A
D22 -  SS34A  -  Check Farnell SS34A
TVS1  -  60V  -  Farnell - 1458996 Clamping voltage is 10.5V, too low.

I power mine with a 19V DC supply from an old laptop and it works well and it doesn't need a TVS. I know, Sparky's going to jump, toroidal transformer is the best, I won't dispute that. My main problem is the case. I don't want to buy a BK2000, it wouldn't be economical anymore. I'm still looking.[/quote]

Thank you :-)  Typo accepted :-)

I've looked at two different casings.  My choice will depend on the dimensions of my toroidal.  The least expensive I've found so far is to buy and gut one of the ~£25 hot air stations from ebay.  I've also found a much larger casing (looks like mild steel), again on ebay for less than £28.00

Again thanks for the BOM debugging, I'm off to find a better match for that TVS1 fail.

BTW. does anyone know what the proper values are for TVS1 ?
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 09, 2017, 03:03:58 am
[quote author="dumitruv"]Maybe this helps with connections.[/quote]

Hi Dumitruv,

Thank you for your pictures. I think my wiring is same but will check when I return home.

I have a question though.  On the back of the front board, I have made solder bridges but you have only not. Is your board the way it's supposed to be done?

Also, there is a bridge? you made next to the crystal. I do not have that. Does something need to be done there?

Thank you again to everyone for the help. I cannot wait to get home to work on this!
Title: Re: Really universal soldering controller
Post by: dumitruv on June 09, 2017, 03:08:49 am
[quote author="GuruMeditation"][quote author="dumitruv"]

BTW. does anyone know what the proper values are for TVS1 ?[/quote][/quote]

Look on page 66.
Title: Re: Really universal soldering controller
Post by: dumitruv on June 09, 2017, 03:26:36 am
[quote author="ScotY808"]

I have a question though.  On the back of the front board, I have made solder bridges but you have only not. Is your board the way it's supposed to be done?

[/quote]

If you look on the other side of the PCB they are connected together. Once you ground one, you ground them all. And OLED uses only the first and the last row of pins.

[quote author="ScotY808"]

Also, there is a bridge? you made next to the crystal. I do not have that. Does something need to be done there?

[/quote]

Grounding crystal case is good practice mainly in RF but you have to make sure you do it fast and don't damage the crystal. In this case does nothing detectable other than mechanical support. This is not your problem.
Title: Re: Really universal soldering controller
Post by: GuruMeditation on June 09, 2017, 04:13:17 am
I'm building up my BOM right now and I think I might be going nuts.

I see the keystone fuse holder at FUSE1 rated at 5A...  What I'm struggling to find in the BOM is the matching fuse.

I do know that fuses come with different properties - fast/slow blow, etc.

What I don't know is which one I need.  Any ideas ?
Title: Re: Really universal soldering controller
Post by: dumitruv on June 09, 2017, 04:25:04 am
[quote author="GuruMeditation"]
I do know that fuses come with different properties - fast/slow blow, etc.
[/quote]

Any 5A 5mm x 20mm should do it, slo-blo or fast.
Title: Re: Really universal soldering controller
Post by: GuruMeditation on June 09, 2017, 04:51:06 am
[quote author="dumitruv"][quote author="GuruMeditation"]
I do know that fuses come with different properties - fast/slow blow, etc.
[/quote]

Any 5A 5mm x 20mm should do it, slo-blo or fast.[/quote]

Sanity restored. Thank you :-)

Can't wait to build it as it will be a massive step up from the 25W Antex - "fixed" temperature dinosaur I am currently using  :-) :-)

Again, thank you :-)
Title: Re: Really universal soldering controller
Post by: puzzle on June 09, 2017, 08:36:07 am
@GuruMeditation:
On page 63 there is a BOM file in my post. See if it help you for some details - on every element I ordered there's a link to the seller. Most parts are from Comet/Farnell and TME. Mouser wanted too much for delivery of 5 components so we discarded it as a supplier.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 09, 2017, 11:31:23 pm
I am finally home!  Here is my wiring. I'm sorry, I had only white wire. I have connector plugged into the wrong housing for the picture so I could show orientation easier.

I will start measuring the voltages on the caps now.
EDIT: Here is what I measured.  Please advise, sparkybg.  Thank you!
EDIT AGAIN: I am not 100% certain but the first time I connected power to the front board, I thought a heard a soft humming or buzzing sound.  I no longer hear this noise.  It could be I imagined it (getting old and hearing is not so good) but just in case it helps with troubleshooting, I should mention it.

C24 0.022v
C25 0.022
C26 0.017
C27 0.020
C28 0.020
C29 0.017
C30 0.008
C31 0.013
C32 0.017
C33 0.022
C34 0.012
C35 0.016
C36 0.720
C37 0.722
C38 0.717
C39 0.718
C40 0.0
C41 0.007
C42 0.0
C43 0.0
C44 0.0
C45 0.0
C46 0.008

C48 0.001
C49 0.0
C50 0.004
C51 0.001
C52 0.003
C53 0.0
C54 0.0
C55 0.053
C56 0.050
C57 0.014
C58 0.017
C59 0.312
C60 0.0
C61 0.0
C62 0.0
C63 0.185
C64 0.186
C65 0.108
C66 0.0
Title: Re: Really universal soldering controller
Post by: dumitruv on June 10, 2017, 05:42:39 am
Your 3.3V regulator (U1) isn't working or you have bad wiring or a short. You should see 3.3V on C24. Disconnect the front from the back board, power the back and measure voltage on C4. Then connect the front and measure again C4.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 10, 2017, 06:17:03 am
[quote author="dumitruv"]Your 3.3V regulator (U1) isn't working or you have bad wiring or a short. You should see 3.3V on C24. Disconnect the front from the back board, power the back and measure voltage on C4. Then connect the front and measure again C4.[/quote]

Hi Dumitruv,

I disconnect front board and measure 3.28v at C4.  When I reconnect front board, C4 measures 0.028v.  I think my J3/J9 wiring is okay?  It must be a short on the front board but I don't see anything wrong and I cannot figure out the schematics.

I have 3.3v and -0.6v at J3 when front board is not connected.  It is once I connect front board that I cannot measure 3.3v on J9...the 3.3v supply is very low and -0.6v actually goes to about -0.7v.

Thank you for your reply (and pictures you send).
Title: Re: Really universal soldering controller
Post by: puzzle on June 10, 2017, 08:04:41 am
@ScotY808:
Can you make a better picture of the zone around U5? Maybe a closeup of every row of pins of U5.
And look again every IC for shorts.
Schematics become easy to read when you understand how they are written. Every red label is a line coming or going to corespondent red label. every 3.3V label is a 3.3v line coming. and if you look at oscillator schematic  you see OSC1, OSC2 and GND labels. Now GND I suppose you understand where it goes, and if you try to find where the OSC lines go, you will find them at pins 40 and 39 respectively at U5. If you see the same red label in any part of a schematic it means it is connected to that same line... Hope you understand! Reading a schematic is a major knowledge used all the time in electronics.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 10, 2017, 08:32:27 am
Hi puzzle,

Attached picture for you to see. I checked the front board again and thought I saw maybe a solder bridge on U11. It maybe was just flux residue but I cleaned it and nothing has changed.

Thank you for your help!  Hopefully, sparkybg can help me. My JBC parts arrived today so it is quite sad that I have problems.
Title: Re: Really universal soldering controller
Post by: puzzle on June 10, 2017, 08:48:34 am
Look very carefully every pin of U5, and make sure you see it as a single unit - no residues, no noting touching it and adjacent pins!
They are small and easily overlooked.

I edited my previous post wile you were writing so read the part about schematics.

Edit:
I can not see very well those pins(marked red) - can you recheck them if they are not touching anything else?
[attachment=0]
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 10, 2017, 09:31:01 am
Thank you, puzzle...I will keep checking to see if I can find something wrong. In the meantime, do you have any tips for soldering the OLED?  Is it best to tin the PCB first, apply flux? to OLED connector, then heat it up to join them?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 10, 2017, 10:42:38 am
SS310A means 3A, 100V schottky. Any Schottky with the same ratings will do.
SS34A means 3A, 40V schottky. Any Schottky with the same ratings will do.
60V TVS is just a 60V TVS. Any 60V TVS ot close to this will do. For example 1.5KE62A

Transformer is OK.

AOYUE tweezers are TOTAL CRAP in any respect. The tips are really nasty, the temperature regulation is awfull, the whole instrument is HUGE.
Title: Re: Really universal soldering controller
Post by: GuruMeditation on June 10, 2017, 12:08:02 pm
[quote author="sparkybg"]SS310A means 3A, 100V schottky. Any Schottky with the same ratings will do.
SS34A means 3A, 40V schottky. Any Schottky with the same ratings will do.
60V TVS is just a 60V TVS. Any 60V TVS ot close to this will do. For example 1.5KE62A

Transformer is OK.

AOYUE tweezers are TOTAL CRAP in any respect. The tips are really nasty, the temperature regulation is awfull, the whole instrument is HUGE.[/quote]

Thanks :-) 

I was hoping that the AOYUE's problem was just in it's bulk, something that I could bodge as all the nice tweezers are way more than I can afford :-(

Again, thank you :-)  I really hate spending money on stuff everyone else knows is crap. But I also hate missing something affordable that can be tweaked into service :-)

I'm guessing that the following from Yihua is likely to be as bad ? http://http://www.ebay.co.uk/itm/Lotkolben-Yihua-907M-8-polig-Fur-Yihua-Tweezers-Lotstation-938BD-938D-/122492302387?hash=item1c851c3433:g:Vv0AAOSwblZZFaAj.

Anyone seen/used those ones ?  I can't judge the scale from the pictures but they kinda look like the pictures I've seen of the Hakko ones.  This is my last ask on the tweezer front, if they are crap I'll shut up and save up for a proper brand name set.
Title: Re: Really universal soldering controller
Post by: dumitruv on June 10, 2017, 01:31:29 pm
[quote author="ScotY808"][quote author="dumitruv"]Your 3.3V regulator (U1) isn't working or you have bad wiring or a short. You should see 3.3V on C24. Disconnect the front from the back board, power the back and measure voltage on C4. Then connect the front and measure again C4.[/quote]

Hi Dumitruv,

I disconnect front board and measure 3.28v at C4.  When I reconnect front board, C4 measures 0.028v.  I think my J3/J9 wiring is okay?  It must be a short on the front board but I don't see anything wrong and I cannot figure out the schematics.

I have 3.3v and -0.6v at J3 when front board is not connected.  It is once I connect front board that I cannot measure 3.3v on J9...the 3.3v supply is very low and -0.6v actually goes to about -0.7v.

Thank you for your reply (and pictures you send).[/quote]

Lool, I missed that, you plug the cable into the wrong connector on the back board. That is IRON, power is PWR.
Title: Re: Really universal soldering controller
Post by: afedorov on June 10, 2017, 02:13:21 pm
dumitruv,
[quote author="ScotY808"]I have connector plugged into the wrong housing for the picture so I could show orientation easier.
[/quote]
The problem is around or under the controller, maybe touching up the pins will help, otherwise he could desolder the chip and try without it.
Title: Re: Really universal soldering controller
Post by: dumitruv on June 10, 2017, 05:35:36 pm
Sorry, I missed that part.
Title: Re: Really universal soldering controller
Post by: puzzle on June 10, 2017, 06:20:53 pm
[quote author="ScotY808"] In the meantime, do you have any tips for soldering the OLED?  Is it best to tin the PCB first, apply flux? to OLED connector, then heat it up to join them?[/quote]

Well, I totally messed up the first time - I soldered it backwards, even when I was checking 3-4 times to be correct way then I had a soldering bridge under the cable so I don't know if my way was correct.
I will try to find the video I used to learn and will post it here.

https://www.youtube.com/watch?v=IsPtvdQ7zbc (https://www.youtube.com/watch?v=IsPtvdQ7zbc)
https://www.youtube.com/watch?v=Z99P0WTT06Y (https://www.youtube.com/watch?v=Z99P0WTT06Y)

First i tried like in first video, then I saw my mistake and had to desolder the OLED, then there was solder on the pins and I made it like in second video but I had solder bridges...maybe if it is made with les solder on the pins... but how I would know how much is enough...
But now I know an easy way to fix solder bridges under the cable :D
With a hot Iron at soldering temp. use a narrow tip and glide it between the pins with pressure(but not much) till the bridge is gone. The bridge will be visible true the transparent cable!

Cheers
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 10, 2017, 09:06:12 pm
[quote author="afedorov"]dumitruv,
[quote author="ScotY808"]I have connector plugged into the wrong housing for the picture so I could show orientation easier.
[/quote]
The problem is around or under the controller, maybe touching up the pins will help, otherwise he could desolder the chip and try without it.[/quote]

Afedorov (and puzzle, too),

Thank you, your advice was correct!!!  I could not see any problems with U5 pins but I decided to try your advice and resolder it.  I do not know where the problem was, but now I see 3.3v on J9 and a few caps I have checked also show 3.3v!  I think because so many of the capacitor voltages were low, it must have been a component with many connections = U5.  I have to go now, but when I come back, I will check more the board voltages and then see if controller is alive!

Question...is there a proper way to clean flux residue from under U5?  I use no-clean paste flux and I clean with alcohol and wipes and small brush many times, but still I can see residue behind the pins (and I am sure under the chip).

P.S. Thank you, puzzle, also for the OLED soldering tips.  I must also do that later today.
Title: Re: Really universal soldering controller
Post by: DinikS on June 10, 2017, 09:38:08 pm
[quote author="ScotY808"]

Question...is there a proper way to clean flux residue from under U5?  I use no-clean paste flux and I clean with alcohol and wipes and small brush many times, but still I can see residue behind the pins (and I am sure under the chip).

[/quote]

If you use no-clean flux - you can leave it as it is. Nothing bad can be happened.
If look at it from an aesthetic point of view you can soak the board in alcohol for some time. Buzzer and display must be removed from board. I use Ultrasonic cleaner. Bettwen IC's pads the residue can be removed mechanically. The good tool for that is dentist equipment ;-). But it needs to be very careful.
Title: Re: Really universal soldering controller
Post by: afedorov on June 11, 2017, 01:32:19 am
[quote author="ScotY808"]it must have been a component with many connections[/quote]
Not necessarily true, it is a power bus and it runs everywhere. It was mentioned before, your capacitors voltage list is more important in such troubleshooting. But some capacitors are in signal paths or in secondary supplies, do not take those into account.
[quote author="ScotY808"]Question...is there a proper way to clean flux residue from under U5?[/quote]
Flux usually do not make dead shorts, there must be another reason. Check (DMM in diode test mode) voltage drop between pin 57 and 41 of the chip: in forward direction DMM should show overload, and in reverse direction it should be one or two diode drops (0.5~1.2V)
Title: Re: Really universal soldering controller
Post by: dumitruv on June 11, 2017, 02:44:34 am
[quote author="ScotY808"]
Question...is there a proper way to clean flux residue from under U5?  I use no-clean paste flux and I clean with alcohol and wipes and small brush many times, but still I can see residue behind the pins (and I am sure under the chip).

P.S. Thank you, puzzle, also for the OLED soldering tips.  I must also do that later today.[/quote]

In general, the NC flux must be activated to be harmless, meaning it has to go through the reflow oven. In case of the flux-cored wire, it gets activated when you touch it with the iron. The flux from the bottle may be corrosive if left on the board that was assembled manually and your board will degrade in time. I always use water wash paste or wire, then I wash the board and dry it quickly if the components are washable. If not, I use NC paste but I put the board through reflow oven (toaster oven modified).
IPA is not the preferred solution for cleaning NC flux in a manufacturing environment. It doesn't dissolve properly NC and leaves residues. The cleaner that we use is Vigon EFM from Zestron.

How to soler the OLED:
1. Apply very little solder on OLED and PCB contacts. Use a wick to remove the excess solder if necessary. You should not see a bump of solder.
2. Align the OLED contacts to the PCB and touch the first and the last contacts with the soldering iron.
3. Apply Kapton tape on top of the OLED contacts.
4. Solder all the contacts by moving a wide tip on top of the Kapton tape.

I hope this helps.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 11, 2017, 03:19:46 am
[quote author="afedorov"][quote author="ScotY808"]it must have been a component with many connections[/quote][/quote]
Quote
Not necessarily true, it is a power bus and it runs everywhere. It was mentioned before, your capacitors voltage list is more important in such troubleshooting. But some capacitors are in signal paths or in secondary supplies, do not take those into account.
Quote

Thank you, afedorov.  Okay, that makes sense...power bus that runs throughout the board. But how do you know to suspect the chip from list of capacitor voltage?
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 11, 2017, 03:31:38 am
Dumitru,

Thank you for the OLED soldering tip. I will try later today.

About flux residue...activated means heated up and sticky?  I will try to find Vigon EFM here but I think maybe it is not possible. I have a spray can of electronic contact cleaner. Is that a similar product?  It dries really fast and is very expensive. I usually only use it for removing sticky adhesive tape residue.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 11, 2017, 03:50:03 am
I am still showing strange voltages on some capacitors. :-(  I have measured them all again and here is what I found below.
EDIT: I have been looking at the schematics (struggling to figure it out) but all the caps with the strange voltages do not seem to be connected directly to 3.3v or -0.6v.  So, maybe, everything is okay?

C24 3.275
C25 3.275
C26 3.275
C27 3.275
C28 3.275
C29 3.275
C30 3.275
C31 3.275
C32 3.275
C33 3.275
C34 3.275
C35 3.275
C36 0.667
C37 0.667
C38 0.662
C39 0.662
C40 1.891
C41 3.275
C42 0.002
C43 0.000
C44 0.000
C45 3.275
C46 3.275

C48 3.275
C49 3.275
C50 3.275
C51 3.275
C52 3.275
C53 0.115
C54 0.000
C55 0.430
C56 0.690
C57 ~1.8v and slowly decreases to almost zero
C58 1.225
C59 0.007
C60 0.0
C61 0.0
C62 0.0
C63 0.689
C64 0.687
C65 0.432
C66 0.003
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 11, 2017, 04:44:37 am
So, I tried to program chip using the correct software that sparkybg said to use and following puzzle's instructions.  MPLAB sees target, and program/verify says okay.  But now the speaker makes a continuous noise.  I think someone else had this problem before?  I do not yet have OLED display connected but will do that tonight.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 11, 2017, 10:08:34 am
[quote author="sparkybg"][quote author="overheater"]Hello Sparky,

so, after downloading and flashing new it is 13 again!  (I did it two times because I didn't trust)[/quote]

OK then... It cannot turn on the I2C of the MCU.

You have a problem with I2C bus. It is either a short circuit to ground or to 3.3V somewhere, or a device on the bus does not behave as expected.

Take a good look at U8, U10, U11, U15, R27, R28, and the traces of the I2C bus. From my personal experience, the easiest part to fry while soldering it is the offset DAC (U11), then the gain pot (U15), then the current source pots(U10), and finally the EEPROM(U8). The DAC is the smallest one, with many small terminals, and in very small package. I fried one myself on one of the previous versions of this controller, but in the I2C bus it behaved properly - only the output was malfunctioning.

Also, before anything other, measure the VCC around any of these chips. There must not be any considerable voltage drop there.[/quote]

Well, I have the OLED temporarily connected to the front board and I also get 13 displayed, along with constantly beeping speaker.  I checked all the chips and did not see anything wrong.  I do not know what to do now...very frustrated.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 11, 2017, 11:13:29 am
Measure the resistance between I2C lines, and between each I2C line and ground.

The rest is said in the post you quoted.
Title: Re: Really universal soldering controller
Post by: cbi7333 on June 11, 2017, 01:07:00 pm
Hi ScotY808, Sparky, afedorov, dumitruv, puzzle and any others I may have missed these last few pages,

Thanks to all of you for this good info debugging Scot's board.  I'm sure much of it will be helpful for me once I start soldering.  I'm starting to copy some extracts into a xls file to keep handy as a troubleshooting guide.  I also see that the search function has either been improved or I'm finally able to work with it correctly.  No 'too many results' errors have appeared lately.

Cheers!
Title: Re: Really universal soldering controller
Post by: Bug82 on June 11, 2017, 02:01:49 pm
Hello everyone!

Thank you sparkybg for sharing this great project!

Currently I am soldering two sets of unisolder boards. Yesterday my OLEDs arrived and I could finally start testing. The first set works fine, it managed to get it running. (Did not test it with a soldering Iron yet because of the following problems with the second set).

The display of the second pcb set did not show anything until now. What i tried so far:

I could connect the Pickit to the microcontroller and upload the Bootloader/Firmware.

Tested the Back and OLED pcb of the second set with the working front pcb of the first set, That worked.
Tested the front pcb of the not working set with the back and OLED pcb from the first set, without success.
-> I assume the problem is on the front pcb of the second set, not on the OLED board

I noticed that the voltage behind Q16 is not stable. Sometimes it is 3.25V, sometimes 0, sometimes in between.
->I replaced Q16, but that did not help. Is it possible that it is a problem with Pin48 on the microcontroller? It think that one is connected to Q16.

Any suggestions what the problem could be an what i should try next?

Thank you!
Title: Re: Really universal soldering controller
Post by: afedorov on June 11, 2017, 02:48:00 pm
[quote author="Bug82"]I noticed that the voltage behind Q16 is not stable. Sometimes it is 3.25V, sometimes 0, sometimes in between[/quote]
Check for shorts (to GND, VDD or adjacent pins) on output pins of the MC (refer to the schematics), when MC starts operating it may trigger VDD drop and restart.
UPD:
As you have some activity on pin 48, firmware runs to the OLED initialization, and since OLED doesn't show anything, the problem with OLED pins, I suppose.
check OLED pins 49, 50, 51, 52, 54 for shorts to VDD, GND and adjacent pins.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 11, 2017, 07:03:41 pm
[quote author="sparkybg"]Measure the resistance between I2C lines, and between each I2C line and ground.

The rest is said in the post you quoted.[/quote]

I search the schematics for the front board and cannot find this I2C.  I don't know how to test.  Can anyone explain this to me?

Thank you!

EDIT:
I discover R27 and R28.  I measure resistance (while resistor soldered to board) of R27 is 1.8kohm as it should be.  R28 only measures about 700 ohm.  This does not seem right?

I measure resistance between R27 and R28.  On one end, resistance is 0...this makes sense because it must be connected to 3.3v line.  On the other end, it is small resistance which rises to about 3.3kohm.  I do not know what this means.

Resistance between ground pin on J9 and R27 (SCL) - slowly rising to about 700 ohm
Resistance between ground pin on J9 and R28 (SDA) - slowly rising to about 700 ohm
Title: Re: Really universal soldering controller
Post by: afedorov on June 11, 2017, 09:31:03 pm
ScotY808,
you could also measure voltage on I2C lines. There may be a part that tying line to ground when it powers up.
Title: Re: Really universal soldering controller
Post by: Bug82 on June 11, 2017, 09:40:26 pm
[quote author="afedorov"][quote author="Bug82"]I noticed that the voltage behind Q16 is not stable. Sometimes it is 3.25V, sometimes 0, sometimes in between[/quote]
Check for shorts (to GND, VDD or adjacent pins) on output pins of the MC (refer to the schematics), when MC starts operating it may trigger VDD drop and restart.
UPD:
As you have some activity on pin 48, firmware runs to the OLED initialization, and since OLED doesn't show anything, the problem with OLED pins, I suppose.
check OLED pins 49, 50, 51, 52, 54 for shorts to VDD, GND and adjacent pins.[/quote]

Thanks for your advise! The problem must have been somewhere on the MC. I could not find the error on the OLED pins. Then i used some solder wick around the MC and soldered some pins again. Suddenly it worked.

Two other things that i noticed:
1) I am using toroidal transformers as recommended, but DC is displayed after startup. (on both pcb sets)
2) The calibration procedure did not work. R: 2087 is displayed (I use 10 Ohm). Turning the potentiometer does not change anything. (also same behavior on both sets)
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 11, 2017, 11:49:18 pm
Voltage between ground pin on J9 and R27 (SCL) - 1.66v
Voltage between ground pin on J9 and R28 (SDA) measured on side closest to chip - 0.00v
Voltage between ground pin on J9 and R28 (SDA) measured on side furthest chip - 3.27v

Does this mean R28 is bad?  It seems the wrong resistance which I measure at 700 ohms.  But, if it is actually 700 ohms, I think I should see more than 0.00v?  It is funny there is no 700 ohm resistor in BOM...I don't have previously any SMD components so where did it come from unless it got damaged.
Title: Re: Really universal soldering controller
Post by: dumitruv on June 12, 2017, 12:48:11 am
[quote author="ScotY808"]Voltage between ground pin on J9 and R27 (SCL) - 1.66v
Voltage between ground pin on J9 and R28 (SDA) measured on side closest to chip - 0.00v
Voltage between ground pin on J9 and R28 (SDA) measured on side furthest chip - 3.27v

Does this mean R28 is bad?  It seems the wrong resistance which I measure at 700 ohms.  But, if it is actually 700 ohms, I think I should see more than 0.00v?  It is funny there is no 700 ohm resistor in BOM...I don't have previously any SMD components so where did it come from unless it got damaged.[/quote]

It means that most likely you have a short to GND on the SDA line. You measure in circuit so you may expect different resistance than out of the circuit but 0V on one side while 3.3V on the other side of the resistor means short.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 12, 2017, 01:00:35 am
I changed R28 and it is the same as before.  SDA line only goes to chip?  Is it pin 5?  It seems there is nowhere else it can short out except at chip?

EDIT: Okay, I am see many connections...

U8 pin 8 = 3.27v
U11 pin 3 = 3.27v
U15 pin 8 = 3.27v
U10 various pins = 3.27v

I now do not know what to check.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 12, 2017, 01:19:30 am
[quote author="Bug82"]
Two other things that i noticed:
1) I am using toroidal transformers as recommended, but DC is displayed after startup. (on both pcb sets)
2) The calibration procedure did not work. R: 2087 is displayed (I use 10 Ohm). Turning the potentiometer does not change anything. (also same behavior on both sets)[/quote]

It looks like wiring problem between front and back. Double check that your wiring is correct (maybe the flat cable is reversed), and double check that all your resistors is placed exactly like in the picture in the first post.

[quote author="ScotY808"]I changed R28 and it is the same as before.  SDA line only goes to chip?  Is it pin 5?  It seems there is nowhere else it can short out except at chip?[/quote]

Both SDA and SCL are wired to the MCU, DAC, EEPROM and two digital pots. The nasty thing about buses with many devices on them is that if single device is malfunctioning in the "proper way", the entire bus does not work. From what I can see form pictures, the EEPROM is a little bit misplaced on the PCB. Double check that all the mentioned chips are placed right (some of them, the DAC for example, can be rotated 180 degrees pretty easily and you need a lens to see its marking) and there are no shorts on their pins.

If someone can measure the resistances on their front PCBs, it will be very helpful.

The easiest chip to fry while soldering is the DAC. As I wrote some posts ago, I fried one myself on my first prototype. But the bus worked - only the output of the DAC was not working.

afedorov, thanks for you help. It is of great value to all others trying to make this project. :)
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 12, 2017, 01:25:24 am
Hello sparkybg!
I have checked some other things and have edited my post above.  This is what I measured:
U8 pin 8 = 3.27v
U11 pin 3 = 3.27v
U15 pin 8 = 3.27v
U10 various pins = 3.27v

Last night I have removed U8 EEPROM and resoldered it.  It is more ugly looking because it's hard to solder now with all parts installed, but I am pretty sure it has no shorts.  I cannot figure out what is shorted out.

I double checked...all IC mounted in the correct orientation.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 12, 2017, 02:26:12 am
Have you tried it with desoldered EEPROM?

I am out of ideas. Maybe the last thing to do is to desolder all I2C parts and to solder them one by one, and trying after each soldering.

This is nasty, I know. If someone has another ideas - feel free to share them.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 12, 2017, 02:33:04 am
Thank you sparky, and also everyone else, for the help!

I have not tried without EEPROM soldered on. I guess I can take them all off and replace one at a time...I think I will have to. Also, I guess I should place an order for spare parts in case any are damaged.

Just for confirmation, I should be able to see 3.3v on both sides of R28...is this correct?  Is this okay place for measuring? 

EDIT: I have removed and replaced MCU.  I think it is okay.  Unfortunately, nothing has changed...number 13 and continuous noise from speaker. 
I think it maybe easier (possibly) to remove each chip in turn, rather than take all off and replace one at a time.  But I need help to know when it is "fixed."  If I measure 3.3v on ecah side of R28, does that possibly mean I found the wrong component?  Will OLED and beeping stop once the first chip is removed?
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 12, 2017, 02:41:16 am
BTW...soldering tip for newbies like me. I don't recommend "drag" technique I watched on YouTube. This is where you drag across all pins in a row. It is fast but maybe makes solder bridges. I think it is much safer to tack solder corners, then use tiny drop of solder on iron, and then drag each pin one at a time...drag away from chip. Sometimes with very fine pins, you can use the drag method and then drag away from the pin to clear bridges.

A good iron is very helpful. If I ever get this thing working, I will use it to build another one and make it much nicer. :-)
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 12, 2017, 07:20:57 am
Update...I have removed U11 and there was no change (still number 13 and constant beeping), so I put it back on. 

I have removed U8...no change but I have not yet put it back on. 

I have removed U15 and the beeping has stopped!  I see number 21 briefly when powering up, then number 45.  There is no "normal" display like it should be...just number 45.

I see 1.6v after R28 which is now the same as after R27. 

So...I do not know what is the problem with U15???  I will try and put it back on and see.  The soldering looked very nice so I don't have too much hope.  I don't have extra part.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 12, 2017, 09:30:48 am
[quote author="ScotY808"]
I think it maybe easier (possibly) to remove each chip in turn, rather than take all off and replace one at a time.  But I need help to know when it is "fixed."  If I measure 3.3v on ecah side of R28, does that possibly mean I found the wrong component?  Will OLED and beeping stop once the first chip is removed?[/quote]

When it is fixed, it will either stop beeping or change the error number.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 12, 2017, 10:21:28 am
[quote author="sparkybg"]Are you using DC power? Then 21 for around half second is OK. When AC power is used it shows it just briefly, maybe for 1/10 of a second. In this step the controller detects if it is powered with AC or DC, and the frequency of AC, if used.

45 means I2C or EEPROM failure. Maybe something is still wrong with I2C bus or there is malfunctioning device on the I2C bus. Tell me tha exact part number of the DAC you used - it's address is factory written and there are parts with many addresses. If it is with wrong address, the MCU waits for it to respond and  will stay at step 45.

At step 45 of the initialization it sends the commands to DAC and 2 pots, then it tries to load what is saved in the EEPROM. These are all four I2C devices, so it may be any of them. I haven't figured out yet how to make it more specific - it is a bit problematic from programming point of view.

Does it stay on 45 or just shows it for a moment and then starts normally?[/quote]

This sounds like same problem as I have now. U8 and U15 are not installed at the moment.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 12, 2017, 10:49:27 am
Then your previous problem was with U8 or U15. Install one of them and try again.
Title: Re: Really universal soldering controller
Post by: afedorov on June 12, 2017, 02:11:29 pm
[quote author="ScotY808"]
Just for confirmation, I should be able to see 3.3v on both sides of R28...is this correct?  Is this okay place for measuring? 
[/quote]
When the bus is in idle state you should see 3.3V on both lines (right sides of R27 and R28). But when the bus is busy you get pretty much half a voltage.
It seems when communication with the device failed, firmware retries continuously, and that explains why you have 1.6v.
I've measured resistances on my board and it's 1.8kOhm between line and VDD and 3.6kOhm between lines, as expected.
Title: Re: Really universal soldering controller
Post by: neddrag on June 12, 2017, 02:13:13 pm
Здравей, sparkybg. Изглежда има нянкакъв проблем с гербер файловете за изработка на печатните платки. Пуснах почръчка, но ми я анулираха. Не получих обяснение за причината. Нили могъл да провериш има ли такъв проблем или да ми кажеш къде в България могат да ми изработят платките по тези файлове, ако няма проблем? Благодаря предварително.

Поздрави,
Недялко Драганов
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 12, 2017, 08:27:53 pm
[quote author="sparkybg"]Then your previous problem was with U8 or U15. Install one of them and try again.[/quote]

I first reinstalled U8.  Voltage after R28 is still 1.6v but still get number 21, then 45.

I then reinstalled U15.  Now voltage after R28 is 1.6v!  But, I still have number 21, then 45.

So, something is still wrong.  I am avoiding removing U10 since it is most difficult to remove and solder looks good.  I think maybe it is okay since I now have voltage after R28.  I suspect U15 maybe is bad?  What do you think?  I think I have no choice but to order parts and replace U15, and possibly others?  Does this sound like a good idea?

Or could there be problem with firmware upload to MCU because I removed EEPROM and other parts?
Title: Re: Really universal soldering controller
Post by: cbi7333 on June 12, 2017, 08:58:17 pm
ScotY808,
Anything heating up?  If you can't tell the difference by the touch test can maybe try a few drops of alcohol to see if any particular UXX makes the alcohol evaporate much faster.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 12, 2017, 08:59:02 pm
[quote author="afedorov"][quote author="ScotY808"]
Just for confirmation, I should be able to see 3.3v on both sides of R28...is this correct?  Is this okay place for measuring? 
[/quote]
When the bus is in idle state you should see 3.3V on both lines (right sides of R27 and R28). But when the bus is busy you get pretty much half a voltage.
It seems when communication with the device failed, firmware retries continuously, and that explains why you have 1.6v.
I've measured resistances on my board and it's 1.8kOhm between line and VDD and 3.6kOhm between lines, as expected.[/quote]

Thank you, afederov, for the explanation. I didn't know how the I2C worked. I will order more parts and try to replace them. But maybe now I will reflash MCU just in case.  I didn't have OLED connected the first time I did it.
EDIT: reflash did not fix anything.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 12, 2017, 09:01:03 pm
[quote author="cbi7333"]ScotY808,
Anything heating up?  If you can't tell the difference by the touch test can maybe try a few drops of alcohol to see if any particular UXX makes the alcohol evaporate much faster.[/quote]

No, I can't feel any difference in temperature. Sparky had said you couldn't tell. That makes sense because it's 3.3v and I measured the current when shorted and it's about 0.5 amps. That's 1.6 watts power loss...seems much to small to notice heating.
Title: Re: Really universal soldering controller
Post by: Bug82 on June 12, 2017, 09:18:05 pm
[quote author="sparkybg"][quote author="Bug82"]
Two other things that i noticed:
1) I am using toroidal transformers as recommended, but DC is displayed after startup. (on both pcb sets)
2) The calibration procedure did not work. R: 2087 is displayed (I use 10 Ohm). Turning the potentiometer does not change anything. (also same behavior on both sets)[/quote]

It looks like wiring problem between front and back. Double check that your wiring is correct (maybe the flat cable is reversed), and double check that all your resistors is placed exactly like in the picture in the first post.
[/quote]

Hi sparkybg,

I think I had a reversed flat cable and mixed up SenseA and SenseB. Now the calibration is working.

But the display still shows that it is running on DC. Its weird that i have the same problem on both sets.
I checked the resistors again, i could not find an error. Especially R27, R28, R63, R65 are in the right orientation.

Another minor thing, i have the following speaker: https://store.comet.bg/en/Catalogue/Product/20878/ (https://store.comet.bg/en/Catalogue/Product/20878/)
Do I have to remove Q20 and D17 to make it work?
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 12, 2017, 09:37:45 pm
Can anyone check my parts that I am using to make sure they are the correct items?

U8 datasheet  Mouser part number 579-24LC64-I/SN
http://www.mouser.com/ds/2/268/21189h-21840.pdf (http://www.mouser.com/ds/2/268/21189h-21840.pdf)

U10 datasheet  Mouser part number 579-MCP4651-503E/ST
http://www.mouser.com/ds/2/268/DS-22096a-36447.pdf (http://www.mouser.com/ds/2/268/DS-22096a-36447.pdf)

U11 datasheet  Mouser part number 579-MCP4716A0TECH
http://www.mouser.com/ds/2/268/22272A_MCP4706-14915.pdf (http://www.mouser.com/ds/2/268/22272A_MCP4706-14915.pdf)

U15 datasheet  Mouser part number 579-MCP4561T-503E/MS
http://www.mouser.com/ds/2/268/22107B-285083.pdf (http://www.mouser.com/ds/2/268/22107B-285083.pdf)

Thank you!  I have reordered them with spares...hopefully they are the correct parts.
Title: Re: Really universal soldering controller
Post by: dumitruv on June 13, 2017, 04:29:45 am
[quote author="Bug82"][quote author="sparkybg"][quote author="Bug82"]
Two other things that i noticed:
1) I am using toroidal transformers as recommended, but DC is displayed after startup. (on both pcb sets)
2) The calibration procedure did not work. R: 2087 is displayed (I use 10 Ohm). Turning the potentiometer does not change anything. (also same behavior on both sets)[/quote]

It looks like wiring problem between front and back. Double check that your wiring is correct (maybe the flat cable is reversed), and double check that all your resistors is placed exactly like in the picture in the first post.
[/quote]

Hi sparkybg,

I think I had a reversed flat cable and mixed up SenseA and SenseB. Now the calibration is working.

But the display still shows that it is running on DC. Its weird that i have the same problem on both sets.
I checked the resistors again, i could not find an error. Especially R27, R28, R63, R65 are in the right orientation.

Another minor thing, i have the following speaker: https://store.comet.bg/en/Catalogue/Product/20878/ (https://store.comet.bg/en/Catalogue/Product/20878/)
Do I have to remove Q20 and D17 to make it work?[/quote]

1. Check if Pin1 J4 on the back goes to Pin1 J8 on the front.
2. Check if C1 is the right value.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 13, 2017, 10:12:12 am
[quote author="ScotY808"][quote author="sparkybg"]Then your previous problem was with U8 or U15. Install one of them and try again.[/quote]

I first reinstalled U8.  Voltage after R28 is still 1.6v but still get number 21, then 45.

I then reinstalled U15.  Now voltage after R28 is 1.6v!  But, I still have number 21, then 45.

So, something is still wrong.  I am avoiding removing U10 since it is most difficult to remove and solder looks good.  I think maybe it is okay since I now have voltage after R28.  I suspect U15 maybe is bad?  What do you think?  I think I have no choice but to order parts and replace U15, and possibly others?  Does this sound like a good idea?

Or could there be problem with firmware upload to MCU because I removed EEPROM and other parts?[/quote]

The I2C is working now. Just before step 45 it send commanda to the ADC and the pots, then after step 45 it tries to load the data from EEPROM, so if the EEPROM is not on the PCB or malfunctioning, or if any of the other I2C chips as not on the PCB, it will stuck on 45.


[quote author="ScotY808"]Can anyone check my parts that I am using to make sure they are the correct items?

U8 datasheet  Mouser part number 579-24LC64-I/SN
http://www.mouser.com/ds/2/268/21189h-21840.pdf (http://www.mouser.com/ds/2/268/21189h-21840.pdf)

U10 datasheet  Mouser part number 579-MCP4651-503E/ST
http://www.mouser.com/ds/2/268/DS-22096a-36447.pdf (http://www.mouser.com/ds/2/268/DS-22096a-36447.pdf)

U11 datasheet  Mouser part number 579-MCP4716A0TECH
http://www.mouser.com/ds/2/268/22272A_MCP4706-14915.pdf (http://www.mouser.com/ds/2/268/22272A_MCP4706-14915.pdf)

U15 datasheet  Mouser part number 579-MCP4561T-503E/MS
http://www.mouser.com/ds/2/268/22107B-285083.pdf (http://www.mouser.com/ds/2/268/22107B-285083.pdf)

Thank you!  I have reordered them with spares...hopefully they are the correct parts.[/quote]

Looks correct.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 13, 2017, 10:28:40 am
[quote author="Bug82"]
Hi sparkybg,

I think I had a reversed flat cable and mixed up SenseA and SenseB. Now the calibration is working.

But the display still shows that it is running on DC. Its weird that i have the same problem on both sets.
I checked the resistors again, i could not find an error. Especially R27, R28, R63, R65 are in the right orientation.
[/quote]

You still have a problem obviously. But you can diagnose it with oscilloscope. Do you have one?

You should have the rectified but not filtered input voltage on J8's pin 1. The MCU is using it to check if if is running on DC or AC. Then you should have this voltage clipped on pin14 of the MCU, and the same voltage, but not clipped and wilth lower amplitude on MCU's pin 13.

As a start, you should have direct connection between J8's pin 1 and the voltage after the rectifiers, which is present on the bottom terminal of the fuse. (Vin on the chematics).

[quote author="Bug82"]
Another minor thing, i have the following speaker: https://store.comet.bg/en/Catalogue/Product/20878/ (https://store.comet.bg/en/Catalogue/Product/20878/)
Do I have to remove Q20 and D17 to make it work?[/quote]

Q20 and D17 are never installed, no matter what speaker you are using.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 13, 2017, 04:30:32 pm
Thank you, sparkybg!  When parts arrive, I will change EEPROM and hopefully then it will work.
Title: Re: Really universal soldering controller
Post by: ScotY808 on June 13, 2017, 04:38:02 pm
[quote author="sparkybg"][quote author="ScotY808"][quote author="sparkybg"]Then your previous problem was with U8 or U15. Install one of them and try again.[/quote]

I first reinstalled U8.  Voltage after R28 is still 1.6v but still get number 21, then 45.

I then reinstalled U15.  Now voltage after R28 is 1.6v!  But, I still have number 21, then 45.

So, something is still wrong.  I am avoiding removing U10 since it is most difficult to remove and solder looks good.  I think maybe it is okay since I now have voltage after R28.  I suspect U15 maybe is bad?  What do you think?  I think I have no choice but to order parts and replace U15, and possibly others?  Does this sound like a good idea?

Or could there be problem with firmware upload to MCU because I removed EEPROM and other parts?[/quote][/quote]

The I2C is working now. Just before step 45 it send commanda to the ADC and the pots, then after step 45 it tries to load the data from EEPROM, so if the EEPROM is not on the PCB or malfunctioning, or if any of the other I2C chips as not on the PCB, it will stuck on 45.
Quote

I was just wondering...if I understand correctly, the next step would be to replace EEPROM. But is it possible for it to fail yet it does not short out?  I guess that is possible...yes?
Title: Re: Really universal soldering controller
Post by: Bug82 on June 13, 2017, 08:45:08 pm
[quote author="dumitruv"]
1. Check if Pin1 J4 on the back goes to Pin1 J8 on the front.
2. Check if C1 is the right value.[/quote]

Pin1 J4 and Pin1 J8 are connected. Unfortunately i cant measure capacitance at home, and i don't have a replacement for this one at the moment.

[quote author="sparkybg"]
You still have a problem obviously. But you can diagnose it with oscilloscope. Do you have one?

You should have the rectified but not filtered input voltage on J8's pin 1. The MCU is using it to check if if is running on DC or AC. Then you should have this voltage clipped on pin14 of the MCU, and the same voltage, but not clipped and wilth lower amplitude on MCU's pin 13.

As a start, you should have direct connection between J8's pin 1 and the voltage after the rectifiers, which is present on the bottom terminal of the fuse. (Vin on the chematics).[/quote]

There is a connection between J8 Pin1 and the terminal of the fuse and i see signals on Pin13 and 14 of the MCU. A picture of the Signals is attached (Signal on Terminal Fuse, Pin 13 and Pin 14, (all with a 10:1 probe)). Sorry for the bad quality, i only have a DSO 138 DIY at home. The signals on the second pcb set look pretty much the same. The soldering on these pins looks good to me

[quote author="sparkybg"]
Q20 and D17 are never installed, no matter what speaker you are using.[/quote]

removed them and now the speakers are working.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 13, 2017, 09:06:03 pm
The the signals are OK. Maybe due to flat cable reversal the MCUs are malfunctioning.

Does it show "POWER LOST" for a brief moment when you power them down?
Title: Re: Really universal soldering controller
Post by: Bug82 on June 13, 2017, 09:27:55 pm
[quote author="sparkybg"]The the signals are OK. Maybe due to flat cable reversal the MCUs are malfunctioning.

Does it show "POWER LOST" for a brief moment when you power them down?[/quote]

Yes, it shows "POWER LOST" for a moment.

A MCU damage because of the reversed flat cable would make sense because i used the cable for both sets. I have one replacement MCU which i can try next weekend, if there are no other options. A really stupid mistake.
Title: Re: Really universal soldering controller
Post by: afedorov on June 13, 2017, 09:37:09 pm
I'm wandering, may a wrong crystal frequency cause the behavior that Bug82 have?
On normal conditions it seems that 40Hz is the minimal frequency supported before timer would rollover, producing an interrupt which forces the DC mode. 16MHz crystal doubles this frequency. Though, it would be 160MHz system clock which is way to much for this micro.
UPD:
Actually, I forgot that it's a double mains frequency at the Vint. :)
Title: Re: Really universal soldering controller
Post by: Bug82 on June 13, 2017, 10:04:32 pm
I bought the following one. 8 MHz should be correct or?
https://www.digikey.de/product-detail/d ... -ND/284205 (https://www.digikey.de/product-detail/de/citizen-finedevice-co-ltd/HC-49-U-S8000000ABJB/300-6017-ND/284205)
Title: Re: Really universal soldering controller
Post by: afedorov on June 13, 2017, 10:59:04 pm
[quote author="Bug82"]I bought the following one. 8 MHz should be correct or?
https://www.digikey.de/product-detail/d ... -ND/284205 (https://www.digikey.de/product-detail/de/citizen-finedevice-co-ltd/HC-49-U-S8000000ABJB/300-6017-ND/284205)[/quote]
Yes, it's correct. Just thought that the reason of such misbehavior on both of your sets should be something that is common, like a wrong part.
I've evaluated an reversed flat cable connection. Only connection that may be dangerous to the MC is HSEL tied to ground, but it's on another IO block and even if this IO failed, it should not influence VINT operation.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 13, 2017, 11:42:42 pm
[quote author="afedorov"]
I've evaluated an reversed flat cable connection. Only connection that may be dangerous to the MC is HSEL tied to ground, but it's on another IO block and even if this IO failed, it should not influence VINT operation.[/quote]

Yes, you are right, but I am out of ideas how the same problem can happen on two front PCBs. Cable reversal is the only common thing between them.

bug82, can you please upload a photo of your front board?

P.S.: about the crystal - you can measure it's oscillations. Even 10Mhz scope is enough to check it.
Title: Re: Really universal soldering controller
Post by: dumitruv on June 14, 2017, 12:35:14 am
[quote author="Bug82"][quote author="dumitruv"]
1. Check if Pin1 J4 on the back goes to Pin1 J8 on the front.
2. Check if C1 is the right value.[/quote]

Pin1 J4 and Pin1 J8 are connected. Unfortunately i cant measure capacitance at home, and i don't have a replacement for this one at the moment.

[quote author="sparkybg"]
You still have a problem obviously. But you can diagnose it with oscilloscope. Do you have one?

You should have the rectified but not filtered input voltage on J8's pin 1. The MCU is using it to check if if is running on DC or AC. Then you should have this voltage clipped on pin14 of the MCU, and the same voltage, but not clipped and wilth lower amplitude on MCU's pin 13.

As a start, you should have direct connection between J8's pin 1 and the voltage after the rectifiers, which is present on the bottom terminal of the fuse. (Vin on the chematics).[/quote]

There is a connection between J8 Pin1 and the terminal of the fuse and i see signals on Pin13 and 14 of the MCU. A picture of the Signals is attached (Signal on Terminal Fuse, Pin 13 and Pin 14, (all with a 10:1 probe)). Sorry for the bad quality, i only have a DSO 138 DIY at home. The signals on the second pcb set look pretty much the same. The soldering on these pins looks good to me

[quote author="sparkybg"]
Q20 and D17 are never installed, no matter what speaker you are using.[/quote]

removed them and now the speakers are working.[/quote]
 
Does that oscilloscope have DC? You show the waveforms in AC but would be interesting to see what's the DC clip voltage. If it is too high it may not go to LOW enough for the MCU to sense it. It should oscillate between 0.5V - 0.6V and about 3V.
Check the voltage on C12. On mine is about 4V.
Check R43, R46, ZD4, C60.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 14, 2017, 10:31:10 am
Yes, the valley of the signal on pin14 is the important one.

Also, you should have something between 5 and 6V on C12's terminals (C12 is on the back PCB) when no iron is connected.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 14, 2017, 10:35:17 am
[quote author="ScotY808"]
I was just wondering...if I understand correctly, the next step would be to replace EEPROM. But is it possible for it to fail yet it does not short out?  I guess that is possible...yes?[/quote]

Everything is possible.

By saing "I2C works now" I mean that at least it behaves like I2C when idle. The devices on it may or may not be OK, and can fail in many different ways.
Title: Re: Really universal soldering controller
Post by: Bug82 on June 14, 2017, 08:47:03 pm
Hi, i see some deviations from the expected values.

Measured in DC mode the Voltage at Pin 14 is between 1.1 and 4V. Seems to be to high. The ground connection was clamped on the ground terminal of D4 on the back pcb, i hope thats ok. And i am not 100% sure if i can trust this toy oscilloscope. But its reproducible on both sets.

The voltage drop across C12 is 8.3V, which seems to be to high.

Sorry, I had no time to desolder the parts today.
R43 = 10 KOhm measured on the PCB without back pcb.
R46 = 2.8 kOhm measured  on the PCB without back pcb.
Voltage across ZD4 is 2.96 V.

My measurement capabilities at home are very limited. If its not enough i can ask the electro engineers at work next week.
Title: Re: Really universal soldering controller
Post by: afedorov on June 15, 2017, 12:16:25 am
[quote author="Bug82"]Measured in DC mode the Voltage at Pin 14 is between 1.1 and 4V. Seems to be to high.[/quote]
Indeed, minimum pin 14 voltage should be less than 0.9v.
[quote author="Bug82"]The voltage drop across C12 is 8.3V, which seems to be to high. [/quote]
Yes, something wrong with this "feedback" circuit.
As the same zener on the front board seems to have the correct Vz, only Q5 is remaining.
Title: Re: Really universal soldering controller
Post by: dumitruv on June 15, 2017, 01:31:42 am
[quote author="afedorov"][quote author="Bug82"]Measured in DC mode the Voltage at Pin 14 is between 1.1 and 4V. Seems to be to high.[/quote]
Indeed, minimum pin 14 voltage should be less than 0.9v.
[quote author="Bug82"]The voltage drop across C12 is 8.3V, which seems to be to high. [/quote]
Yes, something wrong with this "feedback" circuit.
As the same zener on the front board seems to have the correct Vz, only Q5 is remaining.[/quote]

Actually if you look into the MCU datasheet VIL max for a Schmitt trigger input is 0.2 VDD. In this case where VDD is 3.3V it is 0.66V. If you don't swing below 0.66V the MCU  may not see a pulse.
Title: Re: Really universal soldering controller
Post by: cbi7333 on June 15, 2017, 07:04:13 am
@ Bug82

Just curious - what's this critter at U10 12-13?

May be ok per schematics and not related. Worth a double check?
[attachment=0]
Title: Re: Really universal soldering controller
Post by: sparkybg on June 15, 2017, 09:53:25 am
[quote author="Bug82"]Hi, i see some deviations from the expected values.

Measured in DC mode the Voltage at Pin 14 is between 1.1 and 4V. Seems to be to high. The ground connection was clamped on the ground terminal of D4 on the back pcb, i hope thats ok. And i am not 100% sure if i can trust this toy oscilloscope. But its reproducible on both sets.

The voltage drop across C12 is 8.3V, which seems to be to high.

Sorry, I had no time to desolder the parts today.
R43 = 10 KOhm measured on the PCB without back pcb.
R46 = 2.8 kOhm measured  on the PCB without back pcb.
Voltage across ZD4 is 2.96 V.

My measurement capabilities at home are very limited. If its not enough i can ask the electro engineers at work next week.[/quote]

Your 3V zeners are definitely not 3V. Most likely around 4.5V. You must replace them with the proper ones.

R43 is in parallel connection with R47,R51 and R46, so when you measure it on the PCB it will give (15k*(27k+1k+3k))/(15k+27k+1k+3k) = 10.109K.

There should not be any voltage higher than 3.3V on any MCU terminal, no matter what is connected to the controller.
Title: Re: Really universal soldering controller
Post by: sparkybg on June 15, 2017, 10:15:35 am
[quote author="dumitruv"]
Actually if you look into the MCU datasheet VIL max for a Schmitt trigger input is 0.2 VDD. In this case where VDD is 3.3V it is 0.66V. If you don't swing below 0.66V the MCU  may not see a pulse.[/quote]

I am not using Schmitt trigger but comparator.

And the comparator reference is set to 0.9375V, which is 5.625V on Vin. When the voltage on C12 is that high, it will never go low enough when no heater is connected or the power MOSFETs are not switched on. When the controller initializes, the MOSFETs are switched off, and there is a valley of around 5V on Vin, if the voltage on C12 was normal 5.6V. And the comparator will work. But when the voltage on C12 is 8V, the Vin valley voltage is something like 7.5V, and because this is way above it's Vref, the comparator never changes state and the firmware threats this as DC.
Title: Re: Really universal soldering controller
Post by: dumitruv on June 15, 2017, 02:08:49 pm
Ok, thanks, I didn't look in the code to see how's that input configured.
Title: Re: Really universal soldering controller
Post by: Bug82 on June 15, 2017, 07:11:21 pm
Thanks a lot for this good explanation, sparkybg.

The voltage drop across ZD1 and ZD2 is indeed 4.41V and not 3V. The same on both pcbs. (ZD4 though has 2.96V on both boards).

I ordered 6 of those (https://www.digikey.com/product-detail/ ... ND/2345697 (https://www.digikey.com/product-detail/en/micro-commercial-co/MMSZ4683-TP/MMSZ4683-TPMSCT-ND/2345697)) but they must have delivered 4 wrong parts. I remember that i had packages with 2 pieces of tape, but i cant retrace which parts that were. I always soldered pairwise on both boards, thats why both boards have the same error.

I will order new parts and report back when i have exchanged them. Do you think something else might be damaged because of this mistake, should i order some other parts as well? I guess i have a good chance that the MCU is not damaged? (Can I also use a SOD-123F instead of SOD-123 ?)

@cbi7333: Pin 12, 13 and 14 are all connected to VDD. They are on one big copper pad and the solder mask of the PCB was not good between the pins. Thats why it looks so ugly. Should not be a problem. But thank you for also taking a look at it.
Title: Re: Really universal soldering controller
Post by: afedorov on June 15, 2017, 09:56:06 pm
[quote author="Bug82"]The voltage drop across ZD1 and ZD2 is indeed 4.41V and not 3V. The same on both pcbs.[/quote]
That's weird as marking is the same. At least it's good that those dodgy zeners ended up on the back board and not on the front.
Title: Re: Really universal soldering controller
Post by: Bug82 on June 15, 2017, 10:22:12 pm
[quote author="afedorov"][quote author="Bug82"]The voltage drop across ZD1 and ZD2 is indeed 4.41V and not 3V. The same on both pcbs.[/quote]
That's weird as marking is the same. At least it's good that those dodgy zeners ended up on the back board and not on the front.[/quote]

True, both have a "CJ" marking. I have no explanation for that. Can i do anything wrong measuring it with a multimeter while the unisolder is turned on?
Title: Re: Really universal soldering controller
Post by: afedorov on June 15, 2017, 11:11:12 pm
You're measuring in the right way. Unless the current through it is way to high (and in this case zener will heavily heating up) you should get near 3v on those zeners.
Title: Re: Really universal soldering controller
Post by: canteen234 on June 16, 2017, 07:36:40 am
I have a 220V toroidal transformer lying around, but I am in the United States. Is there a way to reuse the transformer in the United States because 120V toroidal transformers are incredibly expensive here? For example, could I purchase a voltage converter?
Title: Re: Really universal soldering controller
Post by: sparkybg on June 16, 2017, 10:27:26 am
[quote author="canteen234"]I have a 220V toroidal transformer lying around, but I am in the United States. Is there a way to reuse the transformer in the United States because 120V toroidal transformers are incredibly expensive here? For example, could I purchase a voltage converter?[/quote]

The transformer itself is a voltage converter. I don't see how it can be cheaper to connect 2 transformers one after another. You cannot use anything other than transformer in front of another transformer because it needs sinusoidal voltage on its primary winding.

Take a look at:
https://www.digikey.bg/product-detail/e ... ND/2090084 (https://www.digikey.bg/product-detail/en/triad-magnetics/VPT24-6670/237-1346-ND/2090084)
Title: Re: Really universal soldering controller
Post by: sparkybg on June 16, 2017, 10:40:09 am
[quote author="Bug82"]ZD4 though has 2.96V on both boards.
[/quote]

There is not a constant DC voltage on  ZD4. You must measure it with oscilloscope in dc mode and look at its absolute peak voltage.

From what I can see from the oscillograms, with 8V on C12 and 265mV peak-peak on pin 14 with x10 probe, you have 2.65V peak-peak voltage on pin 14. Add 1.2V to this, and you've got 2.65+1.2=3.85V. Definitely NOT OK! It is limited by MCU internal diodes on pin 14 to 0.5V above 3.3V, which is again 3.8V.

So ALL your 3V zeners are indeed 4V zeners, and you definitely have to replace them all!

P.S: I am using BZV55C3V0:
https://store.comet.bg/en/Catalogue/Product/939/ (https://store.comet.bg/en/Catalogu