Really universal soldering controller

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Really universal soldering controller

Postby sparkybg » Thu May 14, 2015 11:18 am

Well, here it is, at last.

UniSolder52_small.jpg


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):
UniSolder52_Schematics.zip
(332.36 KiB) Downloaded 3921 times

UniSolder52_gerber.rar
(436.38 KiB) Downloaded 2619 times

UniSolder52_BOM.zip
(13.47 KiB) Downloaded 2402 times

UniSolder52_Software.zip
(1.37 MiB) Downloaded 663 times


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
JBC C210: https://www.youtube.com/watch?v=iyz-EDf ... e=youtu.be
T12, JBC C210, JBC Microtweezers: https://www.youtube.com/watch?v=-f0KSU0PJzc&t=70s
Chinese T12: https://www.youtube.com/watch?v=u588sh- ... e=youtu.be
Weller WSP80: https://www.youtube.com/watch?v=gd_8w7l ... e=youtu.be
Weller WMRT: https://www.youtube.com/watch?v=eHNJuQE ... e=youtu.be

A comparison of irons/tips used in the movies:
Image

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:
UniSolder52_Cal_Con-1.jpg


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-
Last edited by sparkybg on Mon Apr 03, 2017 5:18 pm, edited 40 times in total.
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Re: Really universal soldering controller

Postby ppsati » Thu May 14, 2015 1:52 pm

Thank´s "sparkybg" the best.
I'll try ...
It works with JBC HT420-A?
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Re: Really universal soldering controller

Postby Erythros » Thu May 14, 2015 2:13 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?)
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Re: Really universal soldering controller

Postby sparkybg » Thu May 14, 2015 2:15 pm

ppsati wrote:It works with JBC HT420-A?


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.
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Re: Really universal soldering controller

Postby sparkybg » Thu May 14, 2015 2:17 pm

Erythros wrote:Will SparkySoft Ltd. sell PCBs?
Did I miss BOM? (Or if not, could you post one, please?)


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.
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Re: Really universal soldering controller

Postby ppsati » Thu May 14, 2015 2:43 pm

sparkybg wrote:
ppsati wrote:It works with JBC HT420-A?


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.


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.
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Re: Really universal soldering controller

Postby ppsati » Thu May 14, 2015 4:15 pm

Sparkybg,

Did you have a components list in Excel, as in the previous version?
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Re: Really universal soldering controller

Postby SZ64 » Thu May 14, 2015 4:17 pm

ppsati wrote:
sparkybg wrote:
ppsati wrote:
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.


I'm also doing ...;)
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Re: Really universal soldering controller

Postby diogoc » Thu May 14, 2015 4:24 pm

Looks nice!
You put a lot of work on it.

Thanks for your work.
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Re: Really universal soldering controller

Postby sparkybg » Thu May 14, 2015 4:25 pm

ppsati wrote:Sparkybg,

Did you have a components list in Excel, as in the previous version?


There will be, soon.

P.S.: BOM is uploaded to the first post.
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Re: Really universal soldering controller

Postby ppsati » Thu May 14, 2015 4:47 pm

sparkybg wrote:
ppsati wrote:Sparkybg,

P.S.: BOM is uploaded to the first post.


Sparkybg,

I can´t open the file UniSolder52_BOM.xls
Somebody has the same problem?
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Re: Really universal soldering controller

Postby sparkybg » Thu May 14, 2015 5:00 pm

ppsati wrote:
sparkybg wrote:
ppsati wrote:Sparkybg,

P.S.: BOM is uploaded to the first post.


Sparkybg,

I can´t open the file UniSolder52_BOM.xls
Somebody has the same problem?


Try again. It should be OK now.
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Re: Really universal soldering controller

Postby mrjoda » Thu May 14, 2015 5:06 pm

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 :)
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Re: Really universal soldering controller

Postby randomone » Thu May 14, 2015 5:23 pm

mrjoda wrote:in second - you choose a hard way i think.


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.
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Re: Really universal soldering controller

Postby ppsati » Thu May 14, 2015 5:43 pm

sparkybg wrote:

Try again. It should be OK now.


Thank´s Sparkybg,

Now is ok.
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