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Auto Reset Jumper
The ESTechnical reflow controller v4 PCB and onwards has a jumper for enabling or disabling the auto-reset behaviour of the MCU. With the jumper connecting the two pins it is possible to easily upload new firmware to the controller via USB to serial connection from a computer. With the jumper open, the MCU will not automatically reset when the serial port is opened by a computer - this is more convenient in normal operation and we suggest that you operate the controller with the jumper open.
Unplug the power cable from the reflow oven.
Turn the oven upside-down.
Remove the drawer from the unit (pull forwards until it stops, then remove the four screws from the underside of the drawer runners and set aside, also set the drawer aside.
Remove the screws that are under the front edge of the lid, there are two screws in the drawer opening, keep these safe.
Turn the unit around so you are looking at the back, remove the screws that hold the lid on the case, keep these safe.
Being very careful not to pull on any cables, carefully lift the back of the lid a little, then gently slide the lid forwards a little, lift off the oven, turn over and place it next to the bottom half of the oven.
Gently pick off the hot glue that's covering the connectors on the control board. A small pair of pointed pliers is helpful here, only try to remove a small amount at a time.
Disconnect all the cables that attach to the control board. Do not pull on cables, pull the connectors apart gently and without twisting.
Completely remove the control board and display and set aside – these items are no longer needed.
At this point, take a moment to familiarise yourself with the wiring that is present. You need to be able to identify the following cables in order to proceed with the installation:
Low voltage AC power cable from the small transformer, has a plug that fits onto two pins.
Small signal cable to the heater solid state relay, fitted with two pin JST connector.
Mains cable that was used to supply the power for the oven cooling fan to the controller, this has a three pin connector with only two terminals populated.
One cable that goes into the back of the oven, this is the oven cooling fan cable and has a two pin connector fitted.
2x thermocouples with coloured crimp ferrules to indicate polarity.
Keypad ribbon cable.
One cable that goes to the two panel LEDs, this has a 4 pole JST connector.
One cable that goes to the small DC cooling fan, with a 2 pole JST connector.
Carefully un-crimp the tubes that hold the thermocouples using a pair of pliers. Gently pull out the thermocouple.
Inspect the thermocouples and if necessary untwist the wires so that the wires only touch when meeting the bead, the wires should not be twisted together leading to the tip. A small pair of pliers is needed – be careful the thermocouple is fragile. This reduces the mass of the thermocouple junction and improves the response time to temperature changes.
In order to fit the ESTechnical Reflow Oven Controller to the case, one of the four fan mounting bolts may need to be removed (two or more designs of T962 lid exist) as it may foul on the edge of the LCD display.
The Neutrik NAUSB-W panel pass-through connector has a reversible section, allowing the USB connection to be either A or B on the outside of the panel. These are supplied with the USB A connector on the outside, for the T962 this section needs to be reversed. Undo the two screws and carefully pull the connector section out of the metal casting. Move the metal clip onto the other end of the connector and reassemble, taking care to correctly orient the connector section into the casting, do not over tighten the screws.
To fit the USB panel connector, a 24mm diameter hole is needed, two 2mm screw holes secure the connector to the panel with self tapping screws. Referring to Diagram 1, above, mark the center of the 24mm hole. Drill/machine/punch this to its final size.
To fit the thermocouple socket a rectangular cutout is needed. Referring to Diagram 1, above, mark the center of the rectangle and mark out the outline of the hole. Drill then file the hole to final size, or use a rectangular punch such as CP-1 from Omega. Alternatively this hole could be machined.
Place the USB connector into the 24mm diameter hole and carefully mark the location of the two screw holes, this prevents misalignment of the screw holes. Center punch and drill the screw holes with a 2mm drill.
Once the panel is prepared and the connectors have been tested to ensure a proper fit in the panel, clean all burrs from the newly cut holes.
Grind/file/sandpaper away the powder coated covering until you reach bare metal around one screw hole on the rear of the lid. This provides an earth connection to the back panel.
The matching area on the rear panel of the oven also needs to be prepared in the same way so good metal on metal contact will be achieved when the oven is reassembled.
Mount the USB pass-through connector in the panel with the two self tapping screws (supplied).
Test fit the connectors in the panel to ensure a proper fit.
Prepare the thermocouple cable; strip back 20-30mm of the outer sheath, strip off the insulation from about 6mm of each wire, connect the thermocouple cable to the thermocouple connector being sure to observe the correct polarity of the cable. The green sleeved conductor of the cable is the positive (+) and the white is the negative (-).
Thread the cable through the panel cutout and the plastic retaining clip for the connector, seat the connector in the hole and push the plastic clip into place. Cover the plastic retaining clip with hot glue to prevent it being pulled off when disconnecting the thermocouple.
Screw the supplied stand-off posts into the four screw posts at the corners of the display window.
Identify the oven thermocouple. The thermocouple that will be mounted in the oven drawer needs to be connected to the A input (thermocouple connector closest to the ESTechnical Reflow Controller's power connector) – this is important for the correct function of the ESTechnical Reflow Controller. Make sure you observe the polarity of the thermocouple, it has one lead marked red (this is positive, marked + on the board) and the other is blue (-).
Connect the cable from the thermocouple panel socket to input B of the ESTechnical Reflow Controller.
Place the ESTechnical Reflow Controller on the mounting posts for the display, making sure you have it the correct way round. The keypad ribbon cable should curl round and line up with the keypad connector on the ESTechnical Reflow Controller.
Screw down the ESTechnical Reflow Controller using the supplied M3 x6mm bolts – do not over tighten.
Plug in the thin ribbon cable for the keypad, the connector is labeled 'Keypad'.
Identify the cable that connects to the panel LEDs, plug this onto the pins labeled 'LEDs' on the ESTechnical Reflow Oven Controller.
Find the cable for the small cooling fan, plug this into CONN5, being careful to observe the polarity marked on the board. In some ovens, the fan polarity is not clearly marked, damage will not occur if it is connected in reverse, but the fan will not run. You may need to come back and reverse this connection.
At this point your ESTechnical Reflow Controller should look like the following photo.
Locate the thermocouple connectors on the old controller PCB, de-solder these and remove them as they will obstruct you cutting the PCB in the next step. See the photo in the next step, this shows the board once the thermocouple connectors have been de-soldered.
Now you need to separate the Triac board from the old controller board. Using a hacksaw and with the old controller PCB held gently in a vice by the edges, saw across the PCB to separate the two parts of the old controller. On the smaller part is needed, this provides mains switching for the fan and heater.
Clean the cut edge of the PCB with a file.
It is necessary to cut one track on the PCB. Cut with a sharp knife where indicatedby the red mark. Confirm that the connection between pads 1 and 3 of the connector has been broken completely.
Identify the six pads near the white MOC3021 ICs, the top two are the heater control input, the next two are the fan control input. The last pair of holes should be ignored.
Solder the supplied signal leads into the top four holes of the terminal. These leads include an 820R resistor to suit the inputs of the MOC3021 ICs. Apply hot glue to provide strain relief for the wires where they meet the PCB.
Fit this PCB back into the lid of the oven using three of the original screws, make sure to put back the insulating sheet behind the PCB.
Connect the signal leads for the heater and fan control to the terminals on the ESTechnical Reflow Controller, the polarity must be observed, pins 1 and 3 of the terminal on the Triac board are the positive inputs, 2 and 4 negative.
At this stage, your installed ESTechnical Reflow Controller and Triac board should look the photo below.
It is necessary to improve the earth connection to the case of the oven, since the original manufacturer powder coats the panels and does not provide a good earthing connection. Unscrew the bolt securing the earth cable to the panel, remove the earth connection and refit the bolt.
Being careful not to damage the cables, drill a 3.5mm or 4mm hole near the mains inlet.
Sandpaper or grind away the coating around the newly drilled screw hole on the inside surface of the back panel. Be sure to expose the metal surface properly for a good earth connection.
Also prepare the area around the screw hole which matches up with the screw hole on the lid, prepared earlier. This ensures the lid and the back panel are well connected to the electrical earth.
Using the supplied M3x8 bolt and self locking nut, bolt the earth connection from the inlet to the newly prepared earthing area.
Confirm that there is a low resistance connection between the earth pin of the power inlet and the metal case. Test between a screw head on the rear panel (but not the newly fitted earth bolt) and the earth pin of the power inlet. The resistance measured here must be less than 1 Ohm. Using a multimeter with a low Ohms range, the typical reading is about 0.15 Ohms. If the resistance is too high, confirm the correct function of the meter and if necessary improve the contact between the earth connection and the metal panel.
The masking tape in the T962 should be removed and replaced using the 30mm wide kapton tape. Heating the masking tape with a hair dryer helps soften the tape and adhesive and makes it easier to remove. Apply kapton tape to cover the aluminium foil, stick it down neatly without bubbles.
Identify the output cable from the small mains transformer. The ESTechnical Reflow Controller is fitted with a screw terminal for the AC power, cut off the plug, strip the insulation off the end of the cable to expose about 5mm of the conductors, then clamp the conductors into the AC power screw terminal. The two wires can be connected either way round, as this is low voltage AC.
Re-fit the oven thermocouple into one of the mounting tubes, bend the thermocouple toward the front of the oven (the thermocouple mounting tubes are not in optimal locations!) and position the tip 10-15mm above the surface of the drawer. The thermocouple tip should extend past the front heater tube. Gently crimp the tube to hold the thermocouple in place – do not crush the wires.
Identify the mains supply cable with the three pin header plug (only two wires are populated). Plug onto the connection for the Triac board on the three pin header.
Identify the heater cable, connect this to the heater connector on the Triac board, this is the two pin header next to the main input. See photo above.
Identify the fan cable, connect this to the fan connector on the Triac board. See photo above.
Inspect and confirm that the fan and heater connections are made correctly, if the fan and heater connections are swapped, you may damage the oven and pose a hazard to yourself and others.
Carefully inspect the wiring of the whole oven, there should be no loose strands of wire sticking out from connectors, if there are any, redo the connection being careful to correctly insert all the strands into the screw terminal before tightening the screw. There should also be no plugs that are not plugged in or loose cables – if there are, go back and check.
If you are unsure of the mains wiring please consult a qualified electrician.
Being very careful not to pull on or trap any of the cables, reassemble the oven by carefully placing the lid on (slightly forwards of where it needs to end up) and then slide it towards the back of the oven.
Fit the screws at the front of the oven in the drawer opening.
Fit the screws on the rear panel of the oven.
Now the oven is ready for testing.\\Plug in the power and switch on the oven, the display should illuminate and the ESTechnical Reflow Controller will display the main item of the menu. (If the display does not illuminate, switch off the power immediately and go back and check connections.)
Check the small cooling fan is running, if not, go back and check the connections.
Press OK to start a reflow cycle, the main fan should begin to gently idle and the heater should begin to heat up. Press the 'S' key to stop the cycle. The ESTechnical Reflow Controller will go into cool-down mode. The fan will stop when the oven returns to room temperature. The cooling down display can be interrupted without interrupting the cooling of the oven to get to the menu, just press the 'S' key again.\\If the fan does not start or heater does not begin to heat up, switch off the oven immediately to prevent any possible damage and go back to checking all connections.
It is necessary to correctly adjust the idle speed of the fan. The fan is run at a fixed 'idle speed' during reflow to provide a small amount of air movement in the oven. The fan should idle very slowly, to adjust the idle speed:
Fan settings in the menu;
Idle Speed will display on the screen;
OK to edit;
As a guide, the T962 requires a very low setting (6-10) we advise 8 as a starting point, whereas the T962A requires a value of around 35 (this is the default setting for the ESTechnical Reflow Controller, so it is important you update this value and save it).
Save and press
Test the idle speed by starting a reflow cycle, the fan should start up easily but not run so fast as to cause the oven to be cooled dramatically during reflow.
It is very important this value is set high enough for the fan to start every time the cycle is started (at very low values, the fan will not be able to start spinning) but it is equally important not to set this speed too high, otherwise the fan pushes too much cool air into the oven and reduces the efficiency of reflow soldering or makes it impossible to reach the peak temperature required.
Refit the drawer to the runners, secure with the four original screws.
Proceed to the operating instructions.
ESTechnical accept no responsibility or liability for personal injury or damage to property – Perform testing on waste boards until you are confident the settings are correct for your oven, boards and parts density etc.
Place the reflow oven on a hard, level and heat resistant surface. Do not cover any holes in the oven housing – the airflow is necessary, damage to the oven and/or your PCBs will result if airflow is impeded.
Always allow the oven to cool to below 50 degrees (as reported on the display) before stopping the cycle or attempting to remove the boards from the drawer. Do not stop a reflow cycle and begin another without first allowing the oven to cool to near ambient air temperature.
Never start a reflow cycle with hot PCB(s) - allow to cool first.
Ensure adequate ventilation in the work area, air extraction is essential if working in a confined space.
Place boards to be soldered centrally in the drawer of the oven. If a small board is being soldered, it is best to position this below the thermocouple towards the front of the oven. This will provide the most accurate temperature control. Always ensure there is PCB below the oven thermocouple.
|Controller does not power on when oven is switched on||Incorrect connection of low voltage AC supply to controller||Check connection of low voltage AC power supply to the ESTechnical Reflow Controller.|
|Mains power is not supplied to the 9V transformer||Check the primary winding of the 9V transformer is connected between the switched live feed of the oven and the neutral terminal|
|Fan or heater does not work during a reflow cycle||Incorrect connection of signal cable between Reflow Controller and Triac board||Check the polarity of the connection and correct if necessary|
|Incorrect mains power or Triac board connections||Check the connections between the mains power, Triac board and loads (heater and fan) are made as per the instructions|
|DC cooling fan does not start||Incorrect connection of the DC cooling fan to the ESTechnical Reflow Controller||Check (and possibly reverse) the connection on the controller to the DC cooling fan, the wiring colours used by the original oven manufacturer are inconsistent and can be misleading|
|LED indicators do not light during a reflow cycle||Incorrect polarity connection of the LEDs to the ESTechnical Reflow Controller||Check (and possibly reverse) the connection on the controller to the LEDs, the wiring colours used by the original oven manufacturer are inconsistent and can be misleading|
|When a reflow cycle is started the temperature reported on the display drops instead of rising||Thermocouple connection is reversed||Correct the reversed thermocouple connection|
|Controller displays “Thermocouple input open circuit”||Incorrect connection of the thermocouple to input A of the ESTechnical Reflow Controller, or broken thermocouple||Disconnect the thermocouple from input A and measure the resistance of the thermocouple, it should measure less than 10 ohms. If the thermocouple is open circuit, replace the thermocouple.|
|Controller displays “Temperature following error during heating”||Thermocouple is incorrectly placed||Confirm the placement of the thermocouple is as per the installation instructions and adjust if necessary|
|There is no PCB in the oven drawer||The temperature following error can occur when the oven drawer is empty and a cycle is run, test with a PCB below the oven thermocouple|
| The || Ensure the
| The || Reduce the
EC Declaration of Conformity
12 Ormonde Road,
in accordance with the following Directive(s):
|2004/108/EEC||The Electromagnetic Compatibility Directive|
hereby declare that:
ESTechnical Reflow Oven Controller
when installed and operated as per the supplied instructions the equipment named above complies with all applicable Essential Requirements of the Directives.
Signed by: Ed Simmons
Carried out at:
12 Ormonde Road,
16th September 2013
Copyright ESTechnical 2012-2015