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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.
Ensure the toaster oven to be converted is unplugged from the power.
Remove the screws that fasten the oven cover, set these aside. Remove the cover.
Take a moment to familiarise yourself with the wiring that is present. You need to be able to identify each of these cables in order to proceed with the installation:
Heater supply cables
Fan supply cables
Mains power into the oven – it is particularly helpful if this can be connected to a reusable terminal block (not supplied) as several connections need to be made to the live and neutral terminals
Earthing of the oven
Confirm that the oven has a sound earth connection to the metal case.
Disconnect all the wiring from the controls of the oven. Optionally remove the controls.
Multiple options are available for mounting the ESTechnical Reflow Controller:
Option A: Make a suitable mounting pattern for the ESTechnical Reflow Controller and keypad. See diagram 1. This will require marking out the pattern, drilling the required mounting holes and cutting out the opening for the display. The keypad cable cable slot can be made by drilling a row of overlapping holes and then filing the edges until the correct shape. The keypad ribbon cable may be harmed by sharp edges so make sure the edges are well finished.
Option B: Using the Mounting Plate for ESTechnical Reflow Controller (available separately ). The mounting plate requires a single square cutout in the panel and 4 screw/bolt/rivet holes.
Option C: Using the 3d Printed Pod for ESTechnical Reflow Controller (available separately ). The pod reqiures one cable access hole and four screw holes.
Mount the two solid state relays and 9v transformer onto a flat metal surface inside the oven, somewhere that will remain cool during operation of the oven and within easy reach of the cables inside the oven. Front or rear metal panels of the oven are good locations.
Once you have chosen a location for each item to be fitted, mark the location of the required drill holes with the marker pen and check against the item to be mounted (be sure that nothing will obstruct the terminals once mounted).
When you are certain the marks are correct, make a punch mark on each pen mark to aid the drill starting in the right place.
Secure the Solid State Relays and 9v transformer using the supplied M4 bolts.
Assemble the supplied stand off posts onto the four corners of the Reflow Controller, fasten these with the supplied M3 nuts.
Mount the controller onto the inside of your chosen mounting method using the M3 bolts provided.
Mount the keypad onto the panel by removing the cover on the self adhesive back, then carefully threading the connector through the hole in the panel and firmly press the keypad into place on the panel.
Referring to diagram 3, connect the primary winding of the mains transformer to the mains supply of the oven. For 110/115V mains (USA), connect both primary windings in parallel. For 220/230V mains, use both primary windings connected in series. The terminals are labeled on the transformer. Insulate the terminals with heat shrink sleeve.
Connect one of the heater supply wires to the neutral terminal of the incoming mains power.
Decide which solid state relay is going to control the heater and label it to prevent mistakes.
Connect the remaining heater supply wire to one of the mains terminals (labeled ~) on the heater solid state relay.
Connect the remaining terminal of the heater solid state relay to the live terminal of the mains supply. Use wire of a suitable current and temperature rating, ideally recycle as much of the existing wiring of the oven as possible. Do not use cable that is thinner than the existing heater wiring for any part of the heater connections.
Connect one of the supply cables for the fan to the neutral terminal of the mains supply to the oven.
Connect the other fan supply wire to one of the mains terminals (labeled ~) of the fan solid state relay.
Connect the remaining terminal of the fan solid state relay to the live of the mains supply to the oven.
Now the heater and fan mains wiring should be completed. Check the connections made so far. The original controls of the oven should no longer be connected to any of the oven wiring.
Mount the oven thermocouple (this has bootlace ferrules, the other thermocouple has a plug) into the oven by drilling a hole in the oven casing at a suitable location for the cable to enter. Feed in enough cable so that the thermocouple is placed close to the surface of the board to be reflowed. The tip of the thermocouple should be about 15mm above the board to be reflowed. Secure the thermocouples in place using kapton tape. Also apply tape to cover the hole where the cable enters the oven.
Connect the oven thermocouple to the A input on the controller board paying attention to the polarity of the thermocouples. The thermocouple cables are colour coded, the red wire from the thermocouple should go to the + (positive) terminal of the thermocouple input.
Connect the supplied small signal cables to the control inputs of the solid state relays.
Plug in the other end of these cables to the controller outputs, these are labeled 'heater' and 'fan' on the board. Pay attention to the polarity of these connections (shown in diagram 4).
If you wish, you can connect panel mounted LEDs (not supplied) to indicate the operation of the heater and fan to the LED connector on the PCB, this connector is next to the solid state relay outputs.
Connect the low voltage secondary winding of the mains transformer to the AC input of the ESTechnical reflow controller board. The transformer provides two sets of 9V AC output, connect just one pair of terminals and insulate the connections with heat-shrink tube.
The controller and keypad should be mounted onto a panel to suit your oven.
Plug the keypad into the controller board.
At this point there should be no remaining cables to connect. There should also be no cables remaining on the original controls of the oven. Check all the connections, particularly verify polarity of the solid state relay control signals and thermocouples.
Reassemble the oven using the original housing and screws.
Now the oven is ready for testing. Plug in the power and switch on the oven, the display should illuminate and the 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 (optional) 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 back/stop key to stop the cycle. The 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 back/stop key again. If the fan does not start or heater does not start to heat up, switch off the oven immediately to prevent any possible damage and go back and check all connections.
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 SSR||Check the polarity of the connection and correct if necessary, the polarity is marked on the controller and the SSR terminals|
|Incorrect mains power or SSR connections||Check the connections between the mains power, SSRs 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|
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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