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ESTechnical Reflow Oven Controller, Manual

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ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A

14 of 50

Plug in the thin ribbon cable for the keypad, the connector is labeled 'Keypad'.

33.

Keypad connection
Identify the cable that connects to the panel LEDs, plug this onto the pins labeled 'LEDs' on the

34.

ESTechnical Reflow Oven Controller.

LEDs connection
Find the cable for the small cooling fan, plug this into CONN5, being careful to observe the

35.

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.

Summary of Contents for Reflow Oven Controller

Page 1: ...Overview of Operation 40 Initial Set Up for new PCB designs 40 Production of PCBs 41 Menu Layout navigation 41 Re ow Pro le Testing 41 Data Logging Re owViewer Software 44 Operating Instructions 45 St...

Page 2: ...ESTechnical Re ow Oven Controller Full Upgrade Kit for T962A 2 of 2...

Page 3: ...arning IMPORTANT mains electrical wiring is involved in the installation of this controller but no mains voltages are connected directly to the controller If you are in any doubt please consult a qual...

Page 4: ...it pull forwards until it stops then carefully undo the clips 2 gently move the plastic levers that keep the drawer in the runners then slide the drawer out from the runners Set the drawer aside Drawe...

Page 5: ...y careful not to pull on any cables carefully lift the back of the lid slightly then gently 5 slide the lid forwards until it unhooks from the lower part of the oven Lift the lid o the oven turn over...

Page 6: ...from screws and connectors Disconnect all the cables that attach to the control board Do not pull on cables pull the 7 connectors apart gently and without twisting All connections unplugged Completel...

Page 7: ...Mains cable that was used to supply the power for the oven cooling fan to the ESTechnical Re ow Oven Controller this has a three pin connector with only two terminals populated One cable that goes int...

Page 8: ...nd if necessary untwist the wires so that the wires only touch when 12 meeting the bead the wires should not be twisted together leading to the tip A small pair of pliers is needed be careful the ther...

Page 9: ...ng tube and position the tip 10 15mm above 13 the surface of the drawer 45 50mm above the inside of the oven with the drawer removed Set the thermocouple height Gently crimp the tube with strong plier...

Page 10: ...s 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 o...

Page 11: ...into the 24mm diameter hole and carefully mark the location of the two 19 screw holes this prevents misalignment of the screw holes Center punch and drill the screw holes with a 2mm drill Clean all b...

Page 12: ...50 Connector cut outs in lid If necessary clean all burrs from the edges of the holes 22 Grind le sandpaper away the powder coated covering until you reach bare metal around one 23 screw hole on the r...

Page 13: ...metal on metal contact will be achieved when the oven is reassembled Test t the connectors in the panel to ensure a proper t 25 Prepare the thermocouple cable strip back 20 30mm of the outer sheath st...

Page 14: ...ctor in the hole and push the plastic clip into place Cover the plastic retaining clip with hot glue to prevent it being pulled o when disconnecting the thermocouple Thermocouple socket tted into the...

Page 15: ...ouch the display install the controller immediately Place the ESTechnical Re ow Oven Controller on the mounting posts for the display making 31 sure you have oriented it correctly The Keypad ribbon ca...

Page 16: ...el LEDs plug this onto the pins labeled LEDs on the 34 ESTechnical Re ow Oven Controller LEDs connection Find the cable for the small cooling fan plug this into CONN5 being careful to observe the 35 p...

Page 17: ...l Re ow 36 Controller Thermocouple cable connection Fit the FTDI USB to 3 3v TTL serial cable to the inside of the USB panel connector secure this 37 with hot glue to prevent it coming out of the conn...

Page 18: ...the original 39 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 re t the bol...

Page 19: ...the panel Also prepare the area around the screw hole which matches up with the screw hole on the lid 42 prepared earlier This ensures the lid and the back panel are well connected to the electrical e...

Page 20: ...est between a screw head on the rear panel but not the newly tted 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 Ohm...

Page 21: ...w Oven Controller Full Upgrade Kit for T962A 19 of 50 Test the earth connection resistance is lower than 1 Ohm Disconnect and unbolt the heater SSR The small signal cable can be discarded a replacemen...

Page 22: ...h mark caution is required as the oven contains quartz heater elements Before drilling move all the cables out of the path of the drill 48 Pilot drill the SSR bolt holes with a small drill eg 2 3mm 49...

Page 23: ...ESTechnical Re ow Oven Controller Full Upgrade Kit for T962A 21 of 50 Why is masking tape in here anyway...

Page 24: ...ESTechnical Re ow Oven Controller Full Upgrade Kit for T962A 22 of 50 All masking tape removed Apply the 30mm wide kapton tape to replace the masking tape 54...

Page 25: ...ESTechnical Re ow Oven Controller Full Upgrade Kit for T962A 23 of 50 Replace the masking tape with kapton tape Pass the main fan cable under the 9v transformer and tuck the cable out of the way 55...

Page 26: ...et Mount the supplied SSR onto the other mounting holes Ensure they are oriented with the low voltage control terminals in the centre of the oven with the larger power terminals towards the edges this...

Page 27: ...ctions Connect the remaining fork crimp terminal which connects together a group of three wires to 58 the heater SSR terminal labeled 1 See photo above Identify the cable that goes to the exhaust fan...

Page 28: ...ppropriate 60 length to connect to the fan SSR terminal labeled 2 Strip the insulation from the wire for about 5mm from the end twist together the strands and then crimp on one red fork crimp supplied...

Page 29: ...minal of SSR Identify the cable that previously supplied mains power to the fan driver on the original 62 controller board You can follow this cable back to the mains switch mounted on the back panel...

Page 30: ...y pulling the two halves away from each other 63 Take care not to damage the insulation or pull on the wires too hard Identify the Neutral wire this can be followed back into the group of wires connec...

Page 31: ...d is shown coiled Connect the Neutral wire using the other red fork crimp into the SSR terminal labeled 1 You 65 can shorten this cable to suit the new location Fan SSR neutral connection Place both t...

Page 32: ...he 67 switch terminals These wires should be joined by rst twisting together then soldering to form an overlap of at least 6mm Fan wire connection this needs to be soldered Shrink the heat shrink slee...

Page 33: ...Kit for T962A 31 of 50 Sleeved connection Connect the two supplied 50cm signal cables to the two input terminals of the SSRs 69 SSR signal connections Slide these cables through the heat resistant sle...

Page 34: ...nections At this stage the nished mains wiring should look like the following photo 71 Finished SSR installation Identify the output cable from the small mains transformer and cut o the plug 72 Strip...

Page 35: ...echnical Re ow Oven Controller Full Upgrade Kit for T962A 33 of 50 Prepared ends of the cable from the 9v transformer Optionally t bootlace ferrules to the ends of the wires not supplied and optional...

Page 36: ...ull Upgrade Kit for T962A 34 of 50 Optionally t bootlace ferrules not supplied At this point you should have the cables prepared as shown these are the 9v AC power to the 75 controller SSR signal cabl...

Page 37: ...ontroller The two wires can go into the connector either way round as this is low voltage transformer isolated AC Controller power connection Identify the thermocouple cable The thermocouple mounted i...

Page 38: ...ontroller PCB Observe the polarity marked on the controller board and SSR SSR signal connections Plug the cable that goes to the Fan SSR onto the connector on the ESTechnical Re ow Oven 79 Controller...

Page 39: ...this test depending on the meter s you have available Using an insulation resistance tester Measure the resistance using an insulation 1 resistance test mode set to 250v between one of the 9v AC power...

Page 40: ...heck connections Check the small cooling fan is running if not go back and check the connection 90 Choose Cycle Start navigate the menu with the and keys and press Ok to start a 91 re ow cycle The mai...

Page 41: ...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 Re ow Controller Mains power is not supplied to...

Page 42: ...ow the oven thermocouple The Fan Idle Speed is set too high Ensure the Fan Idle Speed is set to the correct value as suggested in the installation instructions The Ramp up Rate is set too high for the...

Page 43: ...avigation Navigate the menu using the keypad keys to move through the menu items press Ok to select a menu item Pressing Back will return you to the previous level of the menu The menu is organised as...

Page 44: ...ure the peak temperature is not exceeding the manufacturer s stated limits Small boards with few parts are often easy to pro le correctly with no parts present as the parts comprise a very small amoun...

Page 45: ...ste to the tip of the thermocouple Only apply a very small amount to ensure good thermal coupling between the PCB and the tip Apply heatsink compound to the thermocouple tip Apply a thin strip of kapt...

Page 46: ...ture for the most sensitive part s are not exceeded Pro le testing can be carried out by carefully watching the temperature reported for the PCB thermocouple or by logging the data via the USB port an...

Page 47: ...be overwritten with the new settings Loading a saved re ow pro le Navigate to Load Profile and press OK using the and keys choose the pro le number you wish to load Press OK the re ow pro le settings...

Page 48: ...PCB Increase the Fan idle speed by 5 10 and repeat the test cycle without changing any pro le settings When the PCB temperature accurately tracks the programmed pro le temperature note the Fan idle sp...

Page 49: ...ooling wait for it to reach ambient temperature before beginning another test cycle Any of these changes alone can be enough to alter the pro le to be suitable for your needs take small steps to avoid...

Page 50: ...internal surfaces of the oven being careful not to damage the oven thermocouple or heaters Flux deposits will harm the performance of the re ow oven remove these with ux thinners or a dedicated re ow...

Page 51: ...ll Metalwork les A container for screws Soldering iron Solder Hot glue gun and glue sticks Hot air gun or other suitable tool for shrinking heat shrink sleeve EC Declaration of Conformity In accordanc...

Page 52: ...l Re ow Oven Controller Full Upgrade Kit for T962A 50 of 50 Position Founder Carried out at ESTechnical 12 Ormonde Road Folkestone Kent CT20 1PG United Kingdom on 16th September 2013 Copyright ESTechn...

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