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ESTechnical Reflow Oven Controller Manual

Full upgrade kit for t962a
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ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A

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  • Page 1: Table Of Contents

    ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Table of Contents Instructions for fitting ESTechnical Reflow Oven Controller Full Upgrade Kit to T962A ..... Installation procedure ......................Reflow Controller Installation Troubleshooting ..............ESTechnical Reflow Oven Controller Operating Instructions ............
  • Page 2 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A 2 of 2...

  • Page 3: Instructions For Fitting Estechnical Reflow Oven Controller Full Upgrade Kit To T962A

    Thank you for your purchase of ESTechnical products. If you have any questions or comments please let us know, we are always keen to hear feedback about our products. Instructions for fitting ESTechnical Reflow Oven Controller Full Upgrade Kit to T962A...
  • Page 4 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Unplug the power cable from the reflow oven. Remove the drawer from the unit (pull forwards until it stops, then carefully undo the clips (gently move the plastic levers) that keep the drawer in the runners, then slide the drawer out from the runners.
  • Page 5 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Front screws Turn the unit around so you are looking at the back, remove the screws that hold the lid on the case, keep these safe. Rear Screws Being very careful not to pull on any cables, carefully lift the back of the lid slightly, then gently slide the lid forwards until it unhooks from the lower part of the oven.
  • Page 6 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Remove all the glue from screws and connectors Disconnect all the cables that attach to the control board. Do not pull on cables, pull the connectors apart gently and without twisting.
  • Page 7 Small signal cable to the heater SSR, fitted with two pin JST connector. Mains cable that was used to supply the power for the oven cooling fan to the ESTechnical Reflow Oven Controller, this has a three pin connector with only two terminals populated.
  • Page 8 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Thermocouple mounting tubes 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 –...
  • Page 9 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Thermocouple tip prepared for refitting Re-mount one thermocouple in the front mounting tube and position the tip 10-15mm above the surface of the drawer (45-50mm above the inside of the oven with the drawer removed).
  • Page 10 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A The Neutrik NAUSB-W panel passthrough 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 T962A this section needs to be reversed.
  • Page 11 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Mark connector locations 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 drill/machine/punch this to its final size.
  • Page 12 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Connector cut outs in lid If necessary, clean all burrs from the edges of the 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.
  • Page 13 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Prepare a bare metal area around a screw hole for good earth continuity in the case 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.
  • Page 14 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Thermocouple connector and cable 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...
  • Page 15 The Keypad ribbon cable should curl round and line up with the keypad connector on the controller. Controller mounting orientation Screw down the ESTechnical Reflow Oven Controller using the provided M3 6mm bolts – do not over tighten these screws. 13 of 50...
  • Page 16 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Plug in the thin ribbon cable for the keypad, the connector is labeled 'Keypad'. Keypad connection Identify the cable that connects to the panel LEDs, plug this onto the pins labeled 'LEDs' on the ESTechnical Reflow Oven Controller.
  • Page 17 Gather the cable neatly and connect it to the FTDI header on the ESTechnical Reflow Oven Controller. Cable tie and hot glue the cable slack in place on the inside of the lid.
  • Page 18 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A FTDI cable installed between controller and USB panel connector The installation of the controller in the lid is now completed, set aside the lid for now. 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.
  • Page 19 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Earth bolt location and lid screw hole prepared on the inside of the panel Also prepare the area around the screw hole which matches up with the screw hole on the lid, prepared earlier.
  • Page 20 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A New earth connection 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.
  • Page 21 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Test the earth connection resistance is lower than 1 Ohm. Disconnect and unbolt the heater SSR. The small signal cable can be discarded, a replacement is provided. 19 of 50...
  • Page 22 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Remove the original heater SSR It is necessary to drill two extra holes so that the two new SSRs mount together as shown. Mark where you will drill first with a fine marker pen or pencil and double check the position of the marks by offering up the SSRs to their new mounting sites.
  • Page 23 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Why is masking tape in here anyway? 21 of 50...
  • Page 24 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A All masking tape removed Apply the 30mm wide kapton tape to replace the masking tape. 22 of 50...
  • Page 25 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Replace the masking tape with kapton tape Pass the main fan cable under the 9v transformer and tuck the cable out of the way. 23 of 50...
  • Page 26 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Pass the fan cable under the transformer Re-mount the JBEN SSR (which was removed from the T962A in a previous step) using the pair of mounting holes nearest to the mains inlet. Mount the supplied SSR onto the other mounting holes.
  • Page 27 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Heater SSR connections Connect the remaining fork crimp terminal (which connects together a group of three wires) to the heater SSR terminal labeled 1 ~. See photo above. Identify the cable that goes to the exhaust fan at the back of the oven. Cut the two wires at the base of the plug.
  • Page 28 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Choose one of the wires from the fan (either wire is OK), shorten this wire to an appropriate 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 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Fan wire connected to lower terminal of SSR Identify the cable that previously supplied mains power to the fan driver on the original controller board. You can follow this cable back to the mains switch mounted on the back panel of the oven.
  • Page 30 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Mains cable (coiled) Separate the two halves of this two core cable by pulling the two halves away from each other. Take care not to damage the insulation or pull on the wires too hard.
  • Page 31 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Feed neutral wire through sleeve (the end is shown coiled) Connect the Neutral wire (using the other red fork crimp) into the SSR terminal labeled 1 ~. You can shorten this cable to suit the new location.
  • Page 32 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Fit both sleeves (provided) onto the fan wire This wire needs to be connected to the remaining live wire, this can be followed back to the switch terminals. These wires should be joined by first twisting together then soldering to form an overlap of at least 6mm.
  • Page 33 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Sleeved connection Connect the two supplied 50cm signal cables to the two input terminals of the SSRs. SSR signal connections Slide these cables through the heat-resistant sleeve that was recovered from an earlier step.
  • Page 34 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Sleeved SSR signal connections At this stage the finished mains wiring should look like the following photo. Finished SSR installation Identify the output cable from the small mains transformer and cut off the plug.
  • Page 35 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Prepared ends of the cable from the 9v transformer Optionally fit bootlace ferrules to the ends of the wires (not supplied and optional). 33 of 50...
  • Page 36 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Optionally fit bootlace ferrules (not supplied) At this point you should have the cables prepared as shown, these are the 9v AC power to the controller, SSR signal cables and main oven thermocouple cable.
  • Page 37 Place the lid of the oven alongside the lower part of the oven. Connect the 9v AC to the power connector on the ESTechnical Reflow Controller. The two wires can go into the connector either way round as this is low voltage transformer isolated AC.
  • Page 38 SSR. SSR signal connections Plug the cable that goes to the Fan SSR onto the connector on the ESTechnical Reflow Oven Controller labeled Fan SSR. Observe the polarity. Carefully inspect the wiring of the oven, there should be no loose strands of wire sticking out...
  • Page 39 Test for mains short circuit (power switch must be in On position) Check there is no accidental connection between the mains wiring and the ESTechnical Reflow Controller. There are two options for this test depending on the meter(s) you have available:...
  • Page 40 The main fan should begin to gently idle and the heaters 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 near room temperature. The cooling down display can be interrupted without interrupting the cooling of the oven to access the menu, just press the S key again.

  • Page 41: Reflow Controller Installation Troubleshooting

    ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A 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.

  • Page 42: Estechnical Reflow Oven Controller Operating Instructions

    ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Issue Cause Solution When a reflow cycle is started the Thermocouple connection is Correct the reversed thermocouple temperature reported reversed connection on the display drops instead of rising Incorrect connection of the...

  • Page 43: Production Of Pcbs

    Save Factory Reset Reflow Profile Testing The ESTechnical Reflow Oven Controller is equipped to make setting up reflow profiles easy – it is essential to carry out this testing correctly to ensure correct profile settings are used for your board(s).
  • Page 44 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A To carry out profile testing, you will require a test PCB, kapton tape and heatsink compound. Test PCB, kapton tape, heatsink paste and thermocouple Decide where to place the thermocouple. Where you place the thermocouple on the PCB depends largely on the design.
  • Page 45 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Stick down the thermocouple cable securely with the tip held in the correct location Apply heat sink paste to the tip of the thermocouple. Only apply a very small amount to ensure good thermal coupling between the PCB and the tip.

  • Page 46: Data Logging - Reflowviewer Software

    Profile testing can be carried out by carefully watching the temperature reported for the PCB thermocouple, or by logging the data via the USB port and using the ESTechnical reflowViewer software (see below). Alternatively it is possible to use an external thermocouple meter to monitor the PCB temperature.

  • Page 47: Operating Instructions

    ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Operating Instructions Starting a reflow cycle Navigate to Cycle start in the menu and press OK. The controller will perform the cycle using the current cycle settings. Stopping a cycle Should you need to abort a reflow cycle, press the S key. The oven will move into the Cool down state.

  • Page 48: Profile Tuning Tips

    ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A The oven's cooling fan is used to provide a small amount of air movement inside the oven, this helps the oven evenly heat the PCBs. The speed of the fan is important, too fast and the oven is being actively cooled while trying to heat up, too slow and the PCB will be heated unevenly.
  • Page 49 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A There is an offset between the air temperature and the board temperature. Often, the peak board temperature is higher than the air temperature measured immediately above the boards. Be aware of this when choosing profile settings as a peak temperature of 220°C can result in a peak board surface...

  • Page 50: Care And Maintenance

    ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Care and Maintenance ESTechnical recommend the following care and maintenance should be carried out at the intervals specified in order to get the best performance and longest useful life-span from your reflow oven.

  • Page 51: What You Will Need (Not Supplied)

    ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A What you will need (not supplied): Screwdrivers Multi-meter (ideally with 250v insulation resistance test mode) Allen keys Wire cutters Wire strippers Crimp pliers Small pliers to help grip the nut when fitting the Solid State Relays (SSRs) Electric drill Various sizes of drill;...
  • Page 52 ESTechnical Reflow Oven Controller Full Upgrade Kit for T962A Position: Founder Carried out at: ESTechnical 12 Ormonde Road, Folkestone, Kent, CT20 1PG, United Kingdom 16th September 2013 Copyright ESTechnical 2019 50 of 50...

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