Difference between revisions of "IReflow"

Latest revision as of 18:51, 10 January 2020

Reflow Oven Controller

Image shows top of iReflow and rear of MyMenu card

Features

IR Oven controller
- Lead free profile
- Lead profile
Type K thermocouple
- Connection via screw terminal block
ATMega328 Microprocessor
- Arduino compatible
- 16 MHz
FTDI connector for serial USB
ISP connector
Buzzer to indicate done
I2C
- MyMenu - OLED plus buttons
2 LEDs
Supports external SSR
49x49mm form factor
4-40 mounting holes spaced 41mm apart

Parts

Solid State Relay SSR-25DA 25A /250V 3-32VDC for PID Temperature Controller TE
Welding Blanket - To over the insides

Toaster

Oster 6-Slice Toaster Oven, Silver tssttvdfl2
- 1440 Watts, 12 Amps

Reflow toaster oven conclusions:

This more expensive oven with 4 elements has more than enough power to meet the most demanding temperature slopes and ranges for reflow soldering of both lead-free and leaded solders.
The oven has too much power due to the 4 elements to be run on manual without heating too quickly. The soak zone in the cycle requires a dwell for about 2x-4x the time that the oven would produce under manual control.
The oven high temp thermostat has quite a bit of hysteresis but the high temperature is above the temperatures for both profiles. Set the oven to highest temp and control it.
Probably doesn't need PID control although it would be cooler if it was.
Definitely need PTouch labels on the door for contaminants "Don't cook food in here" and for heat "Gets hot to touch".

Connectors

J1 - 9V DC Power Jack

Center = +9VDC (nominal)
Shield = GND

J2 - Solid State Relay

Driven by transistor to ground

+5V
SSR-Output

J3 - FTDI

GND
GND
+5V
TxD
RxD
Reset

J4 - I2C OLED

+5V
GND
SCL
SDA

J5 - Thermocouple

Thermo + = Yellow
Thermo - = Red

J6 - ISP Download cable

MISO
+5V (+ marked on PWB)
SCK
MOSI
RESET
GND

J7 - Keypad

N/A with MyMenu card

GND
VCC
SW5WAY - Analog

Programming

Card Driver

Fixing the Device Signature Error in the Arduino IDE

The SMT ATMega328P-AU part has a different signature than the UNO.
When you try to program the IReflow card using Arduino Uno as the board type you get an error

avrdude: Expected signature for ATmega328P is 1E 95 0F
         Double check chip, or use -F to override this check.
Wrong microcontroller found.  Did you select the right board from the Tools > Board menu?

The Arduino IDE needs avrdude.conf changed to program the AU part
In earlier versions of the Arduino IDE finding the avrdude.conf file was relatively straightforward
- From Programming the Atmega328 - AU in Arduino
Correct Signature = 0x1e 0x95 0x14;
Keep old copy too.
In Arduino IDE 1.6.2 the avrdude.conf file is in a different location

Changing it here doesn't work since it's located in a roaming directory at least for Windows 8.1
- C:\Program Files (x86)\Arduino\dist\default_package.zip\packages\arduino\tools\avrdude\6.0.1-arduino2\etc
Other OS versions may be different
Locate the avrdude.conf file
- On my computer it is at: C:\Users\doug_000\AppData\Roaming\Arduino15\packages\arduino\tools\avrdude\6.0.1-arduino2\etc
Find it by turning on verbose download in the IDE

The path will be shown in the output

Edit avrdude.conf

Find the string

part parent "m328"

It should look like

Change to

u8g OLED library

Library notes
- Display characters/variables:
  - Use u8g.print (xx) function, just like the way you did with Serial.print (xx).
- Change the font：
  - Use u8g.setFont (xx) function to change the font, parentheses "xx" can be replaced by the corresponding font library name (you can search font library in u8g.h within U8glib \utility folder);
  - Large font is recommended for u8g_font_7x13, middle font for u8g_font_fixed_v0r and small font for u8g_font_chikitar;
- Change coordinates:
  - Use u8g.setPrintPos (x, y) function to change the display of coordinates
fonts
HelloWorld
- Uncomment

U8GLIB_SH1106_128X64 u8g(U8G_I2C_OPT_NO_ACK);	// Display which does not send ACK

MAX31855 Thermocouple Amplifier

Adafruit Thermocouple Amplifier MAX31855 breakout board (MAX6675 upgrade) - v2.0
Adafruit Thermocouple tutorial
MAX31855 Arduino library code

Other

LiPo Battery Care

Algorithm

Piece-wise Linear

#define TIME0_LEADFREE 0
#define TIMET1_LEADFREE 120
#define TIMET2_LEADFREE 165
#define TIMET3_LEADFREE 210
#define TIMET4_LEADFREE 218
#define TIMET5_LEADFREE 600
#define TEMPT0_LEADFREE 22.0
#define TEMPT1_LEADFREE 150.0
#define TEMPT2_LEADFREE 200.0
#define TEMPT3_LEADFREE 252.0
#define TEMPT4_LEADFREE 252.0
#define TEMPT5_LEADFREE -40.0

double getDesiredTempLeadFree(int currTime)
{
  if (currTime < TIMET1_LEADFREE)
    return (TEMPT0_LEADFREE + ((double)currTime                   * ((TEMPT1_LEADFREE-TEMPT0_LEADFREE)/(float)(TIMET1_LEADFREE-TIME0_LEADFREE))));
  else if (currTime < TIMET2_LEADFREE)
    return (TEMPT1_LEADFREE + ((double)(currTime-TIMET1_LEADFREE) * ((TEMPT2_LEADFREE-TEMPT1_LEADFREE)/(float)(TIMET2_LEADFREE-TIMET1_LEADFREE))));
  else if (currTime < TIMET3_LEADFREE)
    return (TEMPT2_LEADFREE + ((double)(currTime-TIMET2_LEADFREE) * ((TEMPT3_LEADFREE-TEMPT2_LEADFREE)/(float)(TIMET3_LEADFREE-TIMET2_LEADFREE))));
  else if (currTime < TIMET4_LEADFREE)
    return (TEMPT3_LEADFREE);
  return (TEMPT5_LEADFREE); // off
}

Mechanicals

OLED

Layout

Calibration

Lead Solder Profile

Lead-free Solder Profile

Lead Free

On Bake Setting - Manual Control - Heat/Cool

Temp set to 450 deg F
Ran oven until thermostat kicked in then shut off

Observations - Leaded Profile vs Manual Oven

Feature	Lead Solder	Oven (Bake-Manual)	Notes
Ramp Up	< 1.8 deg C/sec	2.2 deg C/sec max	(1)
Soak Temps	150-180 deg C		
Soak Time (L)	30-60 secs	~15 secs	(2)
Ramp to Peak	~1 deg C/sec	1 deg C/sec	
Peak soak	210-224 deg C		
Ramp-down Rate

Peak is a bit too fast but average is right on
Soak time needs to be extended 2x-4x the time

Observations - Lead-Free Profile vs Manual Oven

Feature	Lead-Free	Oven (Bake-Manual)	Notes
Ramp Up	1-4 deg C/sec	2.2 deg C/sec max	(1)
Soak Temps	150-200 deg C		
Soak Time (LF)	60-180 secs	< 30 secs	(2)
Ramp to Peak	1-4 deg C/sec	1.5 deg C/sec	
Peak soak	245-260 deg C	290 max	(3)
Ramp-down Rate	1-6 deg C/sec max	1 deg C/sec

Soak time needs to be extended 2x-4x the time
Max temp should be controlled and oven left at highest temp due to hysteresis of the thermostat (pretty wide range)

Table - Bake Setting

Time (secs)	Temp (deg C)	Slope (degC/sec)
0	25.75	
30	44	0.61
60	87	1.43
90	153	2.20
120	206	1.77
150	245	1.30
180	272	0.90
210	290	0.60
240	276	-0.47
270	264	-0.40
300	234	-1.00
330	213	-0.70
360	196	-0.57
390	183	-0.43
420	171	-0.40
450	162	-0.30
480	154	-0.27
510	147	-0.23
540	141	-0.20
570	134	-0.23
600	128	-0.20
630	123	-0.17
660	119	-0.13

Links

Good video on How-To

Assembly Sheet

IReflow Assembly Sheet

@@ Line 1: / Line 1: @@
-Reflow Oven Controller
+== Reflow Oven Controller ==
-IReflow-MyMenu-P1010248-640px.jpg
+[[File:IReflow-MyMenu-P1010248-640px.jpg]]
 Image shows top of iReflow and rear of MyMenu card
-Features
+== Features ==
-IR Oven controller
-Lead free profile
+* IR Oven controller
-Lead profile
+** Lead free profile
-Type K thermocouple
+** Lead profile
-Connection via screw terminal block
+* Type K thermocouple
-ATMega328 Microprocessor
+** Connection via screw terminal block
-Arduino compatible
+* ATMega328 Microprocessor
-MHz
+** Arduino compatible
-FTDI connector for serial USB
+** 16 MHz
-ISP connector
+* FTDI connector for serial USB
-Buzzer to indicate done
+* ISP connector
-I2C
+* Buzzer to indicate done
-MyMenu - OLED plus buttons
+* I2C
-LEDs
+** MyMenu - OLED plus buttons
-Supports external SSR
+* 2 LEDs
-x49mm form factor
+* Supports external SSR
--40 mounting holes spaced 41mm apart
+* 49x49mm form factor
-Parts
+* 4-40 mounting holes spaced 41mm apart
-Solid State Relay SSR-25DA 25A /250V 3-32VDC for PID Temperature Controller TE
-Welding Blanket - To over the insides
+== Parts ==
-Toaster
-Oster 6-Slice Toaster Oven, Silver tssttvdfl2
+* [https://web.archive.org/web/20190526035423/http://www.ebay.com/sch/i.html?_odkw=25A%2F250V+SSR+White+Solid+State+Relay&_osacat=0&_from=R40&_trksid=p2045573.m570.l1313.TR0.TRC0.H0.TRS0&_nkw=25A%2F250V+SSR+Solid+State+Relay&_sacat=0 Solid State Relay SSR-25DA 25A /250V 3-32VDC for PID Temperature Controller TE]
-Watts, 12 Amps
+* [https://web.archive.org/web/20190526035423/http://www.harborfreight.com/4-ft-x-6-ft-fiberglass-welding-blanket-67833.html Welding Blanket] - To over the insides
-Oster-TSSTTVDFL2-1-512px.jpg
+== Toaster ==
+* [https://web.archive.org/web/20190526035423/http://www.oster.com/toasters-and-ovens/toaster-ovens/oster-designed-for-life-6-slice-toaster-oven-silver/TSSTTVDFL2.html Oster 6-Slice Toaster Oven, Silver tssttvdfl2]
+** 1440 Watts, 12 Amps
+[[File:Oster-TSSTTVDFL2-1-512px.jpg]]
 Reflow toaster oven conclusions:
-This more expensive oven with 4 elements has more than enough power to meet the most demanding temperature slopes and ranges for reflow soldering of both lead-free and leaded solders.
+# This more expensive oven with 4 elements has more than enough power to meet the most demanding temperature slopes and ranges for reflow soldering of both lead-free and leaded solders.
-The oven has too much power due to the 4 elements to be run on manual without heating too quickly. The soak zone in the cycle requires a dwell for about 2x-4x the time that the oven would produce under manual control.
+# The oven has too much power due to the 4 elements to be run on manual without heating too quickly. The soak zone in the cycle requires a dwell for about 2x-4x the time that the oven would produce under manual control.
-The oven high temp thermostat has quite a bit of hysteresis but the high temperature is above the temperatures for both profiles. Set the oven to highest temp and control it.
+# The oven high temp thermostat has quite a bit of hysteresis but the high temperature is above the temperatures for both profiles. Set the oven to highest temp and control it.
-Probably doesn't need PID control although it would be cooler if it was.
+# Probably doesn't need PID control although it would be cooler if it was.
-Definitely need PTouch labels on the door for contaminants "Don't cook food in here" and for heat "Gets hot to touch".
+# Definitely need PTouch labels on the door for contaminants "Don't cook food in here" and for heat "Gets hot to touch".
-Connectors
-J1 - 9V DC Power Jack
+== Connectors ==
-Center = +9VDC (nominal)
-Shield = GND
+=== J1 - 9V DC Power Jack ===
-J2 - Solid State Relay
-Driven by transistor to ground
+* Center = +9VDC (nominal)
-+5V
+* Shield = GND
-SSR-Output
-J3 - FTDI
+=== J2 - Solid State Relay ===
-GND
-GND
+* Driven by transistor to ground
-+5V
-TxD
+# +5V
-RxD
+# SSR-Output
-Reset
-J4 - I2C OLED
+=== J3 - FTDI ===
-+5V
-GND
+# GND
-SCL
+# GND
-SDA
+# +5V
-J5 - Thermocouple
+# TxD
-Thermo + = Yellow
+# RxD
-Thermo - = Red
+# Reset
-J6 - ISP Download cable
-MISO
+=== J4 - I2C OLED ===
-+5V (+ marked on PWB)
-SCK
+# +5V
-MOSI
+# GND
-RESET
+# SCL
-GND
+# SDA
-J7 - Keypad
-N/A with MyMenu card
+=== J5 - Thermocouple ===
-GND
-VCC
+# Thermo + = Yellow
-SW5WAY - Analog
+# Thermo - = Red
-Programming
-Card Driver
+=== J6 - ISP Download cable ===
-IReflow - Arduino Card Driver - on GitHub
-IReflow - Example Code
+# MISO
-Fixing the Device Signature Error in the Arduino IDE
+# +5V (+ marked on PWB)
-The SMT ATMega328P-AU part has a different signature than the UNO.
+# SCK
-When you try to program the IReflow card using Arduino Uno as the board type you get an error
+# MOSI
+# RESET
+# GND
+=== J7 - Keypad ===
+* N/A with MyMenu card
+# GND
+# VCC
+# SW5WAY - Analog
+== Programming ==
+=== Card Driver ===
+* [https://github.com/douggilliland/lb-Arduino-Code/tree/master/libraries/LandBoards_IReflow IReflow - Arduino Card Driver - on GitHub]
+* [https://github.com/douggilliland/lb-Arduino-Code/tree/master/libraries/LandBoards_IReflow/examples IReflow - Example Code]
+=== Fixing the Device Signature Error in the Arduino IDE ===
+* The SMT ATMega328P-AU part has a different signature than the UNO.
+* When you try to program the IReflow card using Arduino Uno as the board type you get an error
+<pre>
 avrdude: Expected signature for ATmega328P is 1E 95 0F
           Double check chip, or use -F to override this check.
 Wrong microcontroller found.  Did you select the right board from the Tools > Board menu?
-The Arduino IDE needs avrdude.conf changed to program the AU part
+</pre>
-In earlier versions of the Arduino IDE finding the avrdude.conf file was relatively straightforward
+* The Arduino IDE needs avrdude.conf changed to program the AU part
-From Programming the Atmega328 - AU in Arduino
+* In earlier versions of the Arduino IDE finding the avrdude.conf file was relatively straightforward
-Correct Signature = 0x1e 0x95 0x14;
+** From Programming the Atmega328 - AU in Arduino
-Keep old copy too.
+* Correct Signature = 0x1e 0x95 0x14;
-In Arduino IDE 1.6.2 the avrdude.conf file is in a different location
+* Keep old copy too.
-Ard1p6.PNG
+* In Arduino IDE 1.6.2 the avrdude.conf file is in a different location
-Changing it here doesn't work since it's located in a roaming directory at least for Windows 8.1
+[[File:Ard1p6.PNG]]
-C:\Program Files (x86)\Arduino\dist\default_package.zip\packages\arduino\tools\avrdude\6.0.1-arduino2\etc
-Other OS versions may be different
-Locate the avrdude.conf file
-On my computer it is at: C:\Users\doug_000\AppData\Roaming\Arduino15\packages\arduino\tools\avrdude\6.0.1-arduino2\etc
-Find it by turning on verbose download in the IDE
-Atmega328-menu.PNG
-The path will be shown in the output
+* Changing it here doesn't work since it's located in a roaming directory at least for Windows 8.1
-Atmega328-avdude-conf-path.PNG
+** C:\Program Files (x86)\Arduino\dist\default_package.zip\packages\arduino\tools\avrdude\6.0.1-arduino2\etc
+* Other OS versions may be different
+* Locate the avrdude.conf file
+** On my computer it is at: C:\Users\doug_000\AppData\Roaming\Arduino15\packages\arduino\tools\avrdude\6.0.1-arduino2\etc
+* Find it by turning on verbose download in the IDE
-Edit avrdude.conf
+[[File:Atmega328-menu.PNG]]
-Find the string
+* The path will be shown in the output
+[[File:Atmega328-avdude-conf-path.PNG]]
+==== Edit avrdude.conf ====
+* Find the string
+<pre>
 part parent "m328"
-It should look like
+</pre>
-Atmega328-avdude-conf-fuses-orig.PNG
+* It should look like
-Change to
+[[File:Atmega328-avdude-conf-fuses-orig.PNG]]
-Atmega328-avdude-conf-fuses-au-version.PNG
-u8g OLED library
+* Change to
-Ireflow-OLED-640px.jpg
-Library notes
+[[File:Atmega328-avdude-conf-fuses-au-version.PNG]]
-Display characters/variables:
-Use u8g.print (xx) function, just like the way you did with Serial.print (xx).
+=== u8g OLED library ===
-Change the font：
-Use u8g.setFont (xx) function to change the font, parentheses "xx" can be replaced by the corresponding font library name (you can search font library in u8g.h within U8glib \utility folder);
+[[File:Ireflow-OLED-640px.jpg]]
-Large font is recommended for u8g_font_7x13, middle font for u8g_font_fixed_v0r and small font for u8g_font_chikitar;
-Change coordinates:
+* Library notes
-Use u8g.setPrintPos (x, y) function to change the display of coordinates
+** Display characters/variables:
-fonts
+*** Use u8g.print (xx) function, just like the way you did with Serial.print (xx).
-HelloWorld
+** Change the font：
-Uncomment
+*** Use u8g.setFont (xx) function to change the font, parentheses "xx" can be replaced by the corresponding font library name (you can search font library in u8g.h within U8glib \utility folder);
+*** Large font is recommended for u8g_font_7x13, middle font for u8g_font_fixed_v0r and small font for u8g_font_chikitar;
+** Change coordinates:
+*** Use u8g.setPrintPos (x, y) function to change the display of coordinates
+* fonts
+* HelloWorld
+** Uncomment
+<pre>
 U8GLIB_SH1106_128X64 u8g(U8G_I2C_OPT_NO_ACK);	// Display which does not send ACK
-MAX31855 Thermocouple Amplifier
+</pre>
-Adafruit Thermocouple Amplifier MAX31855 breakout board (MAX6675 upgrade) - v2.0
-Adafruit Thermocouple tutorial
+=== MAX31855 Thermocouple Amplifier ===
-MAX31855 Arduino library code
-Other
+* Adafruit Thermocouple Amplifier MAX31855 breakout board (MAX6675 upgrade) - v2.0
-LiPo Battery Care
+* Adafruit Thermocouple tutorial
-Algorithm
+* MAX31855 Arduino library code
+=== Other ===
+* LiPo Battery Care
+=== Algorithm ===
 Piece-wise Linear
+<pre>
 #define TIME0_LEADFREE 0
 #define TIMET1_LEADFREE 120
@@ Line 159: / Line 206: @@
    return (TEMPT5_LEADFREE); // off
 }
-Mechanicals
+</pre>
-OLED
-OLED Mechanicals 30654-6.jpg
+== Mechanicals ==
+=== OLED ===
+[[File:OLED Mechanicals 30654-6.jpg]]
+=== Layout ===
+[[File:IReflow-CAD.PNG]]
+== Calibration ==
+=== Lead Solder Profile ===
+[[File:KesterSnPbCurve.PNG]]
+=== Lead-free Solder Profile ===
-Layout
+[https://web.archive.org/web/20190526035423/http://www.aosmd.com/res/application_notes/package/Soldering_Profiles.pdf Lead Free]
-IReflow-CAD.PNG
-Calibration
+[[File:LeadFreeProfile.PNG]]
-Lead Solder Profile
-KesterSnPbCurve.PNG
-Lead-free Solder Profile
+[[File:LeadFreeProfileParms.PNG]]
-Lead Free
-LeadFreeProfile.PNG
+=== On Bake Setting - Manual Control - Heat/Cool ===
-LeadFreeProfileParms.PNG
+* Temp set to 450 deg F
+* Ran oven until thermostat kicked in then shut off
-On Bake Setting - Manual Control - Heat/Cool
+[[File:ToasterOvenBakeHeatCoolManual.png]]
-Temp set to 450 deg F
-Ran oven until thermostat kicked in then shut off
-ToasterOvenBakeHeatCoolManual.png
-Observations - Leaded Profile vs Manual Oven
+=== Observations - Leaded Profile vs Manual Oven ===
+<pre>
 Feature	Lead Solder	Oven (Bake-Manual)	Notes
 Ramp Up	< 1.8 deg C/sec	2.2 deg C/sec max	(1)
@@ Line 189: / Line 246: @@
 Ramp to Peak	~1 deg C/sec	1 deg C/sec
 Peak soak	210-224 deg C
 Ramp-down Rate
-Peak is a bit too fast but average is right on
+</pre>
-Soak time needs to be extended 2x-4x the time
-Observations - Lead-Free Profile vs Manual Oven
+# Peak is a bit too fast but average is right on
+# Soak time needs to be extended 2x-4x the time
+=== Observations - Lead-Free Profile vs Manual Oven ===
+<pre>
 Feature	Lead-Free	Oven (Bake-Manual)	Notes
 Ramp Up	1-4 deg C/sec	2.2 deg C/sec max	(1)
@@ Line 200: / Line 261: @@
 Peak soak	245-260 deg C	290 max	(3)
 Ramp-down Rate	1-6 deg C/sec max	1 deg C/sec
-Soak time needs to be extended 2x-4x the time
+</pre>
-Max temp should be controlled and oven left at highest temp due to hysteresis of the thermostat (pretty wide range)
-Table - Bake Setting
+# Soak time needs to be extended 2x-4x the time
+# Max temp should be controlled and oven left at highest temp due to hysteresis of the thermostat (pretty wide range)
+=== Table - Bake Setting ===
+<pre>
 Time (secs)	Temp (deg C)	Slope (degC/sec)
 	25.75
@@ Line 227: / Line 292: @@
 	123	-0.17
 	119	-0.13
-Links
+</pre>
-Good video on How-To
-Assembly Sheet
+== Links ==
-IReflow Assembly Sheet
+* [https://youtu.be/rZyP5G4Wfm0 Good video on How-To]
+== Assembly Sheet ==
+[[IReflow Assembly Sheet]]

Difference between revisions of "IReflow"

Latest revision as of 18:51, 10 January 2020

Contents

Reflow Oven Controller

Features

Parts

Toaster

Connectors

J1 - 9V DC Power Jack

J2 - Solid State Relay

J3 - FTDI

J4 - I2C OLED

J5 - Thermocouple

J6 - ISP Download cable

J7 - Keypad

Programming

Card Driver

Fixing the Device Signature Error in the Arduino IDE

Edit avrdude.conf

u8g OLED library

MAX31855 Thermocouple Amplifier

Other

Algorithm

Mechanicals

OLED

Layout

Calibration

Lead Solder Profile

Lead-free Solder Profile

On Bake Setting - Manual Control - Heat/Cool

Observations - Leaded Profile vs Manual Oven

Observations - Lead-Free Profile vs Manual Oven

Table - Bake Setting

Links

Assembly Sheet

Navigation menu

Search