instructables

DIY SMD REWORK STATION.

by Maker BR

In this Instructable you can learn how to make a hot
air gun controller using Arduino and other common
components. In this project, PID algorithm is used to
calculate the power required and is controlled by a
isolated Triac driver.
has a K-type thermocouple, 700 watt 230 VAC heater
and a 24 VDC fan.
This controller is efficient and reliable compared to
the commercial one and is easy to build.

this project uses a handle compatible with 858D, it

https://youtu.be/L9gvOLftHnM

Step 1: Gather the Parts.

DIY SMD REWORK STATION.: Page 1

Here is the part list and link from where you can order > Arduino Pro Mini
them.
>1602 LCD + I2C module
1. Modules and Boards :
>Rotary encoder with push button

2. Tools : >0.1uF CAPACITOR : https://lcsc.com/product-detail/

CBB-Capacitors_PAN...
>Hot Air Gun Handle : https://www.banggood.in/700
W-Hot-Air-Gun-Handle-fo... >10nF CAPACITOR : https://lcsc.com/product-detail/
Polyester-Film-Cap...
>Hot Air Gun Handle Holder + Nozzle : https://www.b
anggood.in/Hot-Air-Gun-Handle-Bracket... 6.Resistors:

3.Semi-Conductor devices : >200K TRIM POT : https://lcsc.com/product-detail/Pr

ecision-Potentio...
>BTA12-600B Triac: https://lcsc.com/product-detail/T
hyristors-TRIACs_... >100K RESISTOR : https://lcsc.com/product-detail/C
arbon-Film-Resist...
>IRFZ44 MOSFET : https://lcsc.com/product-detail/M
OSFET_IR_IRFZ44NP... >47K RESISTOR : https://lcsc.com/product-detail/Car
bon-Film-Resist...
>MCP602 OPAMP : https://lcsc.com/product-detail/G
eneral-Purpose-Am... >10K RESISTOR : https://lcsc.com/product-detail/Car
bon-Film-Resist...
>MOC3021 DIAC : https://lcsc.com/product-detail/Tri
ac-Optocouplers... >1K RESISTOR : https://lcsc.com/product-detail/Carb
on-Film-Resist...
>4N25 OPTOCOUPLER : https://lcsc.com/product-de
tail/DIP-Optocouplers_4... >470E RESISTOR : https://lcsc.com/product-detail/C
arbon-Film-Resist...
>BRIDGE RECTIFIER : https://lcsc.com/product-deta
il/Bridge-Rectifiers_... >330E RESISTOR : https://lcsc.com/product-detail/C
arbon-Film-Resist...
>UF4007 DIODE : https://lcsc.com/product-detail/Dio
des-Rectifiers-... >220E RESISTOR : https://lcsc.com/product-detail/C
arbon-Film-Resist...
4.Connectors :
>39E RESISTOR : https://lcsc.com/product-detail/Car
>4-PIN CONNECTOR : https://lcsc.com/product-detai bon-Film-Resist...
l/_Boom-Precision-El...
others:
>3-PIN CONNECTOR : https://lcsc.com/product-detai
l/XH-Connectors_Shen... Buzzer : https://lcsc.com/product-detail/Buzzers_HM
B1206-0...
>2-PIN CONNECTOR : https://lcsc.com/product-detai
l/_Boom-Precision-El...

>2-PIN BIG CONNECTOR : https://lcsc.com/product-

detail/CH-Connectors_CH3-...
DIY SMD REWORK STATION.: Page 2
Female Headers : https://lcsc.com/product-detail/_Bo
om-Precision-E...

5.Capacitors:

DIY SMD REWORK STATION.: Page 3

DIY SMD REWORK STATION.: Page 4
Step 2: Wiring
The following modification should be made to the
arduino pro mini to use it. Since, the I2C pins of
arduino A4 and A5 are not PCB friendly. The pins A4
to A2 and A5 to A3 should be shorted as in the
picture.
Wiring for I2C LCD module:
I2C Module<--------------> Arduino Pro Mini
GND<----------------------->GND<--------->GND
VCC<------------------------>VCC<--------->5V
SDA<------------------------>A2<------------>A4
SCL<------------------------>A3<------------>A5.
Wiring for Rotary encoder module:
Encoder<---------------------->Arduino
GND<--------------------------->GND
+<-------------------------------->NC(Not Connected, code
uses inbuilt input pull-up of arduino)
SW<----------------------------->D5
DT<------------------------------>D3
DIY SMD REWORK STATION.: Page 5
CLK<---------------------------->D4.
Wiring of Handle:(7 wire)
3pin connector - (Green, Black, Red)
Red wire<----------------------->Thermocouple +
Green wire<-------------------->Reed Switch
Black wire<--------------------->Common ground.
2 pin connector - (Blue, Yellow)
Blue wire<--------------------------> Fan +0
Yellow wire<------------------------>Fan - (or GND)
2 Big pin connector -(White, Brown)
White wire<-----------------------> Heater
Brown wire<----------------------> Heater(no polarity)
NOTE :
Thewiring of the hot air gun handle may be different
for different type of wands. So, refer to the wiring
diagram in the photo and follow the path of the wire to
find the respective pins.
Step 3: Circuit Diagram
The circuit consists of 3 parts mainly.
The Interface Part :
It consists of a 1602 LCD display with I2C module
and a rotary encoder with push button. The display
shows the set temperature, current temperature, Fan
speed and applied power and current status of the
handle. The encoder is used for various inputs and to
navigate through the options and controls.
The Sensor Part :
It consists of a K-type thermocouple for temperature
sensing and a reed switch for determining the
position of the handle. The thermocouple's voltage is
Step 4: PCB
The circuit of this project is a bit complicated, So I
recommend you to use a printed board than a dot
PCB. If you want to make your own PCB I have
attached the eagle files in this step. But, If you want
to get them done by a PCB manufacturing company
DIY SMD REWORK STATION.: Page 6
amplified by the op-amp to a voltage level
measurable by the arduino. The gain of the op-amp is
controlled by 200K trim pot.
The Controller Part :
There are mainly 2 controllers in this circuit. The one
is a simple PWM Fan speed controller with a
MOSFET. The other one is a isolated controller for
heater. It consists of a TRIAC driven by a opto-
coupled DIAC and it is done by controlling the
number of wave cycles that is delivered to the heater.
The 4N25 optocoupler helps to maintain the sync with
the AC waveform.
you can order it from JLCPCB
. You can view the Easy EDA design through this link
: https://easyeda.com/ManojBR/harws1-1
 Download
https://www.instructables.com/ORIG/FJ9/HMTL/JO4NHNCF/FJ9HMTLJO4NHNCF.sch
…

Download
https://www.instructables.com/ORIG/FTC/JWKK/JO4NHNCH/FTCJWKKJO4NHNCH.brd
…

DIY SMD REWORK STATION.: Page 7

Step 5: The Code and Libraries.

The program is the most crucial part of the project
and thanks a lot for sfrwmaker writing the program.
The program uses PID algorithm to control the power
to maintain the set temperature. It works by
controlling the number of wave cycles delivered to the
handle per second.
When the controller is turned on the wand will be in
OFF state. By rotating the encoder the temperature
and fan speed can be adjusted. Short press of the
encoder will switch between the Fan speed and Set
temperature adjustment.
The Hot air gun starts heating as soon as it is lifted up
from the holder and shows Ready and make a short
beep when it reaches the set temperature. It will turn
off heating as soon as it is put back into the holder.
But, the fan will continue to blow until it reaches the
safe temperature. After the temperature falls below 50
C it will make a short beep and displays COLD.
When the hot air gun is off, the controller will enter
Setup mode if the encoder is long pressed.
The setup mode has Calibrate, Tune, Save and
Cancel and Reset Config options.
Note: If you are using PCB from easyEDA then you
should change the pin number of reed switch to pin
no. 8 and Buzzer pin to pin no.6
you have to install the Commoncontrols-master
library andtime-master library for the code to work
properly.
go to this GitHub repository to download all the files
in one zip file: https://github.com/ManojBR105/ARDUI
NO-SMD-REWORK-S...

DIY SMD REWORK STATION.: Page 8

 Download
https://www.instructables.com/ORIG/FP9/JS21/JO4NHNIY/FP9JS21JO4NHNIY.ino
…

Download
https://www.instructables.com/ORIG/FPW/QV33/JO8Y8FMY/FPWQV33JO8Y8FMY.rar
…

Download
https://www.instructables.com/ORIG/FLP/PZQ9/JO8Y8FN1/FLPPZQ9JO8Y8FN1.zip
…

Step 6: SETUP

The temperature readings should be calibrated with
the original value to get reasonable readings. So, in
order to do that you should follow the following steps.
First, go to the setup mode and select the Tune
option.In the tune mode the internal temperature (0-
1023) is displayed on the screen.Rotate the encoder
to manually select the applied power to the hot air
gun. Heat the gun to 400 degrees.When the
temperature and dispersion become low, the
controller beeps. Then tune the trim-pot to set the
internal temperature about 900 (in the internal units).
Long press to the encoder return to the menu
Then, go to the setup mode select Calibrate option.
Choose the calibration point: 200, 300 or 400
degrees, press the encoder. The hot gun will reach
the desired temperature and beeps. By rotating the
encoder, enter the real temperature. Then select
another reference point and repeat this process for all
the calibration point.
After this long press and come to main screen and
then again go to Setup mode and select save.
And now the Hot air rework station is done.

DIY SMD REWORK STATION.: Page 9

Step 7: Finished Project:
For power supply, I have used Hi-link 230 VAC - 5
VDC 3 watt isolated power supply module and for 24
VDC have used 12-0-12 500 mA transformer by
connecting the 12 VAC end to a bridge rectifier and
center tapped is left unconnected. Then the rectified
output is fed to a filtering capacitor and then to
LM7824 voltage regulator IC. The output of the IC is
the regulated 24 VDC.
Thank you sfrwmaker for writing the code, Checkout
the other projects by sfrwmaker: https://www.instructa
bles.com/member/sfrwmaker/
Thanks to LCSC for their support. LCSC Electronics
DIY SMD REWORK STATION.: Page 10
is one of the fastest growing suppliers of electronic
components in China. LCSC has been committed to
offering multitudinous, genuine and in-stock items,
since its founding in 2011. Aiming to provide the
whole world with more superior parts from Asia. More
details please visit: https://lcsc.com/
If you have to make your own PCB at home,
checkout this instructable: https://www.instructables.c
om/id/PCB-Making-1/
Thank you.
Hi ! Can you please help me with this problem. I can control the fan speed but it displays a
message " -== Failed ==- ". I used tlc272 ic because i don't know where to buy the mcp ic.
Can you help troubleshoot this problem. Thank you :).
If you have not connected 220v it will show failed error.
Check if the zero cross detector circuit of yours is functioning properly or not.
Thank you fixed it. Can you tell me whats the optimal trimpot value. I have 220k

How did you make the calculations for the resistors before 4N25?

Can you give us more details about heater controller ?

Hardware or software details?

About the wave cycles and the sync with the AC from the plug

br..de brasil?

Sorry, No!

I had to replace the LiquidCrystalDisplay_I2c library with the hd44780_I2Cexp library. Luckily it
was seamless. Unfortunately, I've spent hours trying to troubleshoot the sketch, only to find the
library that fixed it
I did it!!!!!!!!!!!!!! The reed switch isnt deactivating when I take it away from the magnet, for some
reason.... but it's working!!!!! I will have to read your tune and calibration instructions again. Still
figuring out how to set it. What does the 200k precision potentiometer do?
The 200 k pot adjusts the gain of the op-amp which is used to read the temperature. By adjusting
the this potentiometer, you will have to make the actual temperature equal to read temperature by
the controller. You can use external thermometer to measure the actual temperature of the hot air
gun.
Got it. Thanks. I fixed the reed switch situation and now just trying to find an external thermometer
to tune and calibrate it. Thank you for a great instructable
Thanks Maker BR. It works nicely. I've just gotta practise

Glad! To hear.

DIY SMD REWORK STATION.: Page 11