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Expand Up @@ -8,8 +8,10 @@ Interested in purchasing an AxxSolder 3.1? On [Tindie](https://www.tindie.com/st
<a href="https://www.tindie.com/stores/axxaxx/?ref=offsite_badges&utm_source=sellers_AxxAxx&utm_medium=badges&utm_campaign=badge_medium"><img src="https://d2ss6ovg47m0r5.cloudfront.net/badges/tindie-mediums.png" alt="I sell on Tindie" width="150" height="78"></a>

# AxxSolder Overview
AxxSolder is a STM32 based soldering iron controller for JBC C115, C210 and C245 cartridges.
Two different versions are designed around the same PCB and software - one soldering station based on the [JBC ADS stand](https://www.jbctools.com/ad-sf-stand-for-t210-t245-handles-product-2018.html) and one portable version. The hardware takes a DC input source of 9-24V OR a USB-C Power Delivery source. The recommended power supply is a Meanwell [LRS-150-24](#recommended-power-supply) which can power all compatible JBC irons at full power. If a 65W, 20V USB-PD supply is used then NT115 and T210 handles can be powered at full power and T245 at limited power. The power limiting is automatic and AxxSolder reads the power capability of the USB-PD source and reduces output power accordingly. The software is written for the [STM32G431CBT6](https://www.st.com/en/microcontrollers-microprocessors/stm32g431cb.html) and implements a PID for temperature control, TFT display driver, sleep function when the handle is at rest and functions for read/write user settings to flash to name a few. Enclosures for both station and portable versions are 3D printed and design files are available under [/CAD](https://github.com/AxxAxx/AxxSolder/tree/main/CAD). A video showing the AxxSolder station can be found under [DEMO](#demo). A *bill of materials* (BOM) with individual component prices can be found under [/bom](https://github.com/AxxAxx/AxxSolder/tree/main/AxxSolder_hardware/bom).
AxxSolder is a STM32 based soldering iron controller for JBC C115, C210 and C245 style cartridges.
Two different versions are designed around the same PCB and software - one soldering station based on the [JBC ADS stand](https://www.jbctools.com/ad-sf-stand-for-t210-t245-handles-product-2018.html) and one portable version. The AxxSodler hardware takes a DC input source of 9-24V OR a USB-C Power Delivery source. The recommended power supply is a Meanwell [LRS-150-24](#recommended-power-supply) which can power all compatible JBC irons at full power. If a 65W, 20V USB-PD supply is used then NT115 and T210 handles can be powered at full power and T245 at limited power. The power limiting is automatic and AxxSolder reads the power capability of the USB-PD source during the negotiating phase and reduces the output power accordingly.
The software is written for the [STM32G431CBT6](https://www.st.com/en/microcontrollers-microprocessors/stm32g431cb.html) and implements a PID controller for temperature regulation, TFT display driver, sleep functions for when the handle is at rest and various user settings to name a few.
Enclosures for both station and portable versions are 3D printed and design files are available under [/CAD](https://github.com/AxxAxx/AxxSolder/tree/main/CAD). A video showing the AxxSolder station can be found under [DEMO](#demo). A *bill of materials* (BOM) with individual component prices can be found under [/bom](https://github.com/AxxAxx/AxxSolder/tree/main/AxxSolder_hardware/bom).
![coverphoto](./photos/AxxSolder_cover.jpg)

# Questions and support
Expand All @@ -25,7 +27,7 @@ Please use [Discord](https://discord.gg/AwpHEmsyKj) for build related and genera
- [Software Version History and Hardware Compatibility](#software-version-history-and-hardware-compatibility)
- [AxxSolder Station](#axxsolder-station)
- [AxxSolder Portable](#axxsolder-portable)
- [Recommended power supply](#recommended-power-supply)
- [Recommended power supply for tip grounding](#recommended-power-supply-for-tip-grounding)
- [Handle identification and connections](#handle-identification-and-connections)
- [Firmware update](#firmware-update)
- [First start up after build](#first-start-up-after-build)
Expand All @@ -39,11 +41,11 @@ Please use [Discord](https://discord.gg/AwpHEmsyKj) for build related and genera

# Features
- The tip temperature is set by a rotary encoder. Pressing the encoder puts AxxSolder into Sleep mode and heating is turned off, press again to wake up.
- AxxSolder is capable of driving C115, C210 and C245 style cartridges from JBC. With the "H_sense1" and "H_sense2" inputs AxxSolder can determine if the connected handle is either a NT115, T210 or T245 and adjust max output power accordingly. The max power output is limited in software to 130 W for T245, 65 W for T210 and 22 W for NT115 handles.
- When the handle is put into the stand (connected to Stand_sense) AxxSolder goes into "Standby mode". On the portable version an aluminium plate is mounted and allows the AxxSolder to go into Standby mode when the cartridge or handle rests against it. After 10 min in Standby mode AxxSolder goes into "Sleep mode" and turns heating completely off. This is similar to what JBC calls [Sleep and Hibernation](https://www.jbctools.com/intelligent-heat-management.html).
- AxxSolder is capable of driving C115, C210 and C245 style cartridges from JBC. With two handle sense inputs AxxSolder can determine if the connected handle is either a NT115, T210 or T245 and adjust max output power accordingly. The max output power is software limited to 130 W for T245, 65 W for T210 and 22 W for NT115 handles.
- When the handle is put into the stand (connected to Stand_sense) AxxSolder goes into "Standby mode". On the portable version an aluminium plate is mounted in the case and allows the AxxSolder to go into Standby mode when the cartridge or handle rests against it. After 10 min in Standby mode AxxSolder goes into "Sleep mode" and heating is completely turned off. This is similar to what JBC calls [Sleep and Hibernation](https://www.jbctools.com/intelligent-heat-management.html).
- If AxxSolder is left in normal running mode for longer than 30 min, the station automatically goes into sleep mode after 30 min as a safety feature.
- Should the temperature ever go higher than 480 deg C overheating is detected and the station goes into sleep mode in order to protect the tip.
- At start-up any USB-PD source is detected and the highest possible power is negotiated. AxxSolder limits the soldering iron output power to the max output power of the USB-PD source automatically.
- At start-up any USB-PD source is detected and the highest possible power is negotiated. AxxSolder limits the soldering iron output power to the max output power of the USB-PD source automatically. The maximum power output is displayed at the top of the power bar graph on the display.
- User settings are stored in non-volatile flash and can be configured via a settings menu described in [SETTINGS](#settings).
- The two buttons are used to store temperature presets, e.g. 330 deg C and 430 deg C. Both preset temperatures are configurable in the settings menu.
- There is a 3.3 V logic level output (GPIO4) that can be configured to go high when the iron is in Run mode, controlling e.g. fume extractor via a MosFET or relay.
Expand All @@ -68,7 +70,7 @@ The schematic for AxxSolder is shown below. Both station and portable versions u
![AxxSolder_station](./photos/AxxSolder_Schematic.png)

# PCB
The PCBs are designed in KiCad and manufactured by [PCBWay](https://www.pcbway.com/). PCBWay has sponsored this project with PCBs and stencils. As usual the quality of the PCBs is great. As some components have a rather fine pitch (0,5 mm as of the LQFP-48 package of the STM32) and some packages are "no lead" with a bottom thermal pad e.g. the WSON-8 package of the OPA2387 it is suggested to use a stencil to apply solder paste and then reflow the board using either a reflow oven or hot-plate. The boards on the image below were reflowed on a hot-plate (a homemade AxxPlate). A microscope is also recommended and helpful during assembly.
The PCBs are designed in KiCad and manufactured by [PCBWay](https://www.pcbway.com/). PCBWay has sponsored this project with PCBs and stencils. The support and quality from PCBWay is great and therefore PCBWay is the recommender PCB supplier for this project. As some components have a rather fine pitch (0,5 mm as of the LQFP-48 package of the STM32) and some packages are "no lead" with a bottom thermal pad e.g. the WSON-8 package of the OPA2387 it is recommended to use a stencil to apply solder paste and then reflow the board using either a reflow oven or hot-plate. The boards on the image below were reflowed on a hot-plate (a homemade AxxPlate). A microscope is also recommended and helpful during assembly.
Printed Circuit Boards with assembled components are shown in the image below.
![PCB_image](./photos/PCB_image.jpg)
A 3D view (from and back) of the AxxSolder PCB is generated with KiCad and shown below.
Expand Down Expand Up @@ -99,15 +101,20 @@ The preferred setup is to pair AxxSolder with the [JBC ADS stand](https://www.jb
The JBC ADS stand comes with a silicone cable fitted with two Binder 99-0621-00-07 connectors. In order to use this cable a Binder 99-0624-00-07 is mounted into the AxxSolder enclosure and wired as the image below:
![AxxSolder_station](./photos/Station_connections.jpg)
By default, the stand separates the two signals coming from the "tool rest position" and the "tip change position" and does NOT have two separate connections for tip sensing 1 and 2 as is needed if NT115, T210 and T245 handles should all be automatically detected. Therefore, a modification is done to the PCB inside the JBC ADS stand in order to combine the "tool rest position" and the "tip change position" sense into one connection and separate the two tip sense connections. This is shown in the image above. The stand is held together with two PH0 screws from the side.
NOTE: This modification of the stand is NOT necessary if you know that you will not be using NT115 handles and only require automatic detection of T210 and T245 handles.
NOTE: This modification of the stand is NOT necessary if you know that you will not be using NT115 handles and only require automatic detection of T210 and T245 handles.
The JBC ADS stand is a expensice piece and thankfully there are many alternatives online for the one who wants to save some money. The community on the AxxSolder Discord channel has created many enclosures for alternative stands.

# AxxSolder Portable
It is often nice to have a compact and portable soldering iron controller for when you are away from your comfortable desk. A neat powerful package with the same capabilities as your main soldering station. This is why AxxSolder Portable was designed. The only difference between AxxSolder station and Portable is the enclosure. As AxxSolder accepts an input of 9-24 V it is compatible with a range of battery options. The author usually use a battery pack consisting of 12 Samsung INR18650 35E in a 3S4P configuration which works very well. The portable version has an aluminium tab on the enclosure connected to the same input on the PCB as the "handle rest" on the station version. This allows the user to rest the iron onto the aluminium tab and automatically enter sleep mode.
It is often nice to have a compact and portable soldering iron controller for when you are away from your comfortable desk. A neat powerful package with the same capabilities as your main soldering station. This is why AxxSolder Portable was designed. The only difference between AxxSolder station and Portable is the enclosure.
As AxxSolder accepts an input of 9-24 V it is compatible with a range of battery options. The author usually use a battery pack consisting of 12 Samsung INR18650 35E in a 3S4P configuration which works very well.
The portable version has an aluminium tab on the enclosure connected to the same input on the PCB as the "handle rest" on the station version. This allows the user to rest the iron onto the aluminium tab and automatically enter sleep mode.
![AxxSolder_portable](./photos/AxxSolder_portable.jpg)
The connections from the handle to the PCB through the Hirose RPC1-12RB-6P(71) connector is shown below. The blue wire in the portable version is connected to the aluminium plate which tells the AxxSolder to go into sleep mode when in contact with the soldering iron. The yellow wire is connected to pin 6 and is used to determine which handle is connected.
The connections from the handle to the PCB through the Hirose RPC1-12RB-6P(71) connector is shown below. The Stand_sense in the portable version is connected to the aluminium plate which tells the AxxSolder to go into sleep mode when in contact with the soldering iron.
![AxxSolder_portable](./photos/Portable_connections.jpg)
# Recommended power supply
A well-suited power supply with isolated output (SELV) is the Meanwell LRS-150-24. It is rated for 156 W at 24 V. A cover protecting the terminals for this power supply can be found under [/CAD](https://github.com/AxxAxx/AxxSolder/tree/main/CAD).

# Recommended power supply for tip grounding
A well-suited power supply with isolated output (SELV) is the Meanwell LRS-150-24. It is rated for 156 W at 24 V. By using a power supply with isolated outputs (floating negative terminal) the protective earth connector on AxxSolder can be connected directly to mains earth thus keeping the tip of the soldering iron at earth ground potential. There is a 1A fuse after the earth terminal in paralell with a 1M resistor on the AxxSolder.
A printable cover protecting the terminals of the for LRS-150-24 can be found under [/CAD](https://github.com/AxxAxx/AxxSolder/tree/main/CAD).
![LRS-150-24](./photos/LRS-150-24.jpg)
Another suitable power supply is the Meanwell XLG-150-24 which has a slightly different form factor and is fully enclosed.

Expand Down Expand Up @@ -219,7 +226,7 @@ The PID parameters are adjusted to achieve a fast response with minimum overshoo
![AxxSolder_pid](./photos/PID_TUNING.png)
# Cartridge differences
Cartridges from JBC do all contain a thermocouple element to read the tip temperature and a resistive heater element. The configuration of thermocouple and heater element differ slightly between cartridge models. In order to determine the internal configuration of the cartridges two cross sections were done. These show clearly how the C210 and C245 cartridges are constructed internally. The images can be seen here: [https://www.eevblog.com/forum/projects/axxsolder-jbc-soldering-controller](https://www.eevblog.com/forum/projects/axxsolder-jbc-soldering-controller/msg5124267/#msg5124267).
Cartridges from JBC do all contain a thermocouple element to read the tip temperature and a resistive heater element. The configuration of thermocouple and heater element differ slightly between cartridge models. In order to determine the internal configuration of the cartridges two cross sections were done. These show clearly how the C210 and C245 cartridges are constructed internally. The images can be seen here: [https://www.eevblog.com/forum/projects/axxsolder-jbc-soldering-controller](https://www.eevblog.com/forum/projects/axxsolder-jbc-soldering-controller/msg5124267/#msg5124267).
As the thermocouple output also differs (see my measurements [Temperature calibration](#temperature-calibration)) the correct handle/cartridge type has to be set. This is done automatically be the inputs "Handle_sense_1" and "Handle_sense_2" This can be done thanks to the design of the handle connector. For the JCB T210 handle pin 5 and 6 are connected internally in the connector and for NT115 pin 3 and 5 should be connected. This allows AxxSolder to sense which handle is connected and assign correct thermocouple correction, PID parameters and max output power.
# Temperature calibration
Expand All @@ -233,7 +240,8 @@ These are then used in the software to retrieve correct tip temperatures.
# Temperature measurement
As the thermocouple and heater element is connected in series inside the JBC cartridges and the thermocouple voltage measures over the same pins as the heating element we have to be careful when to do the temperature measurement. In order to not disturb the thermocouple measurement with heater element switching, the switching is turned off for 0.5 ms just before the temperature measurement is taken. The 0.5 ms delay ensures that the switching is turned off and the thermocouple signal is stabilized around a stable voltage.
The measured signal over the thermocouple is clamped to 3.3V with a BAV199 Schottky diode in order to protect the op-amp OPA2387. The voltage measurement is taken by the internal ADC in DMA mode with a circular buffer. The buffer holds several measurements which are averaged and filtered in software.
The yellow curve in the image below (Channel 1) shows the PWM signal driving the gate of the MOSFET. The green curve shows the amplified voltage between GREEN and RED wire in the JBC handle for at 330 degree C and 5% power and the purple 25 degree C and at 80% power (the tip held under water trying to heat up).
The yellow curve in the image below (Channel 1) shows the PWM signal driving the gate of the MOSFET.
The green curve shows the amplified voltage between GREEN and RED wire in the JBC handle for at 330 degree C and 5% power and the purple 25 degree C and at 80% power (the tip held under water trying to heat up).
The blue pulse indicates the wait time of 0.5 ms and the purple pulse is where the ADC is sampled.
![Oscilloscope_image_PWM](./photos/temperature_measurement.png)
# Current measurement
Expand Down

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