1 2 3 4 5 6 7 8

Revision Management

858D++ Hot Air Rework Station REV #

001
Date

YYYY-MM-DD
Approved By

*
Changes (Page title, page number; changes made)

Initial Release

A A
Revision: 1
Date: 29-8-2017
Variant: [No Variations]
Status: Draft

DRAFT!!!! Can (will) contain errors. Copy at own risk!

Table of Contents

1. Cover Page

B 2. Thermocouple amplifier, over-temperature comparator, reed switch comparator B

3. Fan driver and monitor

4. Microcontroller and User Interface

5. Heater Driver, Zero-cross detector, +5V board supply

C C

Design Notes Legend

DESIGN NOTE:
Informational design note

DESIGN NOTE:
Cautionary note

DESIGN NOTE:
Note for debugging and firmware

DESIGN NOTE:
Critical design information

D D

LAYOUT NOTE: (C) 2017 Christean van der Mijden (Heart of Technology) www.heartoftechnology.com
Important PCB layout information

www.heartoftechnology.com
This work is licensed under the Creative Commons
Drawing Title: 858D++ Hot Air Rework Station
LAYOUT NOTE:
Critical PCB layout information Attribution-NonCommercial-ShareAlike 4.0 International
Page Title: Cover Page
License. To view a copy of this license, visit Drawn by: CM Revision Variant
http://creativecommons.org/licenses/by-nc-sa/4.0/. Checked by: *
Approved by: *
1 [No Variations]
Date: 29-8-2017 Size A2 Sheet 1 of 5

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

K-Type Thermocouple Amplifier with reference junction compensation

Over-temperature protection Comparator
+5V0 +5V0

PIR701 DESIGN NOTE:

A COR7
R7 DESIGN NOTE: PIR1501 A
10R The circuit must be calibrated for gain and offset after manufacturing. COR15
R15
PIR702 Reference level: 1R
See documentation for procedure.
NL05V00TMP350VCC 5V0 * ( 56.2k / (10k + 56.2k) ) = 4.24V PIR1502
+5V0_TMP35_VCC
DESIGN NOTE:
PIR402 PIC501
This pull-up provides protection in case of open thermocouple by PIR1201 PIC701 PIR1601
COR4
R4
PIU102 COC5
C5

2
pulling the input to the supply rail and saturating the amplifier's 10k COU1
U1 100n +5V0 COR12
R12 COC7
C7 COR16
R16
output. PIR401 PIC502 10k 100n 10k

+Vs
The value of 10M is chosen to make sure as little offset current 4 SHDN PIR1202 PIC702 PIR1602
as possible runs through the circuit. Capacitor is placed to filter PITP101
PIU104
+5V0 COTP1
TP1 Vout
1 NLTMP350OUT
PIU101TMP35_OUT
PIR1 02
noise on the high-value resistor. 0V COR11
R11
°C
+10mV/°C 10R 0V
PIR1 01

GND
3 NL05V00TC0AMP0VCC
+5V0_TC_AMP_VCC PIU308 COU3A
COU3B
U3A COTP6
TP6

8
NC PIU103
3
PIU303
PIR101 PIC101 PIR502 PIR801 PIC601 PITP601
PIU105 TMP35 1
PIU301
NLOTP0ERROR
OTP_ERROR POOTP0ERROR
OTP_ERROR 4, 5

5
COR1
R1 COC1
C1 0V PITP201
COR5
R5 COR8
R8 COC6
C6 NLOTP0CMP0VREF PIU302
OTP_CMP_VREF 2
10M 100n 51k1 10k 100n PITP501 LMV393
PIR102 PIC102 PIC201 COTP2
TP2 PIR501 PIR802 PIU207 PIC602 PIU304

4
7
0 to 500°C COC2
C2 0V COU2
U2 PIR1301 COTP5
TP5
0 to 20.5mV 1n COTP3
TP3 1
PIU201 -123°C to +502°C COR13
R13
SHDN
0V
COR2
R2
PIC202 0V COTP4
TP4 0 to 4.096V 56k
NLTC0POS
TC_POS PIR201 PIR202
PITP301 NLTC0AMP0IN
TC_AMP_IN 3
PIU203
PIR1302
COJ4
J4 10k 6
PIU206
PITP401 NLTC0AMP0OUT
TC_AMP_OUT

1
+5.05mV offset PIC401 2
PIU202
PIJ401 COC4
C4 5
2
PIJ402 10n
NC PIU205
8
NC PIU208
0V
B2B-XH-A COR3
R3
PIC402
NLTC0NEG
TC_NEG PIR301 PIR302 NLTC0REF0COMP
TC_REF_COMP
PIU204 MAX4238ASA+

4
10k
PID10C PID20C PIC301 +41µV/°C COR10

PID10A
COD1
D1
SD05T1G
PID20A
COD2
D2
SD05T1G
COC3
C3
1n
NLTC0AMP0FB
TC_AMP_FB
R10
PIR1001

158k
PIR1002
Anti-Aliasing Filter
PIC302 PIR601 PIR901
COR6
R6 COR9
R9 fc = 15.4 Hz
210R 1k
PIR602 PIR902 COR14
R14
0V 0V NLTC0AMP0FILT
TC_AMP_FILT POTC0AMP0FILT
B PITP1 01 PIR1402 PIR1401 TC_AMP_FILT 4 B
4k7
Common mode: fc = 15.9 kHz
Differential mode: fc = 758 Hz COTP11
TP11 0V PIC80POS
COC8
C8
2µ2 LAYOUT NOTE:
DESIGN NOTE: PIC80NEG 16V Place filter components physically close to
ADC input pin.
The ADC is used in 10 bits mode. The
Kinetis KE02 data sheet states that R14
must be ≤5kΩ. So 4k7 is selected. This 0V
DESIGN NOTE: DESIGN NOTE: leaves room for an aditional 100R resistor
between R14 and the microcontroller pin.
Thermocouple reference junction compensation is done by providing The measurement range for the thermocouple must be 0-500°C. This relates to
an offset voltage of 41µV/°C. This is the near enough the same 0-20.5mV at the amplifier's input, including the reference junction compensation
sensitivity as the K-type thermocouple. voltage.
The temperature sensor gives a 10mV/°C output. The voltage divider
brings this down to the desired 41µV/°C. Additional offset voltage is generated through the 10M pull-up, the 10k RF filter
resistor and the 102R to 0V. This is 5.05mV, and relates to a temperature range of
123°C.

Layout Note: The amplifier's gain of 159 is chosen to make sure that 4.096V (the ADC reference
Place R? and R? next to each other for close thermal coupling. voltage) relates to 502°C as measured by the thermocouple. Due to the additional
Place tracks and copper in such a way both resistors behave the same offset a 0V output of the amplifier now relates to -123°C
thermally.
Calibration of the circuit is required to mitigate circuit tolerances and provide a gain
and offset value for the firmware to calculate actual thermocouple voltage/temperature.

Reed Switch filter and debounce

C C

+5V0

DESIGN NOTE:

The reed switch is NOT referenced to 0V but connected to negative lead of the blower COR21
R21
PIR2101 PIR2102
fan. This means the read switch is connected to 0V through a 2.2Ω resistor (see picture). PIR1701 PIR1901 PIR2 01
COR17 COR19 220k COR22
R17 R19 R22
Fan current can be up to 250mA and has commutation noise on it. This results in a noise 10k 100k 10k
voltage as seen from the reed switch comparator of 250mA * 2.2Ω = 550mV. For this PIR1702 PIR1902 COTP8
TP8 PIR2 02
reason a 74xx14 logic type Schmitttrigger cannot be used as it's input low voltage level U3B COTP10
TP10
can be as low as <0.2V. Hence the choice for an analog comparator and a reference at COTP7
TP7 PITP801 NLREED0CMP0VREF 5
REED_CMP_VREF PIU305
2.5V for convenient resistor choices. COJ5
J5 7 PITP10 1 NLREED0CMP0OUT
REED_CMP_OUT POREED0CMP0OUT
PITP701 COR18
R18 PIU307 REED_CMP_OUT 4, 5
2
PIJ502 NLREED0SW0SENSE
REED_SW_SENSE PIR1801 PIR1802 NLREED0CMP0IN
REED_CMP_IN 6
PIU306
1
PIJ501 220k
PITP901 LMV393

B2B-XH-A PID30C PIC901 PIR20 1

COD3
D3 COC9
C9 COR20
R20 COTP9
TP9
SD05T1G 100n 100k
PID30A PIC902 PIR20 2 DESIGN NOTE:

Output High = handle in cradle (reed switch closed)

0V

DESIGN NOTE: DESIGN NOTE:

Debounce time 20ms Reference voltage 2.5V ± hysteresis of 0.5V

Ref_L = 100||(220+10) / ( 100||(220 + 10) + 100) * 5V = 2.05V

Ref_H = 100 / (100||220 + 100) * 5V = 2.96V

D D

(C) 2017 Christean van der Mijden (Heart of Technology) www.heartoftechnology.com

www.heartoftechnology.com
This work is licensed under the Creative Commons Drawing Title: 858D++ Hot Air Rework Station
Attribution-NonCommercial-ShareAlike 4.0 International Page Title: TC amplifier, OTP, Reed Switch
License. To view a copy of this license, visit Drawn by:
Checked by: *
CM Revision Variant
1 [No Variations]
http://creativecommons.org/licenses/by-nc-sa/4.0/. Approved by: *
Date: 29-8-2017 Size A2 Sheet 2 of 5

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

Fan Driver

3k3, 4k7 or 5k1?

A A

COD4
D4
PID40C PID40A

COTP14
TP14 1N4148 COTP17
TP17
COF1
F1
NLFAN0REG0DC0IN
FAN_REG_DC_IN PITP1401 2
PIQ302 3
PIQ303 PITP1701 NLFAN0REG0OUT
FAN_REG_OUT PIF101 PIF102
C1Q 375 COJ7
J7
PIR2601 PIR2701 COQ3
Q3 PIR2801 PID50C COD5 PIC1801 NLFAN0DRIVE0OUT 1
PIQ301 COC18 FAN_DRIVE_OUT

1
COR26
R26 COR27
R27 TIP122 COR28
R28 D5 C18 PIJ701

1n
NLFAN0CURRENT0SENSE 2
FAN_CURRENT_SENSE PIJ702
3k3 3k3 4k7
PIR2602 PIR2702 PIR2802 DNP
PID50A 1N4148 DNP
PIC1802
COTP15 B2B-XH-A
TP15

COBR1
BR1 NLFAN0REG0CTRL
FAN_REG_CTRL PITP1501
PIBR101

1
MB8S
PIQ203 COTP16
TP16

CCW
PIC1 01 PIC1201 PIR2301 PIC1301 PI 10C W COP1
P1 PIC1601 PIC1701
COC11
C11 COC12
C12 COR23 COC13
C13 COTP13 PITP1601 COC16
C16 COC17
C17

~
PO025VAC0P NL025VAC0P
+25VAC_P 3
PIBR103 4
PIBR104 R23 TP13 1 NLFAN0REG0FB
PIQ201FAN_REG_FB T
PIP10T 10k
5 +25VAC_P 10n 1000µ 100n 100n 470µ
PO025VAC0N NL025VAC0N
+25VAC_N 100k SHLD
5 +25VAC_N PIC10 1 PIC1 02 PIC1202 50V PIR2302 PIC1302 COTP12 PIQ103 PITP1301
COQ2 PIP10CW PIP10SHLD
PIC1602 PIC1702 50V
TP12 Q2

CW
3
COC10 PIQ202

2
C10 MMBT3904 COHS1
HS1 COPad1
Pad1
10n PIBR102 COR24
R24 PITP1201 1 COQ1
Q1 NLFAN0REG0REF07V5
FAN_REG_REF_7V5 PIR30 1
2
PIR2401 PIR2402 PIQ101 FAN_CURRENT_SENSE
PIC10 2 4k7 MMBT3904 COR30
R30
PIR2501 PIZ10C PIC1401 PIC1501 PIR2901 2R2 0V
PIQ102 COC14 COC15 PIR30 2 PIHS101

2
COR25
R25 COZ1
Z1 C14 C15 COR29
R29 240-118AB

1
56k 7V5 10µ 100n 7k5 SPK4-0.006-00-54
PIR2502 PIZ10A PIC1402 PIC1502 PIR2902
0V
PITP1801
COTP18
TP18 LAYOUT NOTE:
Front Panel Account for sil-pad thickness when placing heat sink and triac:
Air Speed Dial (Thickness = 6mil for SPK4-0.006-00-54)

NLFAN0nON0OFF
FAN_nON_OFF
POFAN0nON0OFF
POFAN0NON0OFF
4 FAN_nON_OFF
B B

Fan Monitor

DESIGN NOTE
+5V0
Rising Edge Detector One-Shot Filter Buffer Comparator If the filter voltage falls below a certain value the fan has stalled. Simulation shows that if the
fan is commutating at 250Hz (far below the measured 300Hz) the voltage is still about 1.35V.
The comparator reference is arbitrarily chosen at 1V. This would mean a divider of 40k and
PIR3201 PIR3401 PIR3801 10k. As it happens we already used 56k and 10k in the OTP comparator. These values result
COR32
R32 COR34
R34 COR38
R38 in a reference at 756mV.
1R 1R 10R Due to ripple on the filter output a bit of hysteresis is desired. A 100k value results in the
PIR3202 PIR3402 PIR3802 reference levels being at:
COC24 - falling signal reference level: 688mV ( 10k||100k / (10k+56k) * 5V )
C24
- rising signal reference level: 1.1V ( 10k / (10k + 56k||100k) * 5V )
PIC2401 PIC2402
PIC20 1 PIR3 01 PIC2101 PIR40 1 COR42
R42
PIR4301 Simulation shows that these levels work fine: fan stall detection goes high in <= 100ms
COC20
C20 COR33
R33 COC21
C21 100n COR40
R40 PIR4201 PIR4202
COR43
R43
100n 10k 100n 56k 10k
100k
PIC20 2 PIR3 02 PIC2102 COR36
R36
0V PIR40 2 PIR4302
PIU501
1

PIR3601 PIR3602
COU5
U5 COTP22
TP22 COTP23
TP23 COTP25
TP25
56k U4B
C 0V 0V PIU605 COU6
U6 COTP24
TP24 5 C

5
COR37 PIU405
VS

COTP19
TP19 3 PITP2 01 ONE_SHOT_OUT
R37 NLFILTER
FILTER PITP2301 1 7 PITP2501 NLFAN0STALL
FAN_STALL
OUT PIU503 PIR3701 PIR3702 PIU601 PIU407 POFAN0STALL
FAN_STALL 4, 5
PIU408 COU4A
COU4B
U4A COTP21
TP21 4 BUFFER_OUT PITP2401 6
8

56k PIU604 PIU406

FAN_CURRENT_SENSE
FAN_CURRENT_SENSE PITP1901 2
PIU402
PIR3501 PID60C COD6 PIU603
3 LMV393
1 NLEDGE0CMP0OUT
EDGE_CMP_OUT PITP210 4 COR35
R35 LMV321
COR31
R31 PIU401 PIU504 TRG D6
PIU602

2
3 10k
0V PIR3101

100k
PIR3102 PIU403

PIU40 LMV393 PIR3502 PID60A 1N4148 PIC230POS COR39

R39
PIR4101
PIC1901 COC23 COR41
4

5 C23 R41
GND

THR PIU505 PIR3901 PIR3902

COC19
C19 2µ2 10k
10R
150p PIC2 01 PIC230NEG 16V PIR4102
PIC1902 COC22
PIU502 MIC1555YM5 C22
RPM selection & Anti-Aliasing Filter
2

100n
PIC2 02
PITP20 1
NLBUFFER0OUT
BUFFER_OUT 4k7
PIR4402
COR44
R44
PIR4401 fc = 15.4 Hz
COTP20
TP20 0V NLFAN0RPM
FAN_RPM POFAN0RPM
FAN_RPM 4
NLONE0SHOT0OUT
ONE_SHOT_OUT 0R
PIR4501
COR45
R45
PIR4502

PIC250POS
COC25
C25
2µ2
LAYOUT NOTE: PIC250NEG 16V
LAYOUT NOTE: DESIGN NOTE: DESIGN NOTE: Place filter components physically close to
Route current sense and 0V traces from current sense resistor ADC input pin.
as a pair of traces to the rising edge detector input. Terminate R*C = 1m => K factor is 1.15 (data sheet Reusing the 2µ2 capacitor while getting a fast enough step
0V trace at comparator 0V. figure 2-7, page 8) response and low ripple means the resistor value needs to be 0V
Pulse 'high' period is 1.15ms in the 20k-30k range. 56k was already in the design, so
paralleled here to get to 28k.

DESIGN NOTE:

FAN rpm can be read by the microcontroller using one of two possible ways:
1 Using the direct output of the one-shot which is a pulse-train and the 'real' RPM.
* Place R45 only.
If filtering is required replace R45 with a suitable value and place a suitable capacitor instead of C25

2) Using the filtered pulse-train thus an analog voltage representing the RPM. This is a relatively slow changing
D voltage, lagging behind the real fan speed by 10s of milliseconds. D
* Place R44 and C25. Note that R44 must be <5k, see comment on the thermocouple amplifier's output filter.

(C) 2017 Christean van der Mijden (Heart of Technology) www.heartoftechnology.com

www.heartoftechnology.com
This work is licensed under the Creative Commons Drawing Title: 858D++ Hot Air Rework Station
Attribution-NonCommercial-ShareAlike 4.0 International Page Title: Fan Driver and Monitor
License. To view a copy of this license, visit Drawn by:
Checked by: *
CM Revision Variant
1 [No Variations]
http://creativecommons.org/licenses/by-nc-sa/4.0/. Approved by: *
Date: 29-8-2017 Size A2 Sheet 3 of 5

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

ARM SWD Programming I/F

POREED0CMP0OUT +5V0
2, 5 REED_CMP_OUT

POOTP0ERROR
2, 5 OTP_ERROR
PIR4901 PIR50 1
COR49
R49 COR50
R50
POTC0AMP0FILT 10k 100k
A 2 TC_AMP_FILT COJ8 PIR4902 PIR50 2 A
J8
1
PIJ801 2
PIJ802
NLSWD0DIO
SWD_DIO
3 4 NLSWD0CLK
SWD_CLK
POFAN0RPM
3 FAN_RPM PIJ803 PIJ804
5
PIJ805 6
PIJ806
7
PIJ807
8
PIJ808
NLSWD0nRESET
KE02Z Microcontroller 9
PIJ809 10
PIJ8010 SWD_nRESET

HDR 2x5 M PIC30 1 PIR5101

COC30
C30 COR51
R51
100n 100k LAYOUT NOTE:
CORA1
RA1 Place R49 & C30 physically close to microcontroller pin
1
PIRA101 8
PIRA108
NLFAN0RPM
FAN_RPM PIC30 2 PIR5102
+5V0 COTP26
TP26 COU8
U8 2
PIRA102 7
PIRA107
NLTC0AMP0FILT
TC_AMP_FILT
3 6 NLOTP0ERROR
OTP_ERROR
COR46
R46 NL05V00MCU0VDD
+5V0_MCU_VDD PITP2601 3
PIRA103
4
PIRA106
5 NLREED0CMP0OUT
REED_CMP_OUT
PIR4601 PIR4602 PIU803 VDD PIRA104 PIRA105
0R 26 NLMCU0FAN0RPM
MCU_FAN_RPM
PIC2601 PIC2701 KBI0_P0 / FTM0_CH0 / ACMP0_IN0 / ADC0_SE0 / PTA0PIU8026 150R
25 NLMCU0THERMOCOUPLE
MCU_THERMOCOUPLE 0V
COC26
C26 COC27
C27 KBI0_P1 / FTM0_CH1 / ACMP0_IN1 / ADC0_SE1 / PTA1PIU8025
24 NLMCU0OTP0ERROR
MCU_OTP_ERROR
10µ 100n KBI0_P2 / UART0_RX / I2C0_SDA / PTA2 PIU8024 NLMCU0REED0SWITCH
23 MCU_REED_SWITCH
KBI0_P3 / UART0_TX / I2C0_SCL / PTA3 PIU8023
PIC2602 PIC2702 32
SWD_DIO / ACMP0_OUT / PTA4 PIU8032
SWD_DIO
31 SWD_nRESET
RESET / IRQ / FTM0_CLK / PTA5 PIU8031
20 NLMCU0BUTTON0DOWN
PORT A
FTM2_FLT1 / ACMP1_IN0 / ADC0_SE2 / PTA6 PIU8020
19
FTM2_FLT2 / ACMP1_IN1 / ADC0_SE3 / PTA7 PIU8019
MCU_BUTTON_DOWN
NLMCU0BUTTON0UP
MCU_BUTTON_UP Buzzer
0V 0R
PIR4801
COR48
R48
PIR4802 SWD_CLK +5V0
COTP27
TP27
DESIGN NOTE:
Voltage Reference PITP2701 4
PIU804 VREFH/VDDA
18
KBI0_P4 / UART0_RX / ADC0_SE4 / PTB0 PIU8018
NLMCU0a0L1
MCU_a/L1
Replace with termination resistor (e.g. 22R) if required
17
KBI0_P5 / UART0_TX / ADC0_SE5 / PTB1 PIU8017
NLMCU0b0L2
MCU_b/L2 PIC3102 PIR5 01
+5V0 COU7
U7 16 NLMCU0c0L3
MCU_c/L3 COC31
C31 COR55
R55
KBI0_P6 / SPI0_SCK / FTM0_CH0 / ADC0_SE6 / PTB2PIU8016 100n
15 NLMCU0d
MCU_d 0R
COR47
R47 KBI0_P7 / SPI0_MOSI / FTM0_CH1 / ADC0_SE7 / PTB3PIU8015 LAYOUT NOTE: DESIGN NOTE PIC3101 PIR5 02
PIR4702 PIR4701 NL05V00REF0IN 6
+5V0_REF_IN PIU706 1 NL04V0960VREFH
PIU701+4V096_VREFH 10 NLMCU0e
MCU_e
VDD OUT NMI / ACMP1_IN2 / SPI0_MISO / FTM2_CH4 / PTB4 PIU8010 Place physically close to microcontroller pin
0R 9 NLMCU0f
MCU_f
ACMP1_OUT / SPI0_PCS0 / FTM2_CH5 / PTB5 PIU809 Buzzer: 5mA max @ 50% duty 5V 4kHz squarewave.
4 8 NLMCU0g
MCU_g
PIU704 SHDN XTAL / I2C0_SDA / PTB6 PIU808
PIC2801 PIC2901 PORT B 7
EXTAL / I2C0_SCL / PTB7 PIU807
NLMCU0dp
MCU_dp
MMBT3904 hFE min. 60 ==> ib > 83µA ==> rb < 60k.
0V
PIR5301 PILS101 COLS1
LS1
COC28
C28 COC29
C29 COR53
R53
GND
GND
GND

Since we need pull-down on base, lets take 10k and 100k. 100k CMT-1203-SMT
2µ2 150p 1k
pull down should still be ok for leakage current and preventing Piezo
PIC2802 PIC2902 14
ADC0_SE8 / FTM2_CH0 / PTC0 PIU8014
NLMCU0DIGIT1
MCU_DIGIT1 PIR5302 PILS102
spurrious turn-on if MCU is at High-Z
PIU702 PIU703 PIU705 MCP1501 13
ADC0_SE9 / FTM2_CH1 / PTC1 PIU8013
NLMCU0DIGIT2
MCU_DIGIT2
2
3
5

4.096V 12 NLMCU0DIGIT3
MCU_DIGIT3
B ADC0_SE10 / FTM2_CH2 / PTC2 PIU8012 COTP28 PIQ403 B
5 11 NLMCU0L1L2L3
MCU_L1L2L3 TP28

3
PIU805 VREFL ADC0_SE11 / FTM2_CH3 / PTC3 PIU8011
30 NLSWD0CLK0R
SWD_CLK_R
SWD_CLK / ACMP0_IN2 / RTCO / FTM1_CH0 / PTC4 PIU8030 COR52
R52 PITP2801 COQ4
29 NLBUZZER0PWM
BUZZER_PWM BUZZER_PWM 1 Q4
RTCO / FTM1_CH1 / PTC5 PIU8029 PIR5201 PIR5202 PIQ401
0V 28 NLMCU0UART0RX
MCU_UART_RX
10k MMBT3904
UART1_RX / PTC6 PIU8028
PORT C 27
UART1_TX / PTC7 PIU8027
NLMCU0UART0TX
MCU_UART_TX PIR5401
COR54 PIQ402

2
R54
100k
POHEATER0nON0OFF
POHEATER0NON0OFF
HEATER_nON_OFF 5
PIR5402 1%
DESIGN NOTE 2 NLHEATER0nON0OFF
HEATER_nON_OFF
FTM2_CH2 / SPI1_SCK / KBI1_P0 / PTD0 PIU802 NLFAN0nON0OFF
1
This microcontroller comes with 3 possible program flash sizes: FTM2_CH3 / SPI1_MOSI / KBI1_P1 / PTD1 PIU801
FAN_nON_OFF
22 NLMCU0FAN0STALL
MCU_FAN_STALL
SPI1_MISO / KBI1_P2 / PTD2 PIU8022 NLMCU0ZERO0CROSS POFAN0nON0OFF
POFAN0NON0OFF
FAN_nON_OFF 3
Serial I/F
MKE02Z16VLC2: 16 kB 6
PORT D 21 MCU_ZERO_CROSS
SPI1_PCS0 / KBI1_P3 / PTD3 PIU8021
8
CORA2
RA2
1 COJ9
J9
0V
MKE02Z32VLC2: 32 kB PIU806 VSS/VSSA PIRA208 PIRA201
NLUART0RX
7
PIRA207 2
PIRA202 UART_RX 1
PIJ901
MKE02Z16VLC2: 64 kB NLUART0TX
6
PIRA206 3
PIRA203 UART_TX 2
PIJ902
MKE02Z16VLC2 POZERO0CROSS 5
PIRA205 4
PIRA204 3
PIJ903
All have 256 Byte internal EEPROM 5 ZERO_CROSS
0V
150R PID70C COD7
D7
PID80C COD8
D8 HDR 1x3 M
DESIGN NOTE SD05T1G SD05T1G
MCU pin current limit resistor value.
POFAN0STALL
3, 5 FAN_STALL PID70A PID80A
Maximum voltage is VDD + 300mV or VSS - 300mV. Maximum
injection current is ±2mA per pin, (-5mA + 25mA for all pins at 0V
the same time)
CORA3
RA3
1
PIRA301 8
PIRA308 NLFAN0STALL
FAN_STALL
300mV / 2mA = 150R => Resistor Array of 150R NLZERO0CROSS
2
PIRA302 7
PIRA307 ZERO_CROSS
3
PIRA303 6
PIRA306 BUTTON_DOWN
4
PIRA304 5
PIRA305 BUTTON_UP

150R

C
Display Front panel buttons debouncing C

+5V0
+5V0 +5V0 +5V0 COC33
C33
COR66
R66
PIR6601 PIR6602 PIC3301 PIC3302 +5V0
MCU_DIGIT3

MCU_DIGIT2

MCU_DIGIT1

1R
100n
1%
PIR5701 PIR5901 PIR6101 PIR6401 PIR6701
COR57
R57 COR59
R59 COR61
R61 COR64
R64 0V COR67
R67
100k PIQ502 100k PIQ602 100k PIQ702 100k 100k
2

COR56
PIR5702 1% COQ5
Q5
COR58
PIR5902 1% COQ6
Q6
COR60
PIR6102 1% COQ7
Q7 PIR6402 1% COTP33
TP33 PIU905 COU9A
COU9B
U9A COTP34
TP34 COTP36
TP36 U9B COTP35
TP35 PIR6702 1%

5
DESIGN NOTE: R56 1 MMBT3906 R58 1 MMBT3906 R60 1 MMBT3906
About the display: PIR5601 PIR5602 PIQ501 PIR5801 PIR5802 PIQ601 PIR6001 PIR6002 PIQ701 COR65
R65 COR68
R68
7k5 PITP2901 7k5 PITP30 1 7k5 PITP3101 PIR6502 PIR6501 PITP3 01 PIU901
1 6
PIU906 PITP3401 NLBUTTON0UP
BUTTON_UP NLBUTTON0DOWN
BUTTON_DOWN PITP3601 4
PIU904 3
PIU903 PITP3501 PIR6801 PIR6802

One resistor per element, not one per digit: otherwise brightness changes if 220k 220k
COTP29 PIQ503 COTP30 PIQ603 COTP31 PIQ703 PISW10 PISW102 PISW20 PISW201
3

TP29 TP30 TP31 74HC2G14GV 74HC2G14GV

1% PIU902 1%

1
2

2
1
displayed character changes. PIC3201 PIC3401

2
COSW1
SW1 COC32 COC34 COSW2
SW2
Front Panel C32 C34 Front Panel
Display max DC current: 25mA/segment; 15mA @ Ta = 50°C B3FS-4052P B3FS-4052P
UP Button 100n 100n DOWN Button
Dutycycle 25%: 3 digits + 1 L1..L3 line = 4 lines PIC3202 DESIGN NOTE PIC3402
PISW103 PISW104 PISW204 PISW203

3
4

4
3
+5V0
Debounce time 20ms with 74HC2G14 & VCC = 5V
Assumed: 5mA / segment should give enough brightness. 5mA can be sinked
into MCU pins without problems. Do not change gate type without recalculating component values!
PIR6301 0V Do not substitute 74HC for 74HCT or any other 74xxx series without 0V
Vf @ 5mA = 1.7V COR63
R63 CODS1
DS1 recalculating component values!
VCC = 5V 100k PIQ802
2

R = 660R => 680R PIR6302 1% COQ8

Q8 NLDISPLAY0DIGIT1 1
DISPLAY_DIGIT1PIDS101
COR62
R62 MMBT3906 NLDISPLAY0DIGIT2 Digit 1
MCU_L1L2L3 1 5
DISPLAY_DIGIT2PIDS105
Available resistor array: 680R 5% => OK PIR6201 PIR6202 PIQ801 Digit 2
7k5 PITP3201 NLDISPLAY0DIGIT3 7
DISPLAY_DIGIT3PIDS107
Digit 3
Pmax = I^2 * R = { (5-1.7)/680 }^2 * 680 = 17mW PIQ803
3

COTP32
TP32
b/L2
a/L1

c/L3

Element Pmax = 62.5mW ==> OK NLDISPLAY0L1L2L3 14

DISPLAY_L1L2L3PIDS1014
dp

L1/L2/L3
d

g
e
f

Total current per digit all on: 40mA => cannot drive directly from MCU! LTC-4624JR
PIDS10 2 PIDS10 1 PIDS103 PIDS104 PIDS102 PIDS10 5 PIDS108 PIDS106
12
11
3
4
2
15
8
6

Actual current is a bit less since MCU pins have a small voltage (200mV to
400mV) above GND when sinking current. CORA4
RA4
MCU_a/L1 8 1 NLDISPLAY0a0L1
DISPLAY_a/L1
D PIRA408 PIRA401 D
MCU_b/L2 7
PIRA407 2
PIRA402
NLDISPLAY0b0L2
DISPLAY_b/L2
MCU_c/L3 6 3 NLDISPLAY0c0L3
DISPLAY_c/L3
PIRA406 PIRA403
MCU_d 5
PIRA405 4
PIRA404 NLDISPLAY0d
DISPLAY_d (C) 2017 Christean van der Mijden (Heart of Technology) www.heartoftechnology.com
680R
5%
www.heartoftechnology.com
MCU_e 8
CORA5
RA5
1 NLDISPLAY0e
DISPLAY_e
This work is licensed under the Creative Commons
PIRA508 PIRA501 Drawing Title: 858D++ Hot Air Rework Station
MCU_f
MCU_g
7
PIRA507
6
2
PIRA502
3
NLDISPLAY0f
DISPLAY_f
NLDISPLAY0g
DISPLAY_g
Attribution-NonCommercial-ShareAlike 4.0 International
PIRA506 PIRA503 Page Title: Microcontroller, UI
MCU_dp 5
PIRA505 4
PIRA504
NLDISPLAY0dp
DISPLAY_dp License. To view a copy of this license, visit Drawn by: CM Revision Variant
680R
5% http://creativecommons.org/licenses/by-nc-sa/4.0/. Checked by: *
Approved by: *
1 [No Variations]
Date: 29-8-2017 Size A2 Sheet 4 of 5

1 2 3 4 5 6 7 8
 1 2 3 4 5 6 7 8

DESIGN NOTE:
Safety components must be rated at ≥288VAC
CEI 60950-1: 2005/A2-2013 specifies rated nominal voltage +25%
= 230VAC *1.25 = 288VAC
MainsVoltage Zero Crossing Detector
LAYOUT NOTE:
i
Treat ZERO_CROSS_PULSE and ZERO_CROSS
A Mains +5V0 nets as a clock signal when routing A
Input COR73
R73 NL11VAC0L
230VAC_L 230VAC_L PIR7301 PIR7302 11VAC_L
PIBR203~ COBR2
BR2

3
220k
COJ1
J1
MB8S PIR6901 Pulsewidth ~1ms
1
PIRV101 PIC3701 PIC3801 COR76
R76
COU13
U13 COR69
R69
PIJ101 CORV1
RV1 COC37
C37 COC38
C38 2 1 NLZC0Pos
ZC_Pos NLZC0Pulse
ZC_Pulse 1 4 10k
2 PIBR202 PIBR201 PIR7601 PIR7602 PIU1301 PIU1304
PIJ102 V300LA20AP 100n 1n
1k PIR6902 COR70
R70
10-32-1021
PIRV102 PIC3702 X2 Film PIC3802 1000V PIC3901 2
PIU1302 5
PIU1305
NLZERO0CROSS0PULSE
ZERO_CROSS_PULSE PIR7001 PIR7002
NLZERO0CROSS
ZERO_CROSS POZERO0CROSS
ZERO_CROSS 4
COC39
C39
230VAC_N 230VAC_N
COR74
R74 NL11VAC0N
11VAC_N PIBR204~ 10µ 3 6
10R
PIC3501

4
PIR7401 PIR7402 PIU1303 PIU1306
220k
PIR7501 PIC3902 COC35
C35
COR75
R75 2
PIQ902 3
PIQ903 4N35SM 150p
22k PIC3502
PIR7502 PID90A COQ9
Q9 0V
DESIGN NOTE:
PIQ901

1
COD9
D9 MMBT3904
0V The signal will trigger an interrupt, and software
PID90C 1N4148 filtering is available on all mcu ports. Filter
components serve as placeholder in case filtering is
NLZC0Neg
Transformer MainsVoltage
ZC_Neg
required. Use 0R and no cap during prototyping.
Primary i
COJ2
J2
1 230VAC_L
DESIGN NOTE: DESIGN NOTE: DESIGN NOTE: LAYOUT NOTE:
PIJ201
2 230VAC_N
For 115V mains change value to 100k Surge/Pulse rated Resistors: Capacitor rated at 50V: in case of surge/EFT +5V0 Place filter components physically close to
PIJ202 Rated 500V nominal, 1kV Pulse the MOV clamps at 775V nominal. Residual microcontroller input pin.
10-32-1021 voltage across capacitor may be up to 40V
PIR7102
COR71
R71
1R
PIR7101
PIC3601
Heater Driver COC36
C36 Error Logic DESIGN NOTE:
About the Error Logic.
MainsVoltage 100n
i PIC3602 The microcontroller can turn the heater on by driving pin 2 of the
optocoupler LOW. This turns the LED inside the opto coupler ON,
but only if the output of the NOR gate is HIGH.
COR78 0V PIU1205 COU12
U12

5
NL230VAC0L
230VAC_L
R78 COU14
U14 1 NLREED0CMP0OUT
REED_CMP_OUT
PIR7801 PIR7802 COR72
R72 PIU1201 The output of the NOR gate is HIGH only if ALL three inputs are
B 4 1 NLHEATER0OPTO0IN
HEATER_OPTO_IN NLERROR0GATE0OUT
ERROR_GATE_OUT 4 3 NLOTP0ERROR
OTP_ERROR B
360R PIU1404 PIU1401 PIR7202 PIR7201 PIU1204 NOR PIU1203 LOW. Any error condition means a LOW output on the NOR gate;
PIC40 1 210R 6
PIU1206
NLFAN0STALL
FAN_STALL
COC40
C40 PIQ10 2 COQ10
Q10 thus the Opto LED cannot turn on.

2
5 2
DNP 12n PIU1405 PIU1402
PIU120

2
BTA208-800B 74LVC1G27
PIC40 2 X2 Film 6
PIU1406 ZC 3
PIU1403
3
PIQ1003 NLTRIAC0GATE
TRIAC_GATE NLHEATER0nON0OFF
HEATER_nON_OFF
PIQ10 1 MOC3041SM 0V
1

MainsVoltage PIR7 01 PIR7901

Heater COR77
R77 COR79
R79
i
DNP47R 330R
COJ3
J3 PIR7 02 2W PIR7902 DESIGN NOTE:
1
PIJ301
NL230VAC0HEATER0DRIVE
230VAC_HEATER_DRIVE
2 NL230VAC0N Opto-coupler has internal zero cross
PIJ302 230VAC_N
detection and triggering
10-32-1021

DESIGN NOTE:
For 115V mains: change resistor values:
DESIGN NOTE: 360R -> 180R (T2 to opto-coupler)
Triac rated at 800V since MOV clamps at 775V nominal 330R -> 1k (Gate to T1)
POHEATER0nON0OFF
POHEATER0NON0OFF
4 HEATER_nON_OFF

DESIGN NOTE: POFAN0STALL

3, 4 FAN_STALL
Add silpad between triac and heat sink for electrical isolation
COHS2
HS2 COPad2
Pad2 POOTP0ERROR
2, 4 OTP_ERROR

LAYOUT NOTE:
Account for sil-pad thickness when placing heat sink and triac: POREED0CMP0OUT
2, 4 REED_CMP_OUT
PIHS201 240-118AB
1

(Thickness = 6mil for SPK4-0.006-00-54) SPK4-0.006-00-54

C C

Board +5V0 supply

COD10
D10
PID100C PID100A
LAYOUT NOTE:
1N4148
PIBR303 ~ COBR3 This component needs a heat sink area ≥100mm^2
3

BR3
MB8S COU15
U15 +5V0 (10x10mm) and via stitching to bottom layer ground
plane.
2 1 NL010VAC0RECTIFIED
+10VAC_RECTIFIED 1 3 NL05V0
+5V0
PIBR302 PIBR301 PIU1501 VIN VOUT PIU1503
Input voltage: 10*sqrt(2) - 1.4 = 12.7V
PIC410POS PIC4201 PIC4301 PIC4 0POS Ouptut voltage: 5V
Transformer COC41
C41 COC42
C42 GND COC43
C43 COC44
C44 Dropout voltage: 7.7V
Secondary PIBR304 ~ Estimated continuous current draw: <200mA
470µ 100n
PIU1504 MC78M05 100n 470µ
4

PIC410NEG 50V PIC4202 PIC4302 PIC4 0NEG 50V Power dissipation @ 7.7V & 200mA: 1.54W
COJ6
J6
4 NL010VAC0P
PIJ604+10VAC_P
NL010VAC0N
3 +10VAC_N
PIJ603
NL025VAC0P
2 +25VAC_P 0V
PIJ602 PO025VAC0P
+25VAC_P 3
1 NL025VAC0N
+25VAC_N
PIJ601 PO025VAC0N
+25VAC_N 3
B4B-XH-A LAYOUT NOTE:

Add additional 'local' 10µF MLCC 0805/2012

DESIGN NOTE: capacitors where required, depending on layout of
voltage rail
These capacitor's value and their voltage
rating are chosen because they are the same
component as the fan driver output capacitor.
D D

(C) 2017 Christean van der Mijden (Heart of Technology) www.heartoftechnology.com

www.heartoftechnology.com
This work is licensed under the Creative Commons
Drawing Title: 858D++ Hot Air Rework Station
Attribution-NonCommercial-ShareAlike 4.0 International
Page Title: Heater Driver, Zero-Cross, +5V0
License. To view a copy of this license, visit Drawn by: CM Revision Variant
http://creativecommons.org/licenses/by-nc-sa/4.0/. Checked by: *
Approved by: *
1 [No Variations]
Date: 29-8-2017 Size A2 Sheet 5 of 5

1 2 3 4 5 6 7 8