About this project
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A Flexible Oven Controller for any application
Reflow Soldering Application:
More and more often now, through-hole variations of packages are ceasing to exist. Furthermore, surface mount packages are getting more and more difficult to hand solder. Part of this is because modern components are simply not designed to be hand soldered and often are actually damaged by hand soldering. Where as DIY SMT Reflowing is a quick, reliable, and affordable way to solder surface mount components. This is where the Zallus Oven Controller Kit allows you to easily convert a toaster oven into a fully J-STD-20 compliant Reflow Oven.
Perhaps the most important feature of this system is the Zallus Profile Creator tool on the PC which allows you to easily modify and create your own profiles! This guarantees your controller will work with virtually any oven and allows you to easily verify your profile is safe and Industry Compliant.
Its no secret, solder is quite easy to melt, you simply apply heat. However, actually reflowing solder means you are following an industry specifications that provides a balance between component integrity and forming quality solder joints. Most DIY oven controllers do not have any type of evaluation method as to whether or not the profile your running is safe for the components or optimum for the solder. This is a quality feature that the Zallus Profile Creator tool allows you to easily verify.
Download Profile Creator Beta at:
A Comprehensive Kit:
Ever buy one of those kits that required purchasing a lot of excess parts? Thankfully, the Zallus Reflow oven kit comes with all the fundamental components required to convert a toaster oven into a reflow oven. Each version of the kit includes the following:
- Zallus Reflow Oven Controller
- Low thermal mass high temp rated K type thermocouple
- Solid State Relay rated up to 25A / 250VAC
- Red/Black Wires to connect your relay to your board.
- A USB cable to power or to control your Oven (forgot this in the video, sorry!
- Can operate by PC control or stand alone with LCD Interface & USB Charger
- Comes preloaded with Lead and Lead Free profiles
- Allows for easy custom profile design with Profile Creator
- Custom Profiles are permanently saved to until overridden
- Profiles can be saved and recalled in software tool
- Profile Creator allows for modification to PID Control system gains
The hardware is offered in three different versions as seen below:
- 3.2" Touch Display Controller
- 2.4" Touch Display Controller
- USB Only / Push Button Controller
In order to keep the pricing options flexible, three different versions have been created. Two different display sizes as well as a version without a display that can be activated by USB or through an onboard tactile push button.These variations also ensure that the product will be not crippled should any display versions become temporarily unavailable.
While I only demonstrated the reflow oven application of this controller, the Zallus Oven Controller isn't only limited to that application. With the profile creator tool you can create profiles for just about anything from arts and crafts to cooking. I've been approached by people who have wanted to use this for general cooking, arts and crafts...ect. Numerous applications need flexible and repeatable control of heating elements which this kit allows you to achieve.
3rd. Party App Development:
The Zallus Oven Controller uses a simple CDC AT Command set. You can implement your own app using the command set seen here:
Print your own 3D Enclosure:
1 Material Basic Enclosure:
(Tolerances are a bit tight so you may want to prepare to do a bit of filing)
Kit Instructional Video:
Note to safety:
This kit may involve working with electrical mains voltage! Please do not buy this product or attempt any modification to any electrical product without experience working with mains voltage as well as the applicable theory. You use this product and attempt these modifications at your own risk and you are ultimately responsible to resulting damages to life & property. Your safety and the safety of those around you is far more important than owning any Reflow Oven!
Risks and challenges
Considering the maturity of the design, I don't foresee too many design challenges. However, with that said, there can always be problems.
A large challenge with electronics in general is component availability.
To tackle component availability, I flexibly designed the controller such that there are multiple drop in replacements for the processor as well as the display. Should component sourcing issues arrive, it will simply be a matter of purchasing equivalent replacements.Learn about accountability on Kickstarter
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