Unisolder 5.2 Case

Designed Inspired by: https://www.thingiverse.com/thing:3460761
The buttons are the only thing I directly modified, everything else I created from scratch

This is mostly finalized now, have been using for months with no issues. Let me know if there are any suggestions.

Instructions are NOT COMPLETE. You should have a basic understanding of wiring and electronics. If you do have any questions, feel free to DM me

CNC 1/8in Acrylic Side Panels and 1/16in screen protector are available for 30USD + shipping! Just direct message me if interested.🙂

UPDATE3 2020-11-07T22:00Z Added S3-B Tip Changer and left panels with and without the passthrough for the stand. This is now mostly complete

UPDATE2 2020-11-06T22:34Z Minor update, added an alternative power switch for 220V thanks to the suggestion of @PCW.

UPDATE1 2020-09-14T03:30Z Updated base panel to also use M3 brass heat inserts for consistency

A case for the open source Unisolder 5.2 soldering station control board. You can find more information in the original forum post and notes

Design Notes

I prioritized size and features for my case design. Everything can be printed on a Prusa Mini although it is a little tight (especially for the side panels). I have also tailored the case towards the excellent JBC T245 handles using the proper OEM connectors as well as accessories for an integrated stand (with standby feature) as well as a holder on top to minimize the footprint.

Side panels

I CNCed my side panels from 1/8" thick side panels for low profile socket screws however you should be able to 3d print them instead. If you wanted to instead use regular socket screws, modify the step files to the associated head height.

Notes:

• The power plug can be a little loose, use foam tape on the bottom and right sides to apply some force on the plug to make it more secure.
• Use the foam tape to secure the OLED panel onto the board.
• Most of the mounting holes (to secure the side panels, the front panels to each other, and pcbs to front and back panels relies on the M3 heat inserts. These greatly simplified the design (no longer need to design grooves for M3 nuts) and makes it easier to assemble. Just use a soldering iron to press these inserts in and you should be able to screw into them directly.
• The iron connector for the T245 handle is secured with M2 screws from behind.
• To make the front printable, I split the front panel into two parts, a top and bottom. They are secured using two M3 nuts with additional support from the side panels when screwed in.
• I have not included the Left panel for where the stand mounts because I have not yet finalized the location of where the wires will pass through. Feel free to mirror the right panel to substitute the left panel.
• The pictures posted currently show a 1/4in thick acrylic side panel, I have since changed it to a 1/6in polycarbonate with low profile hex screws to minimize the footprint.

Mains Wiring 💀⚡[CAUTION]⚡💀, you will be wiring Mains voltage, please take proper precautions when handling high voltages]:

1. Neutral to switch 1B position and one side of the primary windings
2. Live to switch 1A position
3. Switch 1 to other side of the primary windings. Please check the switch datasheet for more details.

Core Parts:

• 1x Completed set of Unisolder 5.2 boards (100USD)
• 1x T245 Connector/HR1817-ND/1125812) (3USD)
• 1x 110v Power Switch w/ illumination (2USD)
  • 220v Alternative Switch w/o illumination (2.61)
• 1x Fused Power Plug (3USD)
• 1x 5x20mm 3A Slow Blow Fuse
• 1x 120VA toroidal 24V transformer, I used a 160VA one (50USD)
• 4x Rubber Feet (7USD)

Fasteners/Wires/ETC:

• M2-5mm Socket Screws
• Low Profile M3-8mm Socket Screws
• M3-5mm Socket screws
• M3-3mm Heatset Brass Inserts (6USD)
• M3-4mm Heatset Brass Inserts (6USD)
• OPTIONAL - M3 Heat Insert Soldering tool for Hakko FX888 soldering irons (~10USD)
• M4-8mm Socket screws
• M4-8mm Button Screws (for rubber feet)
• M4-Hex Nuts
• 16-18AWG wires
• 1/4in Quick Connects
• Foam Double-sided tape

ScreenProtector:

• I have also included a screen protector cnc_screen_protector that you can cnc out of 1/16in acrylic and sits flush to the surface of the front panel. Highly recommend it, as mentioned on the top, I'm also selling these screen protectors.

JBC T245 Specific:
In addition to the core case, I have designed accessories further tailored towards the JBC T245. The first is a compact stand holder that works with the touch holder that comes with the Unisolder 5.2 kit. The stand attached to the left has a small hole to route the wire to the compact metal stand to the side of the case. You can mirror this part if you desire a right orientation part.
Using the touch circuit (tiny pcb with a three pin connector on one side and a single pad on the other), wire the one wire sense through the stand side hole, then through the compact stand and secure with the screw. Take care to not pinch the wire when securing the pen holder to the stand.

Stand Parts:

• 1x 0012994 JBC Compact Stand (35USD)
• 1x M6-10mm Button Head Screw (8mm without acrylic)
• 2x M3-45mm Socket (40mm without acrylic)
• 1x M3-8mm Socket
• Ring connector and and maybe dupont for wiring

S3-B Tip Changer Parts NOTE: The particular tip changer has now been discontinued by JBC however some people have already purchased one so I will keep the parts updated here

• 1x JBC S3-B
• 3x M3-45mm Socket (40mm without acrylic)
• Ring connector and and maybe dupont for wiring

Suggested wiring is for stand and tip changer is a wire that splits into two female dupont headers and then individual wires connecting to the stand and tip changer. Recommend a ring connector for a better connection

Pen:

• 1x T245 Handle (74USD)
• C245 Cartridges

DISCLAIMER:
Please note that there are dangers when wiring mains voltage. I do not take responsibility for any injuries that may occur. These instructions are also a WIP and any feedback will be appreciated.

Print instructions

All stls should have the correct orientation, no supports required.

Recommend PETG for thermal and strength

Everything printed on my Prusa Mini, parts can be printed with a 0.4mm at 0.2mm height. The larger parts can be printed using a 0.6mm nozzle and 0.3mm height to increase strength and decrease print time. I also recommend a 0.25mm nozzle for the buttons for finer details.