Mastering Electronics: An In-Depth Look at the Aoyue Int 866 Rework Station

    • by Jean-François Simon
    • Reading time: 11 min

    In the ever-evolving world of electronics, soldering remains a crucial skill. Addressing this need, the Aoyue 866 rework station steps up with a multifunctional approach, combining a hot-air station, PCB preheater, and conventional soldering station into one compact unit. Let's delve into how this versatile tool can revolutionize your soldering tasks.

    general view of the Aoyue 866
    The Aoyue 866, a multipurpose device.

    Comprehensive heating solutions

    The Aoyue 866 Rework Station is a three-in-one multifunction station. Ideal for a range of electronic soldering tasks, it excels in handling both through-hole and SMD components. In my previous repair articles, I've demonstrated desoldering multi-pin components with two soldering irons—a method effective for small parts but cumbersome for larger, multi-pin components.

    When dealing with larger components, a hot-air station becomes indispensable. This tool requires some finesse, as it involves manually operating the heat "gun" and adjusting both temperature and airflow. The objective is to apply sufficient heat to solder or desolder without harming the PCB or nearby components. It's crucial to strike a balance: the airflow must be strong enough to provide adequate heat but gentle enough to avoid displacing smaller components.

    The Aoyue 866 station takes this concept further by featuring an articulated arm and column to securely hold the hot air handpiece, liberating your hands for other tasks. This setup is enhanced by the integrated board preheater, which applies even heat from below. This ensures the entire board is uniformly heated to just below the solder's melting point, allowing for precise application of additional heat with the hot air handpiece. Preheating is especially critical for soldering large components, such as connectors attached to extensive ground planes, as it prevents uneven heating and potential damage.

    Technical specifications of the Aoyue 866 Rework Station

    The Aoyue 866, pronounced "ow you," is a compact yet powerful rework station designed to meet diverse soldering needs. Here’s a closer look at its main specifications:

    Compact and Powerful Design

    • Base Dimensions: The Aoyue 866 features a sturdy 350 x 190 x 110 mm base, which provides stability on your workbench without taking up too much space.
    • Infrared Heater: Equipped with a 550 W quartz tube infrared heater, the station offers a heating surface of approximately 130 x 130 mm. The temperature can be precisely adjusted between 100 and 450°C, making it suitable for various preheating tasks.

    Versatile Hot Air Handpiece

    • Power and Temperature: The hot air handpiece is also rated at 550 W, with an adjustable temperature range from 100 to 480°C. This versatility allows for effective reworking of both small and medium-sized components.

    Efficient Soldering Iron

    • Temperature Control: The 60 W soldering iron features a wide temperature range from 200 to 480°C. It connects to the preheater with a 5.8 mm-diameter, 900 mm-long cable. While the cable is relatively flexible, it is somewhat thick and sheathed in PVC, necessitating careful handling to prevent damage from the soldering iron.

    It’s worth noting that there may be discrepancies in the power ratings as listed in various sources, including the manual, the Aoyue product page, and this review. The wattages provided here are based on my own measurements.

    What's inside the package

    Opening the package of the Aoyue 866 reveals an impressive array of components, each carefully packed to ensure you have everything you need for a comprehensive soldering and rework experience.

    Contents of the package
    That was a hefty package!

    What's Included:

    • Preheater
    • Hot air handpiece: Comes with four nozzles (three round: 6 mm, 8 mm, 12 mm; and one square: 10 mm).
    • Main column: Supports the hot air handpiece with a secure lock ring.
    • Articulated Arm: A 3-section aluminum alloy arm
    • PCB holders: A set of six small parts with associated thumbscrews to hold the PCBs above the preheater.
    • External thermocouple
    • Soldering iron
    • Soldering iron holder including a sponge
    • Brass sponge tip cleaner: Made from genuine brass and not plated steel.
    • Solder spool holder
    • Power cable
    • Accessory toolbox: A small plastic toolbox containing a set of soldering iron tips, a spare heating element for the soldering iron, a spare element for the hot air handpiece, and a pen-style vacuum pickup tool to lift ICs.

    Assembling the station: A simple guide

    Putting together the Aoyue 866 Rework Station is a breeze, even with its brief instructions. Here’s a step-by-step guide to ensure a smooth assembly process:

    Securing the column: Begin by securing the column to the lower frame using a single large screw. Although a 6 mm Allen key is not included, it's not necessary. You can hold the screw head with your fingers and tighten the column by hand. Be cautious not to over-tighten, as the thin steel of the lower frame can bend easily.

    Locking the hot air handpiece: Engage the lockring on the column to keep the hot air handpiece at a consistent height. This ensures stability and precision during use.

    Attaching the articulated arm: Position the tightening knobs on top of the column and attach the three-section articulated arm. Insert the hot air handpiece into the hole in the arm and gently secure it with the side screw.

    Setting up the iron holder: The modular iron holder allows for versatile configurations. You can equip it with the brass sponge, the classic sponge, or both. The sides are interchangeable for your convenience. Additionally, a stand for a solder spool can be attached to either the left or right side, based on your preference. The package includes a metallic bracket and a variety of screws for this purpose.

    Three options for the iron holder
    The holder offers numerous possibilities, with accessories also fitting on the opposite side.

    Operating the Aoyue 866 Rework Station

    The Aoyue 866 is designed for straightforward use. Each component—the hot air, preheater, and soldering iron—has its own dedicated On-Off button, display, and temperature control switches. Additionally, the front panel includes a potentiometer for adjusting the hot air flow rate, ensuring precise control over your soldering tasks.

    the soldering iron
    A classic Aoyue iron.

    Soldering iron: The soldering iron, with a 60 W output, is perfect for a wide range of common tasks. It comes with standard "900M" tips, making replacements easy to find. If you require a specific tip geometry not included in the set, it can be easily purchased separately. The iron's versatility allows it to function as a regular soldering station, making it a reliable tool for most soldering needs.

    using the soldering iron
    The 866 can be used as a regular soldering station.

    Hot air handpiece: The hot air handpiece can be used independently of the preheater, connected to the base with a 1.15 m long cable. With its 550 W heating power, it efficiently reworks many small and medium-sized components. Removing packages like PLCCs becomes a breeze. However, for more massive components such as large BGA packages or multilayer motherboards, the hot air alone may not provide enough power for quick solder melting, risking damage to nearby components or the PCB itself due to prolonged heating.

    using the hot air
    Removing this PLCC package was a breeze.

    Preheater: This is where the preheater proves invaluable. It simplifies challenging tasks with its increased heating power and gentle application of heat from below. The preheater also allows for hands-free operation by placing the hot air handle in its holder, freeing your hands to use tweezers or adjust settings.

    the PCB holders
    Adjustable PCB holders.

    PCB holders: The kit includes six small aluminum brackets that can be attached to the side rails using sliding nuts and hand screws, allowing you to secure PCBs above the preheater. For optimal stability, ensure the board dimensions do not exceed 180 x 110 mm when using the system on all four sides. If brackets are used only at the front and rear, the preheater can accommodate a board up to 180 x 160 mm. Alternatively, you can place a larger board directly on top of the preheater without using clamps, but take care to handle the board carefully to avoid dislodging it. Additionally, covering the entire preheater with a large board can obstruct natural airflow, causing higher surface temperatures and potentially desoldering components on the bottom side.

    Temperature Management: Precision with the Aoyue 866 Rework Station

    When working with the Aoyue 866, it's crucial to understand the temperature readings displayed on the unit. The middle display labeled "preheater" shows the temperature measured by a probe inside the radiant panel, not the actual temperature of the board. Therefore, users need to determine the optimal preheater temperature through trial and error to achieve the best results.

    ready to use preheater
    Ready for removing a Broadcom BGA package.

    Aoyue includes an external K-type thermocouple designed to measure the PCB temperature as close as possible to the reworked component. However, it comes with some challenges. The unit features only one connector, so you can either connect the soldering iron or the thermocouple, but not both at the same time. To switch the display to the external thermocouple mode, you must turn off the soldering iron and press the corresponding “down” button.

    During my use, the thermocouple displayed an ambient temperature of 71°C, which was 47 degrees higher than the actual temperature. At 330°C, the error margin was about 40°C. Unfortunately, Aoyue does not provide a method to calibrate the external thermocouple to reduce this error, though calibration is possible in soldering iron mode (refer to the manual for details).

    Despite this, I found that the temperatures of both the soldering iron and hot air were accurate, so I did not need to use the calibration feature. For the external sensor, you can either mentally adjust the displayed temperature by subtracting approximately 40 degrees or use a separate thermometer for precise measurements. Overall, the tool works effectively. In the following photo, I am desoldering a chip in a BGA package on a router board.

    removing a BGA package
    Ta-daa! Careful, its hot around here.

    Inside the Aoyue 866

    The Aoyue 866 is built with a straightforward and sturdy design. All wires running through the central part of the heater are encased in heat-resistant sheaths, ensuring safety. The connections are well insulated, the soldering iron transformer is robust, and connectors are securely fastened with glue. The soldering is well-executed, though some residual flux remains, which is unlikely to affect the device's operation.

    internal construction
    The insides of the Aoyue 866 are simple.

    The front panel board features an ATmega16 microcontroller from Microchip to manage the user interface and temperature settings. It also includes a 74HC595 shift register and two ULN2003 drivers to control the display segments.

    The main board is single-sided and consists of through-hole components. It includes BTA20-600 and BTA12-600 triacs, as well as MOC3021 optocouplers, to control the heating elements for the preheater, hot air, and soldering iron.

    Who should use the Aoyue 866?

    In conclusion, the Aoyue 866 is an excellent choice for those seeking a versatile and affordable tool for electronics soldering. It is particularly well-suited for repairing smartphones and game consoles with small PCBs. Additionally, it is a great option for those interested in low-cost BGA reballing. While mastering BGA reballing requires extensive practice on sacrificial PCBs, Aoyue provides specific nozzles to aid in the process.

    What makes the Aoyue 866 stand out is its compact and space-saving design, making it a perfect addition to any workshop. It is one of the most affordable options available, offering a comprehensive kit that includes all necessary accessories and spare parts, neatly organized in a handy toolbox. Its mechanical and electronic simplicity ensures reliability and ease of repair, making the Aoyue 866 a standout choice for both electronics enthusiasts and professionals.

     

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