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Old 11th August 2014, 09:23 PM   #1
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Default Problem with Weller soldering iron

The last few days, I noticed my soldering iron has been acting up. When I turn it on (cold) the power light flashes, instead of staying illuminated until it gets to temperature. Seems to take a long time and the temperatures don't seem right. Very seldom will it pulse to maintain the temp. Just stays off or pulses on and off, the stays off again for awhile.

Any ideas of the cause? Maybe replacing the iron, or could it be within the controller?

http://vid1047.photobucket.com/album...pse2b666b9.mp4

Last edited by Deadly Sones; 11th August 2014 at 09:25 PM.
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Old 11th August 2014, 09:36 PM   #2
gofar99 is offline gofar99  United States
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Default Soldering Iron

Hi I had a similar issue with a different but similar brand. There was a frayed connection in the cord as it went into the base unit. The wire in question went to the temperature sensor in the iron. It became intermittent and would act just like you describe. Of course you might have a heating element going bad as well. I would check continuity first before replacing any parts.
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Old 12th August 2014, 12:14 AM   #3
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Don't know if that was the iron/controller discussed in a recent issue of Elektor -- what's the model?
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Old 12th August 2014, 12:45 AM   #4
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My WES51 does that when the tips are too crusty.
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Old 12th August 2014, 03:31 AM   #5
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As first diagnostic step I would replace any capacitor inside it.
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Old 14th August 2014, 06:12 PM   #6
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O.K. The iron station is a WES51. So far I took the PES51 (actual iron) apart and didn't see any problems with the wiring but isolated the wires anyway. That didn't work. Next, I bought a brand new PES51 (just the iron and cord) from Digikey. It even came with a tip (although I have many).... still no power light or heat at all.....

Guess it's time to take apart the controller and see if I can find any issues.

Which capacitors in particular would you be speaking of Kiriakos? This WES51 is only about 1 year old and I haven't even really used it much over the last few months.
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Old 14th August 2014, 06:58 PM   #7
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That iron has a lockout on the temperature control that you lock/unlock with a magnet. It's possible the temp control may be turned to low and locked there.
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Old 14th August 2014, 06:59 PM   #8
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If this is a new purchase? Then activate the warranty plan by contacting Weller.
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Old 14th August 2014, 08:32 PM   #9
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Its a little over a year old. and I just took it apart so might have voided the warranty.

I've been through the service manual and all the checks check out fine. It have 28vac across the red and yellow wires.

Things I did notice is one small smd diode is reading .048v in both directions on diode check. Pretty sure that shouldn't be. Also when checking resistance between legs 1 and 3 of the BTA12 I only get 70 ohms. Not sure if that should be higher or not.

I'm thinking I should pull the BTA12 and test out of circuit or else just buy another one and def replace that one diode. I'm not sure what diode to order for it though.

Thanks for the help,
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Old 14th August 2014, 08:43 PM   #10
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Mine measures pretty close to the same.
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