Question about Cooper Industries Weller Field Soldering Iron, Controlled Output

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Repair wiring on weller soldering iron model ec1002

Need to know where to reconnect cut wires inside soldering iron. Looks like someone bypassed the temp control. Trying to fix back to original stat.

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Gintautas Maldzius

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If the coil wire is snaped then you will need to replace all the coil. usually the power from the outlet goes stright to the coil and connects to both ends of it's windings

Posted on Jul 24, 2009


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I have an old Weller soldering iron model 8250a that I would like to repair. It has burnt up wiring, and I'd like to find a wiring circuit diagram, schematic or ANY kind of electrical drawing, comple

These were very simple and sturdy soldering guns [I still have 5 or 6 of them in various sizes] They basically have a transformer wired so that the heating part is basically a short circuit of the large low voltage secondary winding [very low voltage] and because the tip is higher resistance than the rest of the heat producing end, it gets hotter sooner. The secondary is just a single loop of the tube that holds the tip. Usually the only maintenance is to loosen and re-tighten the tip mounting nuts so that there is a good electrical connection [no connection = no heat; poor connection = poor heat]
There may be another small secondary winding that provides power to the light but I think the older ones just attached the lighting wires to the large secondary.
The primary [line voltage] winding of the transformer is switched such that the higher wattage powers the lesser resistance part of the winding and the lower wattage powers the higher resistance part of the same winding. In other words there is a single wire for the primary that has a tap near one end of the winding for dual heat.
If the two windings to the switch are mixed up the higher heat will just be at a different trigger position; if you don't like it, switch them around.

Also check the connection to the non-switched wire from the cord for a good connection. The switches are still available, at least for the newer models; do a google search for
Weller soldering gun switch
Weller 7324
Untitled Document [for a switch supplier]

Weller Switch Dual Heat Gun 1 Each 7324

Feb 10, 2015 | Weller Welding Tools

1 Answer

I have Weller EC1002, WES51, and WTCPS all with base, cord, and handpieces (complete). On shelf for years. Can you test, quote and do repairs as needed?

yes but shipping alone would eat a lot of $$$
they r pretty basic - u should be able to do that urself.
a multimeter may be necessary
it is either
broken wire in cables
bad connection inside case
thermal cutout
bad tip

Jun 30, 2014 | Weller WES51 SOLDERING STATION

2 Answers

Need a wire diagram for Weller Pes51 50watt Soldering Pencil I hope this helps

Dec 30, 2012 | Weller Pes51 50watt Soldering Pencil

1 Answer

I have a weller EC1201A iron connected to an EC2100D base unit. It is a UK 240V model with digital temp set and display. The iron does not heat up. You can set the desired temp but the display just...

its my be the controler
good luck...

Feb 25, 2011 | Weller Welding Tools

1 Answer

Soldering tip is not getting heated up as well as led is not glowing .i am getting 26 V AC at the output of Transformer for my weller WES51

I had a similar problem. I found that the cable from the transformer to the iron had an open in it. There are two spots where this mainly happens. At the transformer connector, or and probably this is it, at the iron entrance, You can remove the heater on the iron and take a voltmeter and see if you have power there. I found on mine that there was an open. I removed my cable, cut off the end at the iron and re-installed it. It was not easy but I managed to get it repaired. This is a kinda trial and error thing, mostly cables fail at the strain reliefs, this is where there is the most play in the system, and the constant flexing eventually breaks a wire. There are a number of places to get replacement cables, etc. Here is the one I use www. . Please let me know if this has helped.

Jan 28, 2011 | Weller WES51 SOLDERING STATION

1 Answer

Iron will not heat---could it be the tip? How can I check the iron w/o replacing the tip?

If the iron is not getting hot at all then the tip is not the issue. I would goto a local hardware store like home depot or lowes and buy a replacement wall plug. You should first cut, strip back the wires and replace the plug as per its instructions. If the Iron still doesn't heat up after this you should unplug it and dissemble the body of it, you have to unscrew the 3 screws on the top and slide the body down. There will be wire nut connections for the electronics from the wall plug cable to the actual iron, check that they are connected properly. Often there is a break in the pinch point of the cable at the end of the irons body. For solving this I like to cut the wire below the pinch point, strip the wires back and redo fresh connections at the wire nuts. Good luck!

Jan 23, 2011 | Weller Wp35 35watt Professional Soldering...

1 Answer

Before ordering a replacement cord (TC217) for a Weller TC201 handset, I would like to know how the cord is installed on the handset end.

Wiring is easy... look at the parts blowup here. It appears that two of the wires from the cord use wire nuts to attache to the elelment and switch.

Sep 27, 2009 | Weller TC201T: Soldering Iron For Wtcpt,...

1 Answer

Rewireing a handle

black goes to gold white to silver well guess you know where green goes now

Jan 04, 2009 | Weller TC201T: Soldering Iron For Wtcpt,...

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