Author Topic: Weller WD1 Discussion and Repair (Read 53707 times)

quanttrom · « **on:** March 29, 2013, 10:05:10 pm »

I'll just leave this right here in case it's ever useful to anyone..

I got my hands on a broken Weller WD1. This is the rather basic variant with single output and no USB connectivity but it is still a rather nice soldering iron IMHO.

I managed to get the schematics of it and I will try to explain the working of it to the best of my understanding. Corrections and discussions are welcome.

The soldering iron has a transformer with 2 output voltages on it. One is 12V the other is 24V. There are 2 separate boards. First PCB includes all the 24V electronics while the second board is the control and user interface.
First board:
The 12V AC output is rectified with a single diode and then fed straight into the control PCB.
The 24V AC is used to power the heating element. A TLP160J optocoupler (http://www.toshiba.com/taec/components2/Datasheet_Sync/210/4350.pdf) is used for isolating the control circuitry from the heating circuitry. A BTA12 triac is used to turn the heating element on and off.
The zero-crossing detection of the 24V AC is done using a 100k/100k voltage divider with clamping diodes, etc. The output of this is fed into the control board into the /INT1 (pin 9) input of the micro.
Control Board:
The 12V DC from the first board is reduced to 5V through a linear regulator. Run of the mill 7805 (78M05) .
The whole design is based around a PIC18F4620. The buttons on the faceplate are directly connected to the micro. The LCD display is driven by a PCF8576 driver (http://www.nxp.com/documents/data_sheet/PCF8576.pdf) . The PIC and the LCD driver communicate through an I2C bus.

There is some analog circuitry on the temperature probe output that comes in from the soldering iron pencil. It is based around MCP601 op-amp. The positive input is connected through a 1k5 resistor to microcontroller pin 5 - RD7 (I assume they use it as PWM output from the micro) and fed in the opamp
The opamp is used to prove a (what seems to be rather large ~31) gain to the signal from the temperature probe. The output of this circuit is fed into pin 20 (AN1) where they use the build in 10-bit AD converter.

There are some other feedback signals used but I am not sure what their purpose is. One is fed into AN4 (pin 24) and another one into RD2(pin 40) .

Header X3 is used for programming. TE Connectivity 8-215464-0.

And that's all she wrote !

The PIC was damaged...somehow..on the unit that I got. I was able to make a programming header and use it to read the firmware from another good unit and program it into this one. A PICkit2 programmer was used. Overall a rather painless process once I acquired a new micro and the proper connection header. The second unit wasn't mine so I wouldn't be allowed to solder wires and butcher the whole station.

10 bucks and a couple of hours of fidgeting around trying to get all the info proved very useful

Blog post + pics : http://www.quanttrom.com/2013/12/hardware/weller-wd1/weller-wd1-repair/

M. András · « **Reply #1 on:** March 30, 2013, 12:10:36 pm »

it would be good to be able to speed up that display it slow as hell and most of the times i dont know what temp is it displaying but not the actual, while the wd1m i have outputs the actual temp trought usb to the weller software intrestingly

kripton2035 · « **Reply #2 on:** March 30, 2013, 12:21:07 pm »

it is quite extraordinary that you were able to read a PIC' firmware out of a commercial product...

M. András · « **Reply #3 on:** March 30, 2013, 12:30:11 pm »

haha i doubt they did even brother to prevent reading it out, wd1m has the option to upgrade the firmware trough usb but there is no firmware anywhere on their sites and doesnt even reply for for it

quanttrom · « **Reply #4 on:** March 30, 2013, 05:01:58 pm »

The USB is actually done using a serial to USB converter board. There isn't anything magical about it. I believe a different firmware load is also required.

I've hooked up an oscilloscope to the TX/RX pins that typically go to the USB board and I don't see any kind of signals on them. There is a possibility the software needs to send some magical init sequence before they start outputting info.

Actually I am kind of curious. M. Andras would you be interested in reading out the firmware from your WD1M ?

nanofrog · « **Reply #5 on:** March 30, 2013, 06:20:20 pm »

Quote from: quanttrom on March 30, 2013, 05:01:58 pm

The USB is actually done using a serial to USB converter board. There isn't anything magical about it. I believe a different firmware load is also required.

I've hooked up an oscilloscope to the TX/RX pins that typically go to the USB board and I don't see any kind of signals on them. There is a possibility the software needs to send some magical init sequence before they start outputting info.

Actually I am kind of curious. M. Andras would you be interested in reading out the firmware from your WD1M ?

According to the manual I have, the WD1 & WD2 are upgradeable to an M version by adding the USB interface board.

M. András · « **Reply #6 on:** March 30, 2013, 09:28:05 pm »

if you tell me how to do it without taking the thing apart, cos its under warranty for a 1 and a half year, their firmware upgrade tool as i remember only uploads and wont read it back, as for just a serial to usb coverter its right a small raiser board mounted with a rivet dangling freely from the plugging force of the mini usb cable

quanttrom · « **Reply #7 on:** March 31, 2013, 02:53:31 pm »

I don't think you can do it while it is under warranty.

That said, I think nanofrog is right. It is very likely that I just have to pull a signal high or low and it might start spewing some information on the serial port. I will download and have a look at the WD1M software.

M. András · « **Reply #8 on:** March 31, 2013, 05:37:40 pm »

pls link it if you find somehow a firmware for it, as i remember it has 1.00 or 1.01, but i highly doubt it

edit: btw i think there are some component differences between the 2 models only the M model supports the wrmp pencil which has a laser engraving on the handle 12V/55w, now the station supposed to be 24v output

nanofrog · « **Reply #9 on:** March 31, 2013, 07:29:57 pm »

Quote from: M. András on March 31, 2013, 05:37:40 pm

edit: btw i think there are some component differences between the 2 models only the M model supports the wrmp pencil which has a laser engraving on the handle 12V/55w, now the station supposed to be 24v output

You're thinking of the WXMP, which is 12V. The WRMP is 24V (40W), and designed for the WDxM & WR3/3000M series stations.

I presumed that once a user upgraded a standard WD model to an M version, load the software, and connect the station to the computer, it would download the necessary firmware to support the WRMP & WMRT hand pieces. Perhaps the firmware is already present from the factory?

M. András · « **Reply #10 on:** March 31, 2013, 08:07:00 pm »

if its enough proof for you

nanofrog · « **Reply #11 on:** March 31, 2013, 08:18:53 pm »

Quote from: M. András on March 31, 2013, 08:07:00 pm

if its enough proof for you

Wonder what's up with this?

I say this, as I double checked with Apex's site (Weller) prior to posting, which states that the WRMP = 24V.
Source: http://www.apexhandtools.com/brands/CF_Files/model_detail.cfm?upc=037103209047. Same info is duplicated in their brochure (click the literature link).

WTH Weller?

M. András · « **Reply #12 on:** March 31, 2013, 08:29:14 pm »

it had a dedicated station and a vertical stand and these are obsolote now that version was 24v
http://www.weller.de/products/product.php?pid=52

nanofrog · « **Reply #13 on:** March 31, 2013, 08:43:17 pm »

Quote from: M. András on March 31, 2013, 08:29:14 pm

it had a dedicated station and a vertical stand and these are obsolote now that version was 24v
http://www.weller.de/products/product.php?pid=52

I knew they changed the stand, but hadn't heard or seen a change to the iron or station.

Wonder why they haven't updated the US site? Perhaps the older 24V version is still being sold here (find it odd from a systems/manufacturing POV since their owners are all about cutting costs, but possible)?

M. András · « **Reply #14 on:** March 31, 2013, 09:41:26 pm »

it was the wrms kit what used the 24v version of this, i dont know if the wxmp different or not but i dont know the reason too why its not supported by the wd series only the wx stations

nanofrog · « **Reply #15 on:** March 31, 2013, 11:22:31 pm »

Quote from: M. András on March 31, 2013, 09:41:26 pm

it was the wrms kit what used the 24v version of this, i dont know if the wxmp different or not but i dont know the reason too why its not supported by the wd series only the wx stations

I'm guessing the voltage differences (power boards weren't designed to switch between 12V & 24V irons). At least here in the US, searching (both Apex and distributors), all indicate that the WRMP is coming up as 24V and is compatible with the WD1/2 M variants.

Funny thing is, the link I gave from Apex, states the information is for the WRMP, and the photo is of the WRMS (check the larger image). I know companies don't always use the correct image, but rather a common image for a series/product family, but I'd hope the specs listed for the stated P/N are correct.

Currently, I'm trying not to convert my unit given Weller's QC issues (seen issues of both irons and power heads dying in this and later series; very recent news to find the WMD series is the same).

Zapro · « **Reply #16 on:** May 06, 2013, 05:35:53 pm »

I do believe, that you cannot modify a WD1/2 for the WMRP pencil. The WMRP pencil does use a K-type thermocouple, and not a NTC like in all the other stations.

I have a WD1M station, that I have taken apart to see how it works, similarly, i've taken an WD1 station apart to see, what the differences is.

There is no thermocouple-amplifier in the WD1/2 station, so it cannot read a thermocouple iron (e.g. WMRP)

So, it's not all up to software differences.

// Per.

dungad · « **Reply #17 on:** September 18, 2013, 08:26:26 am »

Hi All, I'm new to the forum and need a bit of help.
I've found an old welled WD1 that someone removed bits form the power board(I assume only the BTA12 is missing and have a good idea of where it needs to go) but can someone please post a photo so that I can compare and see what else may be missing form my unit?
Cheers,
Dan

quanttrom · « **Reply #18 on:** September 18, 2013, 12:37:15 pm »

would schematics be adequate?

dungad · « **Reply #19 on:** September 18, 2013, 01:16:46 pm »

Yes, schematics will help more. Can you point me to where I can find them?

nanofrog · « **Reply #20 on:** September 18, 2013, 04:01:12 pm »

Pics can be had too, in the following thread: https://www.eevblog.com/forum/reviews/weller-wmd-3-repair/msg210603/#msg210603

Please note however, that the boards posted by myself and another member (Baliszoft) are different from one another, so there's at least 2 PCB revisions for that model. Specifically, it's the BTA12 that is one of the parts that has a slightly different location. So you may need to trace out your particular board.

Hope this helps.

nanofrog · « **Reply #21 on:** September 18, 2013, 07:46:26 pm »

Here's the schematics for the WD1...

dungad · « **Reply #22 on:** September 20, 2013, 07:06:07 am »

Hi nanofrog,
Thank you for the additional information, my WD1 unit is like Baliszoft's one.
Looks like I'm only missing the triac, will post my result once I get the new triac installed.

pinkman · « **Reply #23 on:** December 05, 2013, 01:03:07 pm »

I recently acquired an WD1 station which works fine for a while, but ends with the degree (oF) indicator flashing and the iron OFF.

Sometimes turning the unit off/on or performing a factory reset corrects this problem for a while, but it always comes back. I have tried swapping in a brand new iron and it has the same symptom, so it appears that the problem is internal.

Has anyone encountered this problem? I downloaded the schematics and I'll analyze them later. I suppose it's time to start poking and prodding this little monster.

SLJ · « **Reply #24 on:** December 05, 2013, 01:26:40 pm »

Not to sound obvious but did you check the settings for standby and auto-off time?

M. András · « **Reply #25 on:** December 05, 2013, 01:59:30 pm »

factory reset should disable the auto off and the setback timers, check the internal connections to the pcb board if its the same stupid connector as in the wd3m the type you see on the patchpanels idc or god knows whats their name can come lose if wasnt pressed in properly

pinkman · « **Reply #26 on:** December 06, 2013, 07:18:26 pm »

Yup. This fault occurs randomly, sometimes immediately after turning on (the iron never warms up). I'm going to inspect the solder joints on everything again, they look OK but I'll inspect with a magnifier and see what I can find.

Quote from: SLJ on December 05, 2013, 01:26:40 pm

Not to sound obvious but did you check the settings for standby and auto-off time?

M. András · « **Reply #27 on:** December 06, 2013, 07:20:57 pm »

it easier if you remelt every joint if you have a spare iron and refit the cabling

Danielw · « **Reply #28 on:** May 07, 2014, 03:13:35 pm »

Glad I found this! Thanks for the schematics

I installed a led mod like this one : http://www.eevblog.com/2012/02/03/eevblog-242-hakko-fx-888-soldering-iron-hack/
I just connected a led in series with a resistor between GND and Triac_ch1 ( I think it was, just probed around to find a good spot to solder near the connector)
Now I wont forget the damn thing turned on for a couple of days in a row!

diogoc · « **Reply #29 on:** October 13, 2014, 01:30:22 pm »

My soldering station have a PIC18f6622 instead the Pic18f4620.
Anyone have the firmware fot ir?

nanofrog · « **Reply #30 on:** October 13, 2014, 08:14:59 pm »

Quote from: Danielw on May 07, 2014, 03:13:35 pm

Glad I found this! Thanks for the schematics

I installed a led mod like this one : http://www.eevblog.com/2012/02/03/eevblog-242-hakko-fx-888-soldering-iron-hack/
I just connected a led in series with a resistor between GND and Triac_ch1 ( I think it was, just probed around to find a good spot to solder near the connector)
Now I wont forget the damn thing turned on for a couple of days in a row!

But I have to ask, any reason to do this over looking at the switch to see if there was any red visible?

diogoc · « **Reply #31 on:** October 16, 2014, 10:18:20 am »

I get the firmware for the Weller WD2 (with PIC18f6622), so if anyone need it ask me.
With this and adding some components you can convert a WD1 into a WD2.

Smith · « **Reply #32 on:** October 25, 2014, 07:13:07 am »

I like the build and speed of these, but we had a lot of trouble with 4 older versions of the WD2M stations. Undocumented errors, spontaneous lockups one eventually killed itself. Luckely it was mine, now I have one which actually works without flaws

necplusultra · « **Reply #33 on:** December 23, 2016, 10:58:25 am »

greetings,

my WD2 has one channel saying OFF
according to manual, channel cannot be switched on. probable cause overload cut-off

is there any way to have the channel switched on?

diogoc · « **Reply #34 on:** December 23, 2016, 04:17:04 pm »

Quote from: necplusultra on December 23, 2016, 10:58:25 am

greetings,

my WD2 has one channel saying OFF
according to manual, channel cannot be switched on. probable cause overload cut-off

is there any way to have the channel switched on?

You can turn OFF and ON a channel in WD2.
Just press Up and Down at the same time quickly.

nanofrog · « **Reply #35 on:** February 07, 2017, 11:32:03 pm »

Sent you a PM about this.

Smith · « **Reply #36 on:** March 12, 2017, 07:55:27 am »

Finally had some time to make some pictures with my ~~potato~~ phone. Please mind this is a Weller WD 2M!

Smith · « **Reply #37 on:** March 12, 2017, 07:56:57 am »

Some more

Smith · « **Reply #38 on:** March 12, 2017, 07:58:05 am »

even more

Smith · « **Reply #39 on:** March 12, 2017, 08:01:53 am »

Last ones

Smith · « **Reply #40 on:** March 12, 2017, 08:17:19 am »

Some info, just like that:

The station does take the 12V WMRP without any problem.

I had lots of troubles with "stuck channels". They where unable to be enabled by the front (pressing up/down shortly). I did manage to enable the channels multiple times by setting them in the Weller software (via the USB connection of course. I cant remember the exact sequence, but is meant locking and unlocking some features. Newer stations don't seem to have this problem.

Mine killed a number of 10A fuses (The SMD fuse on the left of the power PCB) The irons still work fine on other stations though.

Enabling more than 160W on the WD2 makes the station disable one of the two channels.

If your irons heat up until they break, check the Triacs (BT16-600 types if I recall correctly). I fixed this once on a WR3M channel, which basically seems the same like the WD1 and WD2.

I recall a chat with a salesman: The "older" WD1M and WD2M where sold until they where replaced by the WX series. But because of the demand the WD1 and WD2 came back, basically the same stations, but without the default USB interface. Now you can buy the USB PCB seperately (about. 70 euro's if i remember correctly).

I have heard some people about stations that have seem to have lost their firmware. You can reflash it by reading it off another station with an Microchip ICD programmer (confirmed, this works), and flashing it back in the broken station. The Microchip ICD can be soldered to the USB breakout PCB without any problems.

Smith · « **Reply #41 on:** April 01, 2017, 05:17:52 pm »

Quick update, firmware from a WD2M, extracted with a Microchip ICD 3 programmer:

z01z · « **Reply #42 on:** April 05, 2017, 06:17:09 am »

Thanks for the effort, but the fw file you've posted is just a bunch of zeros. Maybe the PIC was protected?

Smith · « **Reply #43 on:** April 05, 2017, 05:39:33 pm »

Something must have gone wrong while copying, I got the FW from one station, and programmed it to another.

BJB · « **Reply #44 on:** February 02, 2018, 08:49:10 am »

I know the topic has been inactive for awhile... but i also have a weller with a dead microchip 18F6622.
I need the firmware for it, would it be possible for you to post it again?
Thanks!

Mr. Scram · « **Reply #45 on:** February 02, 2018, 09:10:49 am »

Quote from: BJB on February 02, 2018, 08:49:10 am

I know the topic has been inactive for awhile... but i also have a weller with a dead microchip 18F6622.
I need the firmware for it, would it be possible for you to post it again?
Thanks!

What model do you have?

BJB · « **Reply #46 on:** February 02, 2018, 05:07:32 pm »

The WD1M

cluca1969 · « **Reply #47 on:** May 15, 2018, 09:02:03 am »

Please HELP me I need a LCD for a WD1M or WD2M !!! or name for code part number !!!

Mr. Scram · « **Reply #48 on:** May 15, 2018, 09:09:17 am »

Quote from: cluca1969 on May 15, 2018, 09:02:03 am

Please HELP me I need a LCD for a WD1M or WD2M !!! or name for code part number !!!

According to the manual, the display is part of part number 0058758759.

http://www.dhscorp.co.kr/weller/images/download/manual/OI_WD1M_eng.pdf

cluca1969 · « **Reply #49 on:** July 26, 2018, 08:41:59 am »

Thank you very much Mr. Scram

Tatanka1961 · « **Reply #50 on:** September 13, 2018, 02:02:14 pm »

Quote from: diogoc on October 16, 2014, 10:18:20 am

I get the firmware for the Weller WD2 (with PIC18f6622), so if anyone need it ask me.
With this and adding some components you can convert a WD1 into a WD2.

Hi,
I have both a WD1 and a WD1M
I would be very interested in converting 1 of them into a WD2(M). Preferably the M

They do seem to have different PIC chips though: the WD1 has a PIC18f6622 while the WD1M has a Pic18f4620
Is it the difference between the normal and the 'M' or just a newer revision?
Also the 'power' boards are quite different.
Could anyone please provide the binary file for the WD2(M)?

Quote from: Smith on April 01, 2017, 05:17:52 pm

The Microchip ICD can be soldered to the USB breakout PCB without any problems.
Could you please tell us how to connect it?

z01z · « **Reply #51 on:** September 14, 2018, 05:41:44 am »

Quote from: Tatanka1961 on September 13, 2018, 02:02:14 pm

Is it the difference between the normal and the 'M' or just a newer revision?

You really should have read this topic, the answers are there:

Quote from: Zapro on May 06, 2013, 05:35:53 pm

I do believe, that you cannot modify a WD1/2 for the WMRP pencil. The WMRP pencil does use a K-type thermocouple, and not a NTC like in all the other stations.

I have a WD1M station, that I have taken apart to see how it works, similarly, i've taken an WD1 station apart to see, what the differences is.

There is no thermocouple-amplifier in the WD1/2 station, so it cannot read a thermocouple iron (e.g. WMRP)

So, it's not all up to software differences.

// Per.

Quote

Could anyone please provide the binary file for the WD2(M)?

It's also posted a few posts back.

Tatanka1961 · « **Reply #52 on:** September 14, 2018, 09:15:47 pm »

Quote from: z01z on September 14, 2018, 05:41:44 am

You really should have read this topic, the answers are there:

I actually DID read the entire topic.

The difference you pointed out is between the WD and the M version.
I kinda figured out that it's not possible by just looking at the boards, but I don't want to convert a regular one into an M. I want to convert a 1 into a 2.

Quote

It's also posted a few posts back.

As you pointed out yourself:

Quote

Thanks for the effort, but the fw file you've posted is just a bunch of zeros. Maybe the PIC was protected?

So thanks for the comments, but not really helpful...

z01z · « **Reply #53 on:** September 17, 2018, 09:29:15 am »

Quote from: Tatanka1961 on September 14, 2018, 09:15:47 pm

I kinda figured out that it's not possible by just looking at the boards, but I don't want to convert a regular one into an M. I want to convert a 1 into a 2.

Yet what you wrote revolves around the M version, which is kind of misleading.

Quote

As you pointed out yourself:
Quote
Thanks for the effort, but the fw file you've posted is just a bunch of zeros. Maybe the PIC was protected?

You're right, looks like I should have better memory.

Quote

So thanks for the comments, but not really helpful...

OK, to be a bit more helpful then.

You could duplicate the driver for the second channel, that doesn't look that bad.
You'd still need the firmware, the handset connector and possibly a new transformer.
If your goal is to not to swap handsets that often, you could keep the existing transformer, but it would still have a lower power output than a real WD2.
I'm not sure if you can get an original connector. There's a possible workaround, though it requires some mechanical work (the notch in the Amphenol connector is at a different position) , check this for the part number.
As for the firmware, the M version can be updated, there's a Weller program for that. Maybe the firmware can be extracted from it.

Tatanka1961 · « **Reply #54 on:** September 18, 2018, 07:19:19 pm »

Quote from: z01z on September 17, 2018, 09:29:15 am

Yet what you wrote revolves around the M version, which is kind of misleading.

Yes, I can see how this might be confusing.

Quote from: z01z on September 17, 2018, 09:29:15 am

You could duplicate the driver for the second channel, that doesn't look that bad.
You'd still need the firmware, the handset connector and possibly a new transformer.
If your goal is to not to swap handsets that often, you could keep the existing transformer, but it would still have a lower power output than a real WD2.
I'm not sure if you can get an original connector. There's a possible workaround, though it requires some mechanical work (the notch in the Amphenol connector is at a different position) , check this for the part number.
As for the firmware, the M version can be updated, there's a Weller program for that. Maybe the firmware can be extracted from it.

duplicating the driver hardware would indeed not be that hard.
I don't mind the limited power output, I would only be using 1 iron at a time.
Getting the right firmware seems to be the biggest obstacle. I have the software for programming the WD1M, but it doesn't seem obvious to extract the firmware.
I guess all in all it will be more trouble than it's worth, so I'm putting it on hold for now. Maybe I'll look into it again later...

z01z · « **Reply #55 on:** September 18, 2018, 09:25:07 pm »

Quote from: Tatanka1961 on September 18, 2018, 07:19:19 pm

Getting the right firmware seems to be the biggest obstacle. I have the software for programming the WD1M, but it doesn't seem obvious to extract the firmware.

Sorry about that, it was wishful thinking...
It appears that the firmware updater package doesn't contain the firmware after all. The program simply wants to open a file with the firmware, which is not there.

YoYo · « **Reply #56 on:** October 03, 2018, 07:13:47 am »

I have WD2 with dead PIC(( have anybody firmware for this station?

HipHopAst · « **Reply #57 on:** March 31, 2019, 09:14:30 pm »

As a previous OP. Does any have firmware for WD2 Station. I planing to update WD1 to WD2 as 2 channel is almost impossible to buy for decent money and i already have 1 channel version.
Any one have firmware and what components do i need to successfully update my station?? I have PIC18F6622 chip on it.

HipHopAst · « **Reply #58 on:** April 13, 2019, 08:50:24 pm »

Thanks for firmware.
Any one have PCB pictures of WD2??
Or what components i need to add to run as 2 channel?
Regards

OomJan · « **Reply #59 on:** April 16, 2019, 12:14:27 pm »

Good Day!

I also need the firmware file for the Weller WD2 as mine wont start anymore.

with kind regards
Kevin

iacouper · « **Reply #60 on:** April 20, 2019, 07:08:50 am »

Hi everyone, does anyone have the firmware for the WD2M unit? I need to replace and/or re-flash my PIC18F6622.

Mr. Scram · « **Reply #61 on:** April 20, 2019, 04:02:24 pm »

Quote from: HipHopAst on April 13, 2019, 08:50:24 pm

Thanks for firmware.
Any one have PCB pictures of WD2??
Or what components i need to add to run as 2 channel?
Regards

I may be able to help in a while. Please ping me in a month or so.

HipHopAst · « **Reply #62 on:** April 21, 2019, 11:52:31 am »

That's would be great. Thanks. I'll ask you some time in May. Thanks

marjanko · « **Reply #63 on:** September 18, 2019, 11:10:32 am »

Does anyone have WD2 weller software for PIC186622? I am interested in reworking WD1.

googlyone · « **Reply #64 on:** December 28, 2019, 07:16:40 am »

Hey there,
I have a Weller WD1 using the PIC 18F6622 micro that is exhibiting exactly the same symptoms much discussed in this thread.

Has anybody a copy of the firmware for the 18f6622 for the WD1?

If so I would be really grateful if i could grab a copy!

CryoME · « **Reply #65 on:** September 22, 2020, 03:20:07 am »

Hi All,
I am new here, I got a Weller WD2 station. does not work, PIC18F66222 chip seems burnt. I can replace it with a new chip but I dont have microchip programmer. Is there a way to reprogram it wih the weller usb port? does anyone has a hex file for the weller WD2/M?
Thank you!!!!

Khaveer · « **Reply #66 on:** October 03, 2020, 08:16:49 am »

I've managed to dump firmware from both revisions of WD1 stations. I hope someone will find those useful.

stenzer · « **Reply #67 on:** February 09, 2021, 09:23:05 pm »

First of all hi everyone,

I'm following the EEVblog forum for several years as a guest, and of course I'm watching dave's videos regularly.

As I got my hands on a dumped Weller WD1 for 20 € I thought I will give it a try, as there was no stated/indicated error.
By powering up the solder station without a soldering iron attached I get the first attached image below, which looks good to me at first glance.

Should the display should show even more during powering up?

After powering up, the display shows the icons in the second attached image.

As far as I can remember, the display should show at least the three set temperatures (I, II, III). So it seems something is messed up.
I measured the 12 VAC as well its rectivied ~16VDC representation, used to power the front/display PCB. I measured the output voltage of the 7805, which is bang on.
When I'm pressing both error buttons (both buttons to the right of the display) for 2 seconds or 4 seconds, I'm not able to enter the setup mode for setting up the special functions, as described in the manual.
So I assume the MCU (PIC18F6622) is somehow damaged, although I cannot see any physical signs that the MCU has been damaged, see third attached image.

Can someone tell me if it's the MCU? I have seen in reply #66 there is the appropriate HEX file available. I have a PICkit 3, so flashing a new MCU or "reflashing" the current one shouldn't be a problem.
Is there something I have to keep in mind during flashing, or has anyone experience with the provided HEX files (do they work as expected)?

I would appriciate any advise.

BR

PS.: it seems I'm not able to insert the images within the text.

stenzer · « **Reply #68 on:** February 10, 2021, 09:04:36 pm »

Hi,

I was able to take some pictures of the display of a fully functional WD1.
The first attached picture shows the display during startup and the second one when fully powerd up.
As can be seen, both pictures are taken without a soldering iron attached.

I already reflashed the MCU. Still the display is half blind. Afterwards I tested the WD1 with a LR21 solder iron and it is getting hot. I'm able to change the temperature as well.

Next step was measuring the voltages at the individual LCD pins turing power up. I was able to measure a voltage of ~5 V at each pin for a short time during powering up. So I think the LCD display got damaged.

Does anyone know if there is an approproate replacement display available, or the datasheet which shows the pin assignment to the individual segments? I would like to exclude the PCF8576 LCD driver.

BR

stenzer · « **Reply #69 on:** February 11, 2021, 08:17:39 pm »

Hi,

as the display seems to be broken I would like to connect the solder station with my PC. Therefore, I would need the firmware for a WD1M with a PIC18F6622.
I measured the communication signal levels at the pins of the PIC18 (connector X3) with the WD1 (non M) firmware, and there is nothing going on (RX: permanent 0 V; TX: permanent 5 V).

So if someone would be so kind to provide the firmware for the WD1M with a PIC18F6622.

THX & BR

Miwer · « **Reply #70 on:** February 25, 2021, 11:16:43 am »

Hi,

So I just want to share my repair experience on a WD2M. It had a problem where irons connected to channel 1 would have thermal runaway, and get glowing red. I could see the thermal regulation was working (somewhat), because when I set it to a low temperature (say 150*C), the iron would still get so hot that it melted the solder, but eventually settle, and it would throttle the heater to maintain the (too high) temperature, thinking it was only 150*C. Channel 2 did not show this issue and was fine.

After disassembling the unit and scoping the thermocouple signal from channel 1 and the op-amp output associated with that channel, I could NOT reproduce the problem. I reassembled the unit, and the problem would show again.

So I found out there was a lose connection between the power pcb and display pcb, which caused messed up thermocouple readings on channel 1. I went over the connectors with a soldering iron, but that did not solve the problem. Wiggling the ribbon cable would still show the issue. Finally I disassembled the connectors on both ends of the ribbon cable, and simply replaced it with a new piece of ribbon cable, pressing on the same connectors on both ends, and that finally solved the issue.

So to anyone else having unstable temperature issues on these Weller stations: Check the ribbon cable

I also managed to readout the PIC18F6622 chip, so it's attached here in case anyone needs it. Also made nice pic showing the programming connections on this model.

Have a nice day.

stenzer · « **Reply #71 on:** March 24, 2021, 07:35:27 pm »

Hi everyone,

I was able to establish a remote communication with my (non-M) WD1, see attached pictures. There is no dedicated firmware needed. It seems the WD Monitor software is created to be used with a certain USB to UART IC. I suspect this is caused by the NI-VISA Run Time Support/Lab-View realization, which is installed with the WD Monitor software. I was able to establish the communication with a cheap CP2102 board, ordered on Aliexpress.

As I'm more active at an other Forum, please have a look at https://www.edaboard.com/threads/weller-wd1-m-display-repair-replacement.396863/ for further details.

I hope this findings will help some of you, to use their WD1 at least with a PC when the display is already blind.

BR

stenzer · « **Reply #72 on:** March 30, 2021, 04:25:09 pm »

Hi,

here is also the firmware dumped from my WD1. There is also a picture attached showing the label on the backside of the display board, in case the firmware includes some production year/model related calibration values.

BR

BinaryBits · « **Reply #73 on:** May 26, 2022, 09:32:30 am »

Sorry for posting in such an old thread, but does anybody have the firmware for the WD1M station?
There have been firmware uploaded in this thread for most of the other WD stations except the 1M.
So if somebody has it I would really appreciate if you could upload it here.
Thanks.

ascom · « **Reply #74 on:** February 08, 2023, 09:02:17 pm »

Quote from: Danielw on May 07, 2014, 03:13:35 pm

Glad I found this! Thanks for the schematics

I installed a led mod like this one : http://www.eevblog.com/2012/02/03/eevblog-242-hakko-fx-888-soldering-iron-hack/
I just connected a led in series with a resistor between GND and Triac_ch1 ( I think it was, just probed around to find a good spot to solder near the connector)
Now I wont forget the damn thing turned on for a couple of days in a row!

Do you have any photos where you exactly soldered ground and positive of LED? If i not wrong, on the Triac_ch1 is AC power.

floobydust · « **Reply #75 on:** February 08, 2023, 10:17:21 pm »

Uh bump quote a 9 year old post for another product FX888??? This thread is about the WD1...

Miwer · « **Reply #76 on:** February 09, 2023, 08:35:57 am »

Quote from: floobydust on February 08, 2023, 10:17:21 pm

Uh bump quote a 9 year old post for another product FX888??? This thread is about the WD1...

You do know what "LIKE THIS ONE" means, right?
I'm not the author, but if you look at the quoted post, you'll realize, that it IS about the WD1, not the FX888.
And don't complain about bumping an old thread, if people have legit questions about the topic. WD1 is still relevant and in use by people today.

floobydust · « **Reply #77 on:** February 10, 2023, 06:24:14 am »

Quote from: ascom on February 08, 2023, 09:02:17 pm

Quote from: Danielw on May 07, 2014, 03:13:35 pm
Glad I found this! Thanks for the schematics

I installed a led mod like this one : http://www.eevblog.com/2012/02/03/eevblog-242-hakko-fx-888-soldering-iron-hack/
I just connected a led in series with a resistor between GND and Triac_ch1 ( I think it was, just probed around to find a good spot to solder near the connector)
Now I wont forget the damn thing turned on for a couple of days in a row!

Do you have any photos where you exactly soldered ground and positive of LED? If i not wrong, on the Triac_ch1 is AC power.

What I do is use a 5mm RGB common-anode LED, it lights blue for power and switches to red when the heater is on. I've added it to a few different soldering stations.
For just a simple power-on LED you need only a LED, diode and resistor.
Solder a wire to A2/MT2 at the TRIAC or wand connector (for heater ON LED), another for 24VAC "X1" and COMMON "X2". WD1 changed the board a bit over the years and pics seem gone from OP.

costas · « **Reply #78 on:** August 21, 2023, 07:33:56 pm »

Hello ,
At my Weller WD2M soldering station with a defective LCD display (missing segments), I replaced the display with one from a WE10101AN station. WE10101AN soldering stations are quite cheap, without accessories they can be found on Ebay for under $50.


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