Weller TC202 with TC201 iron, what tips?

[BillWojo]

Looking through my old stash of stuff I found 2 old Weller TC202 solder stations. Both have the TC201 iron. Neither have any tips. I see all kinds on Ebay. My first project is going to be assembly of a Geller reference voltage board. Using the leaded solder that comes with the kit, actually all my projects are old stuff, so all lead solder. What temp and style tips should I pick up?
Thank you

BillWojo

[BillWojo]

Well, I dug through my old stash of stuff again and found a tip. Thanks to Ebay I at least knew what to look for. Looks like both TC202 solder stations have bad irons, the TC201 part. I imagine that buying the TC201 would put me halfway to a new Hakko FX-888D unit. Looking on Ebay I don't see any TC201 either. Bummer. Thought I had a solder station covered.

BillWojo

[BillWojo]

Well, I took care of the problem, picked up a nice Weller wtcpt solder station off of Ebay. Not worth fixing the old units. I am not doing any smd work, just through hole stuff and radio type work so I don't think I'll be disappointed with it.

BillWojo

[beatgr]

Bill -

Weller "PT" soldering tips.  For example, PTA7 : 1/16" Screwdriver profile, 700 degree F.

The older TCP units are VERY EASY to repair -- I have been doing it since 1975,
and have hard-to-find spare parts for early units.
The Weller TCP-series is a 24 VAC system and
2 of the first DoD users in 1965/66 were Grumman for Apollo LM construction and Collins for S-line radios, Apollo and avionics systems.  The Weller TCP pencil was first soldering iron taken on Shuttle for early ISS experiments.  The solder ball (and rosin) spins around the soldering tip !

I have attached 2 photos of my restorations, an 1967 original bakelite WTCP and the 1976 W-TCPL (last year sold retail).

Go to BAMA, you will find most of my Weller Tech Sheet library (late 1960s-2003).
http://bama.edebris.com/manuals/weller/

I wrote an update HOW TO for the proper disassembly of the
Weller soldering iron handle/cord set (since 1981).
http://bama.edebris.com/download/weller/handle/Weller_Handle_Disassembly.pdf

Looks like both TC202 solder stations have bad irons, the TC201 part.

Only TWO Key parts in the irons:  Heater (EC234 - plugin or TC208 wired-in) and SW60 magnetic switch.  IF you replace heater, purchase new BA60 (after 2003), Weller changed OD in retooling for RoHS compliance.
===
Over the past 6 weeks, I have been selling Weller parts and restored irons, etc. on eBay.
I do not sell heaters and BA60 or tips, since these are readily available from numerous USA dealers/distributors.

Tri-State Electronics in Arlington Heights, IL has about lowest price
for Weller soldering tips that I have found (went up in 2014).
They handle mail orders daily.
http://www.tselectronic.com/shop/product/Weller-PT-Series-Replacement-Tips/1148

I picked up a nice Weller WTCPT solder station off of eBay.

Other than ESD compliance (WTCPT version released late 1989s),
virtually same as earlier models in series.

greg, w9gb

[BillWojo]

Thanks for the info beatgr. The unit I purchased has the PU120T power supply with the TC201T handle. Supposed to work fine. I also bought some PTH7 tips. They are small screwdriver type tips. I'll pick up some wider ones soon. I look for NOS (new old stock) as I have been reading about problems with the newer tips not being made as well and wearing out very fast.
The 2 old units that I have are TC202 with a TC201 iron. Do you have the info on testing and tearing down the irons? Maybe out of the 2 units I could get one good one.
I didn't get the iron holder with the recess base for the sponge. Are those sponges something special? They seem costly. I have always used a damp paper towel to wipe the tip. I was looking on Ebay for the iron holder, PN PH1201 but they sure are pricey. Was thinking of just machining one out of aluminum and using the spring thing from one of the old TC202 bases.
Thanks for the interesting info.

BillWojo

[beatgr]

I didn't get the iron holder with the recess base for the sponge.
Are those sponges something special? They seem costly.
I have always used a damp paper towel to wipe the tip. I was looking on Ebay for the iron holder,
 PN PH1201 but they sure are pricey.

SPONGES:  NEVER USE PLASTIC SPONGES (common in kitchen supply aisles)
TC205 is proper sized sponge.  Price is same as Hakko and Asian clone sponges !!
You can use copper scrubers (dry) seen in new stations.

Metal PH1201 is same price as aluminum Hakko C1742 iron holder ~ $35.

I purchased TWO proper Weller holders in virtually new condition
on eBay last week for $5 each -- no other bidders!!  You must have missed them.

The 2 old units that I have are TC202 with a TC201 iron.
Do you have the information on testing and tearing down the irons?
Maybe out of the 2 units I could get one good one.

Answered that question, in my first post.  It is ALL in the Weller Tech Sheets.
Those Tech Sheets are at BAMA, just a matter of reading.
These iron and stations are quite easy to service, but a bit of hand dexterity helps.
Handle disassembly (modern ones) even tells you the AMP/Tyco part numbers, how to build tool instead of buy, etc.
====
MODERN IRON: 2 screws hold heater flange
OLDER IRON: 4 screws on heater flange, remove ONLY 3 outer to enable pulling assembly out.
Remove 4th screw (inner one from perimeter) --- you get a mess.

SW60 (1981) Disassembly Sheet (BANA) has best photo.

You can read about 85% of my library at The Boat Anchor Manual Archive (BAMA)
http://bama.edebris.com/manuals/

under the Weller directory.
http://bama.edebris.com/manuals/weller/

A simple VOM or DVM can check the resistance
of the Heater (bad if OPEN, or dead short -- which blows fuse).

Wired in heaters (TC-208) were used from 1965 to around 1981.
TCP Hand-piece redesign occurred in early 1980s, which introduced the EC-234 plug-in heater.
That heater is still used today in the EC1201A and the TC201T irons.

The EC234 plug-in heater sells for around $22, the older TC208 wired heater costs ~ $30.
The TC201 irons both use SW60 Magnistat switches and the BA60 barrel nut.
You will need a NEW barrel nut for new heaters (replacement).
As part of RoHS, Weller swaged (wider at tip) the heaters (2 listed) -- which may provide longer life.

greg