My Weller 1010 has failed... - Page 1
Forum section: electronics / general

author: LektroiD
author_rank: Frequent Contributor
timestamp: September 16, 2019, 09:22:07 am
content: My weller Iron has started to make nasty arcing sounds, I haven't opened it yet, but it's not sounding good. Anyone know of a way to fix it? Typical that it fails just outside the warranty period...

author: Zero999
author_rank: Super Contributor
timestamp: September 16, 2019, 03:59:48 pm
content: Quote from: LektroiD on September 16, 2019, 09:22:07 amI haven't watched the video yet, but in the UK there's no fixed warranty period. Unless you're a business, you might be entitled to a repair, even if the manufacturer's warranty period has elapsed. You need to contact the seller. Of course, this is assuming the seller is also in the UK.UK consumer law doesn't insist on a fixed warranty period for anything. It just states that a product shall be fit for purpose and last for a reasonable length of time. This may sound vague, but it's written this way so manufacturers can't design something so it fails, after a certain period of time. What's deemed to be a reasonable length of time, will depend on what you paid for it. The seller is liable, because it is them who you have made the contract with. The seller is expected to recoup their losses from who ever sold it to them i.e. the manufacturer.

author: FreddieChopin
author_rank: Regular Contributor
timestamp: September 16, 2019, 06:39:41 pm
content: Maybe there's a bug in it, got stuck on pins of a triac and gets slightly fried every time soldering iron heats up.

author: Shock
author_rank: Super Contributor
timestamp: September 16, 2019, 07:24:23 pm
content: The only thing I think it could be is the small electrolytic under the LCD display or something causing a bad transformer noise. But anyway if you take it apart be aware of the clips this guy breaks. What he says is a filter is actually a 4A 300V fuse. Daves done a video on this model as well.

author: floobydust
author_rank: Super Contributor
timestamp: September 16, 2019, 07:24:55 pm
content: It sounds like a growling, noisy power transformer.I had this problem once and it was a metal chip or hex nut touching the transformer's laminations.The station is off warranty, take it apart and look for loose stuff inside.Very strange Weller does not apply full heat to the iron during warm up, you can hear it's still being pulsed.

author: Shock
author_rank: Super Contributor
timestamp: September 16, 2019, 07:43:53 pm
content: Quote from: floobydust on September 16, 2019, 07:24:55 pmIf you slow the video down you can hear it's heating fairly consistantly but pausing slightly every 500ms or so to measure the temp and refresh the display.

author: rsjsouza
author_rank: Super Contributor
timestamp: September 16, 2019, 09:03:53 pm
content: I am sorry to hear about the issue... Especially just out of warranty!Judging by Dave's video, the electronics are fairly robust and protected, thus I wonder if the transformer is starting to arc through its windings until it reaches a point where the carbonization insulates things again.However, if the issue can be reproduced again - i.e., starting from cold it is noisier at the beginning of the cycle and reduces at the end - the resistance of the element may have something to do with it. When the heater is cold, its resistance is much lower than when it is hot. The excess current draw may be causing the arcing.Or it may not be arcing at all - although it sounds like it.As others have said, tear it down but document everything with photographs and/or film - who knows? Maybe Weller could give you a new one as you helped them uncover a failure;...

author: wraper
author_rank: Unknown
timestamp: September 16, 2019, 09:17:51 pm
content: Seems it happens when voltage is applied to heater. Why won't you take it apart, turn on and check from where this sound comes? It may become obvious instantly.

author: Red Squirrel
author_rank: Super Contributor
timestamp: September 16, 2019, 09:46:23 pm
content: Did you try checking the fuse?Seriously though, it sounds like something loose, I'd open it and see if you can visually see a spark somewhere. If not it may be somewhere harder to see like in the transformer or something.

author: 2N3055
author_rank: Super Contributor
timestamp: September 16, 2019, 10:03:02 pm
content: Quote from: floobydust on September 16, 2019, 07:24:55 pmI agree. That is the sound of when transformer core is not soaked with epoxy right, and individual sheet in laminated core is loose and is flapping when you pull current. Also. it can be screw or piece of sheet metal from nearby shielding.Just open it and take a look.

author: wraper
author_rank: Unknown
timestamp: September 16, 2019, 11:15:39 pm
content: Quote from: 2N3055 on September 16, 2019, 10:03:02 pmNot at all. When there are loose plates, it's just 50 Hz hum, sometimes loud. Nothing like this sound. Not to say it's intermittent but transformer is powered all of the time. Also it's pretty obvious that sound disappears during temperature reading change on display. Also it stops when set temperature is reached.

author: floobydust
author_rank: Super Contributor
timestamp: September 17, 2019, 04:08:55 am
content: It sounds nasty- there are lots of higher harmonics. Louder with the heater load.It could be a mechanical buzz involving the power transformer. Maybe flip it upside down and hit it, even a solder ball can get lodged somewhere and vibrate.Small chance it's a damaged triac/opto that gives 1/2 wave to the heater, but the buzz is still there when the triac is off and the iron's temperature rise rate is OK.Weller WE1010 is not two-wire like Hakko T12. It has dedicated thermocouple wiring and could be able to read temperature without switching off the heater, just filter AC hum in firmware, unless it totally swamps the signal.

author: 2N3055
author_rank: Super Contributor
timestamp: September 17, 2019, 06:06:17 am
content: Quote from: wraper on September 16, 2019, 11:15:39 pmThey are buzzing when you pull current. They will buzz silently with standby current, and when triac starts pulling current it will start flapping around , hitting things and getting loud. It was common thing many years ago when transformers where not always potted in epoxy...

author: tom66
author_rank: Super Contributor
timestamp: September 17, 2019, 06:23:15 am
content: Quote from: Zero999 on September 16, 2019, 03:59:48 pmThis is not quite true. Under the Consumer Rights Act 2015:Within the first 30 days - you are entitled to a full refund if the goods are not fit for purpose.Within the first 6 months - you are entitled to a repair, the onus is on the manufacturer to demonstrate the fault was out of their control, for instance with a car - if you drove into a pothole and broke the suspension then they would not be required to repair it, but if the engine died after 5 months, they may be required.6 months and beyond - you are required to demonstrate, at your own cost, that the fault existed originally with the goods, for example, a design flaw or manufacturing defect. This can be rather difficult.The statutory limit is 6 years in England, Wales & NI, and 5 years in Scotland, because Scotland wants to be different.In addition, all electronics sold in the European Union have a two-year warranty under consumer law (excluding disposable and consumable parts.)

author: soldar
author_rank: Super Contributor
timestamp: September 17, 2019, 06:48:25 am
content: Quote from: Zero999 on September 16, 2019, 03:59:48 pmEU law mandates a minimum two year warranty for consumer goods sold commercially and I believe it still applies in the UK.

author: jahonen
author_rank: Super Contributor
timestamp: September 17, 2019, 07:56:47 am
content: Definitely sounds like bad power switch contacts arcing over. Arcing gets worse when the heater is turned on.Regards,Janne

author: Electro Detective
author_rank: Super Contributor
timestamp: September 17, 2019, 09:06:55 am
content: Quote from: Red Squirrel on September 16, 2019, 09:46:23 pmOh yeah, the fuse is the first GO TO thing to check with a Weller.Swap out the fuse and swap out the fuseholder too, just to be sureor just fit in two new fuse holders, one for primary and secondaryNasty humor aside, pull the sucker apart and post some pics here if nothing obviousGood luck, hope it's an easy one

author: amyk
author_rank: Super Contributor
timestamp: September 17, 2019, 11:40:32 am
content: It could just be the audio quality of the video, but that doesn't sound like arcing to me, nor transformer hum. Something loose and vibrating is what I'd best describe it as.

author: Shock
author_rank: Super Contributor
timestamp: September 17, 2019, 11:49:53 am
content: Another quick test is to plug it directly into the mains outlet. Have seen weird power issues on problematic surge protectors and power boards.

author: Electro Detective
author_rank: Super Contributor
timestamp: September 17, 2019, 09:35:13 pm
content: Post the forum and video link to Weller Support, if you can find themIt's their product and a quality control issue that may be widespread, that THEY need to address asapIt should not be making that component sizzling'I'm about to die on this unfortunate user any day now'noiseCheap psu components, no fusing, sounds like the Weller marketards have worked out how to supply TooHungLow quality,timed obsolescence at 13 months, yet keep charging top dollar for the W name