Author Topic: Weller PU81 station mod for DSX80 desoldering handle  (Read 2944 times)

Offline futurist

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Weller PU81 station mod for DSX80 desoldering handle
« on: April 04, 2018, 03:54:12 PM »
Just to quickly share my latest project

I have Weller PU81 soldering station and after watching video on Marco Reps's channel I decided to buy DSX80 desoldering handle. It's completely compatible with my station, heating control works out of the box, and the only thing needed to get it running is to add a vacuum pump. I decided to try small 12V vacuum pump https://www.ebay.com/itm/DC-Electric-12V-Micro-Vacuum-Air-Pump-Booster-For-Medical-Treatment-Instrument/282489988597 which is just 3$ delivered, and could even fit in the station.

For pump speed control and 24V to 12V regulation I decided to make a small 50x50 mm PCB with 555 PWM and LM2596 DC-DC converter





BOM, gerbers, KiCad project of the module are free to use
* buck_pwm_module.zip

Next problem is how to use internal switch to power the pump


There is no way to use the switch directly. Hydron proposed neat solution using AC relay connected to one of the terminals of the transformer and pin 7 on DIN connector (pin 6 on official Weller pinout)

24 VAC relay


Wires for the relay


Biggest part of the job was to fit everything inside existing station enclosure because free space is very limited. Friend helped with drawing models for mounts for the AC relay, PCB and vacuum pump



PCB


Vacuum pump mount


Before soldering


.stl files for 3D printed mounts
* mount.zip


Hope someone finds it useful
« Last Edit: April 04, 2018, 04:03:43 PM by futurist »

Offline oneKone

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Re: Weller PU81 station mod for DSX80 desoldering handle
« Reply #1 on: April 05, 2018, 07:21:06 AM »
I didn't even know desoldering stations existed! How does it perform compared to a spring loaded solder sucker?

Offline futurist

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Re: Weller PU81 station mod for DSX80 desoldering handle
« Reply #2 on: April 05, 2018, 06:43:48 PM »
It's not magic bullet but because the entire tip is heated it's much better than hand held vacuum pumps
Downside is cost, complete Weller WDD 81V desoldering station which needs compressed air to operate is 790 €, and just the handle is ~250 €. I got lucky on eBay and bought new handle for under 150€, which is still very expensive but since I won't be using it on a daily basis it should easily outlast me

Offline Mads Barnkob

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Re: Weller PU81 station mod for DSX80 desoldering handle
« Reply #3 on: April 08, 2018, 10:06:18 PM »
Great project futurist! Rebuilding equipment to expand the features a lower cost is the essence of what we do :)

http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

Offline futurist

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Re: Weller PU81 station mod for DSX80 desoldering handle
« Reply #4 on: April 25, 2018, 05:39:49 PM »
Thanks Mads! :)

Short update on the project
Today I made a simple hose adapter which replaces key plug on the soldering station and allows the DSX80 handle to be connected externally
So far everything works nicely and the small vacuum pump doesn't have any problem sucking the solder. I added fuel filter before the pump to prevent any flux vapor from entering the pump

.stl file of the hose adapter
* hose_adapter.zip
« Last Edit: April 25, 2018, 05:43:56 PM by futurist »

Offline Mads Barnkob

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Re: Weller PU81 station mod for DSX80 desoldering handle
« Reply #5 on: May 08, 2018, 01:07:40 PM »
That is a clever use of a existing product, the gasoline filter, instead of trying to come up with a complete new solution. Its cheap, common and easy to replace :)

Still working good some 2 weeks into use?
http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

Offline rafscipio

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Re: Weller PU81 station mod for DSX80 desoldering handle
« Reply #6 on: September 23, 2019, 12:54:48 PM »
I register to this forum, just to thank Futurist for sharing this cool project.
I already have a Weller WR2 station with desolderin iron DSX120, and i like to have a second one.
Very well done, i'll try to do a similar one, maybe just using more powerful pump: watching your video and comparing to my original, i believe it works better with more suction ;)

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Re: Weller PU81 station mod for DSX80 desoldering handle
« Reply #6 on: September 23, 2019, 12:54:48 PM »

 


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