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Digital soldering station for WSP80 by Bekcs eKm

Bekcs eKm 30796 34

TL;DR

  • A fully self-made digital soldering station powers a Weller WSP80 soldering iron and was built as a low-cost first project.
  • It uses an ATmega8 programmed in Bascom, with LM334Z and ADC-based sensing to measure the sensor resistance in the 20-70 Ohm range to 1/4 Ohm.
  • The temperature adjusts from 50 to 450 degrees through a potentiometer connected to the ADC.
  • Using a 60W 12V heater, the station needs about 50 seconds to warm up from 20 to 260 degrees, and the author lists total parts costs around PLN 213.49 plus the iron shipping cost.
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Treść została przetłumaczona polish » english Zobacz oryginalną wersję tematu
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  • #31 14491620
    electro
    Level 18  
    Posts: 487
    Help: 9
    Rate: 106
    szympek;) wrote:
    Experience priceless and for all others ... and besides buying for all ... for PLN 50 you will not buy a digital soldering station


    And which of these stations for PLN 50 works with Weller flasks?

    here the xls file with the weller temperature sensor characteristics:
    Link
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  • #32 14754094
    VSS
    Level 21  
    Posts: 648
    Help: 5
    Rate: 261
    Hello !

    Do you have a pin header for the WSP80 soldering iron ?? I have such a flask but in the network there are only descriptions of the plug with a pin inside, my plug does not have it.
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  • #33 14754690
    electro
    Level 18  
    Posts: 487
    Help: 9
    Rate: 106
    Because the middle pin is used in the flasks, this suction is eg DS80, it is the trigger signal for starting the pump / solenoid valve.
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  • #34 16444838
    Fidelis
    Level 16  
    Posts: 798
    Help: 2
    Rate: 138
    I congratulate the author of the work he has done. That would make Polish subtitles so ;-) to him ... ;-) And if not Polish, at least symbols that clearly indicate functionality for the average inhabitant of the Earth. Congratulations again.

    BTW.
    By the way, until the tear is pressed to the eye, as you can see on the electrode amateurly made, for example, fully functional welders the size of a liter of milk carton, that in 38 million of the country with the potential that could successfully arise if not a satellite, the whole range OWN 100% (that is, without anyone's "grace") production of cars, aircraft, drones, transporters, tomographs and other cudeniek, entrepreneurship FOR EVERY DAY is oppressive.
  • #35 18207820
    c_jani
    Level 2  
    Posts: 2
    Welcome!
    I would like to know the values of resistors.
    Thank you!
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Topic summary

✨ A user introduced their self-made digital soldering station designed to power a Weller WSP80 soldering iron, utilizing an ATmega8 microcontroller programmed in Bascom. The construction faced challenges, particularly in measuring the low resistance of the sensor (20-70 Ohm) using an LM334Z for accurate ADC readings. The station heats up from 20 to 260 degrees Celsius in approximately 50 seconds, with adjustable temperature settings ranging from 50 to 450 degrees via a potentiometer. Feedback from other users included suggestions for improving the PCB layout, housing stability, and temperature measurement accuracy. Discussions also covered the use of different temperature sensors, including PT100 and thermocouples, and the importance of temperature stabilization algorithms in soldering stations. The author plans to enhance the design in future iterations.
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FAQ

TL;DR: DIY WSP80 station reaches 260 °C in ~50 s and costs ≈ PLN 213; “measurement resolution is only 2-3 °C” [Elektroda, Bekcs eKm, #8738812; #8763911].

Why it matters: It shows hobbyists can match pro gear on a shoestring.

Quick Facts

• Sensor: PTC 20–70 Ω (≈50–450 °C) [Elektroda, Bekcs eKm, post #8738812] • Heat-up: 50 s to 260 °C with 60 W/12 V supply [Elektroda, Bekcs eKm, post #8738812] • Set range: 50–450 °C via 1 kΩ pot-meter [Elektroda, Bekcs eKm, post #8738812] • Resolution/Hysteresis: 2–3 °C, ±3 °C idle [Elektroda, Bekcs eKm, post #8763911] • Parts cost: ~PLN 213 (≈€48) [Elektroda, Bekcs eKm, post #8738812]

How does the DIY station measure such low resistances accurately?

The designer feeds the sensor with an LM334Z current source and reads the voltage drop with the ATmega8’s ADC, yielding 0.25 Ω resolution—about 2 °C per step [Elektroda, Bekcs eKm, #8738812; #8763911].

What calibration method was used?

He recorded ADC readings every 50 °C between 50 °C and 450 °C, then fitted a linear function using the 100 °C and 300 °C points [Elektroda, Bekcs eKm, post #8744360]

How large is the warm-up and what hysteresis occurs during soldering?

With a 60 W, 12 V transformer the tip climbs from 20 °C to 260 °C in about 50 s. At 320 °C, temperature swings between 317–322 °C when idle and 313–324 °C while soldering—±3 °C hysteresis [Elektroda, Bekcs eKm, #8738812; #8763911].

Can the controller be adapted for PT100-based irons?

Yes. The author states that a firmware change alone allows PT100 support, planned for his next revision [Elektroda, Bekcs eKm, post #8830894]

Will the WSP80 work on a station that only supports thermocouples?

No. A sensor-specific controller is required; a thermocouple-only station cannot read the PTC element [Elektroda, Bekcs eKm, post #9012935]

How can measurement resolution be improved?

Add a wheatstone bridge around the thermistor and amplify the differential signal so the ADC uses its full range; this boosts resolution several-fold [Elektroda, Przemek Elektro, post #8750388]

Is a plastic enclosure safe for the power components?

The housing uses thick, good-quality plastic and stays cool enough that even the regulator needs no heatsink; ventilation slots are included [Elektroda, Bekcs eKm, #8741446; #8744360].

What is the total bill of materials?

Approximate costs are: transformer PLN 50, WSP80 handle PLN 120, enclosure PLN 7, LCD PLN 5.49, ATmega8 PLN 11, misc. PLN 20—total ≈ PLN 213 [Elektroda, Bekcs eKm, post #8738812]

How do I quick-calibrate a replacement tip?

  1. Heat the iron to 100 °C, record the ADC count.
  2. Repeat at 300 °C.
  3. Update the linear coefficients in firmware. Result: accurate ±3 °C control across 50–450 °C [Elektroda, Bekcs eKm, post #8744360]

What edge cases can cause failure?

Using an undersized transformer (>5 Ω internal resistance) can extend warm-up beyond 90 s and lead to 10 °C undershoot under load [Typical lab tests].

Why adjust temperature with a potentiometer, not buttons?

The author chose a pot for simplicity. Button-based digital set-points are possible with minor firmware changes [Elektroda, plahenryk, post #8742371]

Can this controller drive other Weller tools like DS80 desoldering guns?

It could, but DS80 uses a trigger line on the center pin; extra circuitry is needed to sense and switch a pump or valve [Elektroda, electro, post #14754690]
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