22G, plain and simple doesn't work very well, regardless of what Evolv says is minimum
Edit: in TC mode
Edit: in TC mode
I'm just going to pull it out. My solder joint looks like junk anyway... bought a new Weller iron and it doesn't even get hot enough to tin the wire. May spend over $20 on the next iron. The reason I used 22AWG is because they used the "larger" pad for the charger, leaving only the smaller pad available for the battery ground. My original plan was to swap them, but the board is hot-glued very well to the chassis and at the time I gave up on trying to remove it.
22G, plain and simple doesn't work very well, regardless of what Evolv says is minimum
Edit: in TC mode
I bought a $20 Weller (40w) and it works great. I've never had any issue using a 40w on 18g wire. Maybe use some flux? Check the tip? Is the tip tinned properly?
Use isopropyl alcohol on the hot glue to remove it. Be generous with it and it will come out easily. I use a q-tip drenched with alcohol and soak the contact point between the glue and material.
I plan on using 20g for the power and ground.

I bought a $20 Weller (40w) and it works great. I've never had any issue using a 40w on 18g wire. Maybe use some flux? Check the tip? Is the tip tinned properly?
Use isopropyl alcohol on the hot glue to remove it. Be generous with it and it will come out easily. I use a q-tip drenched with alcohol and soak the contact point between the glue and material.
I plan on using 20g for the power and ground.
I bought a $20 Weller (40w) and it works great. I've never had any issue using a 40w on 18g wire. Maybe use some flux? Check the tip? Is the tip tinned properly?
30W should be more than enough for 18G.

As far as I know, there is no problem with that as long as you don't solder over a previous lead free solder joint. The rohs compliant solder takes a higher temperature to melt so you risk not bonding properly both components. If it's a clean solder spot, no problem.
Regards
Tony
Sent from my keyboard through my phone or something like that.
KTM, where did you get the $20 Weller (40w) from. I seem to have permanently misplaced my iron.![]()
. The ceramic inside the handle broke so I figured I'd replace it with a new one (it was 20+ yrs old). Think of it like this, one of the major 'fixes' Evolv made to the DNA40 was to use gold tinning of the contact holes, they also strongly suggest to use 18G for battery and 510 connections, That must be due to the need for as robust a power connection as possible, YMMV
I'm pretty sure it was defective. It came with three pre-tinned tips that looked great... it seems as though the iron was getting hot in every single place aside from the tips. This was a home depot special.
Thanks for the tips on the hot glue; I have very little experience with that junk. Off to grab some isopropyl alcohol!![]()
ETA sorry for going off topic, just that I'm into tools.
I own a machine shop (tool and die shop, actually) Plus, I build race cars. Tools be plentiful around me

KTM,
At work and once I bought a Weller soldering station. And like your experience I always found the Ungar tips needed less attention - defies reason considering the Weller soldering station was temperature controlled. Hmmm... just dawned on me that TP seems to be a problem for soldering irons and TP mode Mods.![]()