ok thx. The tiop the iron came with was a little bitty pointed tip and I have switched to a 3.2 mm tip and then up to a 5.1 mm tip. I thought that after reading that the unit needs to be calibrated after each tip change that it was worth a shot. I pulled the plug out and turned the screw about 1/4 to 1/2 turn cw. The iron is back to working like when it was new. Hope this works for the long term!! Thanks guys.
http://www.hakkousa.com/techDoc/Tech...TN00000008.pdf
interesting that they recomend setting the temp at the tip when they said it couldn't be done.