Hi,
The wattage used for soldering rail depends on the capacity of your unit (100W or 250W) and rail size. I use about 40% on my 250W unit, which is about 100W as a starting point. You can easily solder rail with less wattage, so don't worry if you have a 100W unit. The key is being able to solder quickly without overheating (burning) your rail and PC tie stock.
Best advice... Use some scrap rail in the size(s) you will be using, and practice soldering it to some sacrificial PC stock. Start with 50-65W, and move up or down from there.
For soldering rail... I use the tweezers, nothing else. The pliers can take more heat, but they are too cumbersome, and just too big. You don't need their heat capacity anyway. I've never used the "iron" attachment, but I think it wouldn't be that much different than using a regular soldering iron. If someone else has more experience with it, and likes it, please speak up!
I don't use acid flux/solder. I use rosin paste flux and 0.020" diameter silver bearing solder (available at any Radio Shack). It works well enough, but I would like to try the acid fluxed solder, if only to see if it is any better.
Enjoy your resistance unit!! It is a great tool to have... Good luck!
JeffB
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