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Author Topic: ZVS Induction heater 2000W 40A 50V (Read 26253 times)
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strawberry ZVS Induction heater 2000W 40A 50V

« on: March 04, 2017, 01:32:56 pm »
Frequent Contributor

ZV S I nduc tion heater 1 5 ..5 0 V 4 0 A 2 kW

Posts: 272
Stanby los s with 6 c apac itors : 6 A @5 0 V
Country:
M O SFE T S: I RFP 4 2 2 7
C apac itors : WI M A FKP 4 0 .2 2 uF 1 0 0 0 V dc
T ank c oil: D3 5 mm H 3 5 mm 5 w
P C B fabric ator: P C Bway
P ower s upply: DP S-2 5 0 0 A B 2 0 0 0 W P -C LA SS P RO LI A N T BLA DE P O WE R SU P P LY

A ltium s ourc e files : https ://drive.google.c om/open?id=0 BwV LiaRx-c a4 c 2 pJV lhLRmE yN DQ

2kW induction heater sch.jpg (156.53 kB, 1561x1033 - viewed 16213 times.)

2kW induction heater pcb.jpg (273.32 kB, 1333x433 - viewed 4190 times.)

2kW induction heater.jpg (449.76 kB, 2457x789 - viewed 5193 times.)

2kW induction heater 1.jpg (453.11 kB, 2457x783 - viewed 3606 times.)

« Last Edit: March 30, 2017, 10:14:25 am by strawberry » Logged

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bktemp Re: ZVS Induction heater 2000W

« Reply #1 on: March 04, 2017, 01:50:10 pm »
Super Contributor

N ic e des ign. What does your work c oil look like?

Posts: 1623
Country:
O ne neat tric k I have s een is us ing a s mall mos fet ins tead of the diodes (D2 and D3 in your
des ign):
C onnec t the gate to 1 5 V , s ourc e to the gate of the main mos fet and drain to drain of the oppos ite
mos fet. So the gate voltage follows the drain voltage as long it is below ~1 3 V .
U s ing this method all the gate drive power is derived from the tank c irc uit. So you don't need any
pullup res is tor or the addional gate drive s tage.
T he only drawbac k is , the 1 5 V auxiliary s upply mus t be pres ent before the main voltage is
applied, otherwis e it may no s tart up c orrec tly.
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strawberry Re: ZVS Induction heater 2000W

« Reply #2 on: March 04, 2017, 03:48:41 pm »
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C u pipe
Posts: 272
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20170304_161302.jpg (552.92 kB, 2560x852 - viewed 3718 times.)

20170304_161317.jpg (379.29 kB, 2560x852 - viewed 3627 times.)

20170304_161334.jpg (403.88 kB, 2560x940 - viewed 3495 times.)

20170304_161405.jpg (383.96 kB, 2560x1172 - viewed 3739 times.)

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T3sl4co1l Re: ZVS Induction heater 2000W

« Reply #3 on: March 04, 2017, 08:50:59 pm »
Super Contributor

C ute, but how is it different from the c heap junk one made in C hina? I s this one s afe from
exploding when the c oil is open or s hort c irc uited? Does it have power c ontrol? C an it be s c aled
up to prac tic al s izes (1 0 kW+)?

T im
Posts: 15629
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Expert, Analog Electronics,

Seven Transistor Labs, LLC
PCB Layout, EMC
Electronic design, from concept to prototype.
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RadioNerd Re: ZVS Induction heater 2000W

« Reply #4 on: March 04, 2017, 10:28:43 pm »
Contributor

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I t looks like you are not us ing any water c ooling for the work c oil.
Country:
C an you us e it for s everal minutes without overheating?
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strawberry Re: ZVS Induction heater 2000W

« Reply #5 on: March 05, 2017, 09:13:34 am »
Frequent Contributor

I t have new M O SFE T s , ultra low los s c apac itors , 7 0 um P C B tec hnology, unified heats ink(s afty),

2 de 7 19/09/2020 21:42
ZVS Induction heater 2000W 40A 50V - Page 1 https://www.eevblog.com/forum/projects/zvs-induction-heater-2000w/

Posts: 272 no need for gate res is tors (s imple turn on/off), integrated bimetal overheat protec tion, I t all in
Country: s mall 5 0 x1 6 0 mm pc b form fac tor. E ffic ienc y inc reas ed up to 6 A s tb. with s ame konfiguration as
c hines e 1 kW vers ion on ebay.

Work c oil and c apac itors are c apable at more power than 2 kW, When us ed all 1 0 xc apac itors
heating gone realy fas t but c oil reac hed ~4 0 0 °C in 1 0 s . With 6 xc apac itors s till it is not us eable
for s everal min. I c ool it down in water buc ket.

N o it is not protec ted from s hort neither power c ontrol. I t is firs t s uc h powerfull devic e made.
Bec aus e I made it not c hina.
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doktor pyta Re: ZVS Induction heater 2000W

« Reply #6 on: March 05, 2017, 04:38:47 pm »
Frequent Contributor

Few Y ears ago I built s imilar devic e for wireles s energy trans fer. I found that when I tried to turn
Posts: 336
on the power s upply one of five attempts ended with high c urrent c ons umption an ac tivating
Country:
overc urrent protec tion (1 0 A ) of the P S. T his is pos s ible when the s ymmetry in the c irc uit is "too
good". From further inves tigation it was bec aus e the two "drain" induc tors were not c oupled (as a
middle-tapped autotrans former). "working c oil" has no c entral tap. I think that making it s imilar to
Res onant Royer topology would make it work more reliable.
M aybe s omeone has better explanation.

« Last Edit: March 05, 2017, 09:10:39 pm by doktor pyta » Logged

http://rfscientific.eu/our-measurement-laboratory

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strawberry Re: ZVS Induction heater 2000W

« Reply #7 on: March 05, 2017, 05:17:52 pm »
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I nteres ting drain induc tors c onfiguration. I never had s tartup failure before(at no load).
Posts: 272
When turning devic e on with gate power then drains get voltage overs hoot.
Country:
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T3sl4co1l Re: ZVS Induction heater 2000W

« Reply #8 on: March 05, 2017, 09:56:13 pm »
Super Contributor

M os t c ommon failure mode is lac k of os c illation leading to mas s ive power dis s ipation, or gate bias
dropping out before drain c urrent, res ulting in mas s ive overvoltage s pike.

T his is a c urrent-s ourc ing c irc uit, and as with all c urrent s ourc es , it mus t be c ommutated by
bringing the s ourc e to a s hort-c irc uit c ondition. (T he s ourc e s upplying the trans is tors is the
Posts: 15629 induc tor(s ), and whatever c urrent they've been c harged up to. Dis c harging thes e, with a s hort
Country: c irc uit, while there's a c ons tant-voltage s ourc e behind them, is a non-obvious proc edure. T his
Expert, Analog Electronics, highlights another of the fundamental quirks /des ign is s ues of this c irc uit.)
PCB Layout, EMC
T im
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strawberry Re: ZVS Induction heater 2000W 40A 50V

« Reply #9 on: March 29, 2017, 05:08:18 am »
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P C B update
Posts: 272
Country:

2kW induction heater pcb2 Rev1.1.jpg (158.11 kB, 1261x453 - viewed 3809 times.)

2kW induction heater pcb3 Rev1.1.jpg (114.36 kB, 1269x421 - viewed 2534 times.)

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2kW induction heater pcb Rev1.1.jpg (128.53 kB, 1269x497 - viewed 6182 times.)

2kW induction heater sch with protection.jpg (108.98 kB, 965x645 - viewed 14477 times.)

« Last Edit: April 04, 2017, 08:52:18 am by strawberry » Logged

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BlackTM Re: ZVS Induction heater 2000W 40A 50V

« Reply #10 on: May 18, 2017, 07:24:45 pm »
Newbie

Posts: 1
H i s trawberry.
Country:

C an you pleas e tell me at what frequenc y does your induc tion heater work?
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james_s Re: ZVS Induction heater 2000W 40A 50V

« Reply #11 on: May 19, 2017, 12:30:25 am »
Super Contributor

T he induc tion heater I built from a c irc uit I found online us es a s mall 1 5 V s tandby power s upply
Posts: 12308
to get it os c illating and then there is a relay that applies full power when ac tivated. H as n't blown
Country:
up yet.
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strawberry Re: ZVS Induction heater 2000W 40A 50V

« Reply #12 on: September 26, 2017, 06:28:40 pm »
Frequent Contributor

Quo te fro m: BlackTM o n M ay 18, 2017, 07:24:45 p m

Posts: 272
Country: Hi straw berry.

C an you please tell me at w hat frequency does your induction heater w ork?

I t's roughly 9 0 ..1 0 0 kH z( depends on work c oil and c apac itors )

Quo te fro m: james_s o n M ay 19, 2017, 12:30:25 am

The induction heater I built from a circuit I found online uses a small 15V standby pow er supply to get it oscillating
and then there is a relay that applies full pow er w hen activated. Hasn't blow n up yet.

M y s c hematic are the s ame, but additional gate drive emitter follower gives nic e s quare wave for
M O SFE T gates .
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calexanian Re: ZVS Induction heater 2000W 40A 50V

« Reply #13 on: September 26, 2017, 11:23:38 pm »
Super Contributor

Looks good. I have a c ouple of thos e c heap ones from c hina. I als o have a big old lepel RF
generator. I have always wanted to modify one of thes e c irc uits with a s tarter c irc uit that would
always ens ure a proper s tart. I think maybe a quic k one s hot puls e on one s ide to get it going, or
introduc e a low level rec urring puls e on one s ide from a s eparate driver c irc uit that then jus t gets
Posts: 1878 ignored onc e the power devic es get going. I have mine c onnec ted to a foot s witc h and an LE D
Country: riged up when it is running. I f the light does not turn on I let up on the pedal momentarily and when
I s tep bac k on it again it will us ually s tart. I als o us e a variac to c ontrol the power level. I ts a nic e
arrangement. V ery ac c urate. M akes pretty welds in c opper pipe if s older pas te is us ed. Fantas tic
for c opper tube wave guides . Gotta us e water c ooling for that though c aus e c opper is hard to heat.
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Charles Alexanian
Alex-Tronix Control Systems

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strawberry Re: ZVS Induction heater 2000W 40A 50V

Lepel« RF generator
Reply #14 on:is s omething
September new for
27, 2017, me, ispm
07:18:51 it us
» ing vac uum tubes ? Do you have s c hematic ?
Frequent Contributor

I am planing to build mains powered P LL induc tion heater. I am aiming on about 3 kW power
Posts: 272
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calexanian Re: ZVS Induction heater 2000W 40A 50V

« Reply #15 on: September 27, 2017, 09:15:43 pm »
Super Contributor

Lepel is s till in bus ines s . T hey are owned by I nduc totherm now. T he unit I have is tube bas ed but
they make fully modern types now. H ones tly though i jus t us e the ZV S ones now. Les s trouble.
E bay is full of old Lepel tube models , but I would advis e agains t them. O nc e the ins ulation on
things s tarts breaking down ins ide they jus t dont work right anymore and they are truly a pain to
Posts: 1878 rebuild. Way c heaper and eas ier to build one like yours . T here is a c las s ic c irc uit in the RC A
Country: trans mitting tube manual for a 8 3 3 type tube bas ed one that was popular bac k in the day. I ts very
tric ky to get the main c oil and tank c irc uit right, but they evidently worked quite well.
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Charles Alexanian
Alex-Tronix Control Systems

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kelesekrem Re: ZVS Induction heater 2000W 40A 50V

« Reply #16 on: October 03, 2017, 06:38:15 pm »
Newbie

Posts: 3
hi, thanks .
Country:
I want to us e this heater model in 3 d printer, c an I us e it and c an go to high temperatures for
600C
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strawberry Re: ZVS Induction heater 2000W 40A 50V

« Reply #17 on: October 03, 2017, 10:23:59 pm »
Frequent Contributor

Do you mean c as ting metal in 3 D printed molds .. Y es it c ould be pos s ible, by now I have not
Posts: 272
tried to melt s omething with induc tion heater.
Country:
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3DARTjar Re: ZVS Induction heater 2000W 40A 50V

« Reply #18 on: January 31, 2018, 10:20:01 am »
Newbie

Posts: 1
T hank you Strawberry for s haring with us your projec t! I would be interes ted what quantity of
Country:
nonferrous metal c an you melt with this heater in a alumina c ruc ible ? I would like to us e it with a
A E G SA FT N I FE 5 0 V /3 4 A power s upply if it is s uitable ?
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jlkazim Re: ZVS Induction heater 2000W 40A 50V

« Reply #19 on: February 19, 2018, 02:50:00 pm »
Newbie

Posts: 1
H ello I am interes ted in ZV S I nduc tion heater 1 5 ..5 0 V 4 0 A 2 kW but now I want to order 2 0 P C B
Country:
of this mac hine and the c omponents how to do?
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CopperCone Re: ZVS Induction heater 2000W 40A 50V

« Reply #20 on: February 19, 2018, 05:21:03 pm »
Super Contributor

I wanted to build one with h bridge phas e power c ontrol. T his way you c ould us e a ds pic to c ontrol
both phas e and frequenc y.

T his s eems les s parts heavy then des igning a high power adjus table s upply for the c irc uit in this
thread. T he only benefit i s ee is that it operates at the res onant frequenc y without tuning, but it
Posts: 1415 s eems to have a potential s tartup problem.
Country:

*knock knock* I s there any benefit to us ing dual s tages vs full h bridge c ontrol with an adjus table induc tion
heater.

H owever as your melt gets hot the induc tanc e c hanges s o the res onanc e frequenc y c hanges and
you get power los s ... So this method may be better then phas e c ontrol for that reas on.

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I gues s that you would need to add a pll trac king c irc uit to the mc u and have the mc u periodic ally
s ample the pll output to adjus t the c enter frequenc y..
« Last Edit: February 19, 2018, 05:55:09 pm by CopperCone » Logged

T3sl4co1l Re: ZVS Induction heater 2000W 40A 50V

« Reply #21 on: February 19, 2018, 07:02:38 pm »
Super Contributor

Bac k in indus try, I us ed a s ingle s tage, full wave, frequenc y offs et c ontrol. Simples t power s tage,
but c rappy to c ompens ate. Wanted to try phas e c ontrol, but the driver and output s tage didn't
have the logic to s upport it. Y es , you need a P LL to trac k res onanc e, or s omething near it in any
c as e. P has e s hift P WM gives you effec tively a variable voltage s ourc e, exac tly what you need.
With the s ys tem at res onanc e, the amplitude res pons e is a (s ingle or repeated?) pole at the tank
Posts: 15629 time c ons tant, low Q and eas y to c ompens ate.
Country:

Expert, Analog Electronics, Downs ide is 1 0 0 % s witc hing los s and E M I . A tri-level inverter (a half bridge with a s horting-to-
PCB Layout, EMC zero mode) might be preferable for this reas on.

T im
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Electronic design, from concept to prototype.
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j2000 Re: ZVS Induction heater 2000W 40A 50V

« Reply #22 on: August 05, 2018, 05:06:12 am »
Newbie

Posts: 1
H ey Strawberry...thanks for the s c hematic ...
Country:
Did u s ell DI Y kit c omplete?

Regards
Joel
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IvanLazarov Re: ZVS Induction heater 2000W 40A 50V

« Reply #23 on: August 09, 2018, 02:46:49 pm »
Newbie

Posts: 1
H i Strawberry, thanks for s haring the s c hematic s for your induc tion heater. I will try to build it
Country:
mys elf.

C an you pleas e advic e what s hould be the c urrent rating of c hokes L1 and L2 ? I f the total power is
2 KW, does that mean that eac h c hoke s hould be rated at minimum of 2 0 A ?

What is the purpos e of the additional c irc uit on the right hand s ide that you inc luded in the lates t
revis ion the drawing?

C heers ,
I van
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strawberry Re: ZVS Induction heater 2000W 40A 50V

« Reply #24 on: August 09, 2018, 10:00:13 pm »
Frequent Contributor

1 /I f you want do s erious s taff with it, then L1 L2 will be redes igned.
Posts: 272
2 /I t is protec tion c irc uit idea
Country:
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