Author Topic: Help for people buying the "12-48 Volt 1800/2500 Watt ZVS induction Heater"  (Read 64915 times)

Offline petespaco

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Quote
The copper tubing is less prone to temperature degradation but resistive heating will lead to higher resistance and more loss, and eventually power limiting, depending a bit on the actual design. Contacting the tubing is probably the limit here. Or what is the general opinion?

In my opinion, you should always be water cooling the  copper tubing, so "resistive heating" should not become an issue, since the tubing never even gets close to 100°C (in my experience).

Regarding capacitors:
The zvs induction heaters that I have all use this capacitor:

BM brand.
0.33 mfd  630VAC, ((1200VDC)
Type MKP

The 1000 watt units have 6 of them in parallel
The 1800 watt units have 9 of them in parallel
The 2500 watt units have 12 of them in parallel
So far, I have never had one of them fail.

I always force air-cool the induction heater boards, pushing the air downwards towards the circuit components.


Offline T3sl4co1l

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Incidentally, one could even operate with no resonant capacitors at all, just brute force inverter capacity.  This maximizes transistor use, putting all reactive power through them -- but if they're cheap, maybe that's not such a big deal.  The catch is, you still need to handle that current somewhere, somehow; in this case it comes back to the DC link / inverter bypass caps, which need to handle all that ripple current.  The only consolation is that the ripple voltage is small, so much lossier, bulkier types can be used -- DC link film, "filmlytic", the kind with the bolt studs, and even polyester (MKS) and electrolytic are suitable, as long as you have enough of them.  I think it's a poor tradeoff overall, that you'll end up spending more here (in cost or size) than the resonant version.

The one upside is that frequency can be freely controlled, which makes for interesting possibilities in special applications (like variable depth case hardening).  Of course, this requires industrial scale machines to be practical (100s kW, to heat up the surface fast enough while the core of the part remains cool).

Tim

Offline petespaco

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If you do decide to use the same capacitor that is on the units that I have, they cost about USD$1.00 each.  Here's one example:
Ebay Item  174496593032


Offline rikkitikkitavi

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Those I recocgnise, they are typically used in a half bridge simple induction cooking stove plate. Due to that topology they are subjected to high voltage stresses. 

Considering that only a few , 2-4 or so is used in each cooking plate with a output of 1+kW parallelling a bunch explains why they can take a lot of power.
Normally it is not thte caps that fail in those cooking tops, but the IGBTs.
Have become hero of the neighbourhood  as I fix expensive  4 plate stoves for a handful of dollars , compared  to  what the dealers charge for a replacement module (no warranty give n though as other parts might have taken a beating, but I always rely on the circuit breakers for that...)

I have seen these black boxes, a  grey box and some round white caps with axial leads (probably more inductive )

Unfortunately no datasheet with specs easiliy avialable but your  table is good data to be used as an indication

Thanks for the input!
« Last Edit: April 11, 2021, 09:27:57 PM by rikkitikkitavi »
A man can not have too many variacs

Offline petespaco

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New work coil related video----
 Finally trying to actually forge and then harden something using the 2500 watt ZVS induction heater as the sole heat source.
-I went through a LENGTHY process of (mostly) empirical coil "design" that may be of interest to some:

/>
  You WILL need to have a fresh cup of coffee or your favorite beer to watch this one.

Pete Stanaitis
---------------


Offline hightemp1

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Cold quart of milk is my perferred poison. 

That is a great way to heat those strikers. 
Maybe even cover with a nice warm kaowool blanket.

Offline hightemp1

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This blacksmith architect toasts three ZVS 2500W heaters before learning about AC initial voltage surges from transformers. 
At 6:35 in video - reminds me of superman bending steel - very cool  8) 
/>Now, the powerful small coil may be ramping up the amps above 2.5kw?  Judging by time it took bend metal rod -maybe running at or near 3kw - doubt if over 3kw, else PS's over-current of approx. 60 amps would have kicked in?
Pete and company enlighten him on the finer points of induction heating. Maybe a FAQ page at the start of this thread would be a good idea, esp. since I have diluted much of the meat so badly.

« Last Edit: April 24, 2021, 04:31:14 PM by hightemp1 »

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