Author Topic: induction heater troubleshooting help  (Read 385 times)

Offline aes92000

  • High Voltage Enthusiast
  • *
  • Posts: 3
  • Karma: +0/-0
    • View Profile
induction heater troubleshooting help
« on: June 30, 2020, 04:08:34 PM »
Hey all, new to forum and about to loose last hair trying to figure out issue.

i have reverse engineered the pcb from an 1800W induction heater from bangood.

i re-used all the parts EXCEPT i replaced the irfp540 with irfp4668.  it was working awesome.  48-54vdc @ ~75a.
where the 3 connectors for coil connected to pcb started to burn through. most likely from me always changing coils for work being performed.

i have since then tried to replicate same board but it will not work.

it will either turn on and pop (another hair lost) or just short power supply and shut down.

i bought new 4668 mosfet and about to try again but i have question that i am wondering if it is causing issue.
is it because of the length for coil mounts on new design???

i have included pictures of original, upgraded working/bad and new design


Offline ritaismyconscience

  • High Voltage Technician
  • ***
  • Posts: 159
  • Karma: +3/-0
    • View Profile
Re: induction heater troubleshooting help
« Reply #1 on: June 30, 2020, 09:01:55 PM »
Try checking for shorts
It's really easy for a solder bridge to form between two parts with bare copper boards

Offline aes92000

  • High Voltage Enthusiast
  • *
  • Posts: 3
  • Karma: +0/-0
    • View Profile
Re: induction heater troubleshooting help
« Reply #2 on: June 30, 2020, 10:34:36 PM »
thank you.
i will put on my scope so i can zoom in for bridges or other defects

will the longer copper bars for coils be an issue?

Offline petespaco

  • High Voltage Technician
  • ***
  • Posts: 159
  • Karma: +9/-0
    • View Profile
    • French Creek Valley Activities
Re: induction heater troubleshooting help
« Reply #3 on: July 01, 2020, 12:03:08 AM »
What are you using for a power supply?
 When you say that the board "shorts the power supply", I wonder if the board's current draw might be causing the power supply to go into current limit mode, which can reduce the voltage enough to make the mosfets lock up.
I didn't know they used IRFP540's on those boards.  I thought they were IRFP260N's.

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

Offline aes92000

  • High Voltage Enthusiast
  • *
  • Posts: 3
  • Karma: +0/-0
    • View Profile
Re: induction heater troubleshooting help
« Reply #4 on: July 01, 2020, 02:33:07 AM »
it is a rectifier module
120/240VAC input
48-54VDC output
75A max (@ 240VAC)
if i can get working again, i will get another rectifier and share load for higher amps.  they wire for load sharing.

the power LED flickers on and then off as it shuts down and you hear the rectifier fans kick in and alarm light comes on.
i always turned power on to stabilize voltage before turned on heater.
i do not have coil loaded when starting and it still shuts down so it can't be overloaded, can it?
the first board i upgraded did not have that issue. 

as you can see from pics for upgraded board, i was able to get up almost max amps for supply and i always started with unloaded coil .
it would melt 1oz copper within 20 minutes.

Offline petespaco

  • High Voltage Technician
  • ***
  • Posts: 159
  • Karma: +9/-0
    • View Profile
    • French Creek Valley Activities
Re: induction heater troubleshooting help
« Reply #5 on: July 02, 2020, 01:02:02 AM »
Do you have an oscilloscope so you can check to see if the circuit is oscillating at all?
I can't see the voltage ratings of those caps.   Are any of them shorted? 
Have you checked to make certain that none of your Mosfets are shorted?  Maybe wiped out out by an earlier error in wiring or ????
You say "it would melt 1oz of copper in 20 minutes". What does that mean?  WHEN?  Original board or YOUR board?  Did your board ever work?  Did it ever start up with a low "idling current"?

 "it was working awesome.  48-54vdc @ ~75a.":  Which one?
that's double the power that the original board was designed for.  No wonder it failed.
What dimension of work coil were you using when you got those readings?


Offline petespaco

  • High Voltage Technician
  • ***
  • Posts: 159
  • Karma: +9/-0
    • View Profile
    • French Creek Valley Activities
Re: induction heater troubleshooting help
« Reply #6 on: July 06, 2020, 06:53:26 PM »
It would be nice to hear from the OP.
 

High Voltage Forum

Re: induction heater troubleshooting help
« Reply #6 on: July 06, 2020, 06:53:26 PM »

 


* Recent Topics and Posts

post Air Gap: why and how much?
[Transformer (Ferrite Core)]
HighVoltageRulezz
Today at 06:23:24 PM
post Re: making HV bobbins for ferrite transformers
[Transformer (Ferrite Core)]
HighVoltageRulezz
Today at 06:15:16 PM
post Re: How about some Tesla Coil memes
[General Chat]
AstRii
Today at 05:26:47 PM
post Re: First DRSSTC, No Sparks on Breakout
[Dual Resonant Solid State Tesla coils (DRSSTC)]
TMaxElectronics
Today at 05:25:43 PM
post Re: How about some Tesla Coil memes
[General Chat]
TMaxElectronics
Today at 05:23:40 PM
post Re: First DRSSTC, No Sparks on Breakout
[Dual Resonant Solid State Tesla coils (DRSSTC)]
AstRii
Today at 05:23:37 PM
post Re: Bipolar high voltage multiplier project - more than 70cm hot arc discharge
[Voltage Multipliers]
kilovolt
Today at 01:44:24 PM
post How about some Tesla Coil memes
[General Chat]
AstRii
Today at 01:09:16 PM
post First DRSSTC, No Sparks on Breakout
[Dual Resonant Solid State Tesla coils (DRSSTC)]
Yak
Today at 12:41:06 PM
post Re: X-ray image intensifier
[X-ray]
AlexanderHun
Today at 11:01:46 AM
post Re: Easy to build Polyphonic MIDI Interrupter
[Computers, Microcontrollers, Programmable Logic, Interfaces and Displays]
AstRii
Today at 02:09:13 AM
post Re: Charging a LiPo Battery with an LED driver
[Electronic Circuits]
davekni
August 12, 2020, 11:08:35 PM
post Re: making HV bobbins for ferrite transformers
[Transformer (Ferrite Core)]
davekni
August 12, 2020, 10:49:52 PM
post Re: Moving to a new lab!
[Laboratories, Equipment and Tools]
Mads Barnkob
August 12, 2020, 10:30:54 PM
post Re: making HV bobbins for ferrite transformers
[Transformer (Ferrite Core)]
Teravolt
August 12, 2020, 09:00:50 PM
post Re: making HV bobbins for ferrite transformers
[Transformer (Ferrite Core)]
SteveN87
August 12, 2020, 07:16:43 PM
post Re: making HV bobbins for ferrite transformers
[Transformer (Ferrite Core)]
Teravolt
August 12, 2020, 02:54:33 PM
post Re: Charging a LiPo Battery with an LED driver
[Electronic Circuits]
TMaxElectronics
August 12, 2020, 12:42:50 PM
post Re: Charging a LiPo Battery with an LED driver
[Electronic Circuits]
Twospoons
August 12, 2020, 12:23:58 PM
post Re: Single sided use of Xray XFMR
[Transformer (Ferrite Core)]
HighVoltageRulezz
August 12, 2020, 11:15:07 AM
post Re: making HV bobbins for ferrite transformers
[Transformer (Ferrite Core)]
davekni
August 12, 2020, 04:41:24 AM
post Re: Charging a LiPo Battery with an LED driver
[Electronic Circuits]
davekni
August 12, 2020, 04:06:09 AM
post Re: Charging a LiPo Battery with an LED driver
[Electronic Circuits]
TMaxElectronics
August 12, 2020, 01:58:47 AM
post Re: Charging a LiPo Battery with an LED driver
[Electronic Circuits]
Twospoons
August 12, 2020, 12:56:02 AM
post Charging a LiPo Battery with an LED driver
[Electronic Circuits]
TMaxElectronics
August 11, 2020, 11:24:18 PM
post Re: making HV bobbins for ferrite transformers
[Transformer (Ferrite Core)]
Teravolt
August 11, 2020, 06:34:05 PM
post Re: Fun with wireless power
[Solid State Tesla Coils (SSTC)]
Lightning On Demand
August 11, 2020, 04:19:01 AM
post Re: Fun with wireless power
[Solid State Tesla Coils (SSTC)]
Lightning On Demand
August 11, 2020, 04:17:27 AM
post Re: Fun with wireless power
[Solid State Tesla Coils (SSTC)]
Lightning On Demand
August 11, 2020, 04:10:34 AM
post Re: Single sided use of Xray XFMR
[Transformer (Ferrite Core)]
klugesmith
August 11, 2020, 03:33:02 AM
post Single sided use of Xray XFMR
[Transformer (Ferrite Core)]
HighVoltageRulezz
August 10, 2020, 12:23:05 PM
post Re: XRay Tank- any ideas about what is inside
[Transformer (Ferrite Core)]
HighVoltageRulezz
August 10, 2020, 12:18:04 PM
post Re: making HV bobbins for ferrite transformers
[Transformer (Ferrite Core)]
johnf
August 10, 2020, 10:24:54 AM
post Re: making HV bobbins for ferrite transformers
[Transformer (Ferrite Core)]
davekni
August 10, 2020, 06:20:04 AM
post Re: Welcome new members, come say hello and tell a little about yourself :)
[General Chat]
RoadReaper
August 10, 2020, 05:40:19 AM
post Re: Easy to build Polyphonic MIDI Interrupter
[Computers, Microcontrollers, Programmable Logic, Interfaces and Displays]
Max
August 10, 2020, 02:07:26 AM
post making HV bobbins for ferrite transformers
[Transformer (Ferrite Core)]
Teravolt
August 10, 2020, 01:27:22 AM
post A Tesla coil and an antenna
[General Chat]
TheFreq
August 09, 2020, 09:02:32 PM
post Re: Fun with wireless power
[Solid State Tesla Coils (SSTC)]
Steve Ward
August 08, 2020, 10:22:04 PM
post Re: Fun with wireless power
[Solid State Tesla Coils (SSTC)]
T3sl4co1l
August 08, 2020, 03:36:40 PM
post Re: Fun with wireless power
[Solid State Tesla Coils (SSTC)]
acmq
August 08, 2020, 02:07:52 AM
post Re: LSI Nitrogen Laser tear-down and Homemade TEA Nitrogen and Dye Lasers
[Light, Lasers and Optics]
LesWright
August 06, 2020, 10:20:12 PM
post Re: LSI Nitrogen Laser tear-down and Homemade TEA Nitrogen and Dye Lasers
[Light, Lasers and Optics]
Weston
August 06, 2020, 08:45:59 PM
post Re: Cathodes in Compact Fluorescent Lamps
[Light, Lasers and Optics]
klugesmith
August 06, 2020, 05:41:04 PM
post Re: Dual MOT tesla coil
[Spark Gap Tesla Coils (SGTC)]
Jun
August 06, 2020, 03:53:58 PM
post LSI Nitrogen Laser tear-down and Homemade TEA Nitrogen and Dye Lasers
[Light, Lasers and Optics]
LesWright
August 06, 2020, 03:28:14 PM
post Re: Easy to build Polyphonic MIDI Interrupter
[Computers, Microcontrollers, Programmable Logic, Interfaces and Displays]
AstRii
August 06, 2020, 12:59:03 PM
post Re: Easy to build Polyphonic MIDI Interrupter
[Computers, Microcontrollers, Programmable Logic, Interfaces and Displays]
Mads Barnkob
August 06, 2020, 10:51:43 AM
post Re: How much is the voltage used in Corona Discharge tubes for ozone Generation?
[Transformer (Ferrite Core)]
UB_Serpent
August 06, 2020, 08:40:57 AM
post Re: compact midi interrupter
[Computers, Microcontrollers, Programmable Logic, Interfaces and Displays]
TMaxElectronics
August 06, 2020, 03:22:38 AM

Sitemap 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 
SimplePortal 2.3.6 © 2008-2014, SimplePortal