Banggood 1000 Watt 12-48 Volt ZVS Induction Heater At 40KHz

[@dalenassar9152]

The formula that relates the work coil frequency (f) , the inductance of the work coil (L), and capacitance on your LC oscillator circuit is 1/ [2*PI * sqrt (LC)] is working perfectly here! First you gave f=87Khz, C=1.98uF (0.00000198 F), Tells you that the original working coil has an initial inductance of: L=1.69uH. The formula also tells that if ONLY the coil OR ONLY the capacitor (C) is doubled that (f) is REDUCED by sqrt(2) = 1.414. This is why 87Khz dropped to 62kHz: 87kHz divided sqrt(2) = 62kHz. Also when you doubled both L and C you get a reduction x2 and 87kHz divided by 2 = 43.5kHz. So we also know that your bigger coil is 3.38uH (1.96uH divided by 2). This is about the closest I have seen components match the related formula.

[@dalenassar9152]

The sinewave distortion AND the frequency drop under load is likely due to those two on-board chokes getting into saturation. GREAT VIDEOS & INFORMATION THAT IS HARD TO FIND!!!!

[@AjLloyd-uy2tr]

I just bought one of these and your video was super helpful!!! Thanks!

[@robertanderson8613]

Thanks for putting this on I do know coil diameter according to what you want to heat is very important and frequency I'm building one and am trying to find info what frequency is best for annealing brass cartridges to 750f actually stopping around 650f because they seem to coast a bit

[@frenchcreekvalley]

Right this moment I don't have the answer to your question. I have just built a 4 X2 turn work coil to test an idea for magnetic flux concentration with brass annealing in mind, since I have been asked that question often. As soon as I get a frequency meter permanently connected to my 1000 watt unit. I will begin testing it and other coils for applicability in annealing various shell casing. With these heaters, you don't have the choice to go very much higher than about 125 kHz or so without some negative effects on system life and reliability.

[@kyle.2344]

What a well put together video! thanks!

[@rdalemd76]

Hi, Can a 120V input, 100 khz Induction Heater be converted to 40 to 50 kHz? Thanks

[@frenchcreekvalley]

I'd say "it depends". Adding capacitance to the tank circuit without changing the system inductance will certainly lower the frequency. for a given work coil, but without knowing how the circuitry can handle the change, you could be in for trouble. And--- some available induction heaters use specialized water cooled tank capacitors making it hard to modify the "C" of the tank without creating new problems. Of course adding inductance to the tank will also reduce frequency. But even that is complicated by not knowing how machine's driver circuitry is designed.

[@waterfuel]

Doesn't the choke coil L inductance add to the work copper coil L with capacitance for the general frequency?? It's in the same positive 12v line going to work coil.

[@frenchcreekvalley]

Not really. The chokes are there to stabilize current flow. They are not actually in the LC tank itself.

[@marmac567]

Hi,, I have a few arc welders,, AC & DC output,,,, 48v could that power these units??? Thanks

[@frenchcreekvalley]

The DC units probably can power these 1000 watt and 2500 watt induction heaters, but you may have to do some capacitive smoothing of their output. I haven't tried doing that yet.

[@marmac567]

@@frenchcreekvalley Ahh, Im an engineer and dont understand capacitive smoothing,,, only smoothing metal with a hammer... The power supply units seem very expensive

[@frenchcreekvalley]

@@marmac567 The DC current from most DC welders has "humps", all above the zero voltage point, just like a piece of iron that you have just fullered with a large fuller. We need to "hammer" those humps down to some degree so the overall surface is relatively smooth. Capacitors keep the "humps" from going quite so high by sucking up some of the incoming voltage and then slowly spit it back out during the valleys between humps. Yes, a good 48 volt 50 amp "server" power does cost close to USD$100.00. But once you have it, you have a good reliable power source. Four new car batteries will cost you more than that, and you still need a battery charger to recharge them.

[@marmac567]

@@frenchcreekvalley The ones Ive seen for sale are £250 at least ... Any idea what size cap Id need to get for welder,,, and do I just strap it between pos and neg??? Thanks for your help .... Martin UK

[@frenchcreekvalley]

@@marmac567 I use this one: usa.banggood.com/AC-200V-250V-To-DC-48V-50A-2400W-Power-Supply-For-ZVS-High-Frequency-Induction-Heating-Module-p-1279188.html?cur_warehouse=CN&rmmds=search It costs USD$90.00 Sorry but I'd have to do a significantly expensive evaluation of a specific welder to answer your question about capacitance. In the end, the capacitors could cost more than the power supply that I mentioned above. On the other hand, the welder might work okay as a power supply without adding any. However, as a minumum, you/I would need to know the voltage output of the welder. Some have a pretty high open circuit voltage, which could wipe out your induction heater right away.

[@ftwproject658]

Thank you for this analysis. Although you ran this test in 2017, it is the type of information I need for my experiments. It's good to know that these boards are extendable, opening the future opportunity to build a PCB with the added capacitance capability. It maybe something that even the manufacturer would be willing to modify to the customer specs. BTW, How long did you circuit operate at 40 kHz before you had to turn it off due to high operating temperatures. My experiments require a 10 minute continuous operation. Thanks again :)

[@frenchcreekvalley]

Thank you for your kind words. To answer your question: I did not run THAT test for any longer than what you saw. But I can run the 48 volt system continuously that way since it has water cooling and fan cooling for the circuit board.

[@tomhadoulias7571]

Thank you for your videos on induction. One comment and one question, one comment was made as to separating the work coil from the ZVS board. I have found that after many methods the one that works best with the lowest transmission loss is a coaxial cable. Since this is an RF resonant circuit it was logical to me to use 50 ohm RG8U with PL259 and SO239 connectors for easy attachment of various coil configurations to the board. I have had success with 5 Ft lengths working fine to the remote coil. My question is, on the DSO 112 oscilloscope, exactly where was the lead placed to read the frequency. It's hard to see with the other wires in the video. Appears to be joined from the black lead on the scope to a red wire with an insulated alligator clip to a resistor between the toroid and mosfet? Would appreciate a clarification before I blow a scope and/or board. Thank you, keep up the great work!

[@frenchcreekvalley]

Interesting that the coax works well for you. I'd have thought it would heat up pretty quickly without some form of cooling. Were you drawing 1000 watts from your power supply when you were doing that? Did the coax heat up? I think I had the DSO112 connected across the gate zener. It's going to clamp the gate to 12 volts, right? The tectronix scope was connected directly across the work coil. It would be pretty hard to develop a very high voltage across 3 feet of 1/4" OD copper pipe. Current, of course, would be a different story. Both scopes have pretty high input impedances, so they won't take much power from the system. I don't know how you would hurt either scope or blow a board with those connections.

[@tomhadoulias7571]

Thanks for the reply! I learned the hard way with the Chinese boards used in the induction cooktops. They are floating grounds and it took me a couple of boards to realize that my scope was a grounded IEC cord and every time I tried to read a trace I blew the caps off the IC's and power section. Now I have isolated leads so that problem was solved or I just used a un-grounded electrical cable to the scope. Regarding the Coax cable, it did warm up at the frequency the ZVS 1000 operates at but not too bad. Maybe around 130 F after a few minutes of operation operating off a 20V 5AH battery. I have noticed that operating off of the lower frequency cooktop boards 20KHZ I get virtually no heating of the coax at all at 1800 watt output. I like that little DSO 112 for frequency readout real-time. I ordered one and anxious to play with it. Thank you for the fine videos you put out!

[@7Zone-youtube-channel]

hello, I'dont understand. Did you work with the working coil RG8U? 5 ft working coil length? I will be happy If you answer.

[@7Zone-youtube-channel]

If the coil runs at 20 KHZ, the heated metal (iron) consumes how many watts and how many volts. (4cm diameter iron pipe)

[@geterdone4462]

Hi, can the induction heater be started with a piece of metal already inserted into the coil? Cheers.

[@frenchcreekvalley]

Hello Get'ER Done. Good question! I just tried starting two different setups and they both worked normally when started with work already in the coil. One unit runs on 48 volts and the other one runs on 24 volts. So, in both cases, the chances of the Mosfet gates getting LESS than 12 volts (which can cause one Mosfet to latch and destroy it self) is very slim (unlikely to happen). But I have not tried this (and I won't try this) with only 12 volts for a power supply.

[@alexandrosalexiou9713]

Hello. The temperature remains constane? 950 - 970° celsius? Thanks

[@frenchcreekvalley]

Hello Alexandros. I did not discuss temperature on this video. If you saw another video where I did measure temperature, I was probably reading the MAXIMUM temperature that the work material would reach for that test.

[@alexandrosalexiou9713]

Good morning. I ask if i can stop the temperature to whick i want. Thanks

[@frenchcreekvalley]

@@alexandrosalexiou9713 Thank you. Now I understand. These ZVS induction heaters do NOT have a way to control the power going to the work coil. I have seen a few videos where the guy inserts a thermocouple into or onto the work and uses a temperature controller to turn the DC POWER to the ZVS heater on and off. There are many inexpensive temperature controllers on the market today but they usually are designed to switch AC current. But you need to switch the DC current because many of the power supplies do not come up to full output fast enough to prevent the Mosfets on the board from both latching and blowing out components. This problem can be solved by obtaining a DC rated relay and using the temperature controller to switch that relay, If my explanation lacks clarity, please feel free to ask more questions.

[@alexandrosalexiou9713]

@@frenchcreekvalley ok. Thank you very much

[@ajofscott]

By the way you can parallel driver modules, doubling switch capacity as well as doubling the resonator capacitance.

[@nandanams7220]

I want to use 1000 Watt ZVS induction heater for the purpose of instant heating of iron oxide nano particles dispersed in water solution, taken in a test tube of 2 cm dia and 10 cm in length. Can you please suggest the coil dimension to be used to get operating frequency of at least 100 kHz or above, and also please suggest the the induction heater model that best suits this application.

[@frenchcreekvalley]

I have no experience in heating iron oxide, in any form. But this sounds like a very interesting project. As you know, there are different forms of iron oxide. I suppose these different forms would perform differently in the induction coil, since at least one form is magnetic and others are not. If I was going to undertake this project, I would go out into my shed and scrape some red rust off of old iron, put it into a test tube with some water, and just see what happens. Then, if the material heats up at all, I would gather some black iron scale from around my blacksmith anvil and see it that material behaves any differently. But I still have no idea how my large particles would react compared to your "nano" particles. I don't have any idea of the concentration of the oxide in the water, either. The diameter of the work coils that come with these 1000 watt ZVS induction varies from about 1 1/2 inch ID to about 2 inch ID. The 1 1/2 inch ID coil produces a tank frequency of just over 100 kHz, so that's close to the range you request. These coils are about 2 inches tall. In summary, I don't have an exact answer for you. Since the 1000 watt ZVS unit isn't too expensive, I'd suggest getting one of those just to see if the iron oxide nano particles in the water respond at all to the magnetic fields.

[@nandanams7220]

@@frenchcreekvalley Thank you for the suggestion. I would go with 1000 Watts zvs and see how it works with this nano particle.. thank you sir

[@CoruscantMe]

Whats the resulting affectation of the time it takes to heat the target rod in it with the double inductance/capacitance as compared to the original configuration? I would think with a lower frequency, the time it takes to heat would be Longer than at the higher frequency, is that what you observed?

[@frenchcreekvalley]

The lower frequency does a better job of heating steel, but the opposite is true for non ferrous electrically conductive metals like copper. "They" say that lower frequencies cause deeper penetration for steel. I do see higher currents for a given work piece when heated with the lower frequencies.

[@MindTrip888]

@@frenchcreekvalley My understanding about resonant frequency is that every metal, indeed, every element, has their own resonant frequency. Being that two metals in an alloy one will melt at a different frequency to the other, independent of melting temperature. Like a radio is tuned into, that a sweet spot will be found that will be best for a particular material/metal. As a metal detector also detects and discriminates to determine what metal it is detecting from much advanced design over the years. That a signature can be determined by trial and error, or others research and tables, for best effecting of a specific metal. So in a way I am surprised that there is not a variable frequency. But I hear you say there are PLL devices on some more costly IH driver boards. I just got myself a frequency meter and frequency generator and am looking to experiment. Though I am worried about current and self destruction, so this is what got me looking in the direction that led me here to see your wonderful presentation, giving me some great feedback in my learning curve. Thanks. I also bought a bunch of Mosfets on ebay from China to drive things. I will have to tread carefully. Also you might be interested in frequency separation of Hydrogen from salt water at about 13.56 MHz. I am wondering what it might be to do it with clean distilled water. As HHO gas being put back through distilled water is being sold for a fortune for health rejuvenation. Not that I want to sell it. But there are dangers in using electrolysis with caustic or even salt, with other side effect gases given off. It would be nice to have just pure oxygen and hydrogen for testing the effects to see if its more than a placebo. I also hear the Navy is using salt water for its own fuel now, from a video I saw from 2013 or so. Very interesting things with the right frequency to induce resonance. Even with sounds, that can shatter glass, winds that shake a bridge to pieces etc. Fascinating that Tuning In has so much of a 10x amplification factor. That even thoughts and healing intentions with this theory, make the concepts of "miracles" or "magic" by thought and emotion logically possible if resonance of those frequencies is achieved. As radio waves carry other waves of sound etc... its a really marvellous universe we live in. Even seeing cymatics with sand or salt on a vibration plate that jumps into a new pattern as each frequency is reached showing a resonating almost magical view that sound is a lot more than a mere sine wave. Thanks for sharing your experiments. Its a new world with all this extra data available to us. :D

[@MrIlangovans]

Can you try using a coil with a larger inner diameter from 2" to 6" and test it??? I seen only small diameter coils in most of the videos. Want to know if we can use this to heat a cylindrical pot :)

[@frenchcreekvalley]

The direct answer to your question is: No, I probably won't make any coils larger than about 2" inside diameter for use on this induction heater. One reason is because I don't need to heat anything larger at this time. However---, I think that, if you made a 6" diameter coil and put a 5" diameter cast iron pot inside the coil, the system would draw too much current and it would fail quickly.

[@MrIlangovans]

So the diameter of the coil is proportional to the current draw ???

[@MrIlangovans]

Check this out kzbin.info/www/bejne/Z6fddHyhoNJkZ80

[@frenchcreekvalley]

Not necessarily. But, if you have a 6" diameter coil and put a 5" diameter steel pot into it, the power coupling will be very good and so the current draw will be very high. High enough to probably cause this board to fail because it has no way to limit current. The larger diameter coil will have a lower inductance and it will want to operate at a much higher frequency than what you see on this video. This might cause oscillation problems.

[@MrIlangovans]

Iam not into forging or melting of metals. Just looking for a solution to melt some plastic with a bean can /tin ...is it possible to add a current limiter to this circuit???

[@CapApollo]

what material you use to isolate the coil? how its call?

[@frenchcreekvalley]

I use this fiberglass sleeving: F240-2AWG (6.68mm) 240°C Fiberglass high temperature sleeving I found it on Ebay.

[@chesterwheeler279]

CSW:In Search Of Zero Point energy the coil should be supercooled and bifilar volume collecting coils placed on both sides of the induction heating coil probably extremely efficient in the dark side of a craft. Then to create intense lumen production halogen lights..and those in closed containment of photovoltacic receptors useing the cold electricity to produce invertable DC power to AC. The ultimate natural environment would be to make use of this in space where there is a natural vacuum. Perhaps simple refrigeration could be used to regulate the primary induction coil .The cold electricity from the secondaries passed through bridge rectificalion and ballasted could maintain and supply even discharging usage from the inverted sine signals and is refed to the primary induction coil FROM THE TRANSFORMER PRODUCING THE hIGH FREQUENCY CAPACITATED HZ TO THE PRIMARY COIL. In addition to the surplus light that can be produced with minimal input the halogen bulbs could also produce heat to heat entire rooms or an entire house or depending on the question of how much energy do you need to use. I It's not perpetual but utilizes more of the release of volume than one aspect of E expressing it's self as of amplified strength. The use of such configured spacetime may appear to some as over unity because of the effect of opening the floodgate of Teslas' concept of energy volume like riding on the crest of a wave the height of which having the greatest potential.I know there are far reaching potentials for this technology:CSW

[@frenchcreekvalley]

Sorry, CSW, but I really don't know where you are going with your comments. P= E X I, no matter how you play with it. You don't see much "bifilar" winding in the induction heating industry. Not having a "natural vacuum" handy, I don't see how this applies. But I do know that a high vacuum doesn't come for free, energy wise, either.

[@hello5301]

its my dream to complete this application . aim following you from some days and you well don . very very nice work mine is 35 vdc input with 100 amp rectifier going to my mosfets and then to my tank capacitor fix parallel with my coil my coil is 8 cm in 7 turn . capacitor is 18 farad 660 volt and i can make a 20 mm of metal got a red color in about 1 minute but can not melt any thing yet ... please help me to melt i think some thing need to increase power finally i like your work your components your tools thanks . and waiting for your answer really thank you

[@The_Unobtainium]

Thank you for your vids! One quick Q: does this ZVS 1000W search for resonant frequency of its own when one change some element in resonant circuit? Or it needs to be tunned somehow?

[@frenchcreekvalley]

Hello, 105bogus. Yes, it does use the natural resonance of the LC tank circuit to determine the frequency at which it operates. So, when either the L or the C changes, so does the resonant frequency. There really is NO way to tune the resonance of this particular kind of circuit other than to add or subtract capacitance and/or inductance. More complex and expensive units have separate oscillator drivers to "tell" the circuit what frequency to run at. These are often refered to as "PLL" or "Phase Locked Loop" circuits. I also note that, when the operator inserts a work piece into the work coil of these ZVS units, the work usually lowers the resonant frequency as well as causing an increase in system current...

[@dalenassar9152]

@@frenchcreekvalley Upon inserting the workpiece, the increase in current is normal...however, the frequency reduction is NOT: this is due to the filter chokes acting in parallel to the workcoil. They are either saturating or are have too large of an inductance relative to the workcoil. The chokes' inductance each need to be at least 10x greater than that of the workcoil.

[@frenchcreekvalley]

@@dalenassar9152 You may be correct about the inductors saturating, but putting just about any metal or conductive material into the work coil changes the tank's inductance which, in turn, would affect the frequency.

[@salemhassen9271]

why there is no any circuit diagram to the project !!!!

[@frenchcreekvalley]

The circuit for the induction heater is at: spaco.org/Blacksmithing/ZVSInductionHeater/1000WattZVSInductionHeaterNotes.htm The rest of the circuitry is simply power supply wiring- switches, current shunt, etc.. If you have any specific questions, please ask me.

[@gabebirbaie8670]

Excellent

[@awufbiswas7380]

Good 👍

[@raynorpro8062]

puede funcionar con una batería de auto

[@frenchcreekvalley]

Yes, this system can run on car batteries, but you need at least 2 of them in series so the system is receiving at least 24 volts. (Three or four car batteries would be better). I know that the description says "12 to 48 Volts", but 12 volts really isn't enough if you want to do very much heating.

[@reymondjosuearguellorojas2519]

Very interesant vídeo greetings from jicaral puntarenas costa rica

[@saulmorales5080]

hola,,soy de caracas venezuela estoy muy agradecido por su video,,me gustaria hacer un calentador igual,,puede ayudarme?

[@frenchcreekvalley]

Hello Saul. Everything that I know about these induction heaters is contained in these videos and on my webpage spaco.org/Blacksmithing/ZVSInductionHeater/1000WattZVSInductionHeaterNotes.htm

[@Alexis3407]

Mostre um diagrama unifilar deste projeto...

[@frenchcreekvalley]

I have not made a schematic drawing of this project as you see it in the video because I constantly keep changing it. But the schematic diagram of the induction heater PC board can be found here: spaco.org/Blacksmithing/ZVSInductionHeater/1000WattZVSInductionHeaterNotes.htm

[@Alexis3407]

Muito bem!!!

[@arthurcooper7031]

Is this guy reading Q card's ?

[@frenchcreekvalley]

Yes, Arthur. I am "this guy" and I usually script my videos so I don't waste your time rattling on about off topic things. By writing a script and testing my script before I make the final video, I try to make sure that each video makes sense so the viewer gets the most out of each one that makes it to youtube..

[@dalenassar9152]

@@frenchcreekvalley NOTHING wrong with that!!!!!

[@anwarbaabooo8853]

I m anwar pakist

[@alexandrosalexiou9713]

Hello. Do you make larger melts 600 - 700 gr of silver?

[@frenchcreekvalley]

The largest melt I have made was 542 grams of copper. My crucible would not hold much more than that: kzbin.info/www/bejne/kJqpZJiPd5qpZrM

[@alexandrosalexiou9713]

The temperature remains constant? 950 - 970° celsius? Thanks

[@frenchcreekvalley]

I have never melted more than 540 grams of copper using a 2500 watt ZVS induction heater. See this video: kzbin.info/www/bejne/kJqpZJiPd5qpZrM