Induction Coil schematic Assistance

Thread Starter

TheDave1214

Joined Jun 26, 2024
3
Below I have a Picture of a schematic I am working with right now (at least variants of), component specifics listed below. a working version that excludes R6/7 and has Q1/2 as a set of matching MOSFETs in parallel, and a non-working version with R6/7 that I cannot discover why it's not working.

The issues I am running into are as follows:
1. When turned on Q1 heats up but nothing else (L3 material). (12Vdc PSU) (MOSFETs are not breaking after tests just slowly building up to ~110F)
2. Q1 immediately fails when exposed my 36Vdc PSU on all version of the build so far.

I got this far on trial and error, and a few dozen online DIY guides, I have no formal training or experience with this type of engineering of any kind, only a very basic understanding of electricity and components, and a lot of safety equipment/precautions.
Screenshot 2024-06-26 122030.png
PSU: S-1200-12 (12Vdc 100A) * (S-1500-36 (36V 41.6A) available / Goal) + Battery Kill Switch 48V 200A (to prevent slow start for the circuit)
R1: 47KR 5W (R1 & LED Removed for now on all builds)
D1: 200V 81A (Automotive Diode) *
R2, R3: 1KR 5W *
R4, R5: 10KR 1/2W *
D2, D3: 1N5439B (12V, 5W) *
D4, D5: FR307 (1KV, 3A) *
R6, R7: 20R (Have a second Build [12 Vdc] without this set that works, but I've seen guides that recommend these be added)
Q1, Q2: IXFK180N25T (180A, 250V, <-200ns) (IRFB4115 Available) *, **
C (All): .33uF (330nF) 1200Vdc Capacitors (Count ranges from 4 to 8 for testing) *
L1, L2: Large inductors (3In rings with varying number of turns for testing different sets) Generally 60uH - 200uH 25A *
L3: Copper Tube Coil (1/4In round Tube, 5 turns, 2.5In ID, lead length 4 inches) *

- I have attempted to upgrade most components to be overrated for safety reasons and to prevent failure.
* = same on working and non-working builds
** = In some practice builds Q1 & Q2 are actually 2 sets of 2 matching MOSFETs in parallel (4 total 2 on each side). *

The goal is to heat a section of metal to a fairly constant ~900 Degrees Fahrenheit, the current working build achieves ~450. Hence my intention to upgrade to a 36Vdc 1500W PSU. I do not have access to one with a higher Wattage output at the moment, but that seems irrelevant if I cannot get the circuit to work with what I have available. Would I need a higher output PSU in the case of requiring a much higher output heat? Alternatively, would my working variant need:
- different capacitance / count / voltage rating?
- different inductance? (I believe rings are large enough to have not reached full saturation) (~60uH seems to be more effective so far, the 200uH heats up but much slower)

lastly, if I desired to add some level of control on the heating output, where in the circuit would I place the controlling components? I'm assuming:
- some value of Potentiometer / Variable Resistor between Vcc and L1/2?
- what value ranges would have meaningful impact on the output heat/frequency?

Any help would be much appreciated, I've been fiddling with this for nearly 4 months and seem to have hit a roadblock hence my reaching out for help, or paraphs my unfamiliarity with the terminology is also causing me strife in not knowing what to look up so if I have stated something wrong, please let me know so I can look for the appropriate research material.
 
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Thread Starter

TheDave1214

Joined Jun 26, 2024
3
Induction Coil / Forge / Furnace / Foundry, they all have nearly the same style ZVS circuit, and I have looked into the variations hence where I'm currently at, I probably assumed the terms were mostly interchangeable given the similarities and it seems I was wrong.

The idea is to use a DC input to convert into a Controllable Square Waveform @ a specific frequency I'm told around 40kH - 100kH would be sufficient. If the input was AC, I would need to rectify it to DC before I could use it with this schematic. At least that's what my research and a few blown MOSFETs has shown me through trial and error, again unless I've done something horribly wrong. Some of the reference material I have found starts with AC but recommend using a Battery or DC + switch / slow start circuit before they finish.
 

Thread Starter

TheDave1214

Joined Jun 26, 2024
3
Does this help at all?
1719504267055.png
D1: 200V 81A (Automotive Diode)
R1, R2: 1KR 5W
R3, R4: 10KR 1/2W
D2, D3: 1N5439B (12V, 5W)
D4, D5: FR307 (1KV, 3A)
Q1 - Q4: IXFK180N25T (180A, 250V, <-200ns) (IRFB4115 Available if better for goal)
C: .33uF (330nF) 1200Vdc
L1, L2: 60uH - 200uH >25A Inductors (85X55X20mm Toroidal Ferrite Core, 2 Strands of 14AWG magnet wire 4 - 12 turns)
L3: Copper Tube Coil (1/4In round Tube, 5 turns, 2.5In ID, lead length 4 inches) Air Core, insert metal for heating

Q1 and/or Q3 fails with 36V
 
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