This post is about 500 Watt Induction Heater Circuit
Coil makes strong magnetic field and it changes very fast.
When metal connects inside a coil then the metal becomes hot.
This happen because of eddy current which goes round and round inside metal.
Metal also heat up little more from its own property but that part is more tricky to explain.
Coil looks small but need big current like 100 amp to work good.
To make this circuit better we add one more part and it is the capacitor which must be of right size for the coil.
Coil and capacitor work together and they need to run at right frequency to give the best result.
What is a Induction Heater Circuit:
500 Watt Induction Heater Circuit is one kind of electronic circuit which uses electromagnetic induction to make metal very hot.
People use this circuit for many things like hardening metal, cooking food, induction cooktop and some factory work.
Main idea is simple it uses high frequency AC current to make strong electromagnetic field.
When metal goes inside this field the eddy current start inside metal and make it hot fast.
Circuit Diagram:
Parts List:
| Component | Description | Quantity |
|---|---|---|
| Resistors | All resistors are 1/4 W MFR unless specified | |
| 100k | 2 | |
| 10k | 1 | |
| 4.7Ω 4W | 1 | |
| 15Ω | 2 | |
| Capacitors | ||
| PPC 330nF 250V | 5 | |
| PPC 330pF 1kW | 1 | |
| PPC 4.7nF 1kW | 1 | |
| PPC 470nF 250V | 2 | |
| Electrolytic 100uF 25V | 2 | |
| Semiconductors | ||
| Diode 1N4007 | 4 | |
| Diode BA159 | 1 | |
| Zener Diode 16V | 2 | |
| MOSFET IRF840 | 2 | |
| IC IR2153 | 1 | |
| Neon Bulb | 1 | |
| Coil copper wire or tube | 1 | |
| Filament Bulb 200 – 500W | 1 |
How to Build:
- Make coil using copper wire or tube and wind it 12 to 30 times around 3 to 10 cm round shape.
- To get right resonance connect at least 6 capacitors.
- Use IR2153 circuit to control MOSFETs.
- Put small heatsinks on MOSFETs so they do not get hot.
- Add neon lamp to show when resonance happen.
- Give 12V to 15V DC power to control circuit if require can use wall adapter or other power source.
- Take ferrite core of 8×10 mm size and wind around 20 turns of 1.5 mm copper wire on it.
- Change air gap to control power.
Tune the Frequency:
- Change frequency with potentiometer between 20 to 200 kHz.
- Watch neon lamp as it shows when resonance is good.
Testing:
- Turn system ON and see how its working.
- Keep checking coil and capacitor if they getting too hot.
Caution:
- Be very careful when doing this 500 watt induction heater.
- There is is very harmful so always follow safety first.
- If anyone is not sure about high voltage stuff then better ask help from expert or electrician.
Formulas:
For Making 500 Watt Induction Heater Circuit:
First need to build it safe and good so that we must think carefully and do some hard calculations.
Here are some important formulas to help in making the circuit:
Power Formula (P):
P = V × I
where:
- P is power in watts
- V is voltage in volts
- I is current in amps
This formula show how voltage and current give power to the 500W heater.
Coil Impedance (Z):
Z = √(R² + X²)
where:
- Z is impedance in ohms
- R is resistance in ohms
- X is reactance in ohms
Use this to know how much the coil resist the current and it depend on coil shape and working frequency.
Resonant Frequency (f):
f = 1 / (2π√(L × C))
where:
- f is frequency in hertz
- L is coil inductance in henrys
- C is capacitor value in farads
This formula help to find correct frequency for running the circuit smooth and need to match coil and capacitor for best heating.
Conclusion:
This circuit uses high frequency and high power which ca be dangerous.
So safety is very important while building or using 500 watt induction heater circuit
Also what we want to heat, what is metal type, or how hot it need to get will change how we design the circuit.
Different materials and temperature needs make the circuit setup different.
References:
Design and Construction of Power System for Induction Heating