10kW H bridge Induction Heater / Inverter / Tesla Coil [READ DESCRIPTION!]

4 months ago 81
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Description

This board is compatible for both full and half bridge. If full bridge is used, neglect R30, R31, D4, U3 and any divider capacitors, for R4, R5 and C8 use first value. If half bridge is used, neglect R7, R9, R11, R13, R18-R21, R26-R29, C11, C12, C15, C16, C19, C20, C23, C24, D6, D8, Q4, Q5, Q8, Q9, Q11, Q13 and U2 for R4, R5 and C8 use second value, the divider capacitors needs to be glued upside down and wired manually at the place of the neglected components. In between "TOSWITCH" and "TOINDUCTOR", there must be a 50A switch, a ferrite core inductor and a shunt resistor in series. IGBTs, the bridge rectifier and the triac must be cooled with large heat sink with appropriate isolation pads. It's better if water cooled. IGBT gate push-pull transistors does not need cooling. Resonant tank capacitor is not included. R3 is leading edge power control, R5 is resonant frequency tuning. It is expected to use an isolation transformer in order to use grounding.

Documents

Sheet_1 copy

PCB_2020-06-28_23-17-20

BOM

ID Name Designator Footprint Quantity
1 2N2222 Q1 TO-92-3_L4.9-W3.7-P1.27-L 1
2 1.8R R16,R17,R18,R19 R_AXIAL-0.6 4
3 100k R36,R37 R_AXIAL-0.6 2
4 BD140 Q3,Q5,Q7,Q9 TO-126_L7.5-W2.5-P2.3-B 4
5 IKW50N65F5FKSA1 Q10,Q11,Q12,Q13 TO-247 4
6 THERMAL H2 HDR-F-2.54_1X2 1
7 FAN H1 HDR-F-2.54_1X2 1
8 470nF C1,C2 CAP-TH_L0.7-W0.4-P0.60-D0.8 2
9 NE555P U3 DIP-8_L9.8-W6.6-P2.54-LS7.6-BL 1
10 Power LED1 LED-TH_BD3.0_GREEN 1
11 470uF C7,C9 CAP-TH_BD10.0/8.0-P5.00-D1.0-FD 2
12 2.2nF/680pF C13 RAD-0.1/0.2 1
13 100nF C6,C10,C14,C15,C16,C17,C18,C19,C20,C21,C12,C8 RAD-0.1/0.2 12
14 10nF C11 RAD-0.1/0.2 1
15 GBJ5010 D1 DIO-BG-TH_PB 1
16 4.7R R20,R21,R22,R23,R24,R25,R26,R27,R28,R29,R30,R31,R32,R33,R34,R35 R_AXIAL-1.2_VERTICAL 16
17 2W10 D2 DIO-BG-TH_2W10 1
18 4700uF C4,C5 CAP-TH_BD16.0-P7.50-D1.2-FD 2
19 10K/4.7K R9 ALPHA 16MM SIMPLE 1
20 50K R5 ALPHA 16MM SIMPLE 1
21 Overheat LED2 LED-TH_BD3.0_RED 1
22 EXT INT H5 HDR-F-2.54_1X3 1
23 INT SW H3,H4 HDR-F-2.54_1X3 2
24 Interrupt LED3 LED-TH_BD3.0_BLUE 1
25 470K R1 R_AXIAL-0.6 1
26 L7815CV U1 TO-220-3_L10.0-W4.5-P2.54-L 1
27 BD139 Q2,Q4,Q6,Q8 TO-126_L7.5-W2.5-P2.3-B 4
28 UF4007 D5 DO-41_BD2.4-L4.7-P8.70-D0.9-RD 1
29 4.7nF C22,C23,C24,C25,C26,C27,C28,C29,C3 CAP-TH_L0.5-W0.2-P0.40-D0.8 9
30 L7812CV U2 TO-220-3_L10.0-W4.5-P2.54-L 1
31 IRS2453D DIP14 U4 DIP-14_L19.0-W7.0-P2.54-LS7.6-BL 1
32 1N4746 D6,D7,D8,D9 DO-41_BD2.8-L4.2-P15.0-D0.7-FD 4
33 1N4148 D3,D4 DO-35_BD2.0-L4.0-P8.00-D0.5-FD 2
34 2.7K/6.8K R8 R_AXIAL-0.4 1
35 15R R12,R13,R14,R15 R_AXIAL-0.4 4
36 1k R3,R4,R2,R10,R6,R7 R_AXIAL-0.4 6
37 10K R11 R_AXIAL-0.4 1
38 IR2153PBF U5 DIP-8_L9.8-W6.6-P2.54-LS7.6-BL 1

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