Hotwire PWM Regulator for Mag D body, JM-PhD-D1

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SafetyBob said:
So let's see:

D regulated driver
C regulated driver (projected)
small torch driver (<500watts projected)
medium torch driver (1000 watts projected)
larger torch driver (8000 watt or lower projected)
Click to expand...
D regulated driver - Check!
C regulated driver (projected) - Working on board design.
small torch driver (<500watts projected) - Hmmm. Info please.
medium torch driver (1000 watts projected) - Schematic in the works. major parts spec'd. Lots of options and a UI to figure out. Maybe an LCD display. 1000W? No problem. 55V? No sweat.
larger torch driver (8000 watt or lower projected) - Just add more FETs to the 1000W design up to 55V. After that, let's talk. Bwaaa haaa haaaa :devil:
 
Mr Happy said:
FETs? Really? I kinda wondered if that would be in borderline IGBT territory... 😀
Click to expand...

You folks should come by and visit my workplace sometime. Our newest power supply uses IGBT's to control 2MW. We give tours, but don't usually show off the boring power supplies, but if I give the tour for special guests we might take a different route... This entire machine is built to make light. Sounds like it might be on topic here... Just not this thread... Here:

http://www.als.lbl.gov

But all (or most of) these neat drivers are OT for this thread as I don't think they'll fit in a M@g D. Unless it was a mile long. Even then probably not.

Reminds me, I got some neat photo renderings today. Have to post them in the other M@gReg Thread...

Jim, what SMD rework station are you getting? I just got another SMD kit for a ham radio project. I'm going to have to get a rework station soon...
 
Alan B said:
You folks should come by and visit my workplace sometime. Our newest power supply uses IGBT's to control 2MW. We give tours, but don't usually show off the boring power supplies, but if I give the tour for special guests we might take a different route... This entire machine is built to make light. Sounds like it might be on topic here... Just not this thread... Here:

http://www.als.lbl.gov

But all (or most of) these neat drivers are OT for this thread as I don't think they'll fit in a M@g D. Unless it was a mile long. Even then probably not.

Reminds me, I got some neat photo renderings today. Have to post them in the other M@gReg Thread...

Jim, what SMD rework station are you getting? I just got another SMD kit for a ham radio project. I'm going to have to get a rework station soon...
Click to expand...
I ordered the AOYUE 968 from sra-solder.com Specs are pretty good. I'll probably not use the soldering iron much, but you can connect a vacuum pickup tool to the built in fume extractor. They have another unit, I forget the exact model, but it's ~$50 cheaper. I read a review on it. They didn't speak well of it. Too little power and imprecise air flow control. I'll be getting the Quartz IR preheater as well. The different tips for the hot air handle are quite reasonable. $13 each. They fit Hakko/Madell units as well. The Weller tips are ~$60 each. It's certainly not the same quality as a Weller or Hakko, but I'm not a professional either. If it starts giving me trouble, I can trade up to a different unit. But for $155, how wrong can I go?
 
I got some stuff during the week while I was away. The soldering station is pretty neat. It came with a few different round nozzles and a square one.
I got the reflow oven controller and parts from Digikey. I'll be getting some more stuff over the course of next week. After that's all set, I'll order boards and parts. Then get crackin'. Whooo hooo I'm getting psyched.
 
I picked up an oven this weekend. We'll see how it goes. I also got a couple of other items as well. So I can start some experimentation.
 
SafetyBob said:
How goes the melting?

Bob E.
Click to expand...
I'm away on business at the moment. So no melting just yet.
I get home tomorrow night. Then, Thursday night I get to work converting the toaster oven. Remove all semblance of controls, insulate it with ceramic refractory, figure out a controls enclosure (an old UPS should do nicely), wire up the controller, and try to start an empty test run. If all that goes well, I'll test out the pre-heater and hot air system on a couple of SMD breakout boards I have. Once everything is set, this will really shorten my development life cycle. He he he he!!!

Edit: The oven I picked up was at Macy's during their One Day Sale. So It was $29.99. But it's a 1500W convection oven without that stupid hump in the back to fit a pizza. It's top is large enough that if I want to supplement it with a couple of IR elements to top-bias the heat delivery, I have room. Nice.
 
Last edited:
Another update to keep those of you following this thread up to date. I finished the build of the reflow oven. Ran it through a profile. The controls work very nicely. However, measurements show that is really only running at 1300W (114V under load), not the 1500W based on 120V. So it can't make time/temperature points recommended by the solder paste mfgs. If you ramp too slowly, the flux activates and dies before the solder melts. Bad for consistency and quality of joints.
So, I've ordered a second oven and will be adding the heaters from that oven to the first. This should deliver 2600W at 220V (228V). I'm running the new circuit from my panel this morning. This is a little setback, but not unforseen. I knew a 1200-1300W oven would be too weak. I don't want to half-a$$ this oven since it will be used for a lot of boards.
So that's the state of things.
 
OK. How is it that when I buy a 250' roll of 12/2 romex, the run from the panel to the outlet is such that the "scrap" of 12/2 I have is enough and I don't even have to open the 250' roll. HOWEVER, I buy a 50' roll of 12/3 and the run from the same outlet area is 55' feet away from the panel. How guys? HOW!
Friggin' luck.
Back to Home Depot!
 
Jimmy, welcome to my world......takes at least 15 trips to change a light bulb these days!!

Glad to see you just about have it done though. When you are done you can come here and help snake some Cat5 wire around for a couple of more POE camera's I am installing.

Shouldn't involve more than a couple of hours of on your stomach in the attic.

Bob E.
 
I've got the 220 circuit in and now I'm just awaiting the arrival of the 2nd oven. It's already shipped. More waiting. If this doesn't do it the way I want, I'll get a B&D Infrawave. This has to be done right. I know there are folks that say, "Oh, you just need a hot-plate", or something else. This oven will be on the money, every-time, no doubt.
 
Alright now.
I've got the oven and the controller all working nicely together now.
Below is a graph of the temperature curve I can get using a convection oven. It looks great.





I'll have to make a couple of runs with something in it now to see how it actually works on a real live board.
 
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