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Author Topic: Capacitor Charged Coil Welding  (Read 36336 times)

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Online Breaktru

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Capacitor Charged Coil Welding
« on: January 07, 2013, 07:03:29 PM »
« Last Edit: December 04, 2018, 05:59:51 AM by Breaktru »

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Re: Capacitor Charged Coil Welding
« Reply #1 on: January 08, 2013, 02:30:25 PM »

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Re: Capacitor Charged Coil Welding
« Reply #2 on: January 08, 2013, 10:31:55 PM »


From Diver on Greek Forum:

I cut 2 pieces of wire and a piece NON 0.20, three millimeters greater than the "clean" length.
I used an e 2,200 MF capacitor to 63 V. Charging him with about 30 V.
Discharge the capacitor through wires (with and without resistance) touching the edges. Created at the point spark, wires melted at this point, and joined quite well.
« Last Edit: January 08, 2013, 10:37:05 PM by Breaktru »

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Re: Capacitor Charged Coil Welding
« Reply #3 on: January 08, 2013, 10:43:51 PM »


Choose one of the 4 positions and press the button for 1 sec.

Position 1: 27 Volts for wires 0.13 - 0.16
Position 2: 31 Volts for wires 0.17 - 0.18
Position 3: 35 Volts for wires 0.2 - 0.23
Position 4: 41 Volts for thicker wire




This looks like the same DC-DC Step-Up converter: EBAY
« Last Edit: January 10, 2013, 09:24:46 PM by Breaktru »

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Re: Capacitor Charged Coil Welding
« Reply #4 on: January 10, 2013, 09:30:20 PM »
I'm going to try building one with a Disposable Camera Flash Circuit. I got the idea from member mre777. Thanks buddy. It's a cheap build and puts out over 300 Volts. Zzzzzzzzap! May have to tone it down. Man this thing could killa.
Got it on my bench almost together. I'll try tomorrow to finish it.

More info on building your own HERE

See attached (members only)
« Last Edit: July 26, 2013, 12:49:10 PM by Breaktru »

Offline beamrider

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Re: Capacitor Charged Coil Welding
« Reply #5 on: January 12, 2013, 09:07:00 PM »
Also works good for zapping NiCd batteries.

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Re: Capacitor Charged Coil Welding
« Reply #6 on: February 05, 2013, 06:47:16 AM »


Choose one of the 4 positions and press the button for 1 sec.

Position 1: 27 Volts for wires 0.13 - 0.16
Position 2: 31 Volts for wires 0.17 - 0.18
Position 3: 35 Volts for wires 0.2 - 0.23
Position 4: 41 Volts for thicker wire




This looks like the same DC-DC Step-Up converter: EBAY

  Hi, I am new to the forum, from Croatian, bad English ... I do welding wire, commissioned by the module, I would ask, how-on 4.2 V battery module can be activated when it is the minimum input voltage of 4.5 V ?, I ga I use with 30V, electrolytic capacitor, which is better for this voltage, 1000mF/50V or 2200mF/50V?, which specifically battery use, and give just one or two in the series? ... lots of questions, I hope you will not be a problem to answer, thanks in advance... :thankyou: ;bow; :help:

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Re: Capacitor Charged Coil Welding
« Reply #7 on: February 05, 2013, 07:40:29 AM »
  Hi, I am new to the forum, from Croatian, bad English ... I do welding wire, commissioned by the module, I would ask, how-on 4.2 V battery module can be activated when it is the minimum input voltage of 4.5 V ?, I ga I use with 30V, electrolytic capacitor, which is better for this voltage, 1000mF/50V or 2200mF/50V?, which specifically battery use, and give just one or two in the series? ... lots of questions, I hope you will not be a problem to answer, thanks in advance... :thankyou: ;bow; :help:

Hi Frenk and welcome to the forum.
You will need two batteries in series for the module.
Diver mentions two different caps. 1000uF and 2200uF. In the photo it is a 1000uF. I would try each one and see which one works best. The voltage rating of the caps should be higher than the output of the module. Do not use a 30v cap if you are outputting 30v or more. 50v or higher should be used.

The voltage to weld different gauge wires are as shown in the post:
27 Volts for wires 0.13 - 0.16
31 Volts for wires 0.17 - 0.18
35 Volts for wires 0.2 - 0.23
41 Volts for thicker wire
This may vary for you and it is something that you will have to determine by trying it out for yourself.

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Re: Capacitor Charged Coil Welding
« Reply #8 on: February 05, 2013, 02:30:20 PM »

 A big thank you, regards

Offline frenk

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Re: Capacitor Charged Coil Welding
« Reply #9 on: February 05, 2013, 06:01:22 PM »

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Re: Capacitor Charged Coil Welding
« Reply #10 on: February 05, 2013, 06:38:04 PM »
  One more thing, is this:
  http://www.ebay.com/itm/130770051722?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649
  and this:
  http://www.ebay.com/itm/160964471344?ssPageName=STRK:MESINDXX:IT&_trksid=p3984.m1436.l2649
  same, identical?
  btw. on E-bay has only the first

They look the same to me. The claims of MAX output voltage are different. One says 42v and the other 60v

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Re: Capacitor Charged Coil Welding
« Reply #11 on: February 05, 2013, 06:55:49 PM »


  ...obvious that someone is lying  :thumbsup:

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Re: Capacitor Charged Coil Welding
« Reply #12 on: February 05, 2013, 07:15:17 PM »

  ...obvious that someone is lying  :thumbsup:

There is a part # YH11053A on the 60v board. I have the 42v board and the part # is YH11053B. The diff is A & B.
If you look at your 60v link and scroll to the last picture, you will see a difference in the board. There is an additional Cap.

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Re: Capacitor Charged Coil Welding
« Reply #13 on: February 05, 2013, 07:24:36 PM »
 

  Then I screwed up, I ordered this to 42V, I thought they were the same, this does not have to 60V ... the wretched  :(

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Re: Capacitor Charged Coil Welding
« Reply #14 on: February 05, 2013, 07:30:58 PM »
 

  Then I screwed up, I ordered this to 42V, I thought they were the same, this does not have to 60V ... the wretched  :(

Why do you need 60v? the originator used 27v to 41v.

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Re: Capacitor Charged Coil Welding
« Reply #15 on: February 05, 2013, 07:49:39 PM »


  Then it's okay, I thought that your module to 60V, now I sleep better, tnx and good night ...

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Re: Capacitor Charged Coil Welding
« Reply #16 on: February 06, 2013, 06:17:33 PM »

  Then it's okay, I thought that your module to 60V, now I sleep better, tnx and good night ...


  Which batteries prefer to welding machine?  :Thinking:

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Re: Capacitor Charged Coil Welding
« Reply #17 on: February 06, 2013, 06:59:31 PM »

  Which batteries prefer to welding machine?  :Thinking:

I would like to say first, I am NOT using this type of welder. I am using the Flash Camera Mod.

There is NO need for a large battery. A small 10440, 14500 or what ever you have will do. You are only charging a capacitor. The welding is done w/ an arc from the cap and not a continuous output voltage. Avoid triggering the module when applying the leads for welding. You WILL damage the module.

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Re: Capacitor Charged Coil Welding
« Reply #18 on: February 27, 2013, 10:33:16 AM »
  Hi, I am new to the forum, from Croatian, bad English ... I do welding wire, commissioned by the module, I would ask, how-on 4.2 V battery module can be activated when it is the minimum input voltage of 4.5 V ?, I ga I use with 30V, electrolytic capacitor, which is better for this voltage, 1000mF/50V or 2200mF/50V?, which specifically battery use, and give just one or two in the series? ... lots of questions, I hope you will not be a problem to answer, thanks in advance... :thankyou: ;bow; :help:

 Well, I finally managed to put together my welding machine, it works well but I have one problem: every time one wire welds, I have to switch off and restart, it seems to me that something needs to be bridged with a diode or something, please support and help, tnx

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Re: Capacitor Charged Coil Welding
« Reply #19 on: February 27, 2013, 02:34:57 PM »


  I may not be well connected the switch and button, a switch in series with the battery and switch IN, and the key is in series with the electrolytic capacitor and go on out, I think you need to switch and go to the key series on IN and OUT on the electrolyte, accurate ?

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Re: Capacitor Charged Coil Welding
« Reply #20 on: February 27, 2013, 03:09:19 PM »

  I may not be well connected the switch and button, a switch in series with the battery and switch IN, and the key is in series with the electrolytic capacitor and go on out, I think you need to switch and go to the key series on IN and OUT on the electrolyte, accurate ?

Frenk,
I'm not familiar with the module that you used. I have one but haven't used it yet. Maybe bapgood can help. He built one with a similar module the LM2577.
I'm pretty sure that they no longer use a diode and put the PB switch on the output with a 470 ohm resistor. Try to PM him.
Personally I think a resistor at the output is a good idea because when you are welding, you are putting a short across the output which can damage the module if the resistor was not there.

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Re: Capacitor Charged Coil Welding
« Reply #21 on: February 27, 2013, 04:16:02 PM »

  My friend, if you can wiring sheme, I'd be grateful ... :Thinking:

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Re: Capacitor Charged Coil Welding
« Reply #22 on: February 27, 2013, 07:02:23 PM »
This diagram/schematic shows parts like bapgood was using but w/ the YH11053A instead of the LM2577.



Here is a link for the LM2577 using a Single Li-Ion battery: ---> LM2577 Circuit
« Last Edit: October 31, 2013, 09:23:57 PM by Breaktru »

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Re: Capacitor Charged Coil Welding
« Reply #23 on: February 28, 2013, 06:50:58 AM »

  :thankyou:

 I've just joined so with the same module, except battery-2x3, 7V in series, capacitor 1000mF/50V without resistor / add I /, the problem is that after every welding must click the switch OFF-ON to continue to brew it again .. . why?

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Re: Capacitor Charged Coil Welding
« Reply #24 on: February 28, 2013, 08:46:42 AM »
  :thankyou:

 I've just joined so with the same module, except battery-2x3, 7V in series, capacitor 1000mF/50V without resistor / add I /, the problem is that after every welding must click the switch OFF-ON to continue to brew it again .. . why?

You are correct. I just looked at the specs and see Input voltage :4.5-32V so two batts in series will do.
"GSA's" drawing calls for a 1000uF but "bapgood" up his to 4700uF. If it welds good with a 1000uF then leave it be.

Do you have the pushbutton in series in the output? This should isolate a direct short across the module output which may shut down the module due to thermal overload or possibly a short protection which would then need a reset by shutting the module off then on.
Also DO NOT hold the PB when welding.
« Last Edit: February 28, 2013, 08:54:13 AM by Breaktru »

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Re: Capacitor Charged Coil Welding
« Reply #25 on: February 28, 2013, 10:28:57 AM »

  Yes, I have a PB at the exit, I just realized that this is happening due to the battery with PCB, PCB now I downloaded, I tried to ... 1 battery for up to 32 volts and do it well, especially with bigger capacity capacitors ... crazy more-I do not know where I stood and where to start ... hehe, now has one less problem for you:
to the AC / DC adapter 5V simplest reduced to 4.2 V?
BTW. I know that to bother you but I see that you are very professional and will help you, congratulations ... I was in Greece before 20-odd years old, keen ... beautiful country ... :beer-toast:

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Re: Capacitor Charged Coil Welding
« Reply #26 on: July 26, 2013, 11:57:11 AM »
I am quite new to this field. I am just wondering if we could modify it for more than 42V. I would like to use it for 60V, do you think it’s possible?

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Re: Capacitor Charged Coil Welding
« Reply #27 on: July 26, 2013, 01:02:54 PM »
I am quite new to this field. I am just wondering if we could modify it for more than 42V. I would like to use it for 60V, do you think it’s possible?

If you are going to use the LM board there are two. One with a 5-42v output and one with a 5-60v output. See Reply #9

If you are going to use the flash camera board the output is over 300v

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Re: Capacitor Charged Coil Welding
« Reply #28 on: August 08, 2013, 03:59:21 PM »
This diagram/schematic shows parts like bapgood was using but w/ the YH11053A instead of the LM2577.



Hello Breaktru , i'm new from France, i have ordered this one on eBay ( YH 11053A)

What capacitor  do you think it's better???  1000 , 2200 or 4700uF???

Thanks a lot ,your forum is very nice  :)
« Last Edit: August 08, 2013, 04:42:00 PM by Breaktru »

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Re: Capacitor Charged Coil Welding
« Reply #29 on: August 08, 2013, 04:46:14 PM »
Hello Breaktru , i'm new from France, i have ordered this one on eBay ( YH 11053A)

What capacitor  do you think it's better???  1000 , 2200 or 4700uF???

Thanks a lot ,your forum is very nice  :)

Welcome Jackson and welcome to the forum.
Modders building this have said that they had better results with the 4700uF cap.

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Re: Capacitor Charged Coil Welding
« Reply #30 on: August 08, 2013, 04:53:01 PM »
Thanks  :thankyou:

I didn't see the topics

I saw the one ,on the spark o matic ,but 300v seems to me a little bit dangerous

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Re: Capacitor Charged Coil Welding
« Reply #31 on: October 31, 2013, 10:11:11 AM »
Thanks  :thankyou:

I didn't see the topics

I saw the one ,on the spark o matic ,but 300v seems to me a little bit dangerous

I know this is a bit late but we are using 75v with a 340uf capacitor. With a voltmeter attached the charge is stopped at 75v.

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Re: Capacitor Charged Coil Welding
« Reply #32 on: November 01, 2013, 11:42:30 AM »
Hello, thanks for the repply  :)

I use exactly the composants on the shema , exept  the  resistance  470ohms that i have removed

And the  weldings are perfects at 26 volts  with inox 316L 0.20 and nickel 0.25

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Re: Capacitor Charged Coil Welding
« Reply #33 on: November 01, 2013, 12:31:40 PM »
Nice Jackson. You are referring to the LM or LM type boards I assume. @dezyner had to remove the resistor also for it to work.

What @d_walk was referring to was the flash camera build and that we don't weld at 300v.

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Re: Capacitor Charged Coil Welding
« Reply #34 on: November 03, 2013, 09:24:20 AM »

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Re: Capacitor Charged Coil Welding
« Reply #35 on: December 03, 2013, 03:22:19 AM »
Hey everyone...

I'm not really new to this forum, but I do believe this is my first actual post. Been reading everything I can on wire welders and have placed my orders for the various parts I think I'm going to need. Some of you may be interested in the step-up module I'm getting, it has an on-board LED voltmeter and can boost to 52v.
http://www.ebay.com/itm/DC-DC-4-5-32V-to-5-52V-XL6009-Boost-Step-up-Module-Power-Supply-LED-Voltmeter-/400601163750?pt=LH_DefaultDomain_0&hash=item5d45b0a7e6
I've also bought a couple of LM2577 type boards to play with, just because they are so damn cheap.
http://www.ebay.com/itm/2PCS-DC-DC-Adjustable-Step-up-boost-Power-Converter-Module-XL6009-Replace-LM2577-/310744534154?pt=LH_DefaultDomain_0&hash=item4859d14c8a
Anyway, I do have a couple questions. First, I'm a little confused as to whether I actually need the 470ohm resister or not? Does anyone see a problem with using USB (5v) input power? I just don't want to fool with batteries if I can help it and I don't really need this to be portable, so I figured why not use something I already have on hand. What do you think?

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Re: Capacitor Charged Coil Welding
« Reply #36 on: December 03, 2013, 08:31:00 AM »
Congrats on your first post  :beer-toast:

You can omit the 470 ohm resistor as shown here: Wire Arc Welder

I would caution the use of USB directly powering these boards. Some have blown the 3A fuse on the board input using batteries. This may damage a computer USB circuit which has a current limit of 500mA for a USB 2.0. USB 3.0 has a current limit of 900mA. Wall plug USB's come in 200mA, 500mA and 2A.

You have to consider other USB devices on a PC that are in use by adding up each USB powered devices used.

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Re: Capacitor Charged Coil Welding
« Reply #37 on: December 03, 2013, 09:00:09 PM »
Thanks Breaktru,

I had already determined that I wouldn't risk powering the welder with the computer USB. I have a 200mA USB wall plug that I planned on using, but if you think batteries would be better, it's not a big deal to change the power source. The step-up module I'm using has a minimum 4.3V input, so I would need to serial 2 18650's for 7.4V or, perhaps, go with a 9V bat. I don't know how to actually figure it, but I understand that if I decrease the input-output differential the amps get boosted up. I don't know at what point it starts to get dangerous and I want to really avoid the potential of getting a significant accidental zapping myself. BTW, I know the fuse needs to be 3A, but what other specs should I be looking for? I'm a very experienced vaper, but pretty much a noob, as I'm sure you can tell, when it comes to all this electronic/electrical circuitry. I don't want to be too much of a bother, but I really appreciate picking your brain.

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Re: Capacitor Charged Coil Welding
« Reply #38 on: December 03, 2013, 09:04:24 PM »
Correction... the USB wall plug is 500mA

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Re: Capacitor Charged Coil Welding
« Reply #39 on: December 03, 2013, 09:50:53 PM »
If you are using the LM2577 the input amperage is 3A max so a USB can not handle it. The input voltage is 3v - 34v or 3.5v - 35v so a single 3.7v battery can be used. If max input to the board is 3A, I would use a 5 or 6A fuse.
Your 52v output board would require 2 series batteries as you stated. A 9v battery can not deliver the amperage needed.

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