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DIY pulse soldering iron

2017-12-21 00:42  
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The biggest benefit I see when working with pulse soldering iron is speed and effectiveness. Of course when you don’t work, it stays cool this means it saves energy, doesn’t evaporates poisonous steam and there is no risk accidentally to burn yourself. Well this one even has has light source for better view when soldering. If you like to hack things you may try this challenge on building a pulse soldering iron.

This iron may be powered from 220V supply and consumes about 70-100W of power. Efficiency reaches about 50%. Heating time takes 5 seconds while cooling to 50?oC takes about 15 seconds.

Soldering iron maybe used in variety tasks including repairing home appliances, replacing electronic parts and other.

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In this pulse iron there is self-oscillating half-bridge driver IR2151 used. IRF740 MOSFETS are used to drive current to load. Working of iron is simple. IR2151 generates pulses that are driven to transformer which transfer energy via diode bridge and C filter powers cooler and LEDs. But this power isn’t enough to heat heating tip. When button S1 is pressed, then values of C2 and C3 capacitors adds up this way generator enters low frequency phase when transformer reaches saturation level. At this level heating tip gets enough energy to heat up to high temperature.

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ll resistors in circuit are 0.25W power just R4 should be at least 0.4W. Recommended color of LED diodes is orange as it is best for illuminating circular cracks. Diode bridge should consist of 1A and 400V diodes . Cooler any 12V a€“ any smaller PC cooler. Transformer is made of two D¨ shape core 30x30x6 2500HM. Primary coil contain 65 windings of 0.25mm2and secondary 4- 5 windings of 0.25mm2. Power winding is made of copper plate 135x10x1.5mm and bended as D?. Tip is made of 1.5mm copper wire which is crewed to copper plate so it makes a loop for current from transformer.

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After solder is assembled you need to choose proper C3 capacitor. To do this jus disconnect soldering tip and connect 40W light bulb. When button S1 isn’t pressed transformer should be ticking silently, LEDs ON and cooler ON, but light bulb should be OFF. When button is pressed, then transformer should stop ticking, LEDs should light more brightly and cooler run faster but light bulb should not light on. It it lights then C3 should be lower value like 2200pF or take smaller R3 resistor value.

If everything works then finish all cosmetics, including oiling cooler, coating PCB with painting in order to prevent short-circuit (anyway you’ll be holding device in your hands). And be careful as it is high voltage device. Author doesn’t take any responsibilities for any injuries.

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