VER 2.5 PROCESSORS ARE AVAILABLE.

Ver 2.5 processors are available. By changing out two zener diodes and adding a resistor to pin 15 on the control board will increase the weld energy from 600Ws to 800Ws. VER 2.5 Processor can work with 20V capacitors by removing the resistor on Pin 15 but the diodes should not be replaced until 25V capacitors are installed. UPDATE:  JANUARY 5th 2016: 25V computer grade capacitors are hard to get at the moment. A  Chinese company manufactured a couple of 1Farad 25VCapacitors for me. These Capacitors are heavy duty and very well built. I tested them and are great,  1.070 Farad with a 0.001 ESR. I can get them for a special price of $45 each. The shipping is expensive though and can only be shipped with DHL for $104. Contact me for more information to order these capacitors.

CAPACITOR DISCHARGE PCB's AND DOCUMENTS ARE AVAILABLE

Here are all the documents to build a fully working micro processor controlled , dual pulse 600Ws capacitor discharge welder. The documents include the processor firmware (Hex file), Gerber files to manufacture the control and the mosfet board, schematics, manuals etc. Look HERE to see what documents are included in this downloadable package.

 This store will close on August 17th 2017

We ship Internationally  with USPS priority mail. For any countries not on the list please email me at sprbok@gmail.com

600Ws CAPACITOR DISCHARGE WELDER PLANS ($40.00)

MOSFET AND CONTROL: PCB'S ($70.00)

CONTROL, MOSFET PCB AND A VER 2.1 PROGRAMMED MICROPROCESSOR ($89.99)

Programmed VER 2.5 Microprocessor ($29.99)

INTELLIGENT LIGHT SWITCH

I moved on to another project that I'm busy developing and it is an intelligent touch screen light switch that will know exactly how many people are in a room . This switch will have many user friendly features and will turn the light on and off when people enter or leave a room. It can be used in any room with one or more doors and will work with  voltages from 90VAC to 277 VAC making it suitable for businesses and domestic use all over the world.
Many people ask me what the difference is between this switch and the passive infrared switches already available. Well, the switches available are really pathetic and resets a timer every time it sees you move. When it doesn't see you and the timer times out the light turns off. To turn the light back on you have to wave at it for 15 seconds before the light turns back on. When you leave a room the lights usually stays on for 30 minutes or more, wasting energy. My switch will count people enter or leaving a room and turn the light off when the last person leaves. It will  have a full color AMOLED touch screen display that can be changed to fit the decor of the room, and many other settings to make it very user friendly including an optional WIFI connection.  

A PEEK AT ALL THE FILES INCLUDED TO BUILD THIS WELDER

THE DOCUMENT BELOW  SHOWS WHAT ARE  INCLUDED IN THE DOWNLOADABLE  PACKAGE.
UPDATE: THE MOSFET PCB OUTLINE FILE (.GKO)CAN NOW BE DOWNLOADED HERE.

ADJUSTING PULSE 1

Pulse 1 on this welder is to burn away oil and dirt and pulse two makes the actual weld. I have many guys telling me that they set pulse one much higher to get two welds in one. Unfortunately, that's not how it works. Pulse one will join the two metals lowering the resistance and the energy of pulse two will take the shortest path to the other electrode doing basically nothing. In other words, If a 3ms pulse is enough to adhere the metals being welded and you set pulse one to 3ms and pulse two to 12ms then you will get one weak weld formed by the 3ms pulse and not the 12ms pulse.

To make decent welds with a dual pulse welder you should turn pulse one off and find a voltage and pulse 2 setting that gives you  good solid welds. Leave the welder on the determined  voltage and set both pulse potentiometers to 0, adjust pulse one to a low setting and make a weld. Keep on adjusting pulse one higher until the metals starts to adhere, decrease pulse one potentiometer about 3%. Set pulse two to the determined setting above and you should get really good welds.

The size of your electrodes and cable to your electrodes makes a big difference. A 4 feet long #0 welding cable will give you twice the current than a 4 Feet #8 welding cable. Do not make your cables shorter than 4 feet though.

UPDATED FIRMWARE AND WELDER FILES AVAILABLE SOON

I've been working on a new version 2.5 firmware for the Capacitor Discharge Welder and also a package that will contain the newest firmware, gerber files, Bill of materials, manuals and an extra 6 pages to explain how the circuit works and trouble shooting procedures etc. I've included Version 2.1 and version 2.5 in case a bug shows up. Version 2.5 has a change to the charging system, taking the stress off mosfet Q4, slowing the charge intervals and two points on the control board can be jumped with a wire to change the maximum voltage of this welder from 20 to 23.2V. This will increase the energy of the welder from 600Ws to  807Ws. You will need 25V capacitors to use this feature and Diode D10 has to be changed. UPDATE: I'm busy doing some final tests on the firmware. I did not get a very big response about making everything available so I'm going to start by making the updated chips available

If you don't know how to program a processor, you can buy one of these programmers.

 This one is $34.95  : K8076 serial programmer   

 This one is $69.95 : Cana USB programmer

It is as easy as starting the software supplied with the programmer, plug your microprocessor into the programmer, connect the programmer to your computer, load the Hex file and click on "write". It will only take a couple of seconds.

NAVIGATION

HERE IS AN EASIER WAY TO NAVIGATE THIS BLOG, click on the links below and read the pages from the bottom, up:

 THE BLOG STARTS HERE: PAGE 1 
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 THIS PAGE: PAGE 7

Pulse Arc Update

My function generator which came a long way with me went up in a plume of smoke. I had to replace it and bought a Rigol DG1022. It's a nice generator but pricey. I am going to use this generator to play with different waves to see if I can get the correct waveforms for the pulse arc welder. I am thinking of designing a new board from scratch, its already halfway drawn on a piece of paper :). The Budget is also a little low on funds and I will start to buy components as soon as possible. This welder will use much smaller and easy to get capacitors.
These things take time and lots of work so don't expect to see it before the end of this year.

ROGER CARR LET ME KNOW THAT FUTURE ELECTRONICS SELLS THE IRFP2907PBF MOSFETS FOR $3.60, THANKS ROGER.UPDATE: FUTURE ELECTRONICS CHANGED THEIR PRICE TO $6.00.....DO NOT BUY FROM THEM!!!!

HAPPY NEW 2011 EVERYONE

PCB"S ON ORDER

PCB's ARE SOLD OUT 02/05/2011

PULSE ARC WELDS

The top three photos was taken when I just started playing with the pulses on the pulse arc welder. The top left photo is two washers welded together,  the middle is two strands from a 12 gauge copper wire welded to a washer and the photo on the right is two strands of a 12 gauge wire that were held against the tungsten electrode while firing a 45ms pulse. The bottom two photos were taken after I managed to manipulate and change the pulses to give better welds. The plasma flame produced here is extremely hot.

I have made thousands of welds and adjustments to get this far and will keep on going until I get it to work perfectly.  I  accidentally made a plasma cutter that cuts through metal when I made the pulses continuous and also managed to weld  a copper wire to aluminum.
I'm limited to the metals I have to do further tests however and will appreciate if someone with knowledge of these welders can help me with some advice. Email me at sprbok@gmail.com