The main difference between the scheme of the presented soldering iron temperature controller and many existing ones is its simplicity and the complete absence of radiating radio interference into the electrical network, since all transients occur at a time when the voltage in the supply network is zero.
Electrical Schematic Diagrams of Soldering Iron Temperature Controllers
Attention, the following circuits of temperature controllers are not galvanically isolated from the electric network and touching the current-carrying elements of the circuit is life-threatening!
To adjust the temperature of the soldering iron tip, soldering stations are used in which the optimum temperature of the soldering tip is maintained in manual or automatic mode. The availability of a soldering station for the home craftsman is limited by the high price. For myself, I solved the issue of temperature control by developing and manufacturing a regulator with manual smooth temperature control. The circuit can be modified to automatically maintain the temperature, but I don’t see the point in this, and practice has shown that manual adjustment is quite enough, since the mains voltage is stable and the room temperature too.
Starting to develop a temperature controller for a soldering iron, I proceeded from the following considerations. The scheme should be simple, easily repeatable, components should be cheap and available, high reliability, minimal dimensions, efficiency close to 100%, no radiating interference, the possibility of modernization.
Classic thyristor regulator circuit
The classic thyristor circuit of the soldering iron temperature controller did not meet one of my main requirements, the absence of radiating interference into the mains and the air. And for a radio amateur, such interference makes it impossible to fully engage in what you love. If the circuit is supplemented with a filter, then the design will turn out to be cumbersome. But for many applications, such a thyristor regulator circuit can be successfully used, for example, to adjust the brightness of incandescent lamps and heating appliances with a power of 20-60 watts. That's why I decided to present this scheme.
In order to understand how the circuit works, I will dwell in more detail on the principle of operation of the thyristor. A thyristor is a semiconductor device that is either open or closed. To open it, you need to apply a positive voltage of 2-5V to the control electrode, depending on the type of thyristor, relative to the cathode (k is indicated in the diagram). After the thyristor has opened (the resistance between the anode and cathode will become 0), it is not possible to close it through the control electrode. The thyristor will be open until the voltage between its anode and cathode (marked a and k in the diagram) becomes close to zero. It's that simple.
The circuit of the classical regulator works as follows. The mains voltage is supplied through the load (an incandescent bulb or a soldering iron winding) to a rectifier bridge circuit made on VD1-VD4 diodes. The diode bridge converts the AC voltage into a DC voltage that changes according to a sinusoidal law (diagram 1). When the middle terminal of the resistor R1 is in the leftmost position, its resistance is 0, and when the voltage in the network begins to increase, the capacitor C1 begins to charge. When C1 is charged to a voltage of 2-5V, through R2 the current will go to the control electrode VS1. The thyristor will open, short-circuit the diode bridge and the maximum current will flow through the load (upper diagram). When you turn the knob of the variable resistor R1, its resistance will increase, the charge current of the capacitor C1 will decrease and it will take more time for the voltage across it to reach 2-5V, so the thyristor will not open immediately, but after some time. The larger the value of R1, the longer the charge time for C1, the thyristor will open later and the power received by the load will be proportionally less. Thus, by rotating the knob of the variable resistor, the heating temperature of the soldering iron or the brightness of the incandescent light bulb is controlled.
The simplest thyristor regulator circuit
Here is another of the simplest thyristor power controller circuits, a simplified version of the classic controller. The number of parts is kept to a minimum. Instead of four diodes VD1-VD4, one VD1 is used. Its principle of operation is the same as that of the classical scheme. The schemes differ only in that the adjustment in this temperature controller circuit occurs only according to the positive period of the network, and the negative period passes through VD1 without changes, so the power can only be adjusted in the range from 50 to 100%. To adjust the heating temperature of the soldering tip, more is not required. If the VD1 diode is excluded, then the power adjustment range will be from 0 to 50%. 
If a dinistor, for example KN102A, is added to the circuit break from R1 and R2, then the electrolytic capacitor C1 can be replaced with an ordinary one with a capacity of 0.1mF. Thyristors for the above circuits are suitable, KU103V, KU201K (L), KU202K (L, M, N), designed for a forward voltage of more than 300V. Diodes are also almost any, designed for a reverse voltage of at least 300V.
The above schemes of thyristor power controllers can be successfully used to control the brightness of the glow of lamps in which incandescent bulbs are installed. It will not work to regulate the brightness of the glow of lamps in which energy-saving or LED bulbs are installed, since electronic circuits are mounted in such bulbs, and the regulator will simply disrupt their normal operation. The bulbs will shine at full power or flash and this may even lead to premature failure.
The circuits can be used for regulation with a supply voltage of 36V or 24V AC. It is only necessary to reduce the resistor values by an order of magnitude and use a thyristor that matches the load. So a soldering iron with a power of 40 watts at a voltage of 36V will consume a current of 1.1A.
Thyristor regulator circuit does not emit interference
Since the regulators that emitted interference did not suit me, and there was no suitable ready-made temperature controller circuit for the soldering iron, I had to take up the development myself. For more than 5 years, the temperature controller has been working flawlessly. 
The temperature controller circuit works as follows. The voltage from the mains is rectified by the diode bridge VD1-VD4. From a sinusoidal signal, a constant voltage is obtained, varying in amplitude as half a sinusoid with a frequency of 100 Hz (diagram 1). Further, the current passes through the limiting resistor R1 to the zener diode VD6, where the voltage is limited in amplitude to 9 V, and has a different shape (diagram 2). The received pulses charge the electrolytic capacitor C1 through the VD5 diode, creating a supply voltage of about 9V for the DD1 and DD2 microcircuits. R2 performs a protective function, limiting the maximum possible voltage on VD5 and VD6 to 22V, and ensures the formation of a clock pulse for the operation of the circuit. With R1, the generated signal is fed to the 5th and 6th outputs of the 2OR-NOT element of the logical digital microcircuit DD1.1, which inverts the incoming signal and converts it into short rectangular pulses (diagram 3). From the 4th output of DD1, the pulses are fed to the 8th output of the D trigger DD2.1, operating in the RS trigger mode. DD2.1, like DD1.1, also performs the function of inverting and signal conditioning (diagram 4). Please note that the signals in diagram 2 and 4 are almost the same, and it seemed that it was possible to apply a signal from R1 directly to pin 5 of DD2.1. But studies have shown that in the signal after R1 there is a lot of interference coming from the mains, and without double shaping, the circuit did not work stably. And it is not advisable to install additional LC filters when there are free logic elements.
On the DD2.2 trigger, a soldering iron temperature controller control circuit is assembled and it works as follows. Rectangular pulses arrive at pin 3 DD2.2 from pin 13 DD2.1, which with a positive edge overwrite at pin 1 DD2.2 the level that is currently present at the D input of the microcircuit (pin 5). At pin 2, the signal is the opposite level. Consider the work of DD2.2 in detail. Let's say on pin 2, a logical unit. Through the resistors R4, R5, the capacitor C2 is charged to the supply voltage. Upon receipt of the first pulse with a positive drop, 0 will appear at pin 2 and capacitor C2 will quickly discharge through diode VD7. The next positive drop at pin 3 will set a logical unit at pin 2 and capacitor C2 will start charging through resistors R4, R5. The charge time is determined by the time constant R5 and C2. The larger R5, the longer it will take C2 to charge. Until C2 is charged to half the supply voltage at pin 5, there will be a logical zero and positive pulse drops at input 3 will not change the logic level at pin 2. As soon as the capacitor is charged, the process will repeat.
Thus, only the number of pulses from the supply network specified by resistor R5 will pass to the outputs of DD2.2, and most importantly, these pulses will fluctuate during the transition of the voltage in the supply network through zero. Hence the absence of interference from the operation of the temperature controller.
From pin 1 of the DD2.2 microcircuit, pulses are fed to the DD1.2 inverter, which serves to eliminate the influence of the thyristor VS1 on the operation of DD2.2. Resistor R6 limits the control current of thyristor VS1. When a positive potential is applied to the control electrode VS1, the thyristor opens and voltage is applied to the soldering iron. The regulator allows you to adjust the power of the soldering iron from 50 to 99%. Although the resistor R5 is variable, the adjustment due to the operation of DD2.2 heating the soldering iron is carried out in steps. With R5 equal to zero, 50% of the power is supplied (diagram 5), when turning through a certain angle it is already 66% (diagram 6), then already 75% (diagram 7). Thus, the closer to the rated power of the soldering iron, the smoother the adjustment works, which makes it easy to adjust the temperature of the soldering tip. For example, a 40W soldering iron can be set to 20W to 40W.
The design and details of the temperature controller
All parts of the temperature controller are located on the printed circuit board. Since the circuit does not have galvanic isolation from the mains, the board is placed in a small plastic box, which is also a plug. A plastic handle is put on the rod of the variable resistor R5. 
The cord from the soldering iron is soldered directly to the PCB. You can make the connection of the soldering iron detachable, then it will be possible to connect other soldering irons to the temperature controller. Surprisingly, the current drawn by the temperature controller control circuit does not exceed 2 mA. This is less than the consumption of the LED in the lighting circuit of the light switches. Therefore, special measures to ensure the temperature regime of the device are not required.
Chips DD1 and DD2 any 176 or 561 series. Any diodes VD1-VD4, designed for a reverse voltage of at least 300V and a current of at least 0.5A. VD5 and VD7 any impulse. Any low-power zener diode VD6 for a stabilization voltage of about 9V. Capacitors of any type. Any resistors, R1 with a power of 0.5 W. The temperature controller does not need to be adjusted. With serviceable parts and without installation errors, it will work immediately.
Mobile soldering iron
Even people who are “you” with a soldering iron are often stopped by the inability to solder wires due to the lack of an electrical connection. If the soldering place is not far away and it is possible to extend the extension cord, then it is not always safe to work with a soldering iron powered by a 220-volt electrical network in rooms with high humidity and temperature, with conductive floors. For the ability to solder anywhere and safely, I offer a simple version of a stand-alone soldering iron.
Powering the soldering iron from the UPS battery of the computer
By connecting the soldering iron to the battery in the following way, you will not be tied to the electrical network and will be able to solder wherever you need without extension cords in compliance with the requirements of the rules for safe work.
It is clear that in order to solder autonomously, you need a battery with a larger capacity. I immediately remember the car. But it is very heavy, from 12 kg. However, there are other sizes of batteries, for example, used in uninterruptible power supplies (UPS) of computer equipment. With a weight of only 1.7 kg, they have a capacity of 7 A * h and give out a voltage of 12 V. Such a battery can be easily transported.
In order to make an ordinary soldering iron mobile, you need to take a plywood plate, drill 2 holes in it with a diameter equal to the thickness of the soldering iron support wire and glue the plate to the battery. When the support is bent, the width of the installation site of the soldering iron must be made slightly smaller than the diameter of the tube with the heat of the soldering iron heater. Then the soldering iron will be inserted with an interference fit, and fixed. It will be convenient to store and transport.
For soldering wires with a diameter of up to 1 mm, a soldering iron designed to operate at a voltage of 12 volts and with a power of 15 watts or more is suitable. The time of continuous operation from a freshly charged soldering iron battery will be more than 5 hours. If you plan to solder wires of a larger diameter, then you should already take a soldering iron with a power of 30 - 40 watts. Then the time of continuous operation will be at least 2 hours.
To power the soldering iron, batteries are quite suitable, which can no longer ensure the normal operation of uninterruptible power supplies due to the loss of their capacity over time. After all, to power a computer, you need a power of 250 watts. Even if the battery capacity has decreased to 1 Ah, it will still ensure the operation of a 30-watt soldering iron for 15 minutes. This time is enough to complete the work of soldering several conductors.
In case of a one-time need to perform soldering, you can temporarily remove the battery from the uninterruptible power supply and return it to its place after soldering.
It remains to install connectors on the ends of the soldering iron wire by pressing or soldering, put them on the battery terminals and the mobile soldering iron is ready for use. Chapter.
In order to get high-quality and beautiful soldering, you need to choose the right soldering iron power and provide a certain temperature of its tip, depending on the brand of solder used. I offer several schemes for home-made thyristor temperature controllers for heating the soldering iron, which will successfully replace many industrial ones that are incomparable in price and complexity.
Attention, the following thyristor circuits of temperature controllers are not galvanically isolated from the electric network and touching the current-carrying elements of the circuit is life-threatening!
To adjust the temperature of the soldering iron tip, soldering stations are used in which the optimum temperature of the soldering tip is maintained in manual or automatic mode. The availability of a soldering station for the home craftsman is limited by the high price. For myself, I solved the issue of temperature control by developing and manufacturing a regulator with manual smooth temperature control. The circuit can be modified to automatically maintain the temperature, but I don’t see the point in this, and practice has shown that manual adjustment is quite enough, since the mains voltage is stable and the room temperature too.
The classic thyristor circuit of the soldering iron power regulator did not meet one of my main requirements, the absence of radiating interference into the mains and the air. And for a radio amateur, such interference makes it impossible to fully engage in what you love. If the circuit is supplemented with a filter, then the design will turn out to be cumbersome. But for many applications, such a thyristor regulator circuit can be successfully used, for example, to adjust the brightness of incandescent lamps and heating appliances with a power of 20-60 watts. That's why I decided to present this scheme.
In order to understand how the circuit works, I will dwell in more detail on the principle of operation of the thyristor. A thyristor is a semiconductor device that is either open or closed. to open it, you need to apply a positive voltage of 2-5 V to the control electrode, depending on the type of thyristor, relative to the cathode (k is indicated in the diagram). After the thyristor has opened (the resistance between the anode and cathode will become 0), it is not possible to close it through the control electrode. The thyristor will be open until the voltage between its anode and cathode (marked a and k in the diagram) becomes close to zero. It's that simple.
The circuit of the classical regulator works as follows. The AC mains voltage is supplied through the load (an incandescent bulb or a soldering iron winding) to a rectifier bridge circuit made on VD1-VD4 diodes. The diode bridge converts the AC voltage into a DC voltage that changes according to a sinusoidal law (diagram 1). When the middle terminal of the resistor R1 is in the leftmost position, its resistance is 0, and when the voltage in the network begins to increase, the capacitor C1 begins to charge. When C1 is charged to a voltage of 2-5 V, current will flow through R2 to the control electrode VS1. The thyristor will open, short-circuit the diode bridge and the maximum current will flow through the load (upper diagram).
When you turn the knob of the variable resistor R1, its resistance will increase, the charge current of the capacitor C1 will decrease and it will take more time for the voltage across it to reach 2-5 V, so the thyristor will not open immediately, but after some time. The larger the value of R1, the longer the charge time for C1, the thyristor will open later and the power received by the load will be proportionally less. Thus, by rotating the knob of the variable resistor, the heating temperature of the soldering iron or the brightness of the incandescent light bulb is controlled.
Above is a classic thyristor controller circuit made on a KU202N thyristor. Since more current is needed to control this thyristor (according to the passport 100 mA, the real one is about 20 mA), the values of the resistors R1 and R2 are reduced, and R3 is excluded, and the value of the electrolytic capacitor is increased. When repeating the circuit, it may be necessary to increase the value of the capacitor C1 to 20 microfarads.
Here is another of the simplest thyristor power controller circuits, a simplified version of the classic controller. The number of parts is kept to a minimum. Instead of four diodes VD1-VD4, one VD1 is used. Its principle of operation is the same as that of the classical scheme. The schemes differ only in that the adjustment in this temperature controller circuit occurs only according to the positive period of the network, and the negative period passes through VD1 without changes, so the power can only be adjusted in the range from 50 to 100%. To adjust the heating temperature of the soldering tip, more is not required. If the VD1 diode is excluded, then the power adjustment range will be from 0 to 50%.
If a dinistor, for example KN102A, is added to the circuit break from R1 and R2, then the electrolytic capacitor C1 can be replaced with an ordinary one with a capacity of 0.1 mF. Thyristors for the above circuits are suitable, KU103V, KU201K (L), KU202K (L, M, N), designed for a forward voltage of more than 300 V. Diodes are also almost any, designed for a reverse voltage of at least 300 V.
The above circuits of thyristor power controllers can be successfully used to control the brightness of the glow of lamps in which incandescent bulbs are installed. It will not work to regulate the brightness of the glow of lamps in which energy-saving or LED bulbs are installed, since electronic circuits are mounted in such bulbs, and the regulator will simply disrupt their normal operation. The bulbs will shine at full power or flash and this may even lead to premature failure.
The circuits can be used for regulation with a supply voltage of 36 V or 24 V AC. It is only necessary to reduce the resistor values by an order of magnitude and use a thyristor that matches the load. So a soldering iron with a power of 40 W at a voltage of 36 V will consume a current of 1.1 A.
The main difference between the circuit of the presented soldering iron power regulator and those presented above is the complete absence of radio interference in the electrical network, since all transients occur at a time when the voltage in the supply network is zero.
Starting to develop a temperature controller for a soldering iron, I proceeded from the following considerations. The scheme should be simple, easily repeatable, components should be cheap and available, high reliability, minimal dimensions, efficiency close to 100%, no radiating interference, the possibility of modernization.
The temperature controller circuit works as follows. The AC voltage from the mains is rectified by a diode bridge VD1-VD4. From a sinusoidal signal, a constant voltage is obtained, varying in amplitude as half a sinusoid with a frequency of 100 Hz (diagram 1). Further, the current passes through the limiting resistor R1 to the zener diode VD6, where the voltage is limited in amplitude to 9 V, and has a different shape (diagram 2). The resulting pulses charge the electrolytic capacitor C1 through the VD5 diode, creating a supply voltage of about 9 V for the DD1 and DD2 microcircuits. R2 performs a protective function, limiting the maximum possible voltage on VD5 and VD6 to 22 V, and ensures the formation of a clock pulse for the operation of the circuit. With R1, the generated signal is fed to the 5th and 6th outputs of the 2OR-NOT element of the logical digital microcircuit DD1.1, which inverts the incoming signal and converts it into short rectangular pulses (diagram 3). From the 4th output of DD1, the pulses are fed to the 8th output of the D trigger DD2.1, operating in the RS trigger mode. DD2.1, like DD1.1, also performs the function of inverting and signal conditioning (diagram 4).
Please note that the signals in diagram 2 and 4 are almost the same, and it seemed that it was possible to apply a signal from R1 directly to pin 5 of DD2.1. But studies have shown that in the signal after R1 there is a lot of interference coming from the mains, and without double shaping, the circuit did not work stably. And it is not advisable to install additional LC filters when there are free logic elements.
On the DD2.2 trigger, a soldering iron temperature controller control circuit is assembled and it works as follows. Rectangular pulses arrive at pin 3 DD2.2 from pin 13 DD2.1, which with a positive edge overwrite at pin 1 DD2.2 the level that is currently present at the D input of the microcircuit (pin 5). At pin 2, the signal is the opposite level. Consider the work of DD2.2 in detail. Let's say on pin 2, a logical unit. Through the resistors R4, R5, the capacitor C2 is charged to the supply voltage. Upon receipt of the first pulse with a positive drop, 0 will appear at pin 2 and capacitor C2 will quickly discharge through diode VD7. The next positive drop at pin 3 will set a logical unit at pin 2 and capacitor C2 will start charging through resistors R4, R5.
The charge time is determined by the time constant R5 and C2. The larger R5, the longer it will take C2 to charge. Until C2 is charged to half the supply voltage at pin 5 there will be a logic zero and positive pulse drops at input 3 will not change the logic level at pin 2. As soon as the capacitor is charged, the process will repeat.
Thus, only the number of pulses from the supply network specified by resistor R5 will pass to the outputs of DD2.2, and most importantly, these pulses will fluctuate during the transition of the voltage in the supply network through zero. Hence the absence of interference from the operation of the temperature controller.
From pin 1 of the DD2.2 microcircuit, pulses are fed to the DD1.2 inverter, which serves to eliminate the influence of the thyristor VS1 on the operation of DD2.2. Resistor R6 limits the control current of thyristor VS1. When a positive potential is applied to the control electrode VS1, the thyristor opens and voltage is applied to the soldering iron. The regulator allows you to adjust the power of the soldering iron from 50 to 99%. Although the resistor R5 is variable, the adjustment due to the operation of DD2.2 heating the soldering iron is carried out in steps. With R5 equal to zero, 50% of the power is supplied (diagram 5), when turning through a certain angle it is already 66% (diagram 6), then already 75% (diagram 7). Thus, the closer to the rated power of the soldering iron, the smoother the adjustment works, which makes it easy to adjust the temperature of the soldering tip. For example, a 40W soldering iron can be set to 20W to 40W.
All parts of the thyristor temperature controller are placed on a fiberglass printed circuit board. Since the circuit does not have a galvanic isolation from the electrical network, the board is placed in a small plastic case of the former adapter with an electrical plug. A plastic handle is put on the axis of the variable resistor R5. Around the handle on the body of the regulator, for the convenience of adjusting the degree of heating of the soldering iron, a scale with conditional numbers is applied.
The cord from the soldering iron is soldered directly to the PCB. You can make the connection of the soldering iron detachable, then it will be possible to connect other soldering irons to the temperature controller. Surprisingly, the current drawn by the temperature controller control circuit does not exceed 2 mA. This is less than the consumption of the LED in the lighting circuit of the light switches. Therefore, special measures to ensure the temperature regime of the device are not required.
Chips DD1 and DD2 any 176 or 561 series. The Soviet thyristor KU103V can be replaced, for example, with a modern thyristor MCR100-6 or MCR100-8, designed for a switching current of up to 0.8 A. In this case, it will be possible to control the heating of a soldering iron with a power of up to 150 W. Diodes VD1-VD4 are any, designed for a reverse voltage of at least 300 V and a current of at least 0.5 A. IN4007 is perfect (Uob \u003d 1000 V, I \u003d 1 A). Diodes VD5 and VD7 any pulse. Any low-power zener diode VD6 for a stabilization voltage of about 9 V. Capacitors of any type. Any resistors, R1 with a power of 0.5 W.
The power regulator does not need to be adjusted. With serviceable parts and without installation errors, it will work immediately.
The circuit was developed many years ago, when computers, and even more so laser printers, did not exist in nature, and therefore I made a printed circuit board drawing using old-fashioned technology on chart paper with a grid pitch of 2.5 mm. Then the drawing was glued with Moment glue to thick paper, and the paper itself to the foil fiberglass. Next, holes were drilled on a home-made drilling machine and the paths of future conductors and contact pads for soldering parts were drawn by hand.
The drawing of the thyristor temperature controller has been preserved. Here is his photo. Initially, the VD1-VD4 rectifier diode bridge was made on the KTs407 microassembly, but after the microassembly was torn twice, it was replaced with four KD209 diodes.
To reduce interference emitted by thyristor power controllers into the electrical network, ferrite filters are used, which are a ferrite ring with wound turns of wire. Such ferrite filters can be found in all switching power supplies for computers, TVs and other products. An efficient, interference-suppressing ferrite filter can be retrofitted to any thyristor controller. It is enough to pass the wire for connecting to the electrical network through the ferrite ring.
It is necessary to install a ferrite filter as close as possible to the source of interference, that is, to the place where the thyristor is installed. The ferrite filter can be placed both inside the instrument housing and on its outer side. The more turns, the better the ferrite filter will suppress interference, but it is enough and just to pass the mains wire through the ring.
The ferrite ring can be taken from the interface wires of computer equipment, monitors, printers, scanners. If you pay attention to the wire connecting the computer system unit to the monitor or printer, you will notice a cylindrical thickening of the insulation on the wire. This location contains a ferrite high-frequency noise filter.
It is enough to cut the plastic insulation with a knife and remove the ferrite ring. Surely you or your friends will find an unnecessary interface cable from an inkjet printer or an old kinescope monitor.
Due to the problem with electricity, people are increasingly buying power regulators. It is no secret that sudden drops, as well as excessively low or high voltage, adversely affect household appliances. In order to prevent damage to property, it is necessary to use a voltage regulator that will protect electronic devices from short circuits and various negative factors.
Nowadays, on the market you can see a huge number of different regulators for the whole house, as well as low-power individual household appliances. There are transistor voltage regulators, thyristor, mechanical (voltage adjustment is carried out using a mechanical slider with a graphite rod at the end). But the most common is the triac voltage regulator. The basis of this device are triacs, which allow you to react sharply to power surges and smooth them out.
The triac is an element that contains five p-n junctions. This radio element has the ability to pass current both in the forward direction and in the opposite direction.
These components can be observed in various household appliances ranging from hair dryers and table lamps to soldering irons, where smooth adjustment is necessary.
The principle of operation of the triac is quite simple. This is a kind of electronic key that either closes the doors or opens them at a given frequency. When opening the P-N junction of the triac, it misses a small part of the half-wave and the consumer receives only part of the rated power. That is, the more the P-N junction opens, the more power the consumer receives.
The advantages of this element include:
In connection with the above advantages, triacs and regulators based on them are used quite often.
This circuit is quite easy to assemble and does not require a lot of parts. Such a regulator can be used to regulate not only the temperature of the soldering iron, but also conventional incandescent and LED lamps. Various drills, grinders, vacuum cleaners, grinders, which initially went without smooth speed control, can be connected to this circuit.
Here is such a 220v voltage regulator with your own hands can be assembled from the following parts:
The circuit has been tested and works quite stably under different types of load..
There is another scheme for a universal power regulator.
An alternating voltage of 220 V is supplied to the input of the circuit, and 220 V DC is already supplied at the output. This scheme already has more details in its arsenal, respectively, and the complexity of the assembly increases. It is possible to connect any consumer (direct current) to the output of the circuit. In most houses and apartments, people are trying to install energy-saving lamps. Not every regulator will cope with the smooth adjustment of such a lamp, for example, it is undesirable to use a thyristor regulator. This scheme allows you to freely connect these lamps and make them a kind of nightlight.
The peculiarity of the circuit is that when the lamps are turned on at a minimum, all household appliances must be disconnected from the mains. After that, the compensator will work in the counter, and the disk will slowly stop, and the light will continue to burn. This is an opportunity to assemble a triac power regulator with your own hands. The ratings of the parts needed for assembly can be seen in the diagram.
Another entertaining scheme that allows you to connect a load of up to 5A and a power of up to 1000W.
The regulator is assembled on the basis of the triac BT06−600. The principle of operation of this circuit is to open the transition of the triac. The more the element is open, the more power is supplied to the load. And also in the circuit there is an LED that will let you know if the device is working or not. The list of parts that will be needed to assemble the device:
Triacs and thyristors are successfully used as starters. Sometimes it is necessary to start very powerful heating elements, control the switching on of powerful welding equipment, where the current strength reaches 300–400 A. Mechanical switching on and off using contactors is inferior to a triac starter due to the rapid wear of the contactors, in addition, an arc occurs during mechanical switching, which also detrimental effect on contactors. Therefore, it would be advisable to use triacs for these purposes. Here is one of the diagrams.
All ratings and parts list are shown in Fig. 4. The advantage of this circuit is the complete galvanic isolation from the network, which will ensure safety in case of damage.
Often on the farm it is necessary to perform welding work. If there is a ready-made inverter welding machine, then welding does not present any particular difficulties, since the machine has a current adjustment. Most people do not have such a welding machine and have to use a conventional transformer welding machine, in which the current is adjusted by changing the resistance, which is rather inconvenient.
Those who have tried to use a triac as a regulator will be disappointed. It will not regulate power. This is due to the phase shift, which is why the semiconductor key does not have time to switch to the “open” mode during a short pulse.
But there is a way out of this situation. It is necessary to apply the same type of pulse to the control electrode or apply a constant signal to the RE (control electrode) until there is a passage through zero. The controller circuit looks like this:
Of course, the circuit is quite complicated to assemble, but this option will solve all the problems with adjustment. Now it will not be necessary to use bulky resistance, and besides, very smooth adjustment will not work. In the case of a triac, a fairly smooth adjustment is possible.
If there are constant voltage drops, as well as under or over voltage, it is recommended to purchase a triac regulator or, if possible, make a regulator with your own hands. The regulator will protect household appliances, as well as prevent their damage.
Everyone who knows how to use a soldering iron tries to deal with the phenomenon of overheating of the tip and, as a result, a deterioration in the quality of soldering. To combat this not very pleasant fact, I suggest you assemble one of the simple and reliable soldering iron power regulator circuits with your own hands.
To make it, you will need a wire-wound variable resistor of the SP5-30 type or a similar one and a coffee tin. Having drilled a hole in the center of the bottom of the can, we install a resistor there, and carry out the wiring
This and very simple device will improve the quality of soldering and will also be able to protect the soldering iron tip from destruction due to overheating.
Genius is simple. Compared to a diode, a variable resistor is neither simpler nor more reliable. But the soldering iron with a diode is rather weak, and the resistor allows you to work without overheating and without undershooting. Where can I get a powerful, suitable variable resistor in terms of resistance? It is easier to find a permanent one, and replace the switch used in the "classic" circuit with a three-position
The duty and maximum heating of the soldering iron will be supplemented by the optimal one, corresponding to the middle position of the switch. The heating of the resistor in comparison with will decrease, and the reliability of operation will increase.
Another very simple amateur radio development, but unlike the first two with higher efficiency
Resistor and transistor regulators are uneconomical. You can also increase the efficiency by turning on the diode. This achieves a more convenient control limit (50-100%). Semiconductor devices can be placed on a single heatsink.
The voltage from the rectifier diodes is supplied to a parametric voltage regulator, consisting of resistance R1, a zener diode VD5 and capacitance C2. The nine-volt voltage he created is used to power the K561IE8 counter chip.
In addition, the previously rectified voltage, through the capacitance C1 in the form of a half-cycle with a frequency of 100 Hz, passes to the input 14 of the counter.
K561IE8 is an ordinary decimal counter, therefore, with each pulse at the CN input, a logical unit will be sequentially set at the outputs. If we move the circuit switch to output 10, then with the appearance of every fifth pulse, the counter will be reset to zero and the count will start again, and at pin 3 the logical unit will be set only for the duration of one half-cycle. Therefore, the transistor and thyristor will open only after four half-cycles. With the SA1 toggle switch, you can adjust the number of missed half-cycles and the power of the circuit.
We use a diode bridge in a circuit of such power that it matches the power of the connected load. As heating devices, you can use such as electric stoves, heating elements, etc.
The circuit is very simple, and consists of two parts: power and control. The first part includes the VS1 thyristor, from the anode of which there is an adjustable voltage to the soldering iron.
The control circuit, implemented on transistors VT1 and VT2, controls the operation of the previously mentioned thyristor. It receives power through a parametric stabilizer assembled on a resistor R5 and a zener diode VD1. The zener diode is designed to stabilize and limit the voltage supplying the structure. The resistance R5 dampens the excess voltage, and the variable resistance R2 adjusts the output voltage.
As the body of the structure, let's take a regular socket. When you buy, then choose that it is made of plastic.
This knob controls the power from zero to maximum. HL1 (neon lamp MH3 ... MH13, etc.) - linearizes the control and simultaneously performs the function of an indicator indicator. Capacitor C1 (capacity 0.1 microfarad) - generates a sawtooth pulse and implements the function of protecting the control circuit from interference. Resistance R1 (220 kOhm) - power regulator. Resistor R2 (1 kOhm) - limits the current flowing through the anode - cathode VS1 and R1. R3 (300 Ohm) - limits the current through the HL1 neon () and the control electrode of the triac.
The regulator is assembled in a case from the power supply of a Soviet calculator. The triac and potentiometer are fixed on a steel corner, 0.5 mm thick. The angle is screwed to the body with two M2.5 screws using insulating washers. Resistors R2, R3 and neon HL1 are placed in an insulating tube (cambric) and fixed by surface mounting.
T1: BT139 triac, T2: BC547 transistor, D1: DB3 dinistor, D2 and D3: 1N4007 diode, C1: 47nF/400V, C2:220uF/25V, R1 and R3: 470K, R2: 2K6, R4: 100R, P1 : 2M2, LED 5mm red.
Triac BT139 is used to adjust the phase of the "resistive" load of the heating element of the soldering iron. The red LED is a visual indicator of the activity of the structure.
The basis of the MK PIC16F628A circuit, which carries out PWM control of the power consumption supplied to the main instrument of the radio amateur.
If your soldering iron has a high power of 40 watts or more, then when soldering small radio elements, especially smd components, it is difficult to find the moment when soldering is optimal. And it's simply not possible to solder small things to them. In order not to spend money on buying a soldering station, especially if you do not need it often. I propose to assemble this prefix for your main amateur radio instrument.
A soldering iron is a tool that a home master cannot do without, but the device is not always satisfied. The fact is that a conventional soldering iron, which does not have a thermostat and, as a result, heats up to a certain temperature, has a number of disadvantages.
Soldering iron diagram.
If during short work it is quite possible to do without a temperature controller, then for an ordinary soldering iron, which has been connected to the network for a long time, its shortcomings are fully manifested:
The thermostat for the soldering iron allows you to optimize its operation:
Figure 1. Scheme of the simplest thermostat.
Of course, LATR can be used as a thermostat for a 220 V soldering iron, and a KEF-8 power supply for a 42 V soldering iron, but not everyone has them. Another way out is to use an industrial dimmer as a temperature controller, but they are not always commercially available.
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This device consists of only two parts (Fig. 1):
Figure 2. Scheme of a thermostat operating on capacitors.
This temperature controller works as follows: in the initial state, the contacts of the switch SA are closed and the current flows through the heating element of the soldering iron during both positive and negative half-cycles (Fig. 1a). When the SA button is pressed, its contacts open, but the semiconductor diode VD passes current only during positive half-cycles (Fig. 1b). As a result, the power consumed by the heater is halved.
In the first mode, the soldering iron warms up quickly, in the second mode, its temperature decreases slightly, overheating does not occur. As a result, you can solder in fairly comfortable conditions. The switch, together with the diode, is connected to the break in the supply wire.
Sometimes the SA switch is mounted on a stand and is triggered when the soldering iron is placed on it. During the breaks between soldering, the switch contacts are open, the heater power is reduced. When the soldering iron is lifted, the power consumption increases and it quickly heats up to operating temperature.
Capacitors can be used as a ballast resistance, with which you can reduce the power consumed by the heater. The smaller their capacitance, the greater the resistance to the flow of alternating current. A diagram of a simple thermostat operating on this principle is shown in fig. 2. It is designed to connect a 40W soldering iron.
When all switches are open, there is no current in the circuit. By combining the position of the switches, three degrees of heating can be obtained:
Figure 3. Schemes of triac thermostats.
Capacitors C1 and C2 are non-polar, designed for a voltage of at least 400 V. To achieve the required capacity, several capacitors can be connected in parallel. Through resistors R1 and R2, the capacitors are discharged after the regulator is disconnected from the network.
There is another version of a simple regulator, which is not inferior to electronic ones in terms of reliability and quality of work. To do this, a variable wire resistor SP5-30 or some other one with a suitable power is switched on in series with the heater. For example, for a 40-watt soldering iron, a resistor rated for 25 W and having a resistance of about 1 kOhm is suitable.
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The operation of the circuit shown in fig. 3a, the operation of the previously analyzed circuit in Fig. 1. Semiconductor diode VD1 passes negative half-cycles, and during positive half-cycles, the current passes through the thyristor VS1. The proportion of the positive half-cycle, during which the thyristor VS1 is open, ultimately depends on the position of the variable resistor R1 slider, which regulates the current of the control electrode and, consequently, the firing angle.
Figure 4. Scheme of a triac thermostat.
In one extreme position, the thyristor is open during the entire positive half-cycle, in the second it is completely closed. Accordingly, the power dissipated on the heater varies from 100% to 50%. If you turn off the VD1 diode, then the power will change from 50% to 0.
In the diagram shown in fig. 3b, a thyristor with an adjustable firing angle VS1 is included in the diagonal of the diode bridge VD1-VD4. As a result, the regulation of the voltage at which the thyristor is unlocked occurs both during the positive and during the negative half-cycle. The power dissipated on the heater changes when the variable resistor R1 slider is turned from 100% to 0. You can do without a diode bridge if you use a triac instead of a thyristor as a control element (Fig. 4a).
For all its attractiveness, a thermostat with a thyristor or triac as a control element has the following disadvantages:
To minimize impulse noise and non-linear distortion, it is desirable to install network filters. The simplest solution is a ferrite filter, which is a few turns of wire wound around a ferrite ring. Such filters are used in most switching power supplies for electronic devices.
A ferrite ring can be taken from the wires connecting the computer system unit to peripheral devices (for example, to a monitor). Usually they have a cylindrical thickening, inside of which there is a ferrite filter. The filter device is shown in fig. 4b. The more turns, the higher the quality of the filter. The ferrite filter should be placed as close as possible to the source of interference - a thyristor or triac.
In devices with a smooth change in power, the regulator slider should be calibrated and its position should be marked with a marker. When setting up and installing, you must disconnect the device from the network.
The schemes of all the above devices are quite simple and they can be repeated by a person with minimal skills in assembling electronic devices.
