Zvs flyback driver capacitor testing

This is my 5th attempt at making my own zvs driver. I tested some of my theories, and blew some mosfets up. You can test various types of capacitors to see which one suits your zvs driver well. A zvs driver is a very simple circuit that can oscillate a large amount of power. Buy yosoo w zvs low voltage induction heating board. D4sparks is a great building block for tesla coils, jacobs ladders an co2 laser supplies. I hope that my pictures help to educate a better way to use this flyback transformer and zvs driver for demonstrations and experiments using high voltage. Intro this instructable will show you how to make a simple driver circuit for obtaining high voltage arcs out of a component called a flyback transformer. The waveforms were measured at each test points of the zvs circuit at the 470. Many sites doesnt provide circuits driving these transformers, they simply say that they are bad. I cut my old capacitor in two pieces now i have two 10nf capcitors. I setup the standard zvs flyback driver with the irfp250 mosfets and it worked great. I tested both samples with the flyback tester made from zvs driver. That flyback killed my zvs driver but luckly i have a backup one.

Connect a high voltage rectifier diode to one leg of the output of the transformer, and put your spark gap between the diode and the black wires, and then put your capacitor and primary coil in series across the spark gap. I already had the zvs module, a good flyback transformer with built in hv diode, and lots of hv cables. I spent a lot of time for finding resonant frequency around 15khz and dutyread more. The schematic has been updated to include basic transistor protection in the form of a capacitor and diode. By jestine yong on november 18, 2008 one of my erg member had successfully built a flyback tester base on the schematic from dick smith flyback tester and he agreed to let me post his project for all readers in this blog to see. If possible start with a low voltage like 12v first to test it and check things are not heating up.

Beware of zero voltage switching sanjay havanur, sr. The energy stored in l2 is completely discharged into the boost capacitor via d2 during the. Beware of zero voltage switching mouser electronics. Introduction the mazilli zvs flyback driver is wellknown throughout the high. I used 4 highfrequency capacitors, an 150mh inductor, and 2 irfp260ns. During this phase the q 1 switch is off and q 2 is switched on under the zvs condition. I will not go higher than 36 volts because flybacks and zvs drivers dont like that much current. Most tv flyback transformers will by fried by the high current so a current limiter is a must have when you play with zvs. Actual transformer used in this video is from an old tv, which is not exactly as per the design.

Below is a youtube video of the oscillator powering a flyback transformer at 12. I build this circuit almost a year ago on a vero board, but it kept blowing the thin traces due to high currents flowing. The zvs driver circuit is a royertype pushpull oscillator with a resonated primary that is implemented with fets. This provides the 40 volts 10 amps that powers the zvs driver board. Zvs driver charging capacitor bank electrical engineering stack. You may also use the zvs flyback driver with a ferrite core and a custom made hv. Getting right parts and building zvs flyback correctly. Home forum members member map hvwiki chat room submit news. This type of oscillator can be used to drive the ferrite core of a flyback transformer to generate high voltage. At the moment i am trying to build a zvs driver for my flyback transformer. Q1 then behaves as an ordinary pfc switch, storing energy in the boost inductor l1. I want to use as much stuff that i have already as i can and i will be using only digikey to buy the parts to keep the shipping low. Resonant hybrid flyback, a new topology for high density. Mazilli zvs flyback driver kaizer power electronics.

I now want to build a zvs flyback driver but i really want to get every right parts and build this correctly so i dont have to keep ordering new parts. Problem f can be checked with multimeter set to the highest range measured from anode to abl pin while g can be solved by adding a new monitor blur. I then setup a small tesla coil that i made and things were going pretty good as well. I also used 4 12v batteries in series for 50v input. This is then rectified and filtered to achieve a clean dc voltage that is fed to the zvs oscillator board. The output voltage from the zvs driver and flyback transformer to the. I had derped around with single transistor flyback drivers, but it wasnt anything too serious.

To the right exists a simplified version of the oscillator, so take a good look. How a zvs flyback driver circuit works and how to build one. The waveforms were measured at each test points of the zvs circuit at. A simplified multioutput flyback converter block diagram is shown in figure 1. Typically using old crt flyback transformer it can deliver more than 7000 v and normally its depend on configuration of flyback transformer primarysecondary winding. This driver is capable of pumping upto a kw of power, so impressive arcs can be made. Flyback transformer drivers the 555 driver basic flyback transformers are found in monitors, tvs or anything with a crt, and are sometimes known as line output transformers, or just lopt. Never use an electrolytic capacitor, they will blow up. When powered by the zvs driver at 30v the sparks start at 1. Zvs 2000w high voltage induction heater module flyback. Pdf zero voltage switching driver and flyback transformer for. Well, after fiddling with zvs drivers and similar halfbridge circuits i have returned back to the original 2n3055 driver approach. Buy yosoo w zvs low voltage induction heating board module tesla coil 12v48v flyback driver heater diy online at low price.

Ucc28780 high frequency active clamp flyback controller 1 1 features 1 full and partial zero voltage switching zvs of. Like other power supplies, an smps transfers power from a dc or ac source often mains power to dc loads, such as a personal computer, while converting. Halfbridge driver ucc28780 vo vdd run pwmh pwml fb sws vsw hvg cs vs gnd ntc rdm rtz bur ref. The mazilli zvs flyback driver is wellknown throughout the high voltage community for its simplicity and ability to deliver 2050 kv at high currents for a flyback transformer. A switchedmode power supply switchingmode power supply, switchmode power supply, switched power supply, smps, or switcher is an electronic power supply that incorporates a switching regulator to convert electrical power efficiently. High power full bridge flyback driver circuit under. You may also use the zvs flyback driver with a ferrite core and a custom made hv secondary, see this article. This way the water coolant served to keep both the mosfet and workcoil cool without large heatsinks.

A zvs driver is a very simple circuit that can oscillate a large amount of power with about 90% efficiency. In this video, i explain how the circuit of a zvs flyback driver works. Its very useful if you are looking for high voltage. The mazilli driver uses mosfets and diodes to turn the mosfets on or off depending on the tanks voltage. Zero voltage switching driver and flyback transformer for. W 20a zvs high voltage induction board heating module. According to this site, type 4b flybacks might give us 80kv which we assumed to be the output of our flyback transformer for safety purposes. I understand the schematic to this type somewhat, but i do not know how robust this could be. With zvs, only the discharging half of the energy is delivered to the load and reclaimed.

The actual zvs driver is mounted to the right of the capacitor array. Many of you who are reading this may be asking what is a zvs driver. To filter the dc, add a few capacitors in line with the power rails on your zvs driver board. I think the origins of the peculiar zvs design i was using was as a flyback driver, so it was originally connected to a centertapped transformer.

High voltage enthusiasts, who are familiar with the classic ne555 flyback driver, will notice the foil capacitor across the primary winding, which really makes wonders. I get longer copper pipe, now i can get up to 9 turns. The zvs flyback driver either using bjts or mosfets have been used in high voltage devices such as tesla coils, marx generators, ion experiments, and ccfls. Ucc28780 high frequency active clamp flyback controller. The step 9 page going further now includes a way to measure these illustrious voltage spikes with a regular volt meter. This is because, in a regular zvs driver, if you want higher voltage, you have to feed the driver with higher dc voltage, but this also increases the current through the primary and saturation may happen. The infamous zvs mazilli flyback driver is very efficient in delivering high power current and seen have been used in many commercial appliance that require high voltage and power. Making its output bigger by upgrading it to a zvs driver, we dont know what its output voltage will be so we planned to make bucket capacitors in series. Or you can use a secondary with only a few turns of tick cooper wire, to get a current so high, that can melt thin copper wires connected across the output. The one with the biggest resistance will be secondary ground.

Then jan martis, a czech experimenter, came up with an idea to increase the efficiency of these flyback topologies. I go in depth in my explanation of the different circuit elements and how they. Changing the value of the capacitor can also affect the performance depending on the flyback transformer, again, make sure you use good quality capacitor. It first uses a streetlight transformer to step down the 110 volt mains current to 40 volts. Most of the people in the 4hv community use the mazilli driver to make flyback transformers also known as line output transformers lopt from tvs and computer monitors. Another advantage beside the low heat and the high power of the zvs is the fact that is a full bridge driver, which lets you experiments with ac projects too. Introduction the mazilli zvs flyback driver is wellknown throughout the high voltage community for its simplicity and ability to deliver 2050 kv at high currents for a flyback transformer. Its all a bit thrown together as i only finished assembling it onto a piece wood a few hours ago. Quasiresonant and fixedfrequency flyback comparison. The only difference between the standard zvs and mine was a rectifier diode on the hv out and a 500pf cap for the coil. D4sparks a zvs driver for flyback and other high voltage transformers.

Choosing a tank capacitor for my tesla coil electronics. Coil gun capacitor charger zvs flyback driver youtube. Flyback driver with transistors d718npn make powerful 60100kv,a high voltage generator diy duration. This driver is called zero voltage switching driver cuz it switches current exactly when the voltage across the mosfet equals zero, and give a pure sine wave output, hence behaving like an dcac converter or inverter. The output voltage depends on the oscillator frequency set it to variable 1530khz for output voltage finetuning, number of primary turns and on the resonant capacity. I soldered a copper tab onto each pipe, drilled a hole and then mounted each mosfet on the tabs.

This is my first flyback driver and spark gap setup on a tesla coil. The zvs on the other hand was promised to be the most efficient driver around, and the videos of it only supported this. Ntc 11 9 i this is an interface to an external ntc negative. The most popular zvs flyback driver nowadays amongst hobbyists is that designed by vladimiro mazilli. This modified driver is capable of working at much higher frequency than the original. The first pa rt is a switching circuit with a pair of mosfets irfp260 and zen er diode that step up the input 12 vdc. From what i understand, its probably a much higher frequency probably ok for my purpose, has a much smaller tank and probably less mosfets. How to use zvs driver to power tesla coils primary. Last summer i encountered some videos of the zvs driver online. The item may be missing original packaging and may have been used for testing or demo purposes. Everybody has seen a high voltage arc somewhere, whether it be in the movies, on youtube, or on tv. Zvs tesla coil flyback driver marx generatorjacobladder ignition coil 1236v. Testing flyback transformer will be base on a and b since problem c is visible while problem d and e can be detected by hearing the arcing sound generated by the flyback transformer.

Flyback driver circuits high voltage with a television flyback transformer. The primary side of the transformer now has the same voltage as the capacitor c r. One that i have found is a little board with a coil described as flyback driver, zvs w. My box shows the primary side voltage of the zvs driver being applied with voltage, current, power and energy consumed by the zvs driver. Thats how you would wire a zvs driver to a tesla coil. General description and circuit operation this is an efficient flyback driver for modern cylindrical rectified television flybacks. My first question is the primary coil of the flyback.