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. Like other power supplies, an smps transfers power from a dc or ac source often mains power to dc loads, such as a personal. The way i usually connect the circuit to the transformer is by basically winding my own primary. This driver is capable of pumping upto a kw of power, so impressive arcs can be made. Chapter 6 active clamp zvs flyback converter with output. How a zvs flyback driver circuit works and how to build one. Will one of these new zvs heating coil drivers drive a. Sainsmart zero voltage switching tesla coil flyback driver.
The zvs on the other hand was promised to be the most efficient driver around, and the videos of it only supported this. Last summer i encountered some videos of the zvs driver online. To allow higher voltage inputs and bigger power outputs, get a separate 1216v dc supply a few watt transformer, e. I build this circuit almost a year ago on a vero board, but it kept blowing the thin traces due to high currents flowing. It actually has a center positive and double negative outputs. Flyback driver with transistors d718npn make powerful 60100kv,a high voltage generator diy duration.
Then jan martis, a czech experimenter, came up with an idea to increase the efficiency of these flyback topologies. Has anyone experimented with the zvs or mazilli driver powered directly from mains. When powered by the zvs driver at 30v the sparks start at 1. Normal operation from 12v only results in about 100w, but thats still several times what the 555 drivers will process. He uses an electronic ballast intended for fluorescent light use to drive the transformer. Basic introduction of flybacks and the driver circuit flybacks. Is it possible to simulate a flyback transformer in ltspice. The zvs driver circuit elements are made of high quality, high reliability, strong power. I had derped around with single transistor flyback drivers, but it wasnt anything too serious. How to determine component values and switch deadtimes in a flyback passive snubber circuit. These are the transformers that make the high voltage in crt displays.
This is especially popular for generating high voltage with a flyback. Icstation dc 1230v high voltage arc generator zvs flyback driver. My box shows the primary side voltage of the zvs driver being applied with voltage, current, power and energy consumed by the zvs driver. A flyback transformer, sometimes called a line output transformer, are used in older crt tvs and computer monitors to produce the high voltage required to drive the crt and electron gun.
To the right exists a simplified version of the oscillator, so take a good look. I got it working and the sparks are relatively impressive compared to other drivers i have made, but. Those are potentiometers, part of the flyback s internal resistor network. Already had a new pimary winding and a wire soldered to the hv out pin on the bottom of flyback. Due to the light and shooting angle, pictures may have slightly chromatic aberration. I eventually put the project in a box and forgot all about it. The max17690 is a peak current mode, fixedfrequency switching controller specifically designed for the isolated flyback topology operating in discontinuous conduction mode dcm. Apr 30, 2010 i setup the standard zvs flyback driver with the irfp250 mosfets and it worked great. I then setup a small tesla coil that i made and things were going pretty good as well. And the output can also light up a candle easily well, if the flame is not extinguished by the anodes ionic wind, like in the video, unfortunately. I looks like youre driving the primary of a transformer, and not just driving an inductor. Driver pulls 6 amps, not much compared with induction heater over 11 amps. A significant fraction of energy is lost as heat in the switching elements themselves and this happens because the transition of a switch from the nonconducting state to the conducting state does not happen instantaneously.
Getting right parts and building zvs flyback correctly. You have a choice to either use the irfp260 mosfet, which can handle 48a, or the irfp250 which can handle 33a. Those are potentiometers, part of the flybacks internal resistor network. The gist of it is that while one 2n3055 overheats very quickly, 2 paralleled 2n3055s will be able to split the current load and avoid overheating too rapidly.
I know roughly how they work, and i also know that zvs type circuits exist for flyback transformer drivers, the kind that use tv transformers to generate high voltage, i dont know though if one translates to the needs of the other, i suspect it may since the page says it drives a jacobs ladder, but, its an aliexpress listing description so is. 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. It first uses a streetlight transformer to step down the 110 volt mains current to 40 volts. Jul 20, 2008 for 15cm long sparks a zvs or zerovoltswitching flyback driver would be needed, and those have been known to provide the power needed for 15cm sparks. Supply voltage lower than 910vdc will gives problems with mosfets not. A zvs driver is a very simple circuit that can oscillate a large amount of power with about 90% efficiency. More featureful version of the zvs induction driver, with accessories. Chapter 5 primary zvs based flyback converter with output. More amperes longer hotter arcs, but the 260s are a dollar more. The crt tv already contains all the needed bits to do the job. Since the leakage inductance of the transformer provides the current limiting, and there is never dc component on the primary, arcs can be safely drawn from the transformer without.
Safety is extremely important a flyback is not a toy. I have built a few flyback drivers from 555 controlled to the zvs. The first pa rt is a switching circuit with a pair of mosfets irfp260 and zen er. Since all you lazy fucks didnt want to build a zvs driver, heres a way to make high voltage easier. If so, then you cant add a flyback diode on the inductor, since this wont properly transfer the energy in the transformer to the secondary youre trying to take advantage of the effect that the diode is meant to suppress. As a spark is drawn longer the voltage required to sustain it doesnt necessarily increase as the plasma is already conductive, but the current required to sustain the arc increases. These can be found in anything with a cathode ray tube. So, i have built a zvs flyback driver from this schematic and when i apply power with a 12 volt lead acid battery there is no spark and there is a. Flyback to replace bug zapper hv transformer all about. Reviewed in the united states on february 29, 2016. Mar 18, 2017 i decided to try a high voltage flyback transformer and it works very well. To allow higher voltage inputs and bigger power outputs, get a separate 1216v dc supply a few.
Why are we choosing zvs driver circuits for induction heaters. 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. Jul 04, 2016 i know roughly how they work, and i also know that zvs type circuits exist for flyback transformer drivers, the kind that use tv transformers to generate high voltage, i dont know though if one translates to the needs of the other, i suspect it may since the page says it drives a jacobs ladder, but, its an aliexpress listing description so is. It has high power, emit a little heat and high reliability, it is widely applied to drive sgtc, jacob high ladder, marx generator, induction heating etc. Its based on some work by the people at rmcybernetics on ignition coil drivers, and it seems to work fairly well.
In this video, i explain how the circuit of a zvs flyback driver works. D4sparks is a great building block for tesla coils, jacobs ladders an co2 laser supplies. Input 1224v dc recommended 24v, you can use the switching power supply, leadacid batteries or lithium batterypowered, can also be used by the rectifier transformer power supply filter, filter capacitor is not less than 0uf. 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. The hv from the zvs inverter and offline flyback driver has enough current to kill, so be careful. A number of designs handle the saturation problem by inserting a small airgap in the core. I always have one problem, the power transistors keep burning out. The reason why ive put the 2n3055 driver in quotation marks is simple.
Dc 1236v 10a 300w zvs tesla coil high voltage genrator. Well, after fiddling with zvs drivers and similar halfbridge circuits i have returned back to the original 2n3055 driver approach. 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. This is a nice board, expanding the basic 2transistor zvs driver with an onboard 12v switching regulator module that is used to drive a cooling fan, with external connector for a optional user supplied cooling pump. This circuit is somewhat dangerous, and can give you some nasty shocks and burns if you arent careful, not to mention the possibility of setting things on fire. I used 2 irfp250 mosfets and the results were great. Improving the standard flyback converter for high voltage applications.
This flyback drive circuit, which is used to drive the ignition coil, has zero voltage switching, so it is called as zvs circuit. Is a flyback supposed to have infinite resistance on the secondary arc coil. How reliable are sic fets for high voltage flyback converters. 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 current source is sufficient an old lead acid golf cart battery still giving. This is a fairly configurable and very durable flyback transformer driver. 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 i build this circuit almost a year ago on a vero board, but it kept blowing the thin traces due to high currents flowing. It is possible to generate even higher voltages from a flyback with a even more powerful driver but this may cause secondary coil insulation failure, rendering the flyback dead. Zvs driver module adopts flyback circuit, and it can be used for driving fbt flyback transformer.
A half bridge flyback driver is a neat project for any beginner hv enthusiast, which reflects much of the way a commercial high voltage power supply might be made. I used a long terminal strip to arrange the resistor components. Flyback driver with transistors d718 npn make powerful 60100kv,a high voltage generator diy duration. Although it seems as though it wont become hot as like r1, current inducted on feedback winding uses r2 to reach the ground and this should be added to the calculation. 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. The zvs driver will love you for a stable 48vdc supply, but remember to use 200v rated mosfets, their internal gate structure works the best with that driver scheme and 200v gives you enough. This provides the 40 volts 10 amps that powers the zvs driver board. And finally, you are solely responsible for any harm to others or damage or any other problems that a zvs driver may cause. Zero voltage switching driver and flyback transformer for. Pdf zero voltage switching driver and flyback transformer. You add your own coils, because the ones integrated in the transformer are not suitable for 12v driving. Several videos show this lock up and the high supply currents that result.
Just connect a power source and it ready to power your hv. The circuit input is usually unregulated dc voltage. Why are we choosing zvs driver circuits for induction. One day i was wanting even bigger arcs, and i combined two 12 volt batteries and a 12 volt car jump starter, for 36 volts and the arcs were giant. Integrating an activeclamp circuit with flyback resonant circuit eliminates transformer leakage losses, minimizes turnoff voltage stress across the power switch and achieves zvs in the power switch.
Works just fine and i can draw arcs with no problems. The biggest problem with the basic zvs driver is that it can lock up if the supply voltage is not applied fast enough to kick it into operation. Because it achieves zero voltage switching, it is generally called zvs. This is how you can make high voltage arcs with a flyback transformer. Ok so im planning to make a high power zvs flyback driver i put flyback in quotes because it does not share anything common with it to drive a homemade transformer w 16kv output and 1200w arcing output as the goal. Do not attempt to do this as your first flyback transformer driver project, i recommend you to start with using simple 555 timer flyback drivers before thinking about building an zvs driver. The only difference between the standard zvs and mine was a rectifier diode on the hv out and a 500pf cap for the coil. Flyback transformer driver using an electronic ballast. So if this is your first hv project, stick to the lower power projects first. Zerovoltageswitching zvs and zerocurrentswitching zcs circuits application examples.
Rebuilt mazilli zvs flyback driver high voltage forums. I built a zvs flyback driver a couple months ago, and it worked great and amazed people with the arcs it managed to create. The hot can be driven by its original hot driver transistor and power supply as is after a suitable self oscillating circuit is set up with one of the former voltage secondary outputs. 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. Please do not build this if you dont already have some experience with high voltage electricity. Chapter 5 primary zvs based flyback converter with. The simple 555 flyback generated arcs are a lot less hazardous and a shock is not lethal at low driving voltages, unlike the zvs driver. D4sparks a zvs driver for flyback and other high voltage transformers. More than 50 kilovolts out of a single flyback at 20 volts input. As the input voltage rises the power consumption on r2 27 ohms increases. Introduction the mazilli zvs flyback driver is wellknown throughout the high voltage. You may also use the zvs flyback driver with a ferrite core and a custom made hv secondary, see this article.
Mazilli zvs flyback driver kaizer power electronics. Each is halftime on, halftime off they are also switched in the opposite. I decided to try a high voltage flyback transformer and it works very well. Zvs zero voltage switching flyback transformer driver, capable of generating high voltage and frequency drived by 2 power mosfet. Hello, i am designing a high voltage power supply using an ac flyback transformer and a zvs driver. I setup the standard zvs flyback driver with the irfp250 mosfets and it worked great. This is then rectified and filtered to achieve a clean dc voltage that is fed to the zvs oscillator board. Typically using old crt flyback transformer it can deliver more than 7000 v and normally its depend on configuration of flyback transformer primarysecondary winding. Zvs flyback driver problem all about circuits forums. Mar 12, 2011 this is how you can make high voltage arcs with a flyback transformer. Zvs high voltage induction heating driver board module. Either way, 240 ohms will operate the circuit at voltages as low as 5v without any problems. The device senses the isolated output voltage directly from the primaryside flyback waveform during the offtime of the primary switch.