How To Build A Simple But Powerful Flyback Driver

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Step 4: Construction
Not much to say here, just get your toolbox, read the schematics and build it! :-)
Make sure you use thick wire as it will be handling currents up to 10 amps.
When winding the flyback transformer, make sure both wire go the same way.
If you are going to attach both of your MOSFET's on one heatsink, Use mica insulators! Or other types
of insulators to isolate the MOSFET's tabs fromeach other, otherwise your ZVS driver won't work.
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How To Build A Simple But Powerful Flyback Driver http://www.instructables.com/id/ZVS-Driver/step4/Construction/
1 of 8 15-09-2013 1:45
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Mar 25, 2013. 5:14 AM Reply (C34GQOEHELX73J N)
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astrikos (/member/astrikos/) says:
this is a graph fromthe same circuit but now the 1microfarad MKP capacitor is replaced by a
ceramic 10nanofarad trying to achieve higher frequencies
as you can see the half cycle is 1microsecond which means 500khz frequency
the problem now is that I do not get high voltage on the flyback
as far as I know the ferrite core goes up to 2MHz, may the problembe the capacitor which can not
handle big currents so I will try a more powerfull capacitor
the diode may be another problem because it's not ultrafast
the FET is ok according to the datasheet for this frequency
(/files/deriv/FC4/EHGG/HELX73HI
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XTL (/member/XTL/) in reply to astrikos
Its a resonant tank you are making
with the coil inductance and
capacitor. You are searching for
the resonant frequency so just
driving it faster doesn't mean it wil
be more efficient. You need to
balance the two out and drive it a
frequency where the coil becomes
resonant. Efficiency means the
power will get through.
astrikos (/member/astrikos/) in reply to XTL
I wanted to get high frequency
and high voltage, not necessarily
high power. I found out that this
magnetic core works up to
160khz which is the frequency of
the modern flybacks for big
screens.
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XTL (/member/XTL/) says:
The same driver can be used to heat any metal you put in the red wire loop (replacing the ferrite
core flyback transformer). The cap value and number of turns (less) will need tuning to get the metal
to heat up . The metal acts as a poor transformer core and resists the change in energy flow
thereby disspating the wasted energy as heat. Generally a bad idea unless you want to heat metal
up in an induction furnace.
A great caution to be taken.
When you start up the oscillator and before arching you should hear the 10khz sound.
If not then the oscillator has not started up and this means that on of the FETs is constantly ON and
it will heat up to destruction within seconds.
This type of oscillator for some reason does not always starts up so you must stop the power
supply immediately and start it again. This happens more often when you give low voltages, for
example if you power it with 5 volts it's very difficult to get it oscillating but it is possible.
I managed to melt the case of the FET although I used heat sinks within seconds but the FET is OK.
I will device some method to be sure that the circuit will oscillate 100% if it is powered up.
this is the arching between the ground of the flyback and the high voltage output
the distance at which an arc can start-up strongly depends on the shape and the capacity of the
electrodes
as you can see I have used two wood screws for not damaging the pins when they reach
incadescence. between the tips of screws the arc starts nearly in contact only. between the bodies
of the screws the arc starts at about 1cm.
I will use various other geometries as well as the Wimshurst machine electrodes which are spheres.
Conserning the sound you may hear when not arching, this happens beacause as you can see from
the graphs the frequency reduces to one-fifth of the one when arching, which means that goes down
to 10KHz, this frequency goes back to the power supply making the power supply to vibrate in this
frequency which is an acoustic one.
I suggest that you don't run the ZVS without arching or anyway loading it some way.
(/files/deriv/FHL/D5J Y/HELX6YNL
/FHLD5J YHELX6YNL.LARGE.jpg)
astrikos (/member/astrikos/) in reply to astrikos
a small correction, the 10KHz
vibration and sound comes from
the primary of the flyback, that is
the two 5-turn coils and not from
the power sypply, this is good
beacause it means the choke
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Mar 23, 2013. 3:48 AM Reply (CAEN042HELWVNH0)
toroid coil blocks the AC signal from going back to the voltage source.
yesterday I completed the permanent implementation of the Vladimir Mazili ZVS.
I attach two photos and two oscilloscope graphs of the two FETs. I used both channels of the
oscilloscope, one for each drain of the FETs.
The low frequency and higher voltage graph is valid when there is no load/no arching on the flyback
When the flyback arches then the frequency increases and the voltage drops as you can see on the
respective graph.
The destortion while the FETs go on and of may have to do with the diodes, I will try faster ones
than the FR207.
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yesterday I completed the permanent implementation of the Vladimir Mazili ZVS.
I attach two photos and two oscilloscope graphs of the two FETs. I used both channels of the
oscilloscope, one for each drain of the FETs.
The low frequency and higher voltage graph is valid when there is no load/no arching on the flyback
When the flyback arches then the frequency increases and the voltage drops as you can see on the
respective graph.
The destortion while the FETs go on and of may have to do with the diodes, I will try faster ones
than the FR207.
As you can see on the graph, while the voltage goes down we have a distortion, this is probably due
to not so good biasing of the FETs, that is the voltage divider of the two resistors needs
optimisation, I will go on with tests measuring both FETs and changing the diodes to faster ones.
Even this "simple" circuit has a realmof parametres, practice is much more than theory
J ust think that this circuit in theory does not oscillate!!!!
I will return with more photos, my camer ran out of batteries, and with more theoritical analysis.
My power source is an old AT computer supply fromwhich I get the 12volts (yellow-black cables)
Certainly you should not run your oscillator without some kind of load on the flyback or without
arching, the energy is stored in the circuit and I guess it will explode. The soynd that you can hear is
some part of the circuit that oscillates in a frequency that you can hear.
I attach the image from the USB oscilloscope DSO-2090, this is the graph of the potential between
the ground(source) and the drain of the one of the FETs.
As we can see the one FET is ON for about 10 microsecnods(100KHz) so a full cycle is 50KHz.
The voltage width of the oscillation is about 25 volts that is two times the source voltage.
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Mar 4, 2013. 7:28 AM Reply (C8H2Y3OHDOW6WYU)
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this is the photograph
(/files/deriv/FSA/LCID/HEI3WN3I
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this is my implementation
it's 100% solder free
the flyback is a very old transformer and you can see the its box, I found at the local store for 2
euros
the whole project cost about 15 euros
the FET are IRF540N pin1 gate, pin2 drain, pin3 source
I didn't yet checked the frequency
the capacitor is MKP visaton 1microfarad
the fast diodes are FR207 alternatively you can use BY299 or the SF and HER series
FR207 switches in less than 500 nanoseconds according to the data sheet while UF4007 gives
75nanoseconds max. For our frequencies 500ns is ok
All these in Greece
crazy-blender (/member/crazy-blender/) says:
I am bad at soldering and I put it together
but I got no results. I made the inductor by
winding 20 turns of 16 AWG magnet wire
around a ferrite toroid and I made my own
power supply by connecting the output of a
28 volt transformer to a 600 volt bridge
rectifyer and the output to a 40 volt 34000
uF electrolytic capacitor. I tested the
power supply and it works just fine. I am
pretty sure that all of the components are
connected but when i turn it on the
transformer hums and one of the
MOSFET's gets hot but when I try to draw
arcs I get no arc. I did 5+5 turns on the
flyback for the primary and it is not copper.
Wheni turn on the the driver I get no sound
except the 60 hertz him fromthe power
supply transformer. Sorry don't have any
images I did not take any but I can tell you
I am really bad at soldering and that might
be the problemor if MOSFET's are heat
sensitive I may have cooked one soldering
wires or heat shrinking it. Please respond
soon I need help I Amos jealous of the
people wo have awesome ZVS flyback
drivers.
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says:
Hi i changed the look of the schematics can you say are the MOSFETS corectly in place ? Or
maybe i forgot something. The small dits doesnt matter i will follow your and other information.
Thanks in advance. Besides this instracteble was very helpful ;)
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dalmond1 (/member/dalmond1/) in reply to
if no one has told you, your
modified schematic is correct.
dalmond1 (/member/dalmond1/) says:
I made this today, works great, But I do have one problem, I have built many other flyback drivers,
and they thing I find with this one is my flyback doesn't arc by it's self, it's more like a MOT in the
fact that I have to create a Small arc before a bigger one will be produced upon opening up the
sparkgap, what have I done wrong or is this the way it is ment to work ?
Cheers all for any input you provide :)
jj.inc (/member/jj.inc/) says:
So is winding your own coil around that core an alternative to finding the pins on the normal core.
does it still output dc if you do this, and how does it effect efficiency compared to the original
windings
(/member/%D7%91%D7%92%D7%95%D7%9C%D7%93%D7%91%D7%A8
%D7%92/) in reply to jj.inc
Imnot shure about ac dc but it you with lets say you "play" with 12v all the time and you try
to find the best number of turns for the best arc then yes it is much better then trying and
find the origunal coil because there are usualy 3 coils 1:hv 2:low v 3:not shure but i think
that low v. and the low v 2 coil has pins for other number of windings. SO.... THE BEST
WIND YOUR OWN !!!
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