Zvs flyback driver design

It can also drive a highcurrent aircore work coil for an induction heater. Aug 08, 2011 the most popular zvs flyback driver nowadays amongst hobbyists is that designed by vladimiro mazilli. How a zvs flyback driver circuit works and how to build one. These provide regulation up to 36 vin at a higher efficiency and from a smaller form factor than achievable from conventional hard switching. Eirik uzzors2ks 555based flyback transformer drivers the first driver is a simple 555based directdrive design. Oct 23, 2015 the induction heater is built from a custom zero voltage switching zvs driver and powered by a small 48v, w power supply. It is also known as variable frequency or valley switching flyback and is largely used in low power smps application such as. Intended audience this document is intended for design engineers who wish to evaluate highperformance topologies for highpower smps converters, and develop an understanding of the design process and how to apply the zvs psfb design methods to their own system applications. By tuning it properly you are able to get insane power outputs. Instead of an aircore tesla coil setup, i used a flyback. This is the design of a foreigner flyback driver circuit, used to drive high voltage package, because of the zero voltage switching voltage switching zero and the majority of fans are referred to as zvs. Zvs stands for zero voltage switching, which bascicly means that when there is zero volts across the. This is a fairly configurable and very durable flyback transformer driver.

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. Design guide for qr flyback 4 design note dn 201 v1. High power full bridge flyback driver circuit under. To allow higher voltage inputs and bigger power outputs, get a separate 1216v dc supply a few. 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 output more power than they are designed for to draw arcs. Below is a youtube video of the oscillator powering a flyback transformer at 12, then 24, then 36v. Or until the circuit is interrupted video of it working. Please do not build this if you dont already have some experience with high voltage electricity.

Another point to note is in drawing electrical arcs from the output. Safety is extremely important a flyback is not a toy. The current going into the diodes is limited by the 470 ohm resistors, if im correct. We do resonant switching is an often heard mantra in the design of power converters today. 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.

Zvs psfb in similar power ranges adapted to specific requirements. I used a standard 8pin socket instead of two 4pin sockets for the two ics tc4420 and 555 timer. The ultimate in high voltage records, this device was discussed here and here. The induction heater is built from a custom zero voltage switching zvs driver and powered by a small 48v, w power supply. In the proposed hvps design, we used a commercial crt flyback transformer. Because of its high power, low heat, simple and reliable by fans are widely used in drivi. 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.

This was a fun project and i want to thank you for taking the time to make this an informative and interesting project. Zvs gives a lot of power, but the voltage is not great. This type of oscillator can be used to drive the ferrite core of a flyback transformer to generate high voltage. Jun 14, 2015 one that i have found is a little board with a coil described as flyback driver, zvs w. All parts can be obtained easily from radio shack, including the mosfet. The zvs flyback driver it is probably the most powerful and efficient flyback transformer driver that was fairly recently invented by vladmiro mazilli. This reference design is a lowcost, highdensity usb adapter that uses the ucc28780 activeclamp flyback controller and ucc5304 isolated driver in a zvsflyback topology.

Having cut my teeth thus far i plan to revisit this pwm design. While this makes for an exceptionally small induction heater, its. Now to do this, you will first need to design your circuit on a copper clad board with permanent marker. Dr this is a zvs driver using modern high power transistors instead of the archaic bjt on the most popular flyback driver design. The transition from diodes to synchronousrectification sr mosfets in secondary circuits of flyback converters increases with each new generation of mosfets, improving performance at. 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 technique of zero voltage switching is applicable to all switching topologies. The circuit initially was used as a high voltage driver for crt flyback coils. 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. 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. If you get really good mosfets, it might be even possible to run your zvs flyback driver infinitely. I eventually put the project in a box and forgot all about it. The main advantages of this driver are simplicity of the circuit itself, very high efficiency and easily obtainable parts. It is the standard mazzilli design incorporating two irfp260 mosfets.

However, i dont see why the resistor values are so low. The most popular zvs flyback driver nowadays amongst hobbyists is that designed by vladimiro mazilli. Basic introduction of flybacks and the driver circuit flybacks. The zvs driver circuit is a royertype pushpull oscillator with a resonated primary that is implemented with fets. Mazilli zvs flyback driver introduction the mazilli zvs flyback driver is mzzzilli throughout the high voltage community for its simplicity and ability to. This should make a driver that is able to run flyback transformers found in crt tv sets and compute.

You may also use the zvs flyback driver with a ferrite core and a custom made hv secondary, see this article. This reference design is a lowcost, highdensity usb adapter that uses the ucc28780 activeclamp flyback controller and ucc5304 isolated driver in a zvs flyback topology. Enhance synchronousrectification control in flyback. The maximum power rating is 65 w at 20v output but is adjustable for 20v15v9v5v output voltage and 3 a. Typically using old crt flyback transformer it can deliver more than 7000 v and normally its depend on configuration of flyback transformer primarysecondary winding. I go in depth in my explanation of the different circuit elements and how they. This means the mosfets are designed to switch on or off when. Sp6300p sp6300 ksdi1e002000 zvs flyback driver tv flyback transformer flyback transformer tv zvs driver sp6300p photocopiers s6300p. Zvs flyback driver esquemas eletronicos, aquecimento por. 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.

The step 9 page going further now includes a way to measure these illustrious voltage spikes with a regular volt meter. Also i used a irfp450 mosfet, which is rated about 4a less than the irfp460 mosfet. Beware of zero voltage switching mouser electronics. So as the voltage one side of the lc circuit goes up, it pulls down the gate of the mosfet on the opposite side, through the diode d3 and d4.

The dinky little flyback puts out more power than my neon sign transformer. I built this solid state flyback driver based on a micro solidstate tesla coil circuit created by steve ward. Zero voltage switching zvs is considered the panacea for all the challenges. The next flyback driver is by far the most powerful and efficient. The circuit input is usually unregulated dc voltage. The design combined two mazzilli zvs circuits where each crt flyback was driven by single mazzilli driver. The heating plate is made of militarygrade pcb, and the performance is stable. Induction heating power is great, so fever is normal, be sure to do a good job of cooling. One that i have found is a little board with a coil described as flyback driver, zvs w. The way i usually connect the circuit to the transformer is by basically winding my own primary.

Chapter 5 primary zvs based flyback converter with output. Eirik uzzors2ks more power zvs flyback driver scroll down to more power direct ac drivers. This driver runs cool, because its transistors are far more efficient and have the ideal design for high power switching, which bjts do not. Vicor has utilized zvs topology within our picor coolpower buck regulators. Oh i know that it was designed by vladimiro mazzilli and i have given him credit in the description. Introduction i wanted to design a versatile driver circuit that could drive a half or fullbridge of mosfets or igbts through a gate drive transformer gdt.

In this video, i explain how the circuit of a zvs flyback driver works. 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. Design guide for qr flyback converter mouser electronics. The zvs action applied to q1 removes its miller effect at turn on, allowing the use of a smaller driver and lower gate drive.

This driver is capable of pumping upto a kw of power, so impressive arcs can be made. Unlike the simple 555 timer flyback drivers, the zvs flyback drivers will allow you to run your flyback transformers for much longer periods of time before the mosfets overheat. 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. 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. Because of its big power, low heat, simple and reliable by fans are widely used in the drive spark gap tesla coil sgtc and jacob, ladders, marx generator, etc. The completed flyback driver with a conservative current limit and driven with 36v on the bus was tested up to a measured 120w input power for extended many minutes of continuous run time and remained all cool to the touch. Kilovolt on 4hv youtube video of this driver in action driver no. Completed project can a 07 npn transistor be used as a substitute for a 2n3055 in a flyback driver circuit. From what i understand, its probably a much higher frequency probably ok for my purpose, has a much smaller tank and probably less mosfets. Its based on some work by the people at rmcybernetics on ignition coil drivers, and it seems to work fairly well. Normal operation from 12v only results in about 100w, but thats still several times what the 555 drivers will process. The transition from diodes to synchronousrectification sr mosfets in secondary circuits of flyback converters increases with each new generation of mosfets, improving performance at little or. To the right exists a simplified version of the oscillator, so take a good look. Beware of zero voltage switching sanjay havanur, sr.

Chapter 5 primary zvs based flyback converter with. Up to 40v at at least 10a to drive a flyback transformer for making spark gaps and jacobs ladder. The schematic has been updated to include basic transistor protection in the form of a capacitor and diode. This is an efficient flyback driver circuit, a good and fairly efficient flyback driver circuit. Most tv flyback transformers will by fried by the high current so a current limiter is a must have when you play with zvs. Pdf design and development of a seriesconfiguration mazzilli. I started with 35 vpp and by the time it as rectified and had a large cap in parallel, it was down to 3 vdc. The resonant capacitor uses four 1uf capacitors, two are in series while there are two strings. I have just recently built the zvs driver that is described here after winding my own flyback for the cause. A flyback drive circuit, which is used to drive the ignition coil, as did the zero voltage switching, masses of fans called them zvs circuit. The step 9 page going further now includes a way to measure these illustrious voltage spikes with.

Zero voltage switching tesla coil flyback driver for sgtc. I build this circuit almost a year ago on a vero board, but it kept blowing the thin traces due to high currents flowing. I understand the schematic to this type somewhat, but i do not know how robust this could be. 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. The zvs flyback driver, made popular by vladimiro mazzilli, is one of the most efficient and powerful flyback drivers used by high voltage hobbyists from all over the world.

The schematic is reprinted here with credits to steve ward. Zvs driver a zvs driver is a very simple circuit that can oscillate a large amount of power with about 90% efficiency. Introduction a quasiresonant flyback is simply a dcm flyback having a valley switching turn on. It uses resonant zero voltage switching also know as zvs to drive the flyback transformer. A zvs driver is a very simple circuit that can oscillate a large amount of. Efficient flyback driver high volts circuit using ic555. This page will focus primarily on the design and construction of a halfbridge flyback driver. More than 50 kilovolts out of a single flyback at 20 volts input.