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4hv.org :: Forums :: High Voltage
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ZVS Driver not working when fixed with 50N321 IGBTs

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Newton Brawn
Mon Oct 31 2011, 09:21PM
Newton Brawn Registered Member #3343 Joined: Thu Oct 21 2010, 04:06PM
Location: Toronto
Posts: 311
Hi Josef !

I have similar problem in a one ZVS, and I replace the 100uH 10A ferrite core inductance for one 100uH AIR CORE inductance. Them the ZVS worked very smuth .

The ferrite core inductance saturates before that the comutartion has completed, locking the semiconductors.
Use air core inductance, calculated by Weeller formula;

L(uH) = (N^2)x(D^2)/ (18xD+40xL)

D and L are diameter and lenght of coil, in inches

N= number of turns


Regards
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Alex M
Mon Oct 31 2011, 10:22PM
Alex M Registered Member #3943 Joined: Sun Jun 12 2011, 05:24PM
Location: The Shire, UK
Posts: 552
Newton Brawn wrote ...

Hi Josef !

I have similar problem in a one ZVS, and I replace the 100uH 10A ferrite core inductance for one 100uH AIR CORE inductance. Them the ZVS worked very smuth .

The ferrite core inductance saturates before that the comutartion has completed, locking the semiconductors.
Use air core inductance, calculated by Weeller formula;

L(uH) = (N^2)x(D^2)/ (18xD+40xL)

D and L are diameter and lenght of coil, in inches

N= number of turns


Regards

Wouldn't replacing the inductor with a larger, higher current rated inductor be better in stopping it from saturating? Or does size not matter when it comes to inductors saturating?
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Kiwihvguy
Tue Nov 01 2011, 12:08AM
Kiwihvguy Registered Member #3395 Joined: Thu Nov 04 2010, 08:42AM
Location: Christchurch, New Zealand
Posts: 193
That air core inductor could be an option. However, I recently bought a clampmeter that had a decent capacitance function on it by coincedence.

My resonant cap measured 1,75uF. This I thought was a big assumed giveaway. How would a reso cap that is 3x the capacitance of it should be affect the ZVS oscillator?

Anyway, I've left the ZVS now. Sure, I'd love it if I could get it working again however I suppose I've had my time with it and next goals are SSTCs, VTTCs etc for future aspirations now. I am organising events where people can educate me about them at the moment before I start constructing them.

However if you guys know anythigng that might help educate me with features of SSTCs and general TCs, it would be really appreciated if you tell any anything about it. Cheers!

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Alex M
Tue Nov 01 2011, 02:58AM
Alex M Registered Member #3943 Joined: Sun Jun 12 2011, 05:24PM
Location: The Shire, UK
Posts: 552
Józef C wrote ...

That air core inductor could be an option. However, I recently bought a clampmeter that had a decent capacitance function on it by coincedence.

My resonant cap measured 1,75uF. This I thought was a big assumed giveaway. How would a reso cap that is 3x the capacitance of it should be affect the ZVS oscillator?

Anyway, I've left the ZVS now. Sure, I'd love it if I could get it working again however I suppose I've had my time with it and next goals are SSTCs, VTTCs etc for future aspirations now. I am organising events where people can educate me about them at the moment before I start constructing them.

However if you guys know anythigng that might help educate me with features of SSTCs and general TCs, it would be really appreciated if you tell any anything about it. Cheers!



A larger cap, I think, lowers the frequency (don't quote me though). I have tried upto around 3uF with my ZVS and I did not notice that much of a difference other than my flyback making an audible frequency squeal.

Sorry I don't know much about tesla coils other than how they are supposed to work and how mine never work sad

Maybe you will have more luck than me with tesla coils.
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Kiwihvguy
Tue Nov 01 2011, 05:37AM
Kiwihvguy Registered Member #3395 Joined: Thu Nov 04 2010, 08:42AM
Location: Christchurch, New Zealand
Posts: 193
Alex1M6 wrote ...

Józef C wrote ...

That air core inductor could be an option. However, I recently bought a clampmeter that had a decent capacitance function on it by coincedence.

My resonant cap measured 1,75uF. This I thought was a big assumed giveaway. How would a reso cap that is 3x the capacitance of it should be affect the ZVS oscillator?

Anyway, I've left the ZVS now. Sure, I'd love it if I could get it working again however I suppose I've had my time with it and next goals are SSTCs, VTTCs etc for future aspirations now. I am organising events where people can educate me about them at the moment before I start constructing them.

However if you guys know anythigng that might help educate me with features of SSTCs and general TCs, it would be really appreciated if you tell any anything about it. Cheers!



A larger cap, I think, lowers the frequency (don't quote me though). I have tried upto around 3uF with my ZVS and I did not notice that much of a difference other than my flyback making an audible frequency squeal.

Sorry I don't know much about tesla coils other than how they are supposed to work and how mine never work sad

Maybe you will have more luck than me with tesla coils.

Huh... maybe I but I hope so! It all comes down to knowledge in the first place when you start then it becomes experience. But for now I don't know any more than you do haha smile
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Fractal Universe
Wed Jan 18 2012, 05:13AM
Fractal Universe Registered Member #4349 Joined: Wed Jan 18 2012, 01:23AM
Location:
Posts: 13
I have built a ZVS circuit with IRFP250N mosfets and i am able to run it from 78 volt ( 6 twelve volt SLA's and a 18v drill battery in series) batteries reliably , i can get up to 10 inch arcs at that voltage and the mosfets barely get warm , most people say that those particular mosfets wont handle any more than 48v in a ZVS driver, so i must have done something right , so i will share with you how i made my circuit,

i bought my parts on ebay ; and since you are worried about somebody selling you fake semiconductors , i will tell you the usernames of the reliable sellers

2 x IRFP250N from ebay username " activeparts "
2 x MA7150B 15v 0.8 watt zener diode from ebay user " dipmicro "
1 x vishay 630v 1 microfarad MKP capacitor from ebay user " audiosector "
2 x BYV26E 1kv 1 amp ultra fast diode from Digi - Key; RS components also sells this (very good , reliable fast diode for this application )
2 x 10k ohm 1/4 w resistor nothing special
2 x 540 ohm 10 watt resistors each made from soldering two 270 ohm 5w metal film resistors in series

inductor is a modified unit from a computer P.S.U.
the inductor you need will be the largest one on the circuit board, it should have a core about 27 mm in diameter and about 1 cm thickness
there will be 5 windings on the core:
two red 18 gauge windings both of these are identical in length and wound in the same direction
two tan 18 gauge windings both of these are same length and wound in the same direction and wound in same direction as the red ones
one tan 30 gauge winding , remove this one carefully as it is not needed

solder the two red windings together so they are connected together in parallel in the same direction
solder the two tan windings together so they are connected together in parallel in the same direction
solder the end of the red windings to the start of the tan windings so they form one large winding consisting of two 18 gauge windings in parallel

i included a photograph of the one i made


57 736

02 491

23 116
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Fractal Universe
Wed Jan 18 2012, 05:19AM
Fractal Universe Registered Member #4349 Joined: Wed Jan 18 2012, 01:23AM
Location:
Posts: 13
also be sure to use thick 14 gauge wire to connect the tank capacitor to the circuit , it makes a difference

and be sure to insulate the mosfets from the heat sink with mica insulators
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Patrick
Wed Jan 18 2012, 05:23AM
Patrick Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639
I dont see any special changes youve made, so im puzzled as to how youve done so well, the BVY26E doesnt have any special properities beyond what others have used.


but youve used MOSFETs, not IGBT's as the thread title says...
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Kiwihvguy
Sat Jan 21 2012, 09:57AM
Kiwihvguy Registered Member #3395 Joined: Thu Nov 04 2010, 08:42AM
Location: Christchurch, New Zealand
Posts: 193
Hey guys! Sorry I haven't online for a while, I sort of subconsciously forgot about this website...

-> KOUGSMOTORS454 Hey man, thanks for your help! I really appreciate it, that's nice of you but I would like to make this clear to everyone that I have stopped using the ZVS now and moved on to more advanced stuff like H-bridges and SSTCs.

Maybe you can help if I have problems with H-bridges! hehe


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