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4hv.org :: Forums :: High Voltage
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What causes the mazilli ZVS driver to get hot?

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Platinum
Wed Sept 04 2013, 01:41AM Print
Platinum Registered Member #3926 Joined: Fri Jun 03 2011, 08:32PM
Location: UK.
Posts: 525
My parts for Farnell arrived today, so I built a ZVS driver, and it's getting hot I made the standard circuit, but had to substitute the 10K resistors for 15K resistors, as I unknowingly ordered out of stock 10K resistors. I'm using IRFP260N's, and they get hot, as does the inductor, but nothing else. I'm also using gate drive instead of zener diodes, gate drive is 9V, 1Amp(I suspect this is the cause). What is causing it?


Thanks.
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Newton Brawn
Wed Sept 04 2013, 04:06AM
Newton Brawn Registered Member #3343 Joined: Thu Oct 21 2010, 04:06PM
Location: Toronto
Posts: 311
Platinun

if you provide a complete schematic and all material data and some pictures maybe somebody can answer your question ...


Regards
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Alex M
Wed Sept 04 2013, 04:38AM
Alex M Registered Member #3943 Joined: Sun Jun 12 2011, 05:24PM
Location: The Shire, UK
Posts: 552
Platinum wrote ...

gate drive is 9V


That is probably your problem, standard FET's need at-least 10v to fully turn on. Do you have a farnell link for your inductor too?
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Sigurthr
Wed Sept 04 2013, 08:53AM
Sigurthr Registered Member #4463 Joined: Wed Apr 18 2012, 08:08AM
Location: MI's Upper Peninsula
Posts: 597
What's making it get hot? I2R losses. Why are you getting high loss? Could be a number of things, but insufficient supply voltage is a likely suspect.
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Steve Conner
Wed Sept 04 2013, 09:17AM
Steve Conner Registered Member #30 Joined: Fri Feb 03 2006, 10:52AM
Location: Glasgow, Scotland
Posts: 6706
The ZVS circuit has a number of known issues, search the forum archives for details. Also, since when did it have any 10k resistors in it?
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Platinum
Wed Sept 04 2013, 10:30AM
Platinum Registered Member #3926 Joined: Fri Jun 03 2011, 08:32PM
Location: UK.
Posts: 525
Steve Conner wrote ...

The ZVS circuit has a number of known issues, search the forum archives for details. Also, since when did it have any 10k resistors in it?

Most schematics I've read use a 10K resistor, sadly I only have 15K.

Alex, I used an older inductor which worked in my old ZVS driver perfectly.

Parts are:

IRFP260N x2

470Ohm 5watt x2

15kohm x2

uf4007 x 2

2 parrarel MKP caps (600v, .22Uf)

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Platinum
Wed Sept 04 2013, 01:59PM
Platinum Registered Member #3926 Joined: Fri Jun 03 2011, 08:32PM
Location: UK.
Posts: 525
Sadly my IRFP260N, just blew, I really must use zener diodes, alot simpler.

I can't find where my circuit is failing currently, I have 15v in, not separate gate drive supply, and the primary flyback coil just gets hot, as far as I can tell no voltage is coming out of the drains and I'm using new 25N120 N-channel IGBT's, I have used these before with the same setup and it has worked. What could it be?

Just rebuilt the driver, no gate drive, 19v in, primary coil gets hot, frequency is 150khz, no output on flyback. ? This time I'm not using the 15kohm resistors also I'm using 40n10s now.

Bit of an update, the main cause of circuit failure as others have said is insufficient gate drive voltage I just rewound an audio transformer to 12vDC rectified/smoothed, and now the circuit gives output, I'm inputting 19vDC at 3.5A, and with 5+5 turns the circuit does not pull more than 2A, somthing is wrong here, any ideas, I'm not using the 15K resistors I have used earlier.

Circuit works perfects now.

With 5+5T the primary was heating alot as was the cap bank, not with 10+10, the output is brilliant, my 48v supply drops to 29V and pulls 20amps, also messed around with capacitor values, currently my meter is reading the bank at 0.540uF, I've used different inductors, and found the best. The power being inputted is really pushing these FET's, they don't get even the slightest of warm, they are only 40n10's too. I think I'll experiment with IGBT's, I'll have to rectify my arc welder for more power.
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Dr. Dark Current
Thu Sept 05 2013, 01:13PM
Dr. Dark Current Registered Member #152 Joined: Sun Feb 12 2006, 03:36PM
Location: Czech Rep.
Posts: 3384
well.. do you use a heatsink for the transistors ?

Just asking, I have had people tell me that their transistor is getting too hot, and just then they asked me "the transistor has no heat sink is this ok?"
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Platinum
Thu Sept 05 2013, 01:26PM
Platinum Registered Member #3926 Joined: Fri Jun 03 2011, 08:32PM
Location: UK.
Posts: 525
Yes, decent size too, I have changed 40n10's to 25n120's, because I knew the 40n10's would not last long on 48v ( They are only 100v FET's) while it worked with the 40n10's output was very good, I tried doing induction heating, and they failed. Now with the 25n120 it works again but the arc is screeching and the left IGBT get's hot, any way to troubleshoot this, maybe for IGBT's the circuit must be modified? I'm also going to experiment with 30n60a4d's block IGBT's, as I have seen other use these on youtube. What values must I change to use IGBT's?


Thanks :)
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Inducktion
Thu Sept 05 2013, 06:34PM
Inducktion Registered Member #3637 Joined: Fri Jan 21 2011, 11:07PM
Location: Buffalo, NY
Posts: 1068
What I would recommend doing is ordering 12 volt zeners somewhere, and building the circuit as it is shown in the diagram. Ebay can help out with parts you can't find elsewhere, and try not to substitute too much.

You technically "can" use other types of diodes in place of the UF4007's, but it's not recommended... The way it's built is the way it's proven to work so.
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