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Registered Member #1389
Joined: Thu Mar 13 2008, 12:50AM
Location: Pittsburgh, PA
Posts: 346
I've been working on a ZVS driver for the past month, slowly tuning it and reaching for the sky - 120VAC into a rectifier, straight from the wall. Well, I have finally succeeded after many IGBT failures and some advice from several builders. It uses 2 40n60 IGBTs in an TO-247 package on a scrap heatsink from a computer PSU. Primary cap is .27uF, but is subject to change to modify power input. The flyback has 20+20 primary turns on it and is from back projection TV.
To power the flyback, I have my 3 stack variac connected to a 15A rectifier and 7200uF of filter caps and I tripped the 20A breaker at the end of the run in my video (probably due to poor power factor), as well as partially melting my 14AWG ground electrode.
I know it doesn't look like it, but the maximum arc length is 13". I'll make a better video soon to show it better, and perhaps aim for more power until something gives.
Registered Member #1389
Joined: Thu Mar 13 2008, 12:50AM
Location: Pittsburgh, PA
Posts: 346
Schematic is simply Mazzilli's ZVS flyback driver found here The transformer itself is under mineral oil to prevent flashovers, but it gets toasty after a while. The core itself stays pretty cool.
I need to do more measurements to determine input power and frequency, but I'll get back to you when I figure it out. I'll post waveform pics when I get it scoped out as well.
Registered Member #1389
Joined: Thu Mar 13 2008, 12:50AM
Location: Pittsburgh, PA
Posts: 346
Well, the voltage sags to 155V at 120VAC in, which is just fine by me because the IGBTs failed at 170VDC in. Also, yes the potted windings get hot, not the core.
As far as the gauss, I havent made enough measurements yet to give you an answer.
Registered Member #56
Joined: Thu Feb 09 2006, 05:02AM
Location: Southern Califorina, USA
Posts: 2445
I am surprised you managed to get it running off of 160v, most previous attempts have been plagued with unwanted oscillations. Can you post a picture of the circuit itself, and confirm what size gate resistors you are using?
You might also want to think about winding your own secondary, mine had similar performance to yours but could run all day without overheating (that was at 60v in though, because I ran into destructive oscillations at much higher than that)
Registered Member #1389
Joined: Thu Mar 13 2008, 12:50AM
Location: Pittsburgh, PA
Posts: 346
Whoops. I killed it. :(
Edit: I have an AC flyback core and some 36AWG wire so I'm going to see about winding my own transformer. When I get that finished, I'll take a picture of the whole setup and some scope shots as well.
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Very Very High Power Flyback Driver
