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High Amperage Flyback ZVS Driver?

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AyinYesh

Tue Oct 05 2010, 03:46AM

Registered Member #3274 Joined: Tue Oct 05 2010, 03:41AM
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Posts: 6

I have seen some other posts on this website about ZVS drivers, but I haven't found information as to their tolerance of higher currents. Specifically, I am trying to build one that can handle the output of a specific power supply that I built. What I wanted to know is if the basic ZVS schematic that has been floating around would be about to handle the volts at 86 amps that my supply puts out, or if there is some modifications that need to be made, and if so what? Thank you!

Patrick

Tue Oct 05 2010, 04:30AM

Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639

yikes! how many volts at 86 amps !?

AyinYesh

Tue Oct 05 2010, 05:05AM

Registered Member #3274 Joined: Tue Oct 05 2010, 03:41AM
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14 volts haha. What my end goal is is to build a power supply that can output in the range of a minimum of 320 volts at 20 amps, but what I am aiming for is an output of 15-30kV at 25-40 amps. There really is no upper limit so long as it doesn't go below the 320 volts at 20 amps.

Patrick

Tue Oct 05 2010, 05:15AM

Registered Member #2431 Joined: Tue Oct 13 2009, 09:47PM
Location: Chico, CA. USA
Posts: 5639

well 14V x 86A = 1204 watts
and 320V x 20A = 6400 watts
and 15kV x 25A = 375kW

and im not sure how you intend to impliment such reqiurements in hardware.
what kind of experience do you have with electricity?

AyinYesh

Tue Oct 05 2010, 05:37AM

Registered Member #3274 Joined: Tue Oct 05 2010, 03:41AM
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Posts: 6

All of my experience comes pretty much from experimentation, and personal studying. I think I am going to have to start small considering the limitations of the hardware I have, and space etc. Basically I've rewound a MOT for the 14 volts at 86A, I could rewind the primary as well as the secondary if needed, or change the way I've wound the secondary. The second step, which is what I am working on right now though, is to power a pair of flyback transformers using a ZVS driver or some other suitable circuit, that is powered by the MOT. Its important to try to maintain as much amperage as possible with what I have, which is why I am having trouble. I could easily modify what I have to be pulling 30kV + but the amperage would be negligible... Some of this stuff is extending into areas of electrical engineering beyond that which I currently understand, and I am having a hard time finding useful information, so I came to this forum in hopes that I could state my problems directly :)

Sulaiman

Tue Oct 05 2010, 05:15PM

Registered Member #162 Joined: Mon Feb 13 2006, 10:25AM
Location: United Kingdom
Posts: 3140

You will find it almost impossible to run a high power zvs at 12 V ;

The output voltage can be whatever you like depending upon turns ratio
so I will just look at the primary side...
I'll use 12 V as the 'nominal' supply voltage, 14V would be marginally easier ;)

1) Input power 12 V x 86 A = 1032 W
2) Primary ac voltage assuming 100% efficiency is pi x 12 = 37.7 Vpk = 26.66 Vrms.
3) Primary 'real' current = 1032 W / 26.66 V = 38.7 A(rms)
4) Assume a moderate 'Q' of 5 for the primary ... 193 A(rms) actual primary current.
5) Primary impedance = 26.66V/193A = 0.138 Ohms.

So,
your primary wire has to carry 200 A(rms) at your chosen operating frequency (Fo)
the inductance of your primary should be 0.138 Ohms at Fo
the primary capacitor needs to have an impedance of 0.138 Ohms at Fo

I've not accounted for transistor and wiring resistance and inductance above,

For a high power zvs you'd be better off rectifying the mains for your dc source.

teravolt

Tue Oct 05 2010, 07:34PM

Registered Member #195 Joined: Fri Feb 17 2006, 08:27PM
Location: Berkeley, ca.
Posts: 1111

what sort of power sevice do you have

AyinYesh

Wed Oct 06 2010, 02:24AM

Registered Member #3274 Joined: Tue Oct 05 2010, 03:41AM
Location:
Posts: 6

I am in the U.S. so my mains is 110, I live in an apartment so I don't have access to any 240v outlets on this property.

teravolt

Wed Oct 06 2010, 02:57AM

Registered Member #195 Joined: Fri Feb 17 2006, 08:27PM
Location: Berkeley, ca.
Posts: 1111

how many amps can you suck out of the wall before you pop the breaker. If you multiplier 110v x the max amps from your outlet the maximum volt-amperes you will know how much power is available to you. VA is almost equal to watts so if you have a 15A breaker you can get 1500W safely.

Why do you need so much power? what are you building? If you are running a peace of equipment that runs on a pulse basis like a drsstc than it may be no problem but if you are running a peace of industrial equipment you may have problems. maybe you should be asking what you need and what you can run with the power you have.

AyinYesh

Wed Oct 06 2010, 03:45AM

Registered Member #3274 Joined: Tue Oct 05 2010, 03:41AM
Location:
Posts: 6

When I started reworking the MOT, I originally had 4 windings on the secondary at 16 AWG, I shorted it through a bolt, which made alot of loud pops and flashes, dimmed the lights in my unit, and melted the bolt, but it didn't throw the breaker, so I'm guessing I can pull quite a few amps. Haven't thrown any breakers yet, but my utility bill has gone up a bit haha

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