how to build a simple but powerful flyback driver

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Step 4: Construction

Not much to say here, just get your toolbox, read the schematics and build it! :-)

Make sure you use thick wire as it will be handling currents up to 10 amps.

When winding the flyback transformer, make sure both wire go the same way.

If you are going to attach both of your MOSFET's on one heatsink, Use mica insulators! Or other typesof insulators to isolate the MOSFET's tabs from each other, otherwise your ZVS driver won't work.

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Posted:Jun 2, 2010

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How To Build A Simple But Powerful Flyback Driver http://www.instructables.com/id/ZVS-Driver/step4/Construction/

1 of 8 15-09-2013 1:45

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Mar 25, 2013. 5:14 AM Reply (C34GQOEHELX73JN)

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Aug 26, 2013. 9:17 PM Reply (C4P1760HKUD43NV)

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astrikos (/member/astrikos/) says:

this is a graph from the same circuit but now the 1microfarad MKP capacitor is replaced by aceramic 10nanofarad trying to achieve higher frequencies

as you can see the half cycle is 1microsecond which means 500khz frequency

the problem now is that I do not get high voltage on the flyback

as far as I know the ferrite core goes up to 2MHz, may the problem be the capacitor which can nothandle big currents so I will try a more powerfull capacitor

the diode may be another problem because it's not ultrafast

the FET is ok according to the datasheet for this frequency

(/files/deriv/FC4/EHGG/HELX73HI/FC4EHGGHELX73HI.LARGE.jpg)

XTL (/member/XTL/) in reply to astrikos

Its a resonant tank you are makingwith the coil inductance andcapacitor. You are searching forthe resonant frequency so justdriving it faster doesn't mean it wilbe more efficient. You need tobalance the two out and drive it afrequency where the coil becomesresonant. Efficiency means thepower will get through.

astrikos (/member/astrikos/) in reply to XTL

I wanted to get high frequencyand high voltage, not necessarilyhigh power. I found out that thismagnetic core works up to160khz which is the frequency ofthe modern flybacks for bigscreens.

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XTL (/member/XTL/) says:

The same driver can be used to heat any metal you put in the red wire loop (replacing the ferritecore flyback transformer). The cap value and number of turns (less) will need tuning to get the metalto heat up . The metal acts as a poor transformer core and resists the change in energy flowthereby disspating the wasted energy as heat. Generally a bad idea unless you want to heat metalup in an induction furnace.


A great caution to be taken.

When you start up the oscillator and before arching you should hear the 10khz sound.

If not then the oscillator has not started up and this means that on of the FETs is constantly ON andit will heat up to destruction within seconds.

This type of oscillator for some reason does not always starts up so you must stop the powersupply immediately and start it again. This happens more often when you give low voltages, forexample if you power it with 5 volts it's very difficult to get it oscillating but it is possible.

I managed to melt the case of the FET although I used heat sinks within seconds but the FET is OK.

I will device some method to be sure that the circuit will oscillate 100% if it is powered up.


this is the arching between the ground of the flyback and the high voltage output

the distance at which an arc can start-up strongly depends on the shape and the capacity of theelectrodes

as you can see I have used two wood screws for not damaging the pins when they reachincadescence. between the tips of screws the arc starts nearly in contact only. between the bodiesof the screws the arc starts at about 1cm.

I will use various other geometries as well as the Wimshurst machine electrodes which are spheres.

Conserning the sound you may hear when not arching, this happens beacause as you can see fromthe graphs the frequency reduces to one-fifth of the one when arching, which means that goes downto 10KHz, this frequency goes back to the power supply making the power supply to vibrate in thisfrequency which is an acoustic one.

I suggest that you don't run the ZVS without arching or anyway loading it some way.

(/files/deriv/FHL/D5JY/HELX6YNL/FHLD5JYHELX6YNL.LARGE.jpg)

astrikos (/member/astrikos/) in reply to astrikos

a small correction, the 10KHzvibration and sound comes fromthe primary of the flyback, that isthe two 5-turn coils and not fromthe power sypply, this is goodbeacause it means the choke


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Mar 23, 2013. 3:48 AM Reply (CAEN042HELWVNH0)

toroid coil blocks the AC signal from going back to the voltage source.


yesterday I completed the permanent implementation of the Vladimir Mazili ZVS.

I attach two photos and two oscilloscope graphs of the two FETs. I used both channels of theoscilloscope, one for each drain of the FETs.

The low frequency and higher voltage graph is valid when there is no load/no arching on the flyback

When the flyback arches then the frequency increases and the voltage drops as you can see on therespective graph.

The destortion while the FETs go on and of may have to do with the diodes, I will try faster onesthan the FR207.

(/files/deriv/FLG/XAHB/HELWVNGW

/FLGXAHBHELWVNGW.LARGE.jpg) (/files/deriv/FD1/P2WU/HELWVNGX/FD1P2WUHELWVNGX.LARGE.jpg)

(/files/deriv/F2K/QVSC/HELWVNGY


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yesterday I completed the permanent implementation of the Vladimir Mazili ZVS.

I attach two photos and two oscilloscope graphs of the two FETs. I used both channels of theoscilloscope, one for each drain of the FETs.

The low frequency and higher voltage graph is valid when there is no load/no arching on the flyback

When the flyback arches then the frequency increases and the voltage drops as you can see on therespective graph.

The destortion while the FETs go on and of may have to do with the diodes, I will try faster onesthan the FR207.


As you can see on the graph, while the voltage goes down we have a distortion, this is probably dueto not so good biasing of the FETs, that is the voltage divider of the two resistors needsoptimisation, I will go on with tests measuring both FETs and changing the diodes to faster ones.

Even this "simple" circuit has a realm of parametres, practice is much more than theory

Just think that this circuit in theory does not oscillate!!!!


I will return with more photos, my camer ran out of batteries, and with more theoritical analysis.

My power source is an old AT computer supply from which I get the 12volts (yellow-black cables)

Certainly you should not run your oscillator without some kind of load on the flyback or withoutarching, the energy is stored in the circuit and I guess it will explode. The soynd that you can hear issome part of the circuit that oscillates in a frequency that you can hear.

I attach the image from the USB oscilloscope DSO-2090, this is the graph of the potential betweenthe ground(source) and the drain of the one of the FETs.

As we can see the one FET is ON for about 10 microsecnods(100KHz) so a full cycle is 50KHz.

The voltage width of the oscillation is about 25 volts that is two times the source voltage.

(/files/deriv/F8L/YV5A/HEI3WN3T


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Mar 4, 2013. 7:28 AM Reply (C8H2Y3OHDOW6WYU)

/F8LYV5AHEI3WN3T.LARGE.jpg)


this is the photograph

(/files/deriv/FSA/LCID/HEI3WN3I/FSALCIDHEI3WN3I.LARGE.jpg)


this is my implementation

it's 100% solder free

the flyback is a very old transformer and you can see the its box, I found at the local store for 2euros

the whole project cost about 15 euros

the FET are IRF540N pin1 gate, pin2 drain, pin3 source

I didn't yet checked the frequency

the capacitor is MKP visaton 1microfaradthe fast diodes are FR207 alternatively you can use BY299 or the SF and HER series

FR207 switches in less than 500 nanoseconds according to the data sheet while UF4007 gives75nanoseconds max. For our frequencies 500ns is ok

All these in Greece

crazy-blender (/member/crazy-blender/) says:

I am bad at soldering and I put it togetherbut I got no results. I made the inductor bywinding 20 turns of 16 AWG magnet wirearound a ferrite toroid and I made my ownpower supply by connecting the output of a28 volt transformer to a 600 volt bridgerectifyer and the output to a 40 volt 34000uF electrolytic capacitor. I tested thepower supply and it works just fine. I ampretty sure that all of the components areconnected but when i turn it on thetransformer hums and one of theMOSFET's gets hot but when I try to drawarcs I get no arc. I did 5+5 turns on theflyback for the primary and it is not copper.Wheni turn on the the driver I get no soundexcept the 60 hertz him from the powersupply transformer. Sorry don't have anyimages I did not take any but I can tell youI am really bad at soldering and that mightbe the problem or if MOSFET's are heatsensitive I may have cooked one solderingwires or heat shrinking it. Please respondsoon I need help I Amos jealous of thepeople wo have awesome ZVS flybackdrivers.


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Jun 30, 2011. 5:06 PM Reply (CGGDEXQGPBD3ZPX)

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(/member/%D7%91%D7%92%D7%95%D7%9C%D7%93%D7%91%D7%A8%D7%92/) בגולדברגsays:

Hi i changed the look of the schematics can you say are the MOSFETS corectly in place ? Ormaybe i forgot something. The small dits doesnt matter i will follow your and other information.Thanks in advance. Besides this instracteble was very helpful ;)

(/files/deriv/F4B/UC69/GPBDGR6I/F4BUC69GPBDGR6I.LARGE.jpg)

dalmond1 (/member/dalmond1/) in reply to בגולדברג

if no one has told you, yourmodified schematic is correct.

dalmond1 (/member/dalmond1/) says:

I made this today, works great, But I do have one problem, I have built many other flyback drivers,and they thing I find with this one is my flyback doesn't arc by it's self, it's more like a MOT in thefact that I have to create a Small arc before a bigger one will be produced upon opening up thesparkgap, what have I done wrong or is this the way it is ment to work ?

Cheers all for any input you provide :)

jj.inc (/member/jj.inc/) says:

So is winding your own coil around that core an alternative to finding the pins on the normal core.does it still output dc if you do this, and how does it effect efficiency compared to the originalwindings

member/%D7%91%D7%92%D7%95%D7%9C%D7%93%D7%91%D7%A8/) בגולדברג%D7%92/) in reply to jj.inc

Im not shure about ac dc but it you with lets say you "play" with 12v all the time and you tryto find the best number of turns for the best arc then yes it is much better then trying andfind the origunal coil because there are usualy 3 coils 1:hv 2:low v 3:not shure but i thinkthat low v. and the low v 2 coil has pins for other number of windings. SO.... THE BESTWIND YOUR OWN !!!


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how to build a simple but powerful flyback driver

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