Author Topic: Successful flyback/xformer driver above 3kw  (Read 204 times)

Offline oneKone

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Successful flyback/xformer driver above 3kw
« on: July 30, 2022, 04:55:51 AM »
Just thought I'd put this out there;

How many members here have built a successful flyback/xformer driver that can operate above 3kw (let's say 3-6kw range) without failures. Judging from what I've seen there's not many out there due to the common igbt brick failure (myself is included in this failure scenario)

Offline Mads Barnkob

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Re: Successful flyback/xformer driver above 3kw
« Reply #1 on: July 30, 2022, 10:17:13 AM »
I have only pushed up around 1 kW and burned everything :)
https://kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics
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Offline davekni

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Re: Successful flyback/xformer driver above 3kw
« Reply #2 on: July 31, 2022, 12:14:19 AM »
Does the transformer output need to be high voltage and subject to arc loading to count?

I've build an isolated "PFC" that inputs single-phase 240VAC (or three-phase 208) and outputs isolated adjustable 350-450Vdc.  That feeds my DRSSTC and other projects.  Runs 8-10kW, reliably so far :)  Uses a TO247 IGBT H-bridge to feed a gapped transformer through series resonant MMC.  Transformer secondary is rectified with SiC diode array to bulk caps at 350-450Vdc.

It can handle shorted load, at least for the duration it takes to charge 44000uF of bulk capacitance.  (Charged 200000uF a few times for my low-frequency QCW experiment.)  The H-bridge runs at the higher resonant frequency of transformer's leakage inductance when output voltage is low, and at the transformer's parallel inductance frequency at normal output voltages.  Current waveforms get a bit more unpredictable at intermediate output voltages.  The H-bridge always switches close to zero current.  However, at intermediate output voltages, switching is sometimes after zero-crossing, causing some hard-switching.

Of course, this is nothing compared to Phoenix' 35kW transformer and resulting arcs:
https://highvoltageforum.net/index.php?topic=1976.msg14755#msg14755
« Last Edit: July 31, 2022, 12:18:14 AM by davekni »
David Knierim

High Voltage Forum

Re: Successful flyback/xformer driver above 3kw
« Reply #2 on: July 31, 2022, 12:14:19 AM »

 


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