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DIYHomemadeIgnitionCoilDriverRMCybernetics
ADIYHomemade
IgnitionCoilDriverAHighVoltagePowerSupply
OneofthesimplestwaystomakeabatterypoweredHighVoltagepowersupplyistouseacommoncar
ignitioncoil.IgnitioncoilsareatypeofinductiontransformerbasedontheTeslaCoilinventedbyNikola
Teslain1891.Thevoltageriseisnotgivenbytheturnsratiolikeinastandardtransformer,butis
proportionaltotherateofchangeofcurrentintheprimarycircuit.Thismeanstogetahighoutput
voltageyoumustbeabletostopthepowerflowingintothecoilasquicklyaspossible.Inoldcarsthiswas
simplydonemechanically.ForuseasaHVpowersupplythisneedstohappenrapidlyoverandover.Todo
thisaspacialsquarewavepowersupplyisuseswhichswitchespoweronandofftothecoilhundredsor
thousandsoftimespersecond.
WARNING:HighVoltageisgeneratedbythisdevice!
Standardignitioncoilscanbeobtainedfrommostcarpartsstoresforaround25.Itisnotessentialtouse
two12Vbatterieslikeshowninthecircuitsshownbelow,butitwillallowyoutoobtainbiggersparks.We
havesomecompactinductioncoilsavailableforsaleforunder20.Clickthelinktocheckstock.
Thisdrivercircuitisbasedonthecommonlyused2n3055transistorduetoithighpowerswitchingcapability.
Whilethesearecheapandhightemperaturetolerant,theyaresusceptibletovoltagespikescausedbythe
inductivenatureoftheload(ignitioncoil).Prettymuchanypowertransistor,IGBTorMOSFETcanbeusedin
thiscircuitaslongasitisratedforatlast5Aand100V.Oneswithhighervoltageratingswillbelesslikelyto
bedamagedbyspikes.Furtherprotectionmethodsareoutlinedlowerdownthispageandinthecomments.If
youuseaMOSFETorIGBTinsteadofabipolartransistorlikethe2n3055,youshouldalsoaddapulldown
resistorofabout10kbetweenthebase/gatepinandGND.
TR1
IgnitionCoil
T1
BFY51SmallTransistor
T2
2n3055Power
TransistorsorHV
MOSFETorIGBT
R1
100OhmResistor
D1
1N4007willdobut
preferablya Schottky
Diode
RC1
0.1FCapacitor+10K
Resistor
RC1isusedtohelpsuppresshighvoltagespikesthatcandestroythepowertransistors.
T2representstwopowertransistorsconnectedinparallelandmountedonaheatsink.
Thisnextcircuitisdesignedforahigherpoweredoutput.TwoignitionCoilsareconnectedinparallelbutwith
oppositepolarity.Thismeansthattheoutputvoltagesofeachcoilareoutofphaseoroppositetoeachother
(whenoneispositive,theotherisnegative).Usingthisconfigurationtheoutputistakenfromthetwocoils
outputterminals,whereasthecircuitaboveusestheoutputterminalandground.
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DIYHomemadeIgnitionCoilDriverRMCybernetics
Anewprojecthasbeenaddedandisgreatfordrivingsmallerignitioncoils.
Thesecircuitswillworkgreatfordrivingignitioncoilsforhighvoltagebuttheycanbesusceptibleto
damagefrominductivespikes.Whenanignitioncoilisbeingdrivenunloaded(opencircuitontheoutput)
therewillbesignificantlyincreasedbackemfandriskofdamagingthedrivercircuit.Wesellanignitioncoil
drivermodulewhichhasbuiltinprotectionagainstmostspikesthatwoulddamageadriver.Italsoincludes
anearlywarningindicatorwhichwillshowyouhowseverethebackemfisfromyourload.
ProtectingYourIgnitionCoilDriver
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Ifyoubuildanignitioncoildrivertomakehighvoltage
sparksandarcs,youwillneedsomesortofEMIprotection
foryourcircuit.Withoutit,itisverylikelyyouwilldestroy
thetransistorsordriverICs.
Snubbersareatrickysubject,butingeneraltheyareused
toreduceelectromagneticinterference(EMI)orvoltage
spikes.TherearemanywaystoreduceEMIanditcanoften
beusefultousevarioussnubbersindifferentpartsofthe
circuit.Thesediagramsrepresentafewpossiblewaysyou
cansnubEMIinanignitioncoildriver.Theseareknownas
dissipativesnubbersbecausetheexcessenergyisdisspated
asheatorlight.
Thetopdigramusesaseriesconnectedcapacitorand
resistor.Thevaluesusedwilldependonyourdrive
frequency.(SeeRC1attopofthispage).Generallyspeaking,
abiggercapacitanceandsmallerresistancewillsnubmore,
butalsoabsorbmoredrivepowertheforereducingefficiency.
Acompromisemustbefoundthatbestsuitsyoursetup.
ThenextdiagramusesadeviceknownasaMOV(Metal
OxideVaristor).Thesearesemiconductordeviceswhichwill
onlybeginconductingwhenthevoltagebetweenits
terminalsexceedsitsratedvalue.Itwillstopconducting
whenthevoltagegoeslowagain.Intheexampleshown
above,theMOVwillshortoutanyspikescomingfromthe
load,butitisalsoshortingthedrivercircuitsoutputforthe
samebriefinstant.TheMOVchosenmustbeableto
dissipatethepoweranshaveavoltageratingthatwillcause
ittoactivatebeforethevoltagegetstoohighforthedrive
circuit.
Youcanalsoplaceasmallneonindicatorbulb(Ne1)inseries
witha1kresistorandplacethisbetweenthelowvoltagewirestoyourignitioncoil.Thisbulbwillbeginto
glowwhenthebackEMFreachesabout100Vormore.Ifyouseeitglowing,youneedabettersnubberlike
RC1(topdiagram)oraMOV(varistor)ratedtoclampthevoltagebelowthemaximumyourcomponentswill
tolerate.
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