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MAKE A HIGH VOLTAGE SUPPLY IN 5 MINUTES

by Biotele on June 8, 2008 Table of Contents MAKE A HIGH VOLTAGE SUPPLY IN 5 MINUTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro: MAKE A HIGH VOLTAGE SUPPLY IN 5 MINUTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 1: Some Info on CFLs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 2: Some Info about Flyback Transformers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 3: The Finished Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 4: Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 5: Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 3 4 5 6 6 7 7

http://www.instructables.com/id/MAKE-A-HIGH-VOLTAGE-SUPPLY-IN-5-MINUTES/

Intro: MAKE A HIGH VOLTAGE SUPPLY IN 5 MINUTES

In this Instructable you will learn how to make a High Voltage High Frequency power supply in 5 minutes and for less than $20. All you need is a compact fluorescent light (CFL) and a flyback transformer. Flyback transformers are found in TVs and CRT monitors. They make the high voltage, high frequency current necessary to trace the electron beam across the screen. They are small and compact, and you can take them out from an old computer monitor or TV. CFLs are very popular high efficiency fluorescent lights. They are similar to their ancestor the fluorescent light tubes but use electronic ballasts instead of the big and heavy ballasts in the old technology. The electronic ballast works by generating high frequency currents that are fed to a tiny high frequency transformer that boost the voltage and run the fluorescent tube. It is the high frequency that makes the assembly compact. The electronic ballast generates less than 1000 volts. But by replacing the fluorescent bulb of the CFL with a flyback transformer, spectacular voltages can be achieved. Check out my newest instructable: Hand Cranked Flashlight Mod plus Joule Thief

http://www.instructables.com/id/MAKE-A-HIGH-VOLTAGE-SUPPLY-IN-5-MINUTES/

Step 1: Some Info on CFLs

CFLs can come in a variety of shapes and sizes. Generally the bigger the wattage the larger the voltage output. For this Instructable I got a 65 Watts light bulb. Most CFLs have a similar circuit topology. All of them have 4 wires coming out of them. The wires are in pairs, and each pair connects to a filament inside the light bulb. The CFLs I came across have the high voltage on the outer wires. You only need to connect the outer wires to the primary coil of the flyback transformer. You will find a comprehensive description of CFL circuits on this page

Image Notes 1. Replace fluorescent with flyback transformer. 2. feedback transformer, looks like a small ring with wires wrapped around it. 3. Resonant capacitor and inductor, this is what makes the high voltage for light bulb. 4. The transitors in a push pull configuration. This will drive the flyback at high frequency. 5. Rectifier input circuit. Converts AC into DC.

http://www.instructables.com/id/MAKE-A-HIGH-VOLTAGE-SUPPLY-IN-5-MINUTES/

Step 2: Some Info about Flyback Transformers

Flyback transformers come in all different shapes and sizes. Pick a big one. The challenge with the flyback transformer is to find 3 pins out of 10 to 20 pins. One pin will be the high voltage ground the other two pins will be that of the primary coil that will connect to the CFL's electronic board. If you can get the schematic of the flyback transformer that will save you time. However you can figure out the pins by following the instructions here . Danger - if you are going to get the flyback from a TV or CRT you need to discharge it. It can hold a dangerous charge even days after the TV or CRT is turned off (see picture for details).

Image Notes 1. Connect a voltmeter to the output of the high voltage secondary coil. Connect the other lead to the battery pack. Connect the battery pack to each pin one by one, looking for a volatge read out on the voltmeter. 2. connect three 9 volt batteries in series to look for the pin of the high voltage secondary coil. 3. The ground pin of the high voltage secondary pin can be anywhere at the base of the flyback transformer.

http://www.instructables.com/id/MAKE-A-HIGH-VOLTAGE-SUPPLY-IN-5-MINUTES/

Step 3: The Finished Setup

This is how the finished high voltage supply looks like. Remember, this is a DC supply. The output from the thick wire is positive. In TVs and CRTs this high voltage output drives the negative electrons from the filament to the screen. If you need AC high voltage, you have to remove the built-in diode or find an old flyback transformer that does not have a built-in diode.

http://www.instructables.com/id/MAKE-A-HIGH-VOLTAGE-SUPPLY-IN-5-MINUTES/

Step 4: Troubleshooting
The first time I build the circuit, it worked immediately. I used a 26 watt CFL. Then I decided to get a bigger CFL and I build it exactly like the first circuit. It didn't work. I was disappointed. I thought that the CFL electronics were shot. But when I reconnected the fluorescent tube to the four wires, the CFL worked again. I realized that this type of CFL circuit needed to "sense" the filaments in order to operate. Remember, I was only using the outer wires and leaving the two inner wires alone. So I put a resistor across the outer wire and the inner wire. The circuit worked! But within seconds the resistor was in flames. So I decided to use a capacitor in place of resistor. The capacitor allows AC currents but blocks DC while a resistor allow both AC and DC currents to flow through it. Also a capacitor does not heat up because it provides a low resistance path for AC currents. The capacitor worked great! The arcs produced were very big and thick. So in summary there two things that can go wrong: 1. You wired it wrong, either on the CFL side or the flyback side. 2. The CFL electronics needs to sense the filament and you can use a capacitor as a substitute. Use a high voltage rated capacitor. Mine was 400V and I got it from another CFL circuit. While troubleshooting, be very careful, you are dealing with very high voltages and high currents. When soldering, disconnect the circuit from the power outlet.

Step 5: Disclaimer
The circuits in this Instructable use very high voltages and currents. These currents and voltages are deadly! You can easily hurt yourself, as well. Build this circuit at your own risk. This type of high frequency high voltage current is used in surgical cauterizers. So if you get shocked you will burn yourself and cut your flesh. There is also a considerable fire hazard from the circuit. Use the Nikolai Tesla's safety techniques when working with high voltages: 1. Only use one hand (put your other hand on your lap or pocket) 2. Wear insulating shoes 3. Use a dead man stick or insulated pliers when touching or manipulating the circuit. 4. Use a power bar with a thermal fuse rather than sticking the circuit directly in the socket. This will limit the current that will go through your body. 5. When soldering, disconnect the circuit from the power outlet. Generally, in electricity it is the the current that kills. if the currents are low there is little danger even if the voltages are very high (think of Tesla holding the his Tesla coil). This circuit has high currents which makes it considerably dangerous. a 65W CFL can deliver 65mA easily (65W/1000v).

http://www.instructables.com/id/MAKE-A-HIGH-VOLTAGE-SUPPLY-IN-5-MINUTES/

And if you look at the picture below, at greater than 50mA the little guy is dead.

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How To Build A Simple But Powerful Flyback Driver by Plasmana

Tesla Coils for Dummies (Photos) by Xellers

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MINI TESLA COIL by Jimmy Proton

JACOB'S FORKS? by jacobfork

Comments
50 comments Add Comment view all 722 comments
Mar 7, 2011. 10:00 AM REPLY

Azzlan says:
Love the Instructable - made it and it worked first time :) However the cfl was only 20 w so the arc created was quite small.

What i was wondering was, would it be possible to wire 2 cfl's together and then connect them to the flyback transformer to make it more powerful and to give bigger arcs? E.g. you wire 2 20 watt cfl's together to give a wattage of 40 w going into the flyback transformer and therefore giving a bigger arc Also what I was wondering was, is it possible to wire 2 flyback transformers together to make it more powerful and give bigger arcs? Thanks for your help A

Biotele says:

Mar 9, 2011. 5:03 PM REPLY You can wire two in parallel. Should work in theory, but I won't be surprised if the electronics get fried, because each circuit is not exactly like other. In parallel you augment the current given you a thicker spark, but it will not augment the voltage. If you wire it in series you will increase the voltage but the likelihood of catastrophic destruction of the board is really high. You need to isolate the DC path of the circuits from each other. To do that, you have to connect the the two circuits with a capacitor and not a wire.

http://www.instructables.com/id/MAKE-A-HIGH-VOLTAGE-SUPPLY-IN-5-MINUTES/

I suggest to do an internet search first and see if someone had already connected cfl circuits together. It is really an interesting subject, but one must be willing to take the risks and should have experience with high voltage/ high power electronics in order to avoid accidents and unhappy endings.

Azzlan says:

Mar 10, 2011. 11:33 AM REPLY Thanks for the advice Biotele. I will do my research, and i will think about connecting them together. However, knowing me, i will probably will take the risk, so i will be glad to tell you the results of wiring up in series ... If i am still alive.

Mudbud says:

Mar 8, 2011. 6:42 PM REPLY yes, just like putting batteries in parallel, it increases power.. I would go for it! As for the two flybacks together, I don't think It will make a difference at all.

Azzlan says:
Thanks for the reply - i just wanted to make sure. I'll let you know if it works :)

Mar 9, 2011. 2:54 PM REPLY

J-Five says:
Igor Pull the switch!!!

Mar 1, 2011. 4:30 PM REPLY

PetBennett says:
what happens if u poke it O__O

Feb 13, 2011. 1:21 PM REPLY

bwang says:
I imagine there would be an unpleasant but nonlethal shock. Don't do it.

Feb 21, 2011. 11:38 AM REPLY

Evilthingamabober says:
Does the CFL put out AC or DC? And could it be used to drive a Cockcroft-Walton generator?

Oct 29, 2009. 4:43 PM REPLY

spycept says:

Feb 7, 2011. 10:18 PM REPLY actually a cfl has a bridge rectifier built in to it taking the ac from the mains to dc and uses the transistors to pulse the dc, then the resonating capacitor and inductor take the 45 or so volts (the diodes take half the voltage then the capacitors take out more to smooth the rippled dc) and step it up to 900v or so. so in the end your getting 900v dc pulsed at whatever CFL's run at, and i beleive they are fairly fast as cfls are designed not to "hum" or to visibly flicker. as a whole i think this is a extremely easy was of driving a flyback then making a whole circuit as this is really just a more complex miniature version of those anyways. i could only get a hold of a 40w CFL that i would use for a plasma globe (i have a old AC flyback) and it would last for about 20 seconds before almost overheating. but i ordered some heavier duty transistors as that is what seems to be what goes out. i am going to try to hook up them where the old transistors were (that eventually blew), but i accidentaly hooked them up bacwards and tripped the main breakers haha takes lights out to a new level.

Biotele says:
That's awesome. How did your plasma globe look like?

Feb 8, 2011. 8:39 AM REPLY

spycept says:

Feb 10, 2011. 10:08 PM REPLY it was VERY strong with a 3" clear globe lightbulb (while it lasted) as of right now im waiting for my only store within 300 miles to get more CFL's in stock as i burned up my last 40watt one. and then i can try my new transistors in them with big heatsinks to hopefully be able to run them longer without burning up. it seems that the transistors are the reason for mine blowing. as how a CFL actually works is by have a high voltage to heat the filiment and start the arc, but after the arc is started the resistance across the tube lowers dramaticly so the resonant capacitor and inductor makes less voltage (or current im no electrical engineer xD ) so this puts less stress on the transistors after the "start" cycle. this is why you should always change the lightbulbs when they go bad in regular flourescent lighting, as the ballast is essentially stuck in start mode putting out the full current and voltage reducing the life of the ballast. Once i get another big CFL i will post what results i have with the new transistors.

Idonet says:
Since the output stage goes into a transformer I am pretty sure it delivers AC.

Dec 4, 2009. 9:51 PM REPLY

ingloriouspyro says:
my circuit is always frying! i keep having to replace it.

Jan 28, 2011. 4:14 PM REPLY

http://www.instructables.com/id/MAKE-A-HIGH-VOLTAGE-SUPPLY-IN-5-MINUTES/

ConnorY71 says:

Dec 27, 2010. 10:30 AM REPLY I have a flyback transformer, which I plugged up to 12V AC mains. The voltage was dragged down to around 1V though, so I think it might be broken. Also I had the pinout sorted out pretty well but when I measured the voltage from the secondary it started to drop at a steady rate from around 25V. Can anybody help me?

ConnorY71 says:
I tried 2 other transformers and I got the same result... maybe its the source.

Dec 30, 2010. 5:07 PM REPLY

lasersage says:

Jan 24, 2011. 1:11 AM REPLY Mains frequency isn't high enough to excite these things properly, a flyback is looking for 20KHz and up, not 60Hz mains. Had it produced high voltage you'd have probably damaged your meter as I bet it isn't supposed to handle thousands of volts. Nov 17, 2010. 11:36 AM REPLY

Eric8 says:
i got old tv transformer, it has 12 pins one near the second and i dont know where the **** theprimary coil pins damit! who can help me if know please.

ghost_guard says:
Hey Eric. Try here. It helped me. http://lifters.online.fr/lifters/labhvps/tht.htm

Nov 25, 2010. 4:01 PM REPLY

Eric8 says:
Wow tnx this very helped me!

Nov 29, 2010. 10:46 AM REPLY

fire_fist_ace says:
Does the polarity of the capacitor matter? I can get green caps (well brown caps) but i dont know if i can get hv polarised capacitors.

Nov 29, 2010. 4:27 AM REPLY

waselsded says:
in the bord of floursent 4 ends 2 and 2 any ends i used it to concted to fly back in the picture not clear can someone help me

Nov 28, 2010. 3:53 PM REPLY

waselsded says:
y have complet circuit but not work yet if i test the flyback with 12 volt whats nomber of volt i will see in avometer

Nov 28, 2010. 3:47 PM REPLY

william1k5 says:
hi ther i just did your intructable, but the spark that i have it's very small. Any ideas why?? thank you

Nov 18, 2010. 2:36 PM REPLY

Eric8 says:

Nov 19, 2010. 1:49 AM REPLY i did too but my dont work, try to change the secondary pin(there many pins (secondary) but the voltage is diffrent), if you get it to work can you help me ,guide me how did you it? tnx

Eric8 says:

Nov 14, 2010. 4:27 AM REPLY pliz help me i did this : bought warm white light CFL and found tv transformer i did all right but nothing work, the CFL board output is 70V does it ok? how much volts the transformer can take to primary coil? i tried put 230V on other tansformer and it is burned, idk what to do pliz help me i realy want it and tnx for helpers!

bobyong808 says:
Never put mains voltage into a flyback straight. It turns the core into a bullet.

Nov 17, 2010. 1:47 AM REPLY

bobyong808 says:

Nov 17, 2010. 1:43 AM REPLY Hi, I have a 75W CFL and i'm getting ~400V at the outputs to the flyback. But once I touch the primary leads the voltage drops to zero. Could this be because I am shorting the cfl circuit because the primary coil has such low resistance (0.8 ohms)? Thanks, any help is much appreciated.

maddog101 says:

Nov 4, 2010. 2:02 PM REPLY Hey can somebody help me with how to get the flyback transformer off the circuit board of the CRTmonitor? i don't know if i should break the circuit board or what i should do. can somebody please help me!?

http://www.instructables.com/id/MAKE-A-HIGH-VOLTAGE-SUPPLY-IN-5-MINUTES/

-Jess- says:

Nov 8, 2010. 1:52 AM REPLY you should just,,, "Unsoder it". if you have a sodering iron, then just get it all hot and stuff, and melt all the soder around whare the flyback transformer is atached. i have no idea how big the flyback transformer is, so you might want some tweezers to grab it while that soder is still melted,,, so that you dont burn your fingers.

Biotele says:
Break the board with a pair of pliers. Wear gloves and safety glasses.

Nov 4, 2010. 4:01 PM REPLY

croslandjr123 says:

Dec 17, 2010. 1:21 AM REPLY Breaking the board isn't that good a method. A de-soldering pump usually does the job and saves a heap of hassle when removing the flyback from the board.

maddog101 says:
Thanks, now that i have the flyback how do i find the primary and secondary leads?

Nov 6, 2010. 7:29 PM REPLY

croslandjr123 says:

Dec 17, 2010. 1:25 AM REPLY For every flyback it varies, so you can't say that every flyback the same pin out configuration. Get a multimeter and set in the ohms range and test every pin until you find a pair with a reading at or close to 1 ohm. I have found two pairs of "primaries" so you will just need to test each one for the best HV output. Nov 17, 2010. 3:41 AM REPLY

Eric8 says:
sorry Red Wire _________ /.................... | | 0 0 0 9 .......| | 0 [|||||||||||||||||||] | 0 [|||||||||||||||||||] | 0 0 1... + + | \_________|

Eric8 says:
Red Wire __________ /| |0009| | 0 [|||||||||||||||||||] | 0 [|||||||||||||||||||] |01++| \__________| this transformer : Primary the "+" Secondary min voltage "1" , max voltage "9" the second wire the secondary coil is the big red wire that connect to on the screen.

Nov 17, 2010. 3:37 AM REPLY

i hope helped you, can you help me now? please i bought warm white CFL and this electronic plate output is 70volt, this is ok? i connected this to the pins and "nothing" happend i connected right the pins are right, after it i smashed my transformer with hammer and saw i connected pins right! i dont know why it dont work, pliz help

trekman says:

Nov 6, 2010. 7:56 PM REPLY I like this project but I can't tell from instructable where the A/C input is connected to. I assume you would use the spots that connected to the screw base. Is that correct? My CFL tube connected on one side and 180* on the other side. The connections anr marked 1, 2, 3 and 4 so I guess I should use numbers 1 and 3 or 2 and 4 to connect to the flyback. Dose that seem right? Thanks for any help.

hitachi8 says:

Oct 29, 2010. 2:24 PM REPLY someone have an idea how can i made an high voltage supply but with extremly low Amp ? the kind of i can touch without dieing ?

gigavolt says:
A Van De Graaff generator is a great way to make high voltage at less than a milliamp!

Oct 31, 2010. 7:54 PM REPLY

http://www.instructables.com/id/MAKE-A-HIGH-VOLTAGE-SUPPLY-IN-5-MINUTES/

ElectronicsNub says:

Oct 22, 2010. 2:34 PM REPLY Does anybody know the most compact high voltage supply? Like, how could i get the highest possible voltage in as small of a place as possible? Thanks~~~

Biotele says:
how much powe do you need? what is the voltage.

Oct 25, 2010. 3:18 PM REPLY

ARJOON says:
will it work

Oct 12, 2010. 10:52 AM REPLY i have some flyback transformers. What will happen if i wire the output of the cfl to a primary that i wind which has 10turns and i use 12vdc(after the rectifier)

Biotele says:

Oct 12, 2010. 12:26 PM REPLY No, because the CFL transistors are designed to run between 100 and 200V. When you use 12V the transistor must be handle more current (10 times more) to output the same power as a transistor using ~120V. P=IV, power=current times voltage. "i have some flyback transformers. What will happen if i wire the output of the cfl to a primary that i wind which has 10turns and i use 12vdc(after the rectifier) " you might have a nice fire or maybe nothing at all.

ARJOON says:

Oct 14, 2010. 6:49 AM REPLY i know. but i already made mine. i used 2 switching transisers each rated 65watts and drived a 100w transformer which i rectified to dc and connected it to the cfl. i've used it to charge a defibrillator capacitor and my multimeter fried on the spot. by the way don't come near it if you have long hairs.

ARJOON says:
so i'll better stick to the plasmana driver that i made

Oct 12, 2010. 9:43 PM REPLY

Biotele says:
Maybe you can boost 12V to 120V and drive the CFL. There are these car inverters that does this.

Oct 13, 2010. 6:07 AM REPLY

ARJOON says:
heyt i made it i had exactly the sam transformer if i wind a primary of 5-10 turns on the core will it still work

Oct 17, 2010. 12:15 PM REPLY

lightning r fun says:

Sep 21, 2010. 3:12 PM REPLY would this work if i wound 20-30 turns of wire by hand, and then a feedback coil of 10-15 turns like the picture, and then connected it to the cfl?

lightning r fun says:

btw, i didn't use hand wound coils like the pic

Sep 23, 2010. 2:00 PM REPLY

lightning r fun says:

ok i built it it worked for about 5 seconds then the circuit caught fire and melted any ideas why? bulb was 20W cfl plugged into 120V AC wall plug.

Sep 23, 2010. 1:59 PM REPLY

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