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SPARKY-1 & SPARKY-1E: A 5 VOLT HIGH VOLTAGE BOARD FOR CDI IGNITIONS

Sparky-1 was designed to be used with the open source project Programmable Open Source CD Ignition PIC1840 located on the RC Groups forum but it will work with almost any widely used signal input. In today's age of electronics I don't feel it should be necessary to wind a step-up coil. I also don't really like ZVS , ZCD  or Royer oscillator circuits because they are hard to control, so I used something I know SMPS (Switch Mode Power Supply) technology. With SMPS I can use almost any step-up transformer I want, limit the voltage, and power. Sparky-1E is designed to use an external ignition coil like the Zenoah Grey Coil or the GY6 scooter coil.

I designed the Sparky-1 to be as flexible as possible and I also wanted it to be designed so that it could be easily understood. Another major feature was that it had to run the whole circuit with 5 volts. For detailed description of how the circuit works read the circuit description PDF located below. Sparky-1 is free to use for personal use only, commercial use with written agreement.

The main features of Sparky-1/1E:

  •  Whole circuit runs off 4.5 - 18 volts.
  •  Use 4.8 volt to 18 volt battery power.
  •  Adjustable high voltage output with feedback circuit.
  •  Adjustable power output use only as much as you need and save battery power.
  •  Adjustable frequency to match transformer uH and inductive reactance (XL).
  •  Half-bridge driver cuts out when battery voltage goes down to 4.1 volts.
  •  No complicated circuits, excellent way to learn SMPS and CDI ignitions.

Batteries you can use:

Use a 1500maH or greater battery, for a 4.8 volt NiCad or NiMH don't use a regulator, remove it and jumper the regulator holes, the circuit will shut down at 4.1 volts. With a regulator you can use 6 - 18 volt NiCad or NiMH. For Lithium Ion / Poly / LiFePo you can use 6.6 - 18 volt but you will need a volt monitor so you don't wreck the batteries.

Recommended Regulators:

There are lots of different types of 5 volt positive regulators and which one you use is up to you but, try to use one with at least 2 amps continuous duty and a drop-out voltage of 0.7 volts or lower. Max current with the parts I used was 1.8 amps so it is best to use a 2 amp heatsinked regulator, I plan on using the side of the case for my heat sink.

NOTE: To use the Eagle files you need to use or upgrade to Eagle 6.4.0 otherwise you will get errors. All board files are 1:1 scale.

Any question just email me rrichter@unimatrixtech.com

Sparky-1 Files:

Sparky-1 Circuit Description.pdf A detailed description of how the circuit works.

Sparky-1 CDI HV Schematic IR2302-NE555.pdf PDF of schematic.

Sparky-1 Eagle File CDI HV Schematic IR2302-NE555.sch Eagle file of schematic so you can make changes.

Sparky-1 Eagle File CDI HV Schematic IR2302-NE555.brd Eagle file of board so you can make changes.

BOTTOM LAYER POUR Sparky-1 CDI HV Schematic IR2302-NE555.pdf Bottom board layer with copper pour.

BOTTOM LAYER Sparky-1 CDI HV Schematic IR2302-NE555.pdf Bottom board layer without copper pour.

TOP LAYER POUR Sparky-1 CDI HV Schematic IR2302-NE555.pdf Top board layer with copper pour.

TOP LAYER Sparky-1 CDI HV Schematic IR2302-NE555.pdf Top board layer without copper pour.

Combined Layers Sparky-1 CDI HV Schematic IR2302-NE555.pdf Combined layers 3X enlarged.

Component Layout Sparky-1 CDI HV Schematic IR2302-NE555.pdf Components only layer.

Sparky-1 BOM CDI HV Schematic IR2302-NE555.pdf PDF of Bill Of Materials.

Sparky-1 BOM.xls Bill Of Materials in Excel 97-2003 format

Sparky-1 files.zip All the files zipped into 1 compressed file.

 

Sparky-1E Files:

Sparky-1 Circuit Description.pdf A detailed description of how the circuit works.

Sparky-1E Eagle File CDI HV Board External Ignition Coil.brd Eagle file of board so you can make changes.

Sparky-1E Eagle File CDI HV Schematic External Ignition Coil.sch Eagle file of schematic so you can make changes.

Sparky-1E CDI HV Schematic External Ignition Coil.pdf PDF of schematic.

Sparky-1E NO FILL BOTTOM.pdf Bottom board layer without copper pour.

Sparky-1E NO FILL TOP.pdf Top board layer without copper pour.

Sparky-1E POUR FILL BOTTOM.pdf Bottom board layer with copper pour.

Sparky-1E POUR FILL TOP.pdf Bottom board layer with copper pour.

Sparky-1E files.zip All the files zipped into 1 compressed file

Sparky-1 BOM.xls Bill Of Materials in Excel 97-2003 format, just delete the RT-442 coil

BOM Sparky-1 1E CDI HV Schematic IR2302-NE555.txt Bill Of Materials in TEXT format, just delete the RT-442 coil

 

Movies of Sparky-1:

CDI Spark Design 1

Sparky-1 movie 2

Sparky-1 Movie 3 - 21,000 rpm

Sparky-1 Movie 4 - Hits 37,200 RPM

Sparky-1 Movie 5 - Very Low Power Usage

Sparky-1 Movie 6 - Big Sparks Cool

Inductive reactance Adjust for Power

 

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Last modified: 03/08/15