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1
Induction Launchers, Coil Guns and Rails guns / Hamilton drills model1206
« Last post by Range4Harry on May 16, 2022, 11:25:14 PM »
Greetings everyone! First post here. I'm new to high voltage and hope to build a solid state coil and next a spark gap coil. Anyway, the reason for the post-

Someone gave me this hamilton drills model 1206 Tesla High Voltage Coils gadget. It's just a spark gap machine but I don't know what works and what doesn't. The large Grey cylinder is what I assume to be the coils based in the schematic. How can I check it? What should I know about this thing? Does anyone know?

Thank you!

Ps- I put this here because it is an induction coil not a tesla coil.
2
Spark Gap Tesla Coils (SGTC) / Re: Driving the primary with other than 60Hz
« Last post by Robert3z on May 16, 2022, 02:21:11 PM »
I think 400Hz is probably a good target, it is common in low cost drives, also a common value in older electronics before the SMPS and associated static frequency converters. I'll stick with that.

Loading the outputs of the drive at 240VAC/400Hz/30A or so may be in the scope of home-building an inductor - you need the step-up primary values first though.

Yes - 6 diodes in three full wave rectifiers AB/AC/BC - I just copied Richie's schematic x 3 - it is easier to explain to a non-electrical person. I've found that Deltas and Wyes make most people's eyes cross : ) though I think it's a more attractive way to draw an industrial schematic.

The other good reason for 400Hz: they might appear on the surplus market - first stage of older 400Hz powered radar or comm gear. We'll see about that. Lots of the wrong kinds at Sales and Surplus of Nebraska...but at least 400Hz is there in a large population, mostly filament transformers.

Transformer(s) and Inductor(s) continue to be difficult, and you really can't go forward with the design until they're locked down. I'm going to keep it in mind and watch for inductance for sale!
3
Thank you for your comment. I was thinking this as well, but never having tried building a ZVS driver-based DRSSTC before, the interrupter points you make seem logical. 

I am more of an SGTC person with large builds to 9" dia coils at 8-10KW input power.  I am just getting back into coiling because it is useful for teaching about LC circuits. My Ss. like building them very much.
4
Looks like a successful project already.

Quote
Question - It would be nice if we could interrupt this coil with another MOSFET connected to a PWM driver. I know Arc Angel (of youtube fame) was doing this, but I am unable to get in contact with him  Does anyone have info on doing this? It was suggested that we use a TC4420 MOSFET driver driven by a PWM generator circuit that might work. Does anyone have opinions on this
The closest thread I'm aware of on this forum is about interrupting a ZVS oscillator feeding an HV transformer.  This should be similar.
https://highvoltageforum.net/index.php?topic=1391.msg10563#msg10563

You'll need a FET to switch input current as you mentioned.  Will also need a catch diode after the FET to handle ZVS input inductor current after FET is switched off.  The FET and diode need to be close to the power supply or preferably have a filter capacitor on the input (power supply side) in close proximity.  Minimize wiring inductance of these three parts (filter capacitor, FET, and diode) to minimize FET voltage spike at switch-off.

It will also help to add a power resistor bypassing the FET, so that the OFF state is not fully off.  ZVS oscillator circuits tend to have startup transient issues (high initial current spike from supply, then high voltage spike on ZVS switching FETs).  There are many posts on the forum about ZVS issues (and successes).  A resistor keeping the ZVS weakly oscillating makes startup more gentle.

Good luck!
5
Spark Gap Tesla Coils (SGTC) / Re: Driving the primary with other than 60Hz
« Last post by davekni on May 16, 2022, 04:36:44 AM »
Quote
It will require adequate impedance in the transformer primaries or the drive will fault as it will be "expecting" to see 10 horsepower motor windings or the equivalent.
This is likely your most difficult challenge.  My guess is that you need inductors between VFD and transformers.  HV transformers are not likely to handle VFD switching-frequency voltage swings, and the VFD is likely to have trouble with HV transformers secondary winding capacitance if not isolated by primary inductors.

Quote
I have a box of 30 12KV 1A NTE rectifiers (block mount on heatsink)
At <1kHz, series connection may work.  At 30kHz, the biggest issue I found with diode series strings is variation in reverse recovery charge.  The first diode to recover gets the entire string's reverse voltage, conducting recovery current of other diodes in avalanche breakdown.  Sorting diodes by recovery charge helped, as did using diodes with avalanche energy handling specifications.

BTW, if transformer secondaries are wired as 3-phase, only 6 diodes are required, not 12 as shown in your diagram.

Quote
3 strong step-up transformers
If you can find a 3-phase transformer, that will be lighter and more efficient than 3 separate 1-phase transformers.  Not sure where you will find either, nor the HV inductor.  Good luck with that.  (I used resonant charging on my SRSGTC, using intentional inductance of MOTs and a bit more added inductance in primary since MOT inductance was not quite enough.  Charging tuned to 120Hz to match my 60Hz line frequency.  Synchronous, so no diodes.)

6
My students are just ending a unit on LC circuits for Grade 11 Electronics. As a summative project several of the students fell in love with Tesla Coils and decided to create a smaller version of Arc Angel's ZVS-based coil running an old  48.5V ~10A PSU from the 1980s.  The coil is wound on a 1.5" white PVC pipe used for Vacuum systems, so acc. 1.7",  ~1400x of 30ga wire wound to approx 29cm. The ZVS driver is running ~82.5nF for tank capacitance with a 3" dia  1/4" copper refrigerator tubing primary with 6.5 turns tapped to 2.5 turns.  Output is 15-20cm long, sword-like sparks from a small toroid made from an aluminum coke can with a 14ga soil copper wire discharge lead.  The output from this coil lights fluorescent tubes 3m away with ease.  The coil can be run for up to 2 minutes with little heating of the MOSFETS.  Secondary res. freq. is ~700Khz, ~200m winding length and the res.frequency of the ZVS is ~350Khz.
The res. frequency of the secondary drops with the top-load into resonance. Sparks greatly increase as I put a conductor nearby.  They will easily jump to hand a good 20cm above the discharge lead at full power.  Without a grounded object nearby the sparks are 10-15cm in length. 
   

Question - It would be nice if we could interrupt this coil with another MOSFET connected to a PWM driver. I know Arc Angel (of youtube fame) was doing this, but I am unable to get in contact with him  Does anyone have info on doing this? It was suggested that we use a TC4420 MOSFET driver driven by a PWM generator circuit that might work. Does anyone have opinions on this   


Pictures below -     
7
Spark Gap Tesla Coils (SGTC) / Re: Driving the primary with other than 60Hz
« Last post by Robert3z on May 16, 2022, 02:20:58 AM »
This is the proper subforum!  :P

I spent some time going through the DC schematic on Richie Burnett's website and realized the charging inductor is basically a boost-mode SMPS setup. 2xDC is Awesome! Here are all the thoughts on this Coil idea. My dry-erase board in the workshop is full - attached sketch.

http://www.richieburnett.co.uk/dcreschg.html
Below is from Richie's Website:
"It should be realised that the function of the de-Q-ing diode can be performed by the DC bridge rectifier in 3-phase designs where no HVDC smoothing capacitor is used. The lack of a separate de-Q-ing diode and potentially lethal DC smoothing capacitor make such 3-phase supplies ideally suited to variable speed DC resonant charging."

This is a good idea! So here is Project "10-Horse," a DC Primary "Boost Mode" Asynchronous Rotary Spark Gap Tesla Coil.

You can buy a cheap 7.5KW (7500VA) or 10HP VFD ($300.00 US) that runs on 240VAC mains at 35A and outputs 208/240VAC 3 Phase from 1-400Hz, 1-600Hz or in a few cases, 1-999Hz. "You get the three-phase source without paying the power company for it."  It will require adequate impedance in the transformer primaries or the drive will fault as it will be "expecting" to see 10 horsepower motor windings or the equivalent.

I have a box of 30 12KV 1A NTE rectifiers (block mount on heatsink)
https://www.digikey.com/en/products/detail/nte-electronics-inc/NTE541/11655505

RECTIFIERS
1.) Actual Rectifer output will be 1.414 x Transformer Output; diode voltage ratings must take this into account and have leeway above it.
6000VAC transformer output (25.0 : 1 Step Up) = 8.5KVpp rectifier output. DC doubling = at least 12KV
6500VAC transformer output (27.1 : 1 Step Up) = 9.1KVpp rectifier output. DC doubling = at least 13KV
7000VAC transformer output (29.2 : 1 Step Up) = 9.9KVpp rectifier output. DC doubling = at least 14KV - near rectifier diode limit
7500VAC transformer output (31.2 : 1 Step Up) = 10.6KVpp rectifier output. DC doubling = at least 15KV - rectifier limit

NTE Rectifiers chosen for the project because I have them and they need a home. If a pair of NTE diodes are used in parallel for 2A, then 7-7.5KV are tops.
If a pair are in series, then higher primary voltage may be utilized with lower current.

- 2 NTE 12KV Diodes in series = 1A at app. 13-18KV, possibly 20KV - assumes voltage drops are balanced between the 2 series diodes. All diodes series or parallel will be tested, I don't desire to use balancing resistors. Defeats the DC de-Q-ing diode!

- 2 NTE 12KV Diodes in parallel = 2A at app. 9-10KV max - more current but less voltage

First question on primary circuit - better higher current or voltage?
   
2.) Step-Up Transformers (3)
Drive output is 240VAC at 0-400H, possibly 600Hz. Using higher output frequency allows a smaller step-up transformer to be utilized. Possibly cheaper?
For 6000VAC, a 25 to 1 step-up
For 6500 VAC, a 27 to 1 step-up
For 7000VAC, a 29.2 to 1 step-up
For 7500VAC, a 31.25 to 1 step-up


Design difficulties are the step-up transformers and the choke. I'd like to think I could wind the choke myself given the correct core, but transformers in that power range will probably have to be ordered.

Difficulties:

1.)  3 strong step-up transformers

3.) Choke for resonant charging: high value, high current, high voltage

Has anyone built this design?

In my build queue I have the current Jacob's Ladder with a friend and a McCauley 8.0 DRSSTC to learn that aspect of the hobby. I prefer to study lots and then build a kit or proven design before I try stuff on my own.

For a home-designed project, the above sounds pretty awesome. Choke protects the transformers, diodes and DC keeps the resonant rise in the primary down.

And an awesome rotary gap : )

If you see anything wrong, please post!


8
Solid State Tesla Coils (SSTC) / Re: Problem with SSTC
« Last post by davekni on May 15, 2022, 11:59:37 PM »
Quote
The only thing left for me to try is to remove the interrupter switch (which I actually don't need) and jumper its connector on the board
Good idea to jumper the interrupter switch.  However, given the interruption frequency ramp in your video, I doubt the switch was the problem.

Before risking more IGBTs, it might be worth replacing the 555 socket and examining under the socket before soldering in a new one.

Intermittent problems are hard.  Without finding and fixing the source of the issue, another failure seems likely.  Might be worth adding a fast-acting fuse to AC line input.  Since IGBT failure takes at least a second after interrupter fails to continuous-enable, perhaps a fuse would open first.  (In most cases, fuses aren't useful for protecting IGBTs and FETS.  They fry faster than the fuse.  However, in your case of more mild overload, a fuse might help.  Presumably fuses are cheaper than IBGTs.)
9
Solid State Tesla Coils (SSTC) / Re: Problem with SSTC
« Last post by Nunu00 on May 15, 2022, 11:08:49 PM »
I double-checked the board and everything seems ok. I didn't see any burn marks or any metal whiskers. In addition I did another test without a coil and both the interrupter and the driver work perfectly, I can vary the frequency and the pulse width without problems.
The only thing left for me to try is to remove the interrupter switch (which I actually don't need) and jumper its connector on the board
10
Solid State Tesla Coils (SSTC) / Re: Problem with SSTC
« Last post by davekni on May 15, 2022, 09:43:07 PM »
Quote
The 300 ohm reading was made on the board without 555 and without 0.33uF capacitor because it was the first component that I removed to test its capacity and resistance, and from the measurements it turns out to be good
As a general consideration when chasing intermittent problems, measuring a component to be good is no guarantee.  It might measure good at one time, then fail at another time.

However, since you measured 300 ohms on the board with 0.33uF capacitor removed and 555 removed, the only possibility left is a failure of the socket or board itself.  Some contamination or metal (ie. tin from solder) whisker is intermittently shorting that node to ground.  Are there any spots that were overheated during soldering?  Carbon from charred organic material seems most likely to create 300 ohms.  Metal whiskers are generally lower resistance and ionic conductivity (ie. salty finger prints) are higher resistance.
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Hydron
May 04, 2022, 11:04:19 PM

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