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21
Hi I'm Ben! I'm a College student. Some of you might know me as Temmie on discord. I've been into HV for a few years now and it's been a real fun hobby! My plan is to get an EE degree and work for NASA!
22
« Last post by Michelle_ on April 18, 2024, 09:15:55 PM »
So, the two big resistors near the three output terminals start creeping over 60 degrees if I’m putting in more than 16v, (no fan yet obviously) does that seem wrong to anyone? The rest of the setup looks much cooler from my thermal camera. At 24v in the resistors kept heating up into the high 60s before I turned power off. Power resistors like these are designed to run hot. 200C surface temperature is common. Only real concern is their heat warming adjacent capacitor. A fan will help with that.
200! wow, ok good to know. I have begun a habit of looking at everything with the thermal camera so I can catch problems before they start a fire lol.
23
« Last post by Mads Barnkob on April 18, 2024, 08:50:49 PM »
I've also included shots of the bridge output with phase lead tuned as well as possible at 200A primary current. I'm planning to run it up to at least 600A But that was as high as I could get it with my isolation step down transformer at 40V AC in.
Low voltage testing is deceiving! To get a more accurate picture of switching transients/noise, you need at least 100 VDC on the bridge. IGBT output capacitance (Coes) is a highly voltage dependant and decreases with increasing Vce voltage. This is a problem with zero current switching inverters, as low voltage testing them, introduces high capacitances to resonant with the inductances in the bus/IGBT/etc. Switching spikes at several 100's Volt, at 50 VAC in, might be no bigger than several 10's Volt at full input voltage.
24
On my drsstc I had a fair bit of noise. I found improvement on the RF ground helped. Also if you have two MOTs you can put them together for an 120v isolation transformer
25
« Last post by davekni on April 18, 2024, 07:28:05 PM »
So, the two big resistors near the three output terminals start creeping over 60 degrees if I’m putting in more than 16v, (no fan yet obviously) does that seem wrong to anyone? The rest of the setup looks much cooler from my thermal camera. At 24v in the resistors kept heating up into the high 60s before I turned power off. Power resistors like these are designed to run hot. 200C surface temperature is common. Only real concern is their heat warming adjacent capacitor. A fan will help with that.
26
« Last post by Bobakman on April 18, 2024, 06:30:30 PM »
Thank you all for the help. I have increased confidence now that I’ll be able to accomplish the task. Got a few tests to run like the needle movement verification. I’m still a bit off from completing the project still acquiring parts I’ve got a buddy looking for a sync scope plug, and switch. I now have a lot more tools in my toolbox to help me be successful thanks to all of you! If I have any more questions I know where to ask. Once I complete the project you guys will be the first to see the fruits of “our” labor.
Bob
27
« Last post by Michelle_ on April 18, 2024, 06:03:57 PM »
28
« Last post by Michelle_ on April 18, 2024, 05:26:13 PM »
Hello, Here is my thinking.
First, At the common ZVS oscillator circuit, there're usually two resistors with bigger package that have around hunderds of resistance. They, and the two of fast diodes and the resonant tank are the MOSFETs gate driving circuit. On the other hand, the two smaller ~10k resistors as the pull-down resistors, parallel to the zenor diodes (usually 12V).
So, if you increase the input voltage. This two driver resistors can pass more current for some of the more current pass through Zenor (guess 1) And the MOSFETs gate signal is like 0V/12V (by zenor) ~square wave so the more voltage can constantly shift up Vin-12V the voltage across this two driver resistor (guess 2) Then, I don't know for this kind of resonant circuit, if the Miller effect still plays a big part when the input power been increase (guess 3)
For your sample post SGTC. I was Lucky~ I only use a simple LCR meter to measure the L and C of primary coil, secondary coil, and primary resonant capacitors to approach the resonant frequency.
I think it is a more detailed sample way~
(1) Think of the shape of your secondary coil (it make you have to consider about the coupling), for a SGTC I think you need a longer secondary compares to DRSSTC for avoid the arc flash from the high voltage in the primary to secondary (SGTC tens of kV compares to DRSSTC hundreds V to kv).
(2) Assume the coupling factor like typical 0.1~0.3 and simulte them in SPICE to check how much inductance the primary need (The leakage inductance and capacitance make the resonant freq.)
Then make your circuit and tune them. For the resonant capacitor. I use MS15000V film-capacitor from EACO. I think CDE or WIMA or KEMET or other manufacturer are common on the market.
The current or the voltage as the leader in the primary resonant tank (Same resonant frequency, big L small C or big C small L). I don't know the actual different of their behavior to a SGTC.
By the way, https://www.youtube.com/watch?v=__IYgKmSxGM this was my goal.
Thanks for sharing your thoughts. Right now for my primary I have a pancake designed in javaTC. The diameter of the bottom of my secondary is 3" and the ID of the primary is 5". I will probably make a short wall in between them for good measure. The primary OD is set to 7-8" depending on if I have 1/8" tubing or 1/4" tubing selected (I bought both). It ends up being around 7-8 feet of wire but I have more than that and will tap in. It's saying something like .8-1" between coils on the primary but I will also 3d print recesses/walls to help isolate the windings from one another but leave enough room for the tap. My coupling coefficient is .15, I figured I can raise the secondary relative to the primary to lower it if needed? For 5 turns (Seems like either size tubing) I am getting a .02uf primary capacitor, and for 4 turns a .03 uf primary capacitor. I figured I will go shopping and look for something in that range and adjust the turns of the primary to match what I can get. Based on what I can see if I have capacitors in that range I can tap the primary and get directly in the range of the secondary's resonant frequency and have quite a bit of room for adjustment either way. ALSO: I am reading that you're not supposed to run the ZVS/flyback with no load which could be why it was overheating? That would be good news because it would mean it is otherwise working correctly and the output voltage is high.
29
« Last post by NyaaX_X on April 18, 2024, 04:03:38 PM »
Hello, Here is my thinking. First, At the common ZVS oscillator circuit, there're usually two resistors with bigger package that have around hunderds of resistance. They, and the two of fast diodes and the resonant tank are the MOSFETs gate driving circuit. On the other hand, the two smaller ~10k resistors as the pull-down resistors, parallel to the zenor diodes (usually 12V). So, if you increase the input voltage. This two driver resistors can pass more current for some of the more current pass through Zenor (guess 1) And the MOSFETs gate signal is like 0V/12V (by zenor) ~square wave so the more voltage can constantly shift up Vin-12V the voltage across this two driver resistor (guess 2) Then, I don't know for this kind of resonant circuit, if the Miller effect still plays a big part when the input power been increase (guess 3) For your sample post SGTC. I was Lucky~ I only use a simple LCR meter to measure the L and C of primary coil, secondary coil, and primary resonant capacitors to approach the resonant frequency. I think it is a more detailed sample way~ (1) Think of the shape of your secondary coil (it make you have to consider about the coupling), for a SGTC I think you need a longer secondary compares to DRSSTC for avoid the arc flash from the high voltage in the primary to secondary (SGTC tens of kV compares to DRSSTC hundreds V to kv). (2) Assume the coupling factor like typical 0.1~0.3 and simulte them in SPICE to check how much inductance the primary need (The leakage inductance and capacitance make the resonant freq.) Then make your circuit and tune them. For the resonant capacitor. I use MS15000V film-capacitor from EACO. I think CDE or WIMA or KEMET or other manufacturer are common on the market. The current or the voltage as the leader in the primary resonant tank (Same resonant frequency, big L small C or big C small L). I don't know the actual different of their behavior to a SGTC.By the way, https://www.youtube.com/watch?v=__IYgKmSxGM this was my goal.
30
« Last post by Michelle_ on April 18, 2024, 02:56:40 PM »
So, the two big resistors near the three output terminals start creeping over 60 degrees if I’m putting in more than 16v, (no fan yet obviously) does that seem wrong to anyone? The rest of the setup looks much cooler from my thermal camera. At 24v in the resistors kept heating up into the high 60s before I turned power off.
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