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Messages - Saattvik24

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1
I finally got my first DRSSTC up and running and I'm very happy that it's working, but there are still some issues.
https://youtube.com/shorts/LW7HfMb8ZDw?feature=share

The OCD is currently set to around 350A but it gets triggered when the input voltage reaches around 130VAC yet the sparks I'm getting are still very short. To check if this was an issue with my tuning or not, I removed the secondary and replaced it with a solid piece of metal as the load on top of the primary coil. The OCD still got triggered at around 130VAC input.

I scoped the current waveform using a voltage probe across the 51ohm resistor and got following waveform. The peak voltage is 23.2V which translates to 284A in the primary (I'm using 1:625 reduction CT) Because the primary current looks good I thought I had just tuned it like shit. But I had calculated the secondary resonant frequency using a function generator and an oscilloscope and it came to be 153kHz. So I adjusted the primary tap till I could see the primary current having a frequency of approximately 143kHz (Detune of 10kHz) but still I was not impressed with my arc output. And I couldn't increase the input voltage cause then the OCD LED would be constantly on.


Then I proceeded to scope the comparator inputs for the OCD. The blue waveform is the set point, currently set to approx 2.8V which translates to 343A as the limit. The yellow waveform is the other input of the comparator coming from the feedback. Both of the waveforms have more noise than usual because I had to attach jumper wires to the header J9 so I can easily probe these voltages. The waveform is just when the OCD got triggered.


I'm not sure what the issue is, one possibility is that the ferrite cores I'm using for the CT are not good, as the N30 cores I had ordered were too small, so I had to use some other cores I had laying around. But I had tested them by making a GDT with them and connecting them to the output of the UD2.7C output while using a function generator as the feedback. The output waveforms looked good so I assumed the cores were good enough to use for the CT. (The core for the final GDT is big and of N30 material so that's not the issue)

Other than that I think I've done everything properly, maybe the primary tap is a bit janky but it hey it works. I've attached images so maybe you can figure out if I've done something wrong.

2
Quote
That probe is rated for 100kHz bandwidth.  Delay within probe is likely as much or more than phase lead adjustment range.  Easier and more accurate to measure voltage across 51-ohm CT burden resistor on UD2.7 ECB.  (Or make another CT secondary core/winding with its own burden resistor.)
I got a differential probe and measured the voltage across the 51ohm resistor and got the following waveforms. I tried adjusting the phase lead but the voltage spikes didn't reduce that much. Note: The spikes and noise in the current waveform were due to some interference in the differential probe. They were not present when I was using the current probe.


Quote
Video is a bit too fuzzy to decipher time/division setting on scope.  What is time/div (or what is coil operating frequency)?
time/division is set to 5us. Primary Circuit resonant frequency is approximately 142kHz at the moment.

Quote
BTW, nice variable inductor implementation.  I've made DIY variable inductors, but using friction-fit, not with nice screw adjustment.
Thanks :) Still can be improved much more.

3
Dual Resonant Solid State Tesla coils (DRSSTC) / Phase Lead Questions
« on: March 19, 2024, 06:52:09 PM »
I didn't have access to coilcraft inductors so I decided to make my own variable inductor using a ferrite transformer core from a PC SMPS and a 3D printed structure and screw to adjust the position of the ferrite core. The inductance is tunable from approximately 20uH to 100uH.


This is my current setup. I'm measuring the primary current using a Tektronix current probe rated for 100A.


The yellow waveform is the Collector-Emitter Voltage of one of the IGBTs and the blue waveform is the primary current. I didn't use an isolated voltage probe while taking the measurements as for testing I'm powering the inverter using a lab bench power supply set to 66VDC.

/>
In the video I go from min to max and again to min inductance but still the primary current doesn't get in phase with the collector-emitter voltage. Is it because my inductor is bad? The inductor wire leads are too long? Or because its not shielded?

4
I built a proper gate drive transformer and turned on my bridge for the first time with a 10k resistor as the load, and 15V on the busbars and got the following output.


I think this is how its supposed to look like with a resistive load or are the voltage spikes too high? I think they should reduce once I reduce the GDT connection lead length.

5
This is my first DRSSTC. I've built most of the separate parts, now I just need to assemble them together.

Bridge - SKM100GB12T4 in Full Bridge
Bridge Supply - 0-260VAC, 35A Bridge Rectifier, 4700uF 400V EPCOS Electrolytic Capacitor
Primary Coil - Spiral Primary - 7 turns of 1/4 inch OD copper tube with 10mm spacing and an Inner diameter of 150mm
Secondary Coil - 110mm diameter, 540mm long, 1350 turns, 28SWG enameled copper wire
MMC - 3 strings in parallel of 3 in series of Cornell Dubilier 942C20P15K-F for 0.15uF at 6000VDC
Snubber - 2uF 1kVDC 827V/us dv/dt (KEMET C4BSNBX4200ZBLJ)
Top Load - Toroid -  Minor Diameter-127mm   Major Diameter-490mm 
Driver - UD2.7C Thru Hole
Resonant Frequency - Around 150kHz

I don't have access to a tunable inductor, so I was thinking of making my own. The plan is to 3D print a screw and a housing. The winding will wound on the housing, and there will a ferrite core inside the screw which I'll be able to move up and down by turning the screw. It will be much bigger than a traditional coilcraft inductor, but should work I guess? What are your thoughts? Perhaps when I figure out the inductance value, I can remove it and replace it with a fixed inductor.

While connecting the grounds together, should the 24v supply case be connected to the mains ground or the common rf ground?

I noticed later on, that the skm100's I've bought have slower on/off times compared to some other models. So I hope that wont be an issue. I was planning on setting the OCD to 300A during testing, and increasing it to 500A after proper tuning. Can these IGBT's handle 500A?


I've made some annoying mistakes while building my inverter bridge. The IGBTs are too close together resulting in there not being enough space for the bus capacitor, as you can see it covers up the igbt screw terminals and the snubber capacitors cover up the wire connections. This means the bridge has to be assembled in a particular order, and if I need disconnect anything, I'll have to remove the IGBTs from the heatsink. The only benefit of this layout is lower stray inductance I guess.


I made the toroid out of 5 inch aluminium ducting. I wanted to ask, is the way I've connected the secondary to the ducting good or bad? The top of the secondary goes to a lug connection, connected to a threaded rod, which comes out the top, which is connected to the ducting using aluminium tape.

6
Dual Resonant Solid State Tesla coils (DRSSTC) / Re: UD2.7C Debugging
« on: March 05, 2024, 03:49:52 PM »
After many hours of debugging and replacing components, i bought new mosfets and replaced the old ones, turns out they were bad quality all along. It looks to be working now. I've attached the scoped output of a test gate drive transformer attached to a 10k resistor. I wanted to know if the waveforms are good and correct

7
Dual Resonant Solid State Tesla coils (DRSSTC) / Re: UD2.7C Debugging
« on: March 04, 2024, 06:42:15 PM »
The mosfet Q4 irfp540 keeps dying (2 have died so far). Also i got most of my components from element14, but the mosfets are from a different electronics seller, but its also a reputable brand in my country.

8
Dual Resonant Solid State Tesla coils (DRSSTC) / Re: UD2.7C Debugging
« on: March 04, 2024, 06:04:53 PM »
No other IC seems to be getting hot

9
Dual Resonant Solid State Tesla coils (DRSSTC) / Re: UD2.7C Debugging
« on: March 04, 2024, 02:43:48 PM »
Turns out one of the irf540n mosfet had died. But after replacing it, the driver is still not behaving properly. It still tends to turns off after a few seconds of operation, also the LM7812 voltage regulator gets extremely hot. Even the time in which it is on, the gate drive output waveform doesn't look good and it keeps moving.

10
Dual Resonant Solid State Tesla coils (DRSSTC) / UD2.7C Debugging
« on: March 04, 2024, 12:31:31 PM »
I finally populated my UD2.7C driver board and turned it on for the first time. I noticed it worked for a minute then the 12V and 5V voltage rails fell down to around 1V. So the next day, I started debugging, i removed the UCC27423 driver, and started probing around. The voltage rails were back to normal values.

I've attached the oscilloscope shots of the interrupter output received after schmitt trigger, the comparator output of the feedback, and inputs to the UCC27423 on pin 2 and 4.

I've set the function generator as feedback at 150kHz and the interrupter is to 20Hz. The interrupter is currently on a breadboard, will be put on a pcb. Its a oneTesla interrupter. Also there is nothing connected to the OCD CT terminal block (It should work without that during testing right?)

I wanted to know if my waveforms are good and what could be the possible issues. I haven't adjusted the values of the potentiometers RV1 & RV2 yet, but i don't think thats the issue, as those are for UVLO & OCD.

UPDATE

When reinserted the UCC27423, the voltage rails again fell down. I tested the IC separately and it seems to be working, so I have no clue what the issue could be.

11
I was building the UD2.7 thru hole board but I ordered tantalum capacitors instead of ceramic ones. I wanted to know if they will work as well, as tantalum capacitors are polarized so that might be an issue. Also they are rated for 35V instead of 50V as mentioned in the BOM. I assumed the voltage on the board won't exceed 35V as the supply voltage is 24V. So are 35V rated capacitors enough or I need 50V rated ones at least? Thank you

12
Also I wanted to know which is a good and simple MIDI Interrupter to build? The OneTesla interrupter? Thank you

13
Thank you for the help. I also wanted to know if I need to use TVS Diodes as I already have snubber capacitors. Don't they serve the same purpose? And if I do then will 440V TVS diodes be enough? KaizerPowerElectronics used the same in his DRSSTC. Thank you.

14
Yes sorry that was a typo. oneKone who built a skm100 coil which is in the list of drsstc builds here, he used a 165nF 6kv kemet snubber capacitor mmc, so should I go the same route as him or stay with the cornell dubilier capacitors? The kemet snubbers will be much cheaper, so I would prefer that.

15
Dual Resonant Solid State Tesla coils (DRSSTC) / First time DRSSTC Build
« on: January 23, 2024, 05:32:39 PM »
I am attempting to build a DRSSTC for the first time, having built a small half bridge SSTC before. After having gone through many resources and forums and using JavaTC and other calculators, I have chosen the following parts and specifications for the DRSSTC, I wanted to know if I have chosen them correctly and just needed some feedback before ordering the parts. Thank you.

Bridge - SKM100GB12T4 in Full Bridge
Bridge Supply - 0-260VAC, 35A Bridge Rectifier, 4700uF 400V EPCOS Electrolytic Capacitor (ESR - 28mohm, Ripple Current - 12.6A)
Primary Coil - Spiral Primary - 6 turns of 1/4 inch OD copper tube with 15mm spacing and an Inner diameter of 150mm
Secondary Coil - 110mm diameter, 513mm long, 1600 turns, 28AWG enameled copper wire
MMC - 2 strings in parallel of 2 in series of Cornell Dubilier 942C20P15K-F for 0.15uF at 2000VDC
Snubber - 2uF 1kVDC 827V/us dv/dt (KEMET C4BSNBX4200ZBLJ)
Top Load - Toroid -  Minor Diameter-127mm   Major Diameter-530mm   Capacitance-22.951pF
Driver - UD2.7C Thru Hole
Resonant Frequency - Around 130kHz

16
Solid State Tesla Coils (SSTC) / Re: SSTC Broken
« on: March 09, 2020, 02:39:50 PM »
Unfortunately I don't have a proper oscilloscope, its just a cheap handled dso so I cant diagnose a tesla coil with it. I used the frequency measurement of my multimeter to find out that a signal of frequency 26kHz is on the primary side of gdt.

17
Solid State Tesla Coils (SSTC) / SSTC Broken
« on: March 07, 2020, 12:00:24 PM »
So my sstc based on kaizerelectronics sstc1 stopped working probably when I increased the bus voltage too much but its not the mosfets that died but still i replaced them and also replaced the bus capacitors but still its not working :( Some observations are that when I turn it on nothing happens and theres not current draw from the bus capacitor and the ucc driver ICs also stay cold. So is it possible that something in the driver circuit got damaged due to the magnetic field of the tesla coil??because I hadn't shielded it, it was just sitting beside the secondary coil. I was thinking about building the driver circuit again with new parts. Unfortunately I didn't use sockets on the ICs otherwise I would have tried replacing them. If you have any ideas of how to fix it or whats wrong Ill be happy to hear it. Thanks for the help :)

18
Solid State Tesla Coils (SSTC) / Re: SSTC stopped working HELP
« on: October 07, 2019, 08:14:14 PM »
I checked both the mosfets and they are both working, so what else could be wrong? When I ran the tesla coil I measured the voltage across both the half bridge capacitors, across one of them was the input voltage and across the other it was only 3 volts, so maybe one of the capacitor is dead???

19
Solid State Tesla Coils (SSTC) / SSTC stopped working HELP
« on: October 06, 2019, 08:12:14 PM »
I was driving my half bridge sstc based kaizerelectronics sstc 1 on 100 volt AC input on continuous mode, and after a few runs it stopped working and I know it didn't die due to overheating cause I only ran it for short intervals of time and I even had a fan attached to the heatsinks. Now when I power it, it doesn't make any sparks but it faintly lights a cfl when I bring it very close to the top load, so I guess its not completely destroyed. At first I thought I blew up the bridge rectifier because it was only rated for 4 amps so I got a new one rated for 35 amps but it still does the same thing and doesn't work properly. I think the driver works fine and the problem is with the bridge circuit, maybe the mosfets or the half bridge capacitors or the diodes. So I'll be glad if you can help me diagnose it and fix it :)

20
Solid State Tesla Coils (SSTC) / Re: SSTC not getting interrupted
« on: September 11, 2019, 01:54:59 PM »
MCP14E5 is only available in smd package. Can you suggest me some suitable gate drive IC's in THT package? Can I use IR2184? It's maximum current output is only 1.8A so could that be a problem?

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March 17, 2024, 07:42:55 PM
post Re: 2x Panasonic Inverter Microwaves - what to salvage, dangers?
[General Chat]
Michelle_
March 17, 2024, 04:15:14 PM
post Re: 2x Panasonic Inverter Microwaves - what to salvage, dangers?
[General Chat]
Michelle_
March 17, 2024, 05:05:04 AM
post Re: Where's all this voltage coming from?
[Spark Gap Tesla Coils (SGTC)]
davekni
March 17, 2024, 04:50:51 AM
post Re: 2x Panasonic Inverter Microwaves - what to salvage, dangers?
[General Chat]
Twospoons
March 17, 2024, 04:45:17 AM
post 2x Panasonic Inverter Microwaves - what to salvage, dangers?
[General Chat]
Michelle_
March 17, 2024, 04:17:51 AM
post Where's all this voltage coming from?
[Spark Gap Tesla Coils (SGTC)]
Terry
March 17, 2024, 01:29:32 AM
post Re: DRSSTC Questions
[Dual Resonant Solid State Tesla coils (DRSSTC)]
flyingperson23
March 17, 2024, 12:33:06 AM
post Re: DRSSTC Questions
[Dual Resonant Solid State Tesla coils (DRSSTC)]
Keybored
March 16, 2024, 08:46:20 PM
post Re: Bleeder resistor for MMC
[Dual Resonant Solid State Tesla coils (DRSSTC)]
Hydron
March 16, 2024, 08:39:24 PM
post Re: DRSSTC Questions
[Dual Resonant Solid State Tesla coils (DRSSTC)]
Hydron
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post Best forum for vacuum tube amplifiers?
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