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1
Dual Resonant Solid State Tesla coils (DRSSTC) / Re: SCR precharge
« Last post by davekni on August 07, 2022, 07:28:51 PM »
Quote
Also, you are correct that it should be X2-1, typo on my part. Fixed!
I didn't realize that either notation specified which was neutral.  BTW, if using this circuit on a line-neutral circuit, you could leave off the neutral connection.  Almost no current flows there presuming neutral and ground are at roughly same potential.  Operation will not change if the neutral connection is left open.
If using in a hot-to-hot situation where ground potential is between the two, then the X2-1 connection to - comparitor input is of some value, keeping comparitor input common-mode voltage closer to center supply voltage.
2
Voltage Multipliers / Re: Bipolar CW -- update
« Last post by abstruse1 on August 07, 2022, 07:15:11 PM »
CW Multiplier, Progress to Date

I’ve finally gotten to the point where I’m having good luck with CWs and have a moderately good understanding of the basics (haven’t yet got to working with resonance).

My best effort to date, judged by spark length, is 23” – 24.”  The multiplier should be capable of >24”, but at >23”, I get flashovers under the oil, so I can only get 23” confidently.  I'm running it in an 8" polycarbonate tube.




It’s a 15-stage, fully rectified, using 860pF, 20kV Murata (I think) caps, and 1x or 2x 2CL2FM diodes, 2 in series at first few stages, then singles.  I’ve also used 2CL2FP and HVRL400 diodes, both of which have a higher voltage rating, but with 20kV capacitors, so far I can get by with the lower rated diodes.

Input power is 5x 12v SLA batteries thru a 1kW 14 ohm rheostat.  I always turn the device off and on by ramping down or up with the rheostat.  I was having trouble blowing diodes and guessed that sudden voltage/current changes were responsible.  Looks like I was right.

Then to an inductive heater driver that has been very reliable.  Is specifies 48vdc max input voltage, but I don’t know whether that’s OCV or load voltage.  I'm putting more than 48vdc into it. I measure load current and voltage into the driver (more on that later).

Then to homemade FB that has ~1,000 turns 28AWG secondary in four sectors on the bobbin, and 8 turns 12AWG solid primary.  This has been fairly reliable, altho I have blown a couple of secondaries.  Run in mineral oil that I cooked and evacuated.  I expect that removing one turn from the pri would give me greater output voltage.  Also, I have no gap in the ferrite core, and I have no idea what kind of ferrite it is.




A main problem has been insulating the HV (post-FB and post-CW) wiring.  I use 2-3 layers of silicone and polycarbonate tubing.

With 60vdc output from the driver at 22 Amps at the batteries, I get 23” of a LOUD, high frequency spark.  Note that I differentiate between sparks and arcs, the latter resulting from higher current (I think).  I prefer sparks.

I’m working on being able to measure the voltage out of the FB.  I can’t do that with a DVM above ~30kV due (I think) to EMF that makes the meter blank out,  so I’m trying to get an analog meter to work, using an op-amp (any thoughts here?).

Next step is to duplicate the CW and polarize it oppositely, hoping for a combined ~48”.  We’ll see.

Thanx for the great help I’ve gotten from so many forum members!
3
Impressive run!

I'm guessing that another much-larger-diameter ground strike rail around the primary would further improve survival of your secondary.  If I recall correctly from previous videos, your racing spark issues were often triggered by a normal arc from the top hitting your existing strike rail and/or case first.  That may be making enough local hot plasma and distorted electric field to then trigger racing arcs.  A new strike rail could be a separate loop set into place after moving your coil to operating position.  Avoids issues with a larger diameter initial base during transportation.
Of course, this is just my guess at something to help.  I added larger ground strike rails to my DRSSTC at the same time as more varnish layers and slightly reduced coupling.  Can't say which of those changes were most effective at fixing my initial racing-arc issues.

Hope you find a good day when wind is blowing away from your coil.  May further extend arc length.
4
Dual Resonant Solid State Tesla coils (DRSSTC) / Re: SCR precharge
« Last post by alexhanyuan on August 07, 2022, 06:11:59 PM »
Dave, thanks for the input! Now that I look at it, I'm not even sure why I included those 1n caps in the first place. Also, you are correct that it should be X2-1, typo on my part. Fixed!
5
Well after a long hiatus, BrOdin coil is back, with yet another new and improved secondary coil. The last secondary coil (secondary #3) burned up yet again with racing sparks.

Aftermath:


So secondary #4 was wound with a few changes to hopefully eliminate the racing sparks for good. I applied a base coat of epoxy on the bare secondary and wound the new coil while the epoxy was still slightly soft so that the wire would hopefully sink in slightly and provide extra insulation. 3 coats of epoxy were applied on top giving a thick and even finish. Coupling was also reduced to .141 by starting the winding higher up on the form.







1st runs on new secondary:

Had to cut it short because it was a little too breezy for comfort and the wind was blowing the streamers toward the secondary. I did not want to risk smoking another one so soon, so shut it down to fight another day.

I was also tripping my 100A breaker for the first time. This did not happen before, even when drawing 350A+ for 30ish seconds. Now the breaker is tripping after 12 - 15 seconds at maximum power, so I must be getting more power throughput and drawing more current. Didn't have time to set up the ammeter this time around but will get a measurement next time for sure!




6
Dual Resonant Solid State Tesla coils (DRSSTC) / Re: SCR precharge
« Last post by davekni on August 07, 2022, 03:46:50 AM »
Nice simple circuit.  Even though you have it working well, two suggestions:

1) Either remove C7 and C9 or make R6 and R8 larger than 0 ohms.  If you increase R6 and R8, it would be even better if R9 and R10 (10k pull-down resistors) were moved to the other sides of R6 and R8, directly on logic outputs.  That way FET gate drive voltage isn't reduced by the series resistance.
As is, C7 and C9 are directly on ATTINY output pins, causing large glitches of switching current.  That induces ground bounce inside the chip package.  Although it is working now, the next batch of chips might be more sensitive.  Or the next layout have a bit more ground or +5V trace inductance.

2) If this circuit is used on a single phase (230V in Europe), neutral needs to be X2-1, not X2-2.  (I'm presuming that neutral is roughly the same voltage as ground as would be expected here in USA.)  A label for such might help anyone else copying this.  Or, change to a fully differential comparitor input circuit.
7
Dual Resonant Solid State Tesla coils (DRSSTC) / SCR precharge
« Last post by alexhanyuan on August 06, 2022, 10:23:27 PM »
Hey all! Have some more free time now that I'm finished up with school. Wanted to share a little SCR precharge circuit that has been working quite well for me.

Originally for my DRSSTCs I had been using a precharge resistor and relays, but it's difficult to find cheap relays that are rated for more than 30A. Didn't want to waste the room on large contactors, so Steve recommended I try out SCRs. Big thanks to him for getting me started with this.

I found a bunch of cheap Semikron dual SCR modules that were the same Semipack 1 package as the diode modules I had been using so it was an easy swap. Plus, I got to get rid of two relays and the precharge resistor. I get to charge as slow or fast as I'd like (down to 1 second haha). But the main benefit of this is that it is much more robust. I have yet to blow up any SCRs despite some of the abuse I have subjected them to.

My github has some more info and all of the design files:
https://github.com/alexhanyuan/scr_precharge
8
Great sound and nicely produced video too!  I like the chapter breaks and subtitles.
9
IMO

the primary is way too little in insulation so they would likely jump to each other and cut the primary in maybe just one spire if u are lucky to have it stay that close in the spires.. so maybe lay it down.. and maybe try to space them like 5mm to a cm apart (this would work even in a tube shape configuration but more high you put the spires more voltage rise you have so if you do this ism ore likely to have flashovers between seocndary and primary wich already happend from what i can see) .. also in my experience.. layingi t down is the best way to do it for better spark lenghts...

then i would try to put the NST circuit without a ballast (if thats whats going on there cus i cant really see) and i woul try to directly connect it to the circuit...

Another thing... the capacitors.. they are nice looking.. but try to pack them more close in a "zig-zag" way since its really really long and lice this i think it could pick up some strange interference from the coil perhaps?

Also try to look for capacitance.. in my experience around 50 to 80nf its the best for a coil with 5 to 9kV ... but might be different for you... surely around 20 or less is too little IMO even for a little coil like this..

I also saw that you are running your primary tap wire at the beginning in an arc that is going on the secondary and hitting on it with the sparks.. so you really have to put that UNDER the primary.. not over it.. also talking from experience on this...

the secondary also looks covered in resin or something.. if this is right then the resin mix i think its done wrongly wich is the problem of your arcs over the secondary not riseing to the topload... if its just a pice of tape or tube or something like this it could me air bubbles and electrostatic stuff going on wich also can make this types of arcs.. if its possible try to remove it...

lastly.. try to play with primary position tap... i always like to use my coil primary uninsulated to tap it at any point to tune it more easly.. and thats a huge plus to the coil.. once you have it tuned you could take pics and register the position to then do it with insulated already tapped one if thats the look you want!

Best of luck! Hopeing to see improvements!
10
The resonant frequencies are WAY off from each other, but that is properly because you input 0.94uF and not 0.094uF for the primary capacitor.

Under the power calculations, the SRSG LTR capacitance is given to 0.1383uF, you might have hit some resonance with your 0.094uF and the inductance of the NST secondary, which heats it up and if you are unlucky, destroys it? I am not experienced enough with SGTC and RTG to say much more about this...
do you see anything strange after my updated files Mads? i really need to understand what is going on there haha
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