Author Topic: MonsterDR  (Read 651 times)

Offline Felix B.

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MonsterDR
« on: December 20, 2021, 09:55:26 PM »
Hello,

I built my 1,5m tall DRSSTC about half a year ago and here's the thread for anyone interested: https://highvoltageforum.net/index.php?topic=1628.0 After this coil I wanted something bigger - much bigger. The Idea of MonsterDR was born. It was planned in about a month to be a 2,8m tall freewheeling DRSSTC similar to BrOdin coil although with some adaptions and improvements. I wanted it to be relativly cheap and robust. Now, about half a year later I had the first light. It still needs some work, especially the topload but it is mostly completed. Here are the specs:

  • Inverter: It is a fullbridge built from large FF1000R17IE4P bricks I got very cheap from ebay. The 12 000µF of bus capacitance are charged by a 3 phase 100A rectifier and it has 4x 1µF snubbers (2 per brick). It ways about 30kg all together. I designed it on CAD to be a low inductance laminated busbar design here's the CAD drawing:

    And here some pictures of the real deal:




    The FF1000 bricks:

    And here the laminated busbars with the silicone insulater in between:





  • Driver and GDT: The Driver is a UD+ freewheeling driver from PhilsLab in a shielded aluminium box here is a picture:

    The two GDTs are 10 turns of cat5 ethernet cable on a n30 ferrite core. Here's a picture:


  • Secondary: The Coil was wound on a huge 315mm PVC pipe to about 155cm (the pipe was cut to 170cm long). The wire is 0,71mm thick and the 7kg roll was just enough for about 1960 turns. My dad and I wound the coil on a winding rig made from some rollers which was powerd by a cordless drill. It later was varnished with about 2kg of epoxy resin.






  • MMC: The MMC was built from 1µF 3kV resonant capacitors. They are made by CRE capacitors from china and can do 60Armps and 600Apk. I put 6 in series and 5 in parallel for a MMC of 18kV and 0,85µF which is good for 300Arms. They are connected with 30x2mm copper bars.

  • Primary: The supports were milled out of wood and I wound around 6,5 turns of 12mm copper tubing as the primary (tapped at turn 6 for now but still needs lots of tuning). I mounted some silicone tubing to the primary for water cooling (gets to 100°C in two minutes without water cooling). Here are some pictures:





  • Topload: The topload was designed in CAD to be easy to build and look good. It is based around 10 aluminium pipes (3x32mm) that are 2m long and bend to a radius of 0,6m. They are at a 15° angle and arranged in a circle to form a 150x36cm toroid. The supports were cut on my mostly printed CNC from 12mm plywood and glued to the main circle 1m in diameter. Here the CAD:

    The pipes:


    And my dad holding the finished topload:

    Unfortunatly the topload has huge corona problems because the wood supports slightly conduct and stick further out than the tubes. I just cut the support back so that they don't stick out as much. I hope that fixed the problems but we will see next week ;)

  • Finished coil: The coil is 2,8m tall runs on 32A 3 phase 400V and does 40kW with just getting slightly warm to the touch while spitting out streamers over 4m untuned. Some pictures of the completed coil:




    CAD:


  • Oscilloscope shots: Ch3 measurd with 1:3000CT and 10Ohm burden (1V/300A). The ZVS:


    Freewheeling:



I'm pretty satisfied with these results allthough it still needs some tuning and further tests but anyway here's a video of the first light:
From what I know this is the biggest coil in austria and the biggest in the world built by a 16 year old ;D

felix
« Last Edit: December 21, 2021, 12:07:49 AM by Felix B. »

Offline futurist

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Re: MonsterDR
« Reply #1 on: December 21, 2021, 12:21:06 AM »
Congrats! Nice work and attention to details, no switching spikes. Topload looks great!

How do you pre-charge bus capacitors?

Online davekni

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Re: MonsterDR
« Reply #2 on: December 21, 2021, 02:17:50 AM »
Yes, very impressive coil!

In the first two arc pictures, there appears to be a smoke trail from the coil to far corner of garage.  Are those from previous arcs to that spot on the garage?  I wouldn't expect an arc to leave a smoke trail.  Or, did the smoke trail form from a burn spot, following wind direction?

Where are you probing gate signal for ZCS switching scope images?  The gate signal looks a bit odd for Vge directly.  Normally Vge has a fast fall time (typically with a bit of overshoot) and rising edge that is slower and more rounded due to gate series resistor.  This looks almost backwards (rising and falling edges look reversed).  Gate diodes are in the correct direction in your images, so that is not an issue.

Given your clean switching waveforms, I expect phase lead is correctly adjusted for ZCS.  However, the Vce switching appears to be very slightly after zero current.  Perhaps measurement CT is inducing a bit of phase lead in the scoped signal.

Looks like tuning is fairly close.  Looking forward to seeing what more performance you can squeeze out of this coil.
David Knierim

Offline Duane B

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Re: MonsterDR
« Reply #3 on: December 21, 2021, 04:21:38 AM »
Great looking coil! Congratulations!
Duane Bylund

Offline Mads Barnkob

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Re: MonsterDR
« Reply #4 on: December 21, 2021, 08:18:57 AM »
Congratulations on finishing such a high quality coil Felix! For sure is a good job done at 16 yo! It does also help to have the help of a father with all the right equipment, you are in a good spot to develop yourself further into HV land!

Its really hard to give any critique/constructive feedback, because its very well built. I do however fear that you will at some point see a flashover between the laminated busbars, many people have made these and somehow regular safety distances does not seem to cut it for the high transients that can occur in a high power DRSSTC.

Cylindrical capacitors should not be mounted together directly, terminal to terminal with a threaded rod. Its advised against in the datasheets. Simply because these terminals do 2/3 of the heat dissipation. It really should have some busbar and thermal mass to dump it in. I made the same mistake in my large DRSSTC :)

In the first two arc pictures, there appears to be a smoke trail from the coil to far corner of garage.  Are those from previous arcs to that spot on the garage?  I wouldn't expect an arc to leave a smoke trail.  Or, did the smoke trail form from a burn spot, following wind direction?

I think this is UV ghosting artifacts from the camera sensor. Seems to correspond with being a parallel projection of the main spark channel.
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Offline TMaxElectronics

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Re: MonsterDR
« Reply #5 on: December 21, 2021, 12:24:14 PM »
That topload looks amazing 8) Did you have any issues with unintended streamer breakout from the sharp end of the tubes?

Also quite bold to run it in (what appears to be) a populated area. I'm always way to cautious about them calling the cops on me with noise complaints lol

What resonant frequency is that coil running at? I've had the issue that huge IGBTs like the ones you got are too slow to drive a tesla coil at reasonably high frequencies.

Offline Felix B.

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Re: MonsterDR
« Reply #6 on: December 21, 2021, 05:52:13 PM »
Thanks for all your nice replies!

How do you pre-charge bus capacitors?
I have 3 huge 22 ohm precharge resistors, made from a heating element in a tube full of sand that are shorted out by a large contactor about 1,5s after power-up.

In the first two arc pictures, there appears to be a smoke trail from the coil to far corner of garage. Are those from previous arcs to that spot on the garage?  I wouldn't expect an arc to leave a smoke trail.  Or, did the smoke trail form from a burn spot, following wind direction?

Where are you probing gate signal for ZCS switching scope images?  The gate signal looks a bit odd for Vge directly.  Normally Vge has a fast fall time (typically with a bit of overshoot) and rising edge that is slower and more rounded due to gate series resistor.  This looks almost backwards (rising and falling edges look reversed).  Gate diodes are in the correct direction in your images, so that is not an issue.

Given your clean switching waveforms, I expect phase lead is correctly adjusted for ZCS.  However, the Vce switching appears to be very slightly after zero current.  Perhaps measurement CT is inducing a bit of phase lead in the scoped signal.

The "smoke trail" in the first two pictures is actually a camara arteffect probably due to the bright light reflecting in the camara lens.

Yes I actually hooked up the probe backward on the first couple of oscilloscope shots. Unfortunatly I did not make a screenshot of the correct gate signal but it is just inverted. I will take further measurements next week and post more pictures of some freewheeling (with Vge hooked up correctly to the scope  ;)).

I do however fear that you will at some point see a flashover between the laminated busbars, many people have made these and somehow regular safety distances does not seem to cut it for the high transients that can occur in a high power DRSSTC.

Cylindrical capacitors should not be mounted together directly, terminal to terminal with a threaded rod. Its advised against in the datasheets. Simply because these terminals do 2/3 of the heat dissipation. It really should have some busbar and thermal mass to dump it in. I made the same mistake in my large DRSSTC :)

Yes busbar flashover was also a serious concern for me but I tested it to 3kV for 5min and there wasn't any flashover until I cranced it to about 5kV. I cut the insulating mat larger than the busbars so that there isn't just a 1mm air gap around the edge but a 1mm silicone gap. Thanks for the tip with the capacitors. I haven't really felt them getting warm at all but if it should turn out to be a problem in the future I will adress it for sure!

That topload looks amazing 8) Did you have any issues with unintended streamer breakout from the sharp end of the tubes?

Also quite bold to run it in (what appears to be) a populated area. I'm always way to cautious about them calling the cops on me with noise complaints lol

What resonant frequency is that coil running at? I've had the issue that huge IGBTs like the ones you got are too slow to drive a tesla coil at reasonably high frequencies.
Thanks! not not the sharp end of the tubes but the wood supports. I hope this problem is easy to fix but I think just cutting the supports back a bit will do fine. Our neighbours are fine with it as long as it is not to late and I warn them beforehand.

Primary is set to 36,4kHz and the secondary is 38,4kHz unloaded. Those huge IGBTs are very capabable of running at 36,4kHz and 1500Amps - as long as the ZVS is very good.

Offline fh89

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Re: MonsterDR
« Reply #7 on: December 21, 2021, 08:40:46 PM »
Amazing job and great looking coil! Honored to have at least partially inspired your build!

Offline Felix B.

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Re: MonsterDR
« Reply #8 on: December 21, 2021, 09:08:58 PM »
Thanks a lot! Yes I just saw these thick and bright freewheeling arcs and knew I had to built one myself. ;D

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Re: MonsterDR
« Reply #8 on: December 21, 2021, 09:08:58 PM »

 


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