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1
Dual Resonant Solid State Tesla coils / My first DRSSTC
« Last post by erdal on September 20, 2018, 10:52:53 PM »
Hello all,
Its my first DRSSTC play tubular bells midi

Half Bridge IXGK60N60C2D1 IGBT (same to IXGN60N60C2D1 but TO-264 package)
Bus voltage 170 volt AC (240 volt DC)
MMC - 0.1 uf 4000 v ( 2 serial + 2 parallel 0.1 uf 2000 v polypr.)
Primer 6.2 turn 12 cm dia @ ~200 khz
Seconder 0.2 mm enamelled chopper wire ~1650 turn, 75 mm PVC pipe 38.7 cm long ~215 khz
Driver UD1.3
Topload 4.5 x 38.5 cm toroid
Spark 35-40 cm but not full tuning.


Now, i build new driver like UD2.5 but fdd8424 or IXDD430MYI driver sellectable. Some problem with GDT and phase lead adj.
2
Dual Resonant Solid State Tesla coils / Re: IGBT failure in DRSSTC
« Last post by Felix Bieri on September 20, 2018, 09:45:44 PM »
Thanks a lot for the fast reply. And I'm glad I haven't really designed something completely wrong. If I remember correctly I had steep switching edges and no ringing. But I may have had overshots at my GDT... I can't recall caus my memory stick with the pictures on it is lost in space  :'( and as of now i can't test it again because my Driver broke too from a broken Power Supply.... I really need my stuff to get fixed....  ::) :o
To Mads question. Yes they die with a big bang :)
Anyway thanks a lot. Now i have some clues of what to look at when I'm off testing it again once it's rebuilded.

I'll be updating this thread then as soon as I have new data or questions. If anyone has further suggestions I'd gladly hear them.
Thanks a lot again!
3
Dual Resonant Solid State Tesla coils / Re: IGBT failure in DRSSTC
« Last post by Mads Barnkob on September 20, 2018, 09:30:33 PM »
Hi Felix and welcome to HVF :)

I think you have a sound design here and there is no obvious faults jumping right at me, so I would start looking at the driver/GDT and see how they are driving the IGBTs. SKM200 does not just die like that, but if you start out on full DC bus voltage, you will never know if something is wrong before it just goes bang.

Do they die silently or with a bang?

You need to test with a lower voltage on the DC bus and observe the current use, if it rises dramatically above the forward voltage, you most likely have a short circuit of the IGBTs directly across the DC bus. Either due to driving them at wrong phasing, bridge construction fault or some failed part.

Remember to change everything after the GDT when you have had a IGBT failure! Gate resistors, TVS and diodes might look fine, but could be shorted or damaged! Solder it apart and check each component on its own.

Here is a good resource for trouble shooting the GDT waveform: http://www.richieburnett.co.uk/temp/gdt/gdt2.html
4
Dual Resonant Solid State Tesla coils / Re: IGBT failure in DRSSTC
« Last post by Teravolt on September 20, 2018, 09:10:10 PM »
what is your gate drive waveform look like?
how much drive voltage is at the gate?
is your gate drive waveform messy or wierd or clean?
do you have enough dead time?
what does the wave form at the tesla look like?

  I think you may have shoot through or the gates are being damage or your feedback is bad in some way. before you power every thing up check all of your semiconductors including your bridge recifire and drive electonics. after a failure things can be weakend or damaged. make shure that the bridge changes state at the same time that the tesla is oscilating so your zero cross is correct and there is no phasing problems. if that happened your igbt diode may be comutating or you have hard switching going on.
5
Greetings everyone

My name's Felix, I'm an electronics engineering student in Switzerland. I began building Coils in my apprenticeship and have built my first SGTC with around 300kV output (30cm sparks). Afterwards I immediately started building my DRSSTC which is nearly tripple the size of my SGTC. Well, long story short.... I'm currently stuck caus it won't work, so thats why i'm here :o
I worked with my coils for around 3 years now.

Great to meet you guys  ;D
6
Dual Resonant Solid State Tesla coils / IGBT failure in DRSSTC
« Last post by Felix Bieri on September 20, 2018, 02:42:09 PM »
 [ Invalid Attachment ]  [ Invalid Attachment ] Greetings

I have a problem regarding my DRSSTC. My IGBT's die every time i power up my gate driver. As i have already burnet up 4 of my IGBT modules and the prize for this project now slightly climbs to a costs in which i can't really afford it with my students budget, I'm finally here to ask for help in this more then competent forum (thanks for all the answers i found in threads for my the project so far). I have currently dismantled my DRSSTC for redesign and upgrade purpose and some parts are still on the way from china so i can rebuild it.

The stats of the coil right now is:
Primary coil: 14.76uH
Primary cap: 200nF 6kV
Secondary coil: 116.84mH
Secondary cap: 31.62pF
Resonant Freq.: 65.49kHz
 
IGBT (SKM200GB128D): 1200V 300A continuous (1200A peak)
2 440V TVS over every IGBT
2 33V Zener over ervery IGBT gate
1 Snubber cap: 5uF 800V
Alu-Supercaps : 9mF 800V
 
Driver: UD2.7C from loneoceans
Supply Voltage: 565V (I can power it up with 325V aswell and i have tested everything with 24V before i went up to 565V.... maybe I should have waited at 325 first......)
My GDT consist of 24:24 winding around a ferrit.
(See attachments for pictures)

The improvements would be:
1x 20uF Snubber over each IGBT module
Redesign of the bridge for maintainability purpose
Primary cap: 400nF 12kV

Also, is there a way to calculate my primary peak current? For many calculations the current is needed and some calculations i have found don't make sense to me. Do i just assume a current and implement my OCD for a bit less than my IGBT can switch (1200A peak)? This doesn't seem appropriate and i would like to have propper numbers before i burn some more IGBT's  :o.

I'm very grateful for any suggestions regarding my Problem.
Greetings
7
Dual Resonant Solid State Tesla coils / Re: Drsstc 3
« Last post by oneKone on September 19, 2018, 02:28:27 AM »
Cheers for the heads up dan, I'll swing past Jaycar and get some heatsinks! As for pulse skipping I haven't really looked into it so I'll have a read on your thread.

Cheers for the encouragement mads. You've got the nail on the head! Thankfully buying the main components is over! Just remembering all the smaller components now! I can semi relate with your current circumstances, for me it's repainting and reflooring my house... And I also decided to paint one of my car's in my garage..... Something now I wish I hadn't started! Tbh I still find it amazing you find the time to be a family man, Goto work, renovate a house, run a forum and post YouTube videos...

8
Dual Resonant Solid State Tesla coils / Re: IGBT selection - TO-247 or minibrick?
« Last post by Garyf on September 18, 2018, 05:51:35 PM »
I've been away from the Forum and my workbench for awhile, but I occasionally check aliexpress for more powerful TO-247s.  The IXXH100N60b3 came to my attention recently with an Icm of 480 amps.  But no diode. 
So would a unidirectional TVS diode work?  For example 5KP5.0A is good for a 550 amp pulse, 1ps response time.

The rating is for a single pulse, and it's usefulness for freewheeling service is not clear to me.
9
Electronic circuits / Re: Theremin based on the stm32f103c8t6 and bluepill, stm32duino
« Last post by profdc9 on September 18, 2018, 05:00:57 AM »
I would consider using the STM32F103Rx series if there was a convenient, cheap board like the bluepill you could buy.  The bluepill is $3 on ebay.  It's still much cheaper to use that and a MCP4921 (1.25 USD) than almost any other dev board.  The tinnitus32 theremin (https://github.com/gerdb/tinnitus32) - by the way this is an AWFUL name for a device that is supposed to sound pleasant - uses the STM32F4 but isn't terribly convenient because it doesn't really have a PCB to integrate everything into, though such a thing is possible for the STM32 discovery board.  A form factor like the bluepill or Arduino Nano is very convenient for integrating into projects unlike a whole dev board, though a dev board could be integrated into a project like the OpenTheremin does.

Dan

10
Electronic circuits / Re: Theremin based on the stm32f103c8t6 and bluepill, stm32duino
« Last post by futurist on September 17, 2018, 08:57:40 PM »
Nice job! Do you think it would be possible to omit external DAC if using STM32F103Rx series? That would also be a nice upgrade to gaudi's opentheremin v3
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