Author Topic: Highway to DRSSTC  (Read 301 times)

Offline Laci

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Highway to DRSSTC
« on: November 26, 2017, 01:09:10 PM »
After a short pause I'm back again :)
The concept is simple:make a working DRSSTC.

I've analyzed some DRSSTC circuits.The first question is about the CT feedback.Is this simplified schematic capable of doing a CW mode operation?Or it cannot start the oscillations without an interrupter?Then a simple 555 oscillator connected the the UCC's 3'rd pin will work?

Offline futurist

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Re: Highway to DRSSTC
« Reply #1 on: November 27, 2017, 12:12:21 PM »
Primary current in "normal" SSTCs is limited by the primary reactance which allows for CW mode operation. DRSSTC in CW mode would cause primary current to rise until switching transistors fail

Schematics you drew needs at least 555 interrupter connected to the enable pin to work. However, the interrupter can disable gate drivers when current flowing through IGBTs is not zero, so it would be best to use original schematics with flip-flop added to the interrupter logic

I suggest you read excellent DRSSTC guide written by Mads
http://kaizerpowerelectronics.dk/tesla-coils/drsstc-design-guide/

And short DRSSTC theory of operation
http://stevehv.4hv.org/drsstc_design.htm
http://www.loneoceans.com/labs/drsstc2/

Offline Laci

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Re: Highway to DRSSTC
« Reply #2 on: November 27, 2017, 05:33:52 PM »
What is your opinion about the HFBR-0500Z series optical transmitters & receivers?Which type would you recommend?The optical fiber cable: MIKROE-1473


Offline Mads Barnkob

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Re: Highway to DRSSTC
« Reply #3 on: November 27, 2017, 07:22:51 PM »
Good to see that you take on building a DRSSTC  8)

CW mode is completely out of the question for a DRSSTC, the closest you can come at the moment is properly the very long on-time type of QCWDRSSTC, where 5 to 20ms on-time is normal, but these are a bigger engineering challenge than a DRSSTC.

Regarding the driver, Steve Ward started out simple, as you can see on his schematics, but he also warns against using his older designs as they are not stable and lacks proper IGBT protection. Instead I really advise you on using the UD1.3, it is not as scary and complex as it looks, once you get to test it. http://stevehv.4hv.org/new_driver.html

The fiber optics, in the HFBR-0500Z series, avoid the HFBR-1523Z/HFBR-2523Z as they are only 40kbps, the others are 1Mbps and upwards.
The plastic fiber wire looks exactly like the plastic fiber I am using myself, its easy to cut with a sharp knife and handles easy without damaging it.
http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

Offline Laci

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Re: Highway to DRSSTC
« Reply #4 on: November 27, 2017, 10:09:06 PM »
What kind of mosfets did you use for GDT output stage in the Kaizer DRSSTC I? :)

And the IC8 driver chip?Is the UCC27425P or the UCC27423P any good?

Offline Mads Barnkob

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Re: Highway to DRSSTC
« Reply #5 on: November 28, 2017, 09:16:55 AM »
What kind of mosfets did you use for GDT output stage in the Kaizer DRSSTC I? :)

And the IC8 driver chip?Is the UCC27425P or the UCC27423P any good?

It is IRF540 and IRF9540, I should add that to my website :)

The UCC MOSFET driver ICs are very good, sturdy and hard working, just do not ever run them without a load connected! That will risk destroying them. UCC ICs can however be a little expensive, so you could find cheaper MOSFET driver ICs with a lower peak current like MAX4420/29, but it all comes down to if you need a enable input on the driver.
http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

Offline Laci

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Re: Highway to DRSSTC
« Reply #6 on: November 28, 2017, 05:44:58 PM »
Is that a problem if I use different cores for the CT and for the OCD?
2x B64290L674X830
2x TX42/26/13-3E25
« Last Edit: November 28, 2017, 05:50:13 PM by Laci »

Offline futurist

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Re: Highway to DRSSTC
« Reply #7 on: November 28, 2017, 09:13:34 PM »
It's completely fine  :)

Offline Hydron

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Re: Highway to DRSSTC
« Reply #8 on: November 28, 2017, 11:10:47 PM »
Is that a problem if I use different cores for the CT and for the OCD?
2x B64290L674X830
2x TX42/26/13-3E25

Those should work very well. I have used the first one you mentioned as a GDT core for my QCW coil - it has good properties for driving a high frequency coil (~350kHz) without too many turns (I used 5-6). The current transfomer core also should be fine - it's difficult to get them wrong.

Offline Laci

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Re: Highway to DRSSTC
« Reply #9 on: December 09, 2017, 06:37:09 PM »
So I've got through some bad days...Received some components,including 2x TX42/26-3E25 cores(like the other ones) for the OCD,some logic IC's + a MCP1403 driver,optical fiber cable(the transmitter & receiver is coming from ebay:HFBR1531Z + 2531Z)and 3xIGZ100N65H5XKSA1 IGBT replacement.
The IGBT fullbridge was made in a couple of hours.At one IGBT I've used 2xMUR1560's instead of the 2x 1.5KE440A-E3/54 TVS diodes,since one pair died previously.To test it,I hooked it up to the SSTC driver.The phasings looked correct,so the fullbridge was connected to a power supply of 18V,and to the TC primary.It was working quite well even at such a low voltage.The current drawn was about 0.6A-1.5A depending one the primary number of turns.Then I give it some more juice with the big 55V trafo.Guess what?The multimultimer's current display immediately started to show like 20A.I disconnected everything fast,but two IGBT died..The other two also not worked not for long;at 1Hz interrupted on rectified mains after some massive arcs the whole room lighted out.Another two died IGBT...Still not learning about my bads..Idiot!

Today I started the making of Steve Ward's universal driver.The logic part is done,the OCD looks working,because the LED lights up when the voltage reaches a higher level then the reference at the LM311.I'm interested if this driver can drive a SSTC,since I don't have more IGBT...I would like to change the primary CT to secondary base feedback CT,without using primary resonance capacitor.What do you think?And also what is your opinion about the OCD CT and about the primary CT?At the end same cores were used(because I ordered the parts from TME),wound the same way both.

Offline Laci

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Re: Highway to DRSSTC
« Reply #10 on: December 12, 2017, 08:49:16 PM »
So I received a HFBR-1531Z and a HFBR-2531Z optical sensors with MIKROE-1473 cable.My question is what kind of connector can be used to connect the cable's ends to the sensors?

Offline Mads Barnkob

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Re: Highway to DRSSTC
« Reply #11 on: December 12, 2017, 09:36:30 PM »
It is a shame that you keep blowing up silicon, but did you find out was it wrong? How did you determine that the GDT phasing is correct?

Your CTs look fine and its perfectly good to make exactly the same, you can even have them share just one core that goes on the primary circuit and then have two cores being fed from that one core. Like the red/black one here


I like your simple driver on the protoboard, just shows that easy, cheap and fast can work just as good as Chinese silver screen PCBs, nothing beat building something on the same day that you like to, instead of waiting for 5 weeks for shipping.

I think you need some of these connectors ( https://www.tme.eu/en/details/hfbr-4513z/toslink-transmitters-and-receivers/broadcom-avago/?brutto=1&currency=DKK&gclid=EAIaIQobChMI8-Xqi6iF2AIVlQ8YCh0flAl-EAQYBCABEgKu1PD_BwE ) for the cable, but im not completely sure exactly which fits your transmitter/receiver, as I have used the IFD95T that has a screw clamp quick connect on it.
http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

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Re: Highway to DRSSTC
« Reply #11 on: December 12, 2017, 09:36:30 PM »

 


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