Author Topic: BTC DRSSTC ProjecT working 1300A  (Read 528 times)

Offline SAMGO

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BTC DRSSTC ProjecT working 1300A
« on: January 27, 2022, 06:46:50 PM »
Hey, just want to make an update of where I am with my BTC project. For those who don't know I proposed to my school to build them a big tesla coil that can make music. A budget was fixed and so I started building this coil.

You can find the precedent progress in this post:
https://highvoltageforum.net/index.php?topic=1654.msg12650#msg12650

First I built my H-Bridge:


It's a full bridge with 4700uF at 800V, it used two GD600HFY120C2S from starpower, the heatsink it's from semikron.

Then I assebled the base primary circuit:

I'm still missing some cable management but i wanted to make sure that a first prototype was working before continuing

Next step was having everything toghether just to make a cool photo:

There things that are still not optimized. For example I have too many turns right now on the secondary but it's easyer to take out turns then to add them so I will optimize that in the future. Also the space between toroid and coil it's not necessary and could be shortened.

Resonance check and regulation:
primary:

secondary:


In my school we have a bode100 impedence meter that i used to check for resonances, please note that the impedance is not rappresentative in the secondary circuit because of an added resistor for measures.

IGBTs gate check:

Before powering on the main inverter I checked the gate signals. here I found a problem on my GDT where I've taken the wrong pair of cable to connect to the IGBT.

First power up of the primary circuit:


This was the first test with real power where something could really go wrong. Fortunatly everything has gone as planed and I was able to tune my phase lead and check for things like temps, current waveform, current limit. In the oscilloscope you can see in yellow the bridge output at 600VDC and blue is the current (the distortion is due to my setup that wasn't optimal and the phase is wrong but the amplitude correct 1V=1A). The test was done with an OCD of 600A.

Finally was time to test the entire system:



First I tested the system with 600A limit but soon changed it to 800A limit because it was really wokring well. I still have to adjust the primary coil to check if I'm good tuned but I'm already very happy about the result! In this test I reached 1.3kA current limited using 7kW of 3 phase 400VAC out of a 15A variac.


Specs:
Primary:
  • Full bridge GD600HFY120C2S 3phase 400VAC 4700uF
  • 15x1mm copper flat ribbon for connections
  • 4s2p of FPG86Z1254J for prim. capacitor
  • UD2.7revC
Secondary
  • 2200 turns wih 0.5 enmalled copper wire
  • 30cm diameter PP tube (fu**ing to heavy)
  • 75cm major / 20cm minor
  • 40kHz resonance
Interrupter :USB midistick (it's awesome!!!)


Thank you:
Here I would like to thank you some people that made this possible:
  • HEIA-FR school for the opportunity
  • Steve Wards to start everything
  • Mads Barnkob for the cool documentation
  • Gao Guangyan for realaizind the UD2.7revC
  • Thorben Zethoff for the awesome midi-stick

Video:

https://www.youtube.com/watch?v=u88nMUH2cQo
« Last Edit: February 01, 2022, 11:19:43 AM by SAMGO »

Offline Mads Barnkob

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Re: BTC DRSSTC ProjecT working 1300A
« Reply #1 on: January 31, 2022, 07:47:26 PM »
Thank you and huge applause all around for you!

That is a quality build, well laid out and tested/documented as good as it can be! Thank you for sharing your successful build with us!

That is also quite a nice lab you have at your disposal, makes it easier when all the tools and knowledge of them are inhouse :)

Did you end up taking turns off your secondary coil or just put in spacers to primary coil?

At first I thought "BTC" was due to the bridge heat sink looking like a Antminer for bitcoins ;) But then I saw it must be "Big Tesla Coil"
https://kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics
https://www.youtube.com/KaizerPowerElectronicsDk60/join - Please consider supporting the forum, websites and youtube channel!

Offline SAMGO

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Re: BTC DRSSTC ProjecT working 1300A
« Reply #2 on: February 02, 2022, 10:58:07 AM »
Thank you and huge applause all around for you!

That is a quality build, well laid out and tested/documented as good as it can be! Thank you for sharing your successful build with us!

That is also quite a nice lab you have at your disposal, makes it easier when all the tools and knowledge of them are inhouse :)

Did you end up taking turns off your secondary coil or just put in spacers to primary coil?

At first I thought "BTC" was due to the bridge heat sink looking like a Antminer for bitcoins ;) But then I saw it must be "Big Tesla Coil"

For now I was holding off on removing windings as I wanted to give my manager a DEMO and wanted to avoid changing the coil operation. I will be doing this work in the next few weeks and also would like to better adjust the resonance in working state but am looking for a suitable way to do this.
Maybe by measing the E field near the coil (at low power) with a probe I can see if there is an improvement.

I also fear that by having less turn the resonant frequency will augment (because L it's smaller) and that would not be great.

High Voltage Forum

Re: BTC DRSSTC ProjecT working 1300A
« Reply #2 on: February 02, 2022, 10:58:07 AM »

 


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