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Messages - davekni
Pages: 1 2 [3] 4 5 ... 139
41
« on: March 15, 2024, 08:06:08 PM »
1) If i use 2 GDTs is it better to use one for each of the bricks or one for top IGBTs and other for bottom IGBTs? One GDT per brick (one per half-bridge) is better. Uniform load on both edges for each GDT, one gate rising while other gate is falling. Keeps dead-time uniform. And some pulse-skip drivers require 2 GDTs connected this way (one per half-bridge). 2) If i use signle wires instead of a cat5 cable is it better to have as many primary wires as secondary wires on the GDT? And having them twisted together Yes. Twist each pair (one primary and one secondary) together within coil winding. Twist each primary winding lead pair separately. Parallel the four (or two) primary windings at driver. 3) How much for coil this size does GDT wire crosssection matter and is there optimal crossection for a GDT. Don't think wire gauge is very critical, but get other opinions too. Ratio of wire diameter to insulation diameter does matter some. Thicker insulation is best combined with larger wire diameter too. That keeps parasitic (leakage) inductance from rising. (Leakage inductance for twisted pair windings is proportional to log(wire spacing / wire diameter). 4) Am i correct to assume that its better to keep the GDT wires as short as possible and use shielded wire for the primary? (GDT would be way closer to igbts than the driver circuit) If primary leads are twisted, shielding shouldn't be needed.
42
« on: March 15, 2024, 06:20:47 PM »
It is rare, however I think relying on luck to prevent destruction of IGBTs is not the path I'd take Rare is a relative term. For normal axial-leaded wire wound power resistors, I think "rare" is close enough to never. Meteorite impacts are rare too. I spend no time being concerned about coil destruction by meteorite impact.
43
« on: March 15, 2024, 12:00:51 AM »
What do you mean by a capacitor value which is used in which original circuit? HV flyback transformers were mostly built for CRT displays (TV sets and computer monitors). When used in CRT circuits, drive looked close to your 555 circuit, but with a capacitor across primary winding terminals. Unfortunately I have no way to know what value was actually used for any given flyback primary. Probably less than 0.68uF, perhaps between 10nF and 100nF. If you have an oscilloscope, proper value can be estimated by checking waveforms. Without any capacitor, IRFP260N FET is going into avalanche breakdown on every on-to-off transition. Wastes power and heats FET. I have added the circuit diagram of my Flyback as an attachment. I presume IRFP260N source connects to ground rather than +7V as shown in your 555 schematic. I used the coil between pin 1 and 2 as the internal coil for the 555 Circuit. Do you have a specification for this flyback transformer? There's no way to tell from the schematic which pins were intended for primary drive. Primary winding likely has low resistance (larger wire diameter) than most other windings. Have you tried swapping pins 1 and 2? For flyback drive into rectified secondary, output voltage will be much higher with one polarity than the other. Most CRT flyback primaries are designed to be driven by higher voltage FETs, usually 900V to 1500V FETs. Other primary windings may work well with lower voltage FETs, but also may have higher DC resistance and over-heat with continuous operation. Now i can create much more corona discharge, but is it possible to create the same result with the zvs driver? It is still much more efficient. By "efficient" do you mean it draws less current? That would be expected for a circuit generating less output power. Because ZVS waveforms are symmetric AC sine waves, flyback output can't reach quite the same voltage as with proper flyback drive (555 style drive) into correct primary coil with correct FET voltage capability and parallel capacitor. However, ZVS can likely achieve enough for your interests. Difficult to debug without a scope. I'd suggest first selecting ZVS cap value to hit desired frequency, say 20kHz. Then increase voltage to ZVS circuit until output reaches what you want.
45
« on: March 14, 2024, 05:03:41 AM »
I simulated this thing and seem to have soft switching on both legs of the bridge? I thought this was not possible? Yes, it is possible and desirable. With correct dead time phasing, one FET turns off, remaining (small) primary current causes Vds to rise, then opposite FET turns on as its Vds approaches 0V. Currently using CoolMOS C7 as Quorvo models don't want to converge. Yes, some models have trouble converging, especially IGBT models. Often the old LTSpice IV converges much better than any version since then. I use LTSpice IV most of the time. Haven't found any advantage to newer releases.
46
« on: March 14, 2024, 04:56:51 AM »
I actually have a few more pictures of the circuit and the corona discharge, but when uploading und attaching pictures I always get "Invalid Attachment". I've occasionally experienced the same issue. However, ignore the message and attach anyway. Image shows up at the end of message instead of where it was inserted, but still is there. Images would be very helpful. (I presume you are using an allowed image file type. Mine are always ".jpg".) I can also set the frequency of the 555 circuit. But I can't get to a frequency that you can't hear and that allows the transformer to work at the same time. So I can only operate the transformer with a loud annoying noise. Most DC flyback transformers are designed for at least 15.625kHz (old analog PAL TV standard). Likely to work OK to 20kHz with proper drive. Are you using primary winding built into flyback transformer? Or are you forming a new primary on other leg of flyback's ferrite core? Added primary winding works best with ZVS drive. For 555 drive (conventional flyback drive), internal primary works better. Typically requires a high voltage FET for drive when using internal primary, and a resonant capacitor across primary roughly matching value used in original circuit.
47
« on: March 10, 2024, 06:58:51 PM »
B5 to ground
48
« on: March 10, 2024, 06:49:36 PM »
Looking at the thundermouse's page, it lists on time up to 20ms. This is more likely why its max arc length is so good. You may not need 20ms, but long on times match well with high coupling. The high coupling allows primary-to-secondary energy transfer for longer (over a wider frequency range as arc loading reduces secondary frequency). That's the key advantage of high coupling.
49
« on: March 10, 2024, 03:42:28 AM »
So I guess the question is, is a DRRSTC with such high coupling realistic? Short answer: Yes, I think so. AFAIK, DRSSTCs are better with as high coupling as possible without creating racing sparks along lower part of secondary. Low secondary aspect ratios (height/diameter) allow higher coupling without racing sparks. Low aspect ratios are common for short coils such as this. I think I've seen several such small DRSSTC examples with similar coupling on the forum, but don't recall any specific ones to mention.
50
« on: March 07, 2024, 11:35:01 PM »
I'm winding cable around the ferrite In that case a jump from 12kHz to 50kHz is likely not real either. Perhaps either 16.66kHz or 25kHz. Best way to measure upper frequency may be with transformer secondary shorted rather than arcing. Primary should have a more stable waveform that way. Wich one is the good one? For example, if I put a cockcroft-walton, wich frency is the good one to make the calculations for the cockcroft-walton? For a CW multiplier, starting frequency will be higher one. Capacitors are not charged, so present a high load. As capacitors charge, frequency will switch to lower 12kHz. If transformer coupling is too high (frequency ratio above 1.88x), ZVS oscillators are prone to drop out of oscillation and burn out during the frequency transition region of loading.
51
« on: March 07, 2024, 10:55:40 PM »
What is the purpose of the diode and resistor connected to the gate of the IGBT? I would be very grateful for some help in finding a suitable replacement diode. Purpose is to speed up on-to-off transition of IGBT (falling edge of Vge). Schottky diodes are normal here, as confirmed by your 0.245Vf measurement. Perhaps something like DSS16U or SMD16PL-TP for SMD options. 1N5819 is a common through-hole part used. Any ~1A 40V or higher schottky diode is likely to work fine.
52
« on: March 07, 2024, 10:46:42 PM »
Meanwhile I managed to track down an issue that has been plaguing me during the last few days: Looks like you need a bleed resistor across H-bridge output. That way startup will be consistent. Without resistor, leakage current of IGBTs defines initial bridge output voltage. If output happens to be at same level as first half-cycle drives it, no current is generated. Yet faster startup can be achieved if two resistors are used to bias initial H-bridge output to either + or - Vbus. However, that requires checking which polarity first half-cycle drives H-bridge, then adding resistors to bias output to opposite polarity. I gave the smaller crucible a try though (empty), and it presents a very light load. At 12V / 50% duty cycle it takes ages to heat up and only gets to the point where it is glowing a bit. Any non-magnetic load is likely to be less effective (higher Q), so require higher voltage (higher current and/or higher frequency).
53
« on: March 07, 2024, 10:23:27 PM »
If there is no arc, I measure 12 Khz and if I bring closer the wires of the secondary and the arc starts, i measure 50Khz For ZVS oscillators feeding transformers, it is normal for frequency to increase at high load. Oscillation changes from transformer's normal parallel inductance to transformer's leakage inductance (inductance with secondary shorted). And another question, if a use another DMM if there is no arc, the frequency measured is 12kHz, but when there is an arc, the frequency goes to 100kHz Arcs are erratic loads. And they create EMI that can confuse local electronics such as low-cost DMMs with minimal internal shielding. However, given the 2:1 ratio, perhaps more likely that second DMM is measuring a harmonic frequency. Even first may be measuring a harmonic, with actual frequency being perhaps 25kHz. Are you using the primary winding built into this AC flyback? Or are you winding a new primary on the other leg of the ferrite core as most people do when using ZVS drive?
54
« on: March 07, 2024, 05:12:31 AM »
I don't understand why the tank current would rise "after the temperature reaches the curie point". What ferrous metals are you heating at that time? In my humble (ZVS induction heating) experience, current DECREASES as ferrous metals in the work coil reach the curie point. Yes, same load change at Curie point causes opposite power change. ZVS drive (parallel drive resulting in fixed voltage across coil) consumes less power when load Q increases. H-bridge drive in series with coil consumes more power when load Q increases. I notice a graphite crucible sitting beside the work coil in one picture, but that isn't ferrous, so "curie point" wouldn't apply. Right? I was wondering the same thing. Depends on crucible electrical conductivity and geometry and drive frequency. Test may or may not have included crucible, at least I didn't notice that being specified. If crucible was included, implies it's conductivity is too low to block most magnetic field from center. Higher frequency (resulting in higher volts/turn for same magnetic field) will move more heating to crucible and away from iron in center.
55
« on: March 07, 2024, 03:43:25 AM »
I'd guess a splice to be fine in the upper half of secondary away from primary. Peak volts/turn tends to be lower there. Just make a smooth splice and add a few extra layers of epoxy coating over it as extra protection. Smooth coating will spread out field from remaining splice unevenness as well as insulating splice better.
Hope you get other opinions too. Above is just my speculation. Haven't tried such personally. I've seen one large SGTC with a splice in upper part of secondary (from a local friend who got me started with TCs).
56
« on: March 07, 2024, 01:19:03 AM »
So does this mean I would be better of with a lower capacity, for example half? A quick test shows that I end up around 40kHz with that. Downside is that my Arms will also be cut in half.. Higher frequency generally requires less current to deliver same power to load being heated. However, that depends on load. And you can easily increase current by supplying higher bus voltage. Especially for experimenting before adding impedance matching, higher frequency will be closer to reasonable impedance. edit: I forgot to mention that switching to 15V really improved the temperature of the gate resistors. They still get kinda hot with higher duty cycles, but the larger resistors I ordered will help with that hopefully. Higher frequency increase gate resistor power proportionately. That is one down-side. But gate power resistors are relatively inexpensive. Or change to a buffered circuit. IGBT heatsink started heating up Expected. Switching losses are low with ZCS and low bus voltage. Vce forward drop is the dominant loss, tracking current, not voltage. Btw - is it better to connect one of the supply wires to the other end of the "U" instead for better current sharing between the bus caps? Or is this a bad idea since I will get a huge loop = adding lots of inductance? Unlikely to make any significant difference. Most AC (ripple) current is between IGBTs and caps. Inductance to supply is not very important. Would it be an issue for the PSU if I completely removed the bus caps (since I am using an interrupter)? Probably would be a problem. Most PSU output capacitors are intended to handle ripple current generated within PSU, not huge ripple current from load.
57
« on: March 07, 2024, 01:06:15 AM »
I think this is how its supposed to look like with a resistive load or are the voltage spikes too high? I think they should reduce once I reduce the GDT connection lead length. Looks reasonable. GDT would be better with four parallel primary wires, one twisted with each secondary wire (along with shorter leads).
59
« on: March 05, 2024, 05:18:28 AM »
The mosfet Q4 irfp540 keeps dying (2 have died so far). One likely cause for IRFP540 dying is that the paired IRF9540 is failed shorted. Or that 1k gate pull-up resistor(s) are open (ie. bad solder joint) or 0.1uF coupling capacitor is shorted. Even the time in which it is on, the gate drive output waveform doesn't look good and it keeps moving. Scope traces of the two GDT primary leads (UD2.7 output terminals) would be more useful for debug. It still tends to turns off after a few seconds of operation, also the LM7812 voltage regulator gets extremely hot. Output FETs don't directly connect to +12V, only UCC27423. Since it is still good, implies high load on UCC27423 output(s). Most likely cause is a bad FET with shorted gate. Another reason to suspect an IRF9540 having died (or both). If still problematic, I'd remove all four FETs and test with UCC27423 chip installed. Scope FET gate waveforms and verify supplies are not loaded excessively.
60
« on: March 05, 2024, 03:42:57 AM »
The partition of RF current might depend a lot on the inductance of wires. Exactly what I was thinking, why I guessed wire size was not an issue. Inductance depends on log of (wire spacing / wire diameter), but the empirical formulas are less accurate when the insulation is much thinner than the conductors. Very rough estimates should be fine here. Physical layout prevents twisting for ~half of wire length anyway. Just looking at existing wiring, I'd guess between 0.6uH and 1uH for wires. At 40kHz coil, ripple current is 80kHz. 0.6uH is ~0.3 ohms reactance at 80kHz. 560uF capacitor at bridge is ~0.0036 ohms. Thus very little 80kHz current will flow through wires. Interconnect inductance of 560uH capacitor is likely higher than 0.0036 ohms, so may control wire current more than capacitance. Edit: Forgot about pulse-skipping. That will generate lower frequency ripple current. At 20kHz, current sharing would be closer to 5:1. But I think RMS current component at 20kHz will be lower than 80kHz of full-on operation. Would need to simulate or hand-calculate a bit more to be sure of this. The biggest risk may be if pulse-skipping frequency happens to hit exactly at LC resonant frequency of 560uF and wire inductance. That's where some form of R+C snubbing might be needed at bridge.
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[Beginners]
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alan sailer April 10, 2024, 11:41:46 PM
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Re: Tesla coil safety questions, risk analysis quantified
[Beginners]
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Mads Barnkob April 10, 2024, 11:33:32 PM
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Re: Tesla coil safety questions, risk analysis quantified
[Beginners]
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Michelle_ April 10, 2024, 10:41:33 PM
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Re: Tesla coil safety questions, risk analysis quantified
[Beginners]
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MRMILSTAR April 10, 2024, 10:31:31 PM
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Tesla coil safety questions, risk analysis quantified
[Beginners]
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Michelle_ April 10, 2024, 09:56:35 PM
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Re: Drsstc voltage spike question
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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unrealcrafter2 April 10, 2024, 08:59:26 PM
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Re: Drsstc voltage spike question
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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markus April 10, 2024, 06:35:30 PM
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Re: Drsstc voltage spike question
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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flyingperson23 April 10, 2024, 05:35:14 PM
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Medium Drsstc question
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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unrealcrafter2 April 10, 2024, 03:07:02 PM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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Michelle_ April 10, 2024, 03:42:12 AM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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Michelle_ April 10, 2024, 03:41:04 AM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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sky-guided April 10, 2024, 02:50:23 AM
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Re: DRSSTC V1 using BSM1500
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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Unrealeous April 10, 2024, 01:32:17 AM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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OmGigaTron April 10, 2024, 01:26:29 AM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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OmGigaTron April 10, 2024, 01:18:35 AM
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Re: Big Coil Big Sparks
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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Mads Barnkob April 09, 2024, 07:34:19 PM
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Re: DRSSTC V1 using BSM1500
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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flyingperson23 April 09, 2024, 06:14:27 PM
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Re: CM400 Induction Heater
[Electronic Circuits]
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markus April 09, 2024, 06:08:53 PM
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Re: DRSSTC V1 using BSM1500
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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markus April 09, 2024, 05:15:19 PM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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Michelle_ April 09, 2024, 05:11:04 PM
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Re: Big Coil Big Sparks
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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Benjamin Lockhart April 09, 2024, 06:32:16 AM
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DRSSTC V1 using BSM150
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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Unrealeous April 09, 2024, 04:04:47 AM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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alan sailer April 09, 2024, 03:27:11 AM
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Re: Big Coil Big Sparks
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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davekni April 09, 2024, 03:25:47 AM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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OmGigaTron April 09, 2024, 03:01:40 AM
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Re: Plasma Torid - Class E Self Resonant Dual/Stereo - Plasma Torid Build
[Dual Resonant Solid State Tesla coils (DRSSTC)]
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sky-guided April 09, 2024, 02:46:46 AM
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