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Messages - Laci

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1
Dual Resonant Solid State Tesla coils / Re: DRSSTC Driver Logic
« on: March 17, 2019, 01:54:47 PM »
Thanks to your detailed instructions I managed to make your UD3 bluetooth controlled via a bluetooth - serial android app.The next thing I'd like to do is to make it interrupted from the same bluetooth module.Is this possible?I plan to make an app which can change the settings and work as an interrupter.So far I couldn't connect to my fake HM-10 BLE4.0 module from any simple app I made...


2
Dual Resonant Solid State Tesla coils / Re: DRSSTC Driver Logic
« on: March 13, 2019, 05:22:42 PM »
Thank you,it works!I tried previously to connect it via micro usb,but didn't see the COM changing.  ::)
I'm going to test the driver in a few days and try to include the bluetooth module in your design,so probably some questions incoming. :)

3
Dual Resonant Solid State Tesla coils / Re: DRSSTC Driver Logic
« on: March 13, 2019, 04:51:18 PM »
I think I must write a getting started in the next days^^
The software side of the UD3 is a nearly complete rewrite, the spec sheet from steve is obsolete.

1. Compile
2. Flash
3. Connect micro USB
4. Open putty with the new USB COM-port
5. type help for a list of commands or get for list of parameters
6. set the start freq with "set start_freq 65.6" (in kHz)
7. Configure the CT (windings, OCD, Shunt resistor)
8. save everything with "eeprom save"
9. connect a midi player to the USB Midi port
10. play a midi and type in the pulsewidth "pw 50" (µs)


Could you tell me the settings in putty?I get infinite cycle putting out random characters on serial.

4
Dual Resonant Solid State Tesla coils / Re: DRSSTC Driver Logic
« on: March 11, 2019, 11:21:24 PM »
Hi Laci,  :)

Not sure if this is what's causing your problem, but your FliPC looks like it would update its output whenever the CLK pin is high. Whereas the 74HC74 is edge triggered, meaning that it will only update as the CLK pin changes from a low signal to a high signal. As for CLR signals, a logical LOW on the CLR' pin should cause the flip-flop to output 0 instantaneously (since the PRE/CLR inputs are inverted for both your schematic and the 74HC74).

Generally the OCD should actually disable the driver output on the next ZCS point (the same effect as the interrupter turning off), otherwise the IGBT would have to switch with the full peak current. I think that's what your circuit would do too, if the flip-flops were edge triggered.

Hope this helps,  :)
-sjsimmo

Thanks,sjsimmo!I'll read a few more times your suggestions and hopefully realise what's wrong with my logic when I'll have some time.


Is there a reason why you did not use a standard D Flip Flop w/ Enable like this? https://www.cypress.com/documentation/component-datasheets/d-flip-flop-wenable

Keep in mind that some Set-Reset function blocks have different priorities, most has Reset prioritized higher than Set.

While looking for this flip-flip, I came across this problem with edge triggered signals that might be a help to you: https://community.cypress.com/message/2120#2120
Thanks,Mads.I saw that D flip flop with enable but I only had a day to work with my design,not much time to understand every component's logic.Also that one has 3 inputs,while a 74HC74 has 4.Do you know about some additional logic to make it the same?


What's the reason not to use the UD3? The logic is tested and I had no IGBT failures since I use the UD3. With a simple modification to the logic you can add a simple external interrupter, if you want this.
Netzpfuscher,I really like the multifunctionality of your driver,but I didn't find the settings and it seemed far too complex to modify it so I gave up and started building a simpler,while also learning in PSoC Creator.I tried to follow the instructions on Steve's spec sheet,however I couldn't find the variables.
If I'm wrong please correct me or tell the settings file location. :)


The only purpace of the flip flop is to interupt your on time from the fiber reciever. It will stop the primary current from going higher than your mosfets can handle. the OC LED should show this on the board
Teravolt,I can hardly understand what you mean.The OCD comparator is connected to the CLR input of the flip flop,so it should have some effect on it.I mean the OC LED does light up when an overcurrent occours so the Q output in case of an overcurrent is always low,right?!

5
Dual Resonant Solid State Tesla coils / DRSSTC Driver Logic
« on: March 10, 2019, 04:40:30 PM »
I start this topic to understand the logic part of the universal DRSSTC drivers.The idea is to build the well known UD1.3 then upgrade it with digital phase lead control and freeweeling current limiter.In addition I'd like to make a bluetooth or ethernet interrupter.

The core of my design is a CY8CKIT-059 prototyping kit.

So far my driver looks similar to the UD1.3,expect one little bug:overcurrent has on direct effect on the output.Basically whatever I do at the CLR pin(13)it doesn't change the output.Only interrupter input at CLK pin(11) changes it,while I thought a logic high at CLR(overcurrent)should immediately turn off the drive at least for the set time constant(100us in my case and in case of the UD2.7).Is my theory right and my schematic wrong?
I think my code has no problems as it's really simple,just starting the DACs,comparators and the interrupt for the time constant.

My driver:



The internal of FliPC,which I made as a 74HC74 equivalent:



...and the UD1.3:

6
Dual Resonant Solid State Tesla coils / Re: My first DRSSTC on bricks
« on: March 08, 2019, 08:35:31 PM »
I made a board for the CYC8KIT-059 based UD3

https://github.com/profdc9/DRSSTC-PCB-Pack/tree/master/Psoc5-power

so you don't have to etch a board.

Dan

Looks great,although I'll make most of the driver on a perfboard.

There are no files missing, I think psoc creator didn't find the bootloader files. This is a common issue, go to the schematic of the UD3 QFN project, double click the bootloader component and set the path to the correct booloader binary "\common\binary\UARTldr". Then it should compile.

I have no smaller firmware, because I'm not interested in a step back ^^

If it still not compile send me the log file.

Thanks,it works!Not sure if the bootloader location was the problem or something else,but it's OK now.
I want to use a bluetooth 4.0 BLE module and android app for interrupter instead of fiber optic,which I bought for cheap and it's of course clone and can't pair my phone with it.Firmware update can solve this hopefully.
Another idea was the using of an ethernet module,which I received factory defective:none of the two ethernet LEDs turns on.
Sadly I don't know how to get started with the UD3,so it'll take for a long time to make a working board.




7
Dual Resonant Solid State Tesla coils / Re: My first DRSSTC on bricks
« on: March 02, 2019, 10:14:41 AM »
That's right, 500kHz is the maximum for the UD3.

Perfboard is not ideal for a high current gatedriver. I would prefer SMD mit big ceramic decoupling to keep the switching noise out of the driver.

I drive my SKM400 with a 13 to 10 GDT with 24V on the GDT driver so you get 18V at the gate.
Thanks for the suggestions!I'll try to etch a PCB and use 10uF THT X7R capacitors,two in parallel for each N-P MOSFET pair(IRFZ44NPbF and IRF4905PbF).If I succeed to modify an ATX PSU,then I can change the gate drive voltage.
I also received a CY8CKIT-059 board and checked your UD3 firmware,but some files are missing.Do you have a simpler firmware something like the UD2.7 or I should make one on my own?

the universal driver can do 500khz but the SKM400 probly can not what frequency is your coil? your snubber will not work if you are soldering to aluminuim. at least bridge the cap connection to the screws with copper at the end of your assembly
The SKM400 bricks definitely can't do 500kHz,but hopefully they can 150kHz.I plan to enhance the MMC connections or even make a completely new one if this fails.The snubbers are good,1uF and mounted directly to the bricks with the screws.

8
In my opinion it's still better to burn it down home,than in front of audience. :) Maybe just some ghosts are playing with you. ::)

9
Dual Resonant Solid State Tesla coils / Re: My first DRSSTC on bricks
« on: February 20, 2019, 08:42:24 AM »
Thanks for the suggestions!We talked about switching speeds and losses here: https://highvoltageforum.net/index.php?topic=549.msg3415#msg3415

The MMC is poor because they had no more in the local store.The plan was to build a 4 in series,8 in parallel MMC

I plan to use freewheeling for long pulses if the losses won't be much.Philip probably used 2kV CDE caps,2 in series for 4kV and 4 in parallel just like my MMC.

What about the primary?I can buy copper tube from a local store from 0.6 cm diameter.The thicker tube stays cooler than the thinner?

10
Dual Resonant Solid State Tesla coils / My first DRSSTC on bricks
« on: February 18, 2019, 05:17:53 PM »
I started the building of my first DRSSTC using two used SKM400GB126DH2 modules.Had some problems because not getting what I ordered,but eventually I got generously what I ordered.

The busbar is made out of two 135x22x2mm aluminium rails,with the large DC bus capacitor in the middle for good current sharing.Two 1uF 1250V snubber capacitors are coming,an aluminium heatsink soon and the gate drive components on perfboard/PCB left to do.I'm also trying to modify an ATX PSU for higher voltage and current for proper gate drive supply.

The MMC is rated 0.094uF,4000VDC using 2 in series,4 in parallel WIMA FKP-1 capacitors mounted on a painted piece of tough cardboard(hopefully good enough insulation).Soldering to aluminium was impossible,so soldered the capacitors together using a large solder joint,with a copper wire in the middle.This is probably the weakspot,we'll see how it turns out to be while operating.

Some pictures about the inverter and MMC:




I have a question regarding the inverter and another about the UD3. I see everybody hooking up the CTs between the inverter and the MMC.My MMC fits perfectly on the inverter and that would be satisfying and also really low inductance.Is it possible to connect the CTs to the other side,between the inverter and the primary?
About the UD3:does it uses internal comparators in the Cypress chip instead of external ones,like the TL3116?In this case the expensive comparators are omitted,but is the chip fast enough?(in my case about 150kHz)

12
Can you send us some pictures about your complete setup?It's often hard to solve a problem for the first try,some time for thinking and compatible components does the trick! :)

13
Solid state Tesla coils / Re: Please help me in choosing a driver circuit
« on: February 03, 2019, 04:11:19 PM »
Search for TC/MCP/MIC preffix parts like the TC4429,just make sure you have one inverted and one non-inverted version,with high output current capability and enable pin if you want to easily use an interrupter.
The second option is to use an NPN/PNP output stage,like this:



The secondary coil ratio is really high,as Mads said,with just under a 1:4 ratio secondary coil,the streamers were limited in my case,so had to wind a smaller secondary.

14
Dual Resonant Solid State Tesla coils / Re: Choosing IGBT module
« on: January 31, 2019, 10:17:42 PM »
Thanks Teravolt,but the shipping price of that to EU is almost as much as the actual price.
Nevermind,I ordered two SKM400GB126DH2 modules for 93 EUR(included shipping),crossed my fingers and waiting for them to arrive.Hopefully they'll be alright!

Thanks for the advices and I'll post as soon as they arrive.

15
Dual Resonant Solid State Tesla coils / Re: Choosing IGBT module
« on: January 30, 2019, 10:33:10 PM »
Thanks,Mads!I only have a UD1.3 driver,so no phase lead,but the Semikron modules can deal with that hopefully.I will try to build a mix of UD3 and UD2.7 to avoid the use of ultrafast comparators and variable inductors.

Does anybody know something about the H2 ending of the SKM400GB126DH2 module?I found no information about it,but there's a similar listing(a bit more expensive)with the SKM400GB126D module that has datasheet.Should I go for the expensive one or the H2 is the same?
@Netzpfuscher which type is your module?

16
Dual Resonant Solid State Tesla coils / Re: Choosing IGBT module
« on: January 30, 2019, 06:07:37 PM »
Thanks for the help,Hydron and Netzpfuscher!

@Netzpfuscher
Well,then it's definitely possible to drive them at 150kHz and I probably wouldn't even go up to 1000A with a medium sized coil.

@Hydron
I planned two different GDTs to drive a full bridge,each on IRFZ44N + IRF4905 output stages which can supply plenty of power I guess.
These are the cheapest used IGBTs on ebay that I found in EU.The prices are really close,so I will choose the Semikron modules.The reason to buy modules is the lack of low inductance design with TO-247 modules and I don't want to order PCBs or etch double sided.

Since the Semikron modules are 1200V and using a full bridge on 320V will not make useful their full voltage,a single module on voltage doubler would be the same?

Here are the coil specs from my first topic:
Now i have the components for the secondary let's see what can I do :D
The coil,as calculated should be:125mm dia.,485mm long(1:3.88),1620 turns.

I hope,that if I can make it,it will work with a SSTC driver,then maybe upgrade to DRRSSTC...

17
Dual Resonant Solid State Tesla coils / Choosing IGBT module
« on: January 29, 2019, 09:55:57 PM »
I've benn watching IGBT modules for a while now and found two,but not sure which one is better for my ~150kHz coil.

First,the MG150J2YS40 TOSHIBA module,which is the faster one,with Fmax1=307kHz in the worst case.I planned a full bridge with EU mains rectified to run around at 500A.The datasheet doesn't mention the switching losses so I can't calculate else.



The second is the SKM400GB126DH2 Semikron module (what is the meaning of the H2 suffix?) which is larger than the previous.I calculated Fmax1=350kHz.Sadly,the turn on- and off energy is large ,Eon=29mJ and Eoff=48mJ ,so  Fmax2=20kHz at Tj=80 and Tc=50.This frequency limitation is a bit scary,as I'd like run it at 150kHz.Is it still possible?If the Semikron modules can run at my frequency,a half bridge of it or a full bridge of TOSHIBA modules is more efficient?



Netzpfuscher used similar modules in his Next Gen DRSSTC with lower current rating,but at lower frequency.I bet a medium size coil like mine could produce huge sparks with a compatible Semikron driver and freewheeling,like Philip's DRSSTC V.

The prices are close,two TOSHIBA modules 80 euro,two Semikron modules 105 euro.

Datasheet for the MG150J2YS50,which is newer than what I mentioned,but the same speed:
https://datasheet.octopart.com/MG150J2YS40-Toshiba-datasheet-10733651.pdf

Datasheet for the SKM400GB126D(without H2 suffix):
https://www.semikron.com/dl/service-support/downloads/download/semikron-datasheet-skm400gb126d-22890635.pdf


18
Solid state Tesla coils / Re: SSTC Audio Interrupter Issues
« on: January 27, 2019, 06:19:10 PM »
Q6 is pulled high via R13,so the current across R14 will be the supply voltage / R14 .The power dissipation will be this current squared x R14  ,in  your case over the 0.25W maximum of the resistor.If no signal is at the Q5 base,it will never turn on to pull Q6 base to ground,decreasing the current across R14.
Try using over a 1W resistor for R14 or replace the op amp if that's not working.

19
Dual Resonant Solid State Tesla coils / Re: (DR)SSTC II
« on: January 07, 2019, 08:53:32 PM »
I made a new ugly looking,but low inductance bridge using only thick copper plate.Coincidentally the primary current with 10 ohm burden is noisy again,the bridge output now became noisy sawtooth... :-X
I should leave the thing as it was and move on to a more professional thing with newer driver and brick inverter.No way it gonna repair itself by a snap,just started to make me angry.




20
Dual Resonant Solid State Tesla coils / Re: (DR)SSTC II
« on: January 07, 2019, 12:43:26 PM »
About the IGBT bricks you found, you will have to do some guesswork/extrapolation of the available data, you do know these IGBT calculations? http://kaizerpowerelectronics.dk/tesla-coils/drsstc-design-guide/igbts/
I found no informations in the datasheet about the switching losses,so I mainly compared the switching speeds with CMx00 modules and calculated a Fmax1 of 307kHz.The oneTesla bridge design accentuates the turn-off delay time,which is better than the CM200DU-24F's used by loneoceans at 120kHz in his DRSSTC 2.


Twisted wires will only have a low inductance if it is the two opposite currents flowing in each their wire, the same potential in two twisted wires does not have any effect on inductance. I got some information on busbar, primary circuit and low inductance design collected here: http://kaizerpowerelectronics.dk/tesla-coils/drsstc-design-guide/busbar-and-primary-circuit/
At first I wanted to use twisted cables for bus connections to lower the DC resistance,eventually used up the remaining twisted cable for the other connections.

I assume that the "saw tooth" output is due to too much ESL/ESR in the DC link/bus capacitors - I have seen similar (though not as bad) on my larger coil at high currents.
I desoldered the two 1uF 400VCD polypropylene "snubber" capacitors and made a ESR test on them,on the MMC and on the DC link capacitors accordingly to this video: https://www.youtube.com/watch?v=115erzCCxgE
Interestingly the "snubber" caps and the MMC shows a triangle/sawtooth waveform at 150kHz,but without the "snubbers" and changing the MMC to variations of other capacitors rated for high enough voltage the waveforms are the same,just the frequency changes.
The large DC link capacitors are fine,I don't think they have too high ESL/ESR,they were designed for this kind of purpose.

I feel bad for sweating with such an uncommon bug for weeks.Of course it would be easier to buy a kit and press a button to turn it on.:)

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