Author Topic: Enclosure design considerations for a DRSSTC?  (Read 367 times)

Offline GrantV

  • High Voltage Enthusiast
  • *
  • Posts: 26
  • Karma: +2/-0
    • View Profile
Enclosure design considerations for a DRSSTC?
« on: January 22, 2021, 10:05:28 AM »
Hi all,

I am building my first DRSSTC and am busy designing it's physical layout.

My question is: What design considerations do I need to keep in mind for spacing and/or shielding between the bottom of my primary and the electronics below?

I know that when I was bench testing my SSTC, I had a lot of trouble with any digital equipment in the vicinity (within 2 metres) of the coil and as I am hoping to do a full acrylic build, my electronics will not have the benefit of being in a metal enclosure.

I have seen a number of other coilers do acrylic builds so I may be overthinking the issue?

Your thoughts and words of wisdom would be most appreciated  8)

« Last Edit: January 24, 2021, 10:18:25 AM by GrantV »

Offline acobaugh

  • High Voltage Experimenter
  • **
  • Posts: 60
  • Karma: +0/-0
    • View Profile
Re: Enclosure design considerations for a DRSSTC?
« Reply #1 on: January 24, 2021, 06:09:48 AM »
Avoid putting anything steel within maybe 6" of the primary if you can. If you must have hardware near the primary or base of the secondary, go with aluminum, copper, or brass. Glue any wood pieces if you're using wood, and use brass screws if you must.

I highly recommend putting your driver in a metal enclosure. Depending on the overall power and proximity of the driver to other things, you'll be chasing your tail trying to make it noise resistant without a full enclosure.

Offline GrantV

  • High Voltage Enthusiast
  • *
  • Posts: 26
  • Karma: +2/-0
    • View Profile
Re: Enclosure design considerations for a DRSSTC?
« Reply #2 on: January 24, 2021, 10:26:15 AM »
Thank you Andrew.

Yep, I'll def not have any steel near the components.

My primary worry was the shielding of the electronics. You mention shielding the driver but not the bridge or MMC bank?

I have added my current design to my post and I was wondering if I might have to include a shielding layer below the primary for all of the elctronics below? Maybe using strips of copper tape or similar? (laid out in a closed or unclosed grid pattern?)

Thanks for your input :-)

Offline acobaugh

  • High Voltage Experimenter
  • **
  • Posts: 60
  • Karma: +0/-0
    • View Profile
Re: Enclosure design considerations for a DRSSTC?
« Reply #3 on: January 25, 2021, 08:16:23 AM »
No need to shield the mmc or bridge, as long as the primary isn't mounted right on top of them. Is there a reason you can't shield your driver as-is? It's also recommended to put some ferrite beads on the lines going in/coming out of the driver, especially on the wires going to your GDT(s).

Here's a picture of where my driver is. There is a cover that's not shown. All wires leaving the enclosure have a clamp-on ferrite bead on them to act as a common mode choke. The GDT primary wires are looped through twice through one. Driver enclosure, driver negative, rf ground, safety ground, are all tied together at a single point.

Your picture makes it appear that, as long as you shield your driver and add some basic emi suppression to the wires coming in/out of it, you should be just fine. I take it this isn't exactly a huge coil.

It's also important to realize that nearby electronics can be affected by the radiated RF from the coil, the e-field, and EMI thrown back through the power input to the coil. You can only do so much to mitigate these effects.


Online Mads Barnkob

  • Administrator
  • High Voltage Expert
  • *****
  • Posts: 1658
  • Karma: +33/-0
  • Denmark
    • View Profile
    • Kaizer Power Electronics
Re: Enclosure design considerations for a DRSSTC?
« Reply #4 on: January 25, 2021, 09:20:51 AM »
I will concur that the problems with induced noise / transients is something that gets worse with the power level and seems to grow exponentially :)

If we take a look at my small Tesla coil 400W DRSSTC it has a unshielded driver sitting almost underneath the primary coil and there has never been any issues with instability


If we then move up to my large Tesla coil 20kW DRSSTC it is a whole other story! I had to move the primary coil up on stand-offs off the enclosure to avoid heating and noise issues. I was a little worried with the heat sink sitting just underneath the primary coil. There is also some practicality in the large distance between enclosure and primary coil, like having a primary lead of three parallel pieces of 35 mm² cable, they are a bit stiff in it :)


So it was more a worry about induction heating issues due to proximity and as long as the driver is just in a metal box in the bottom of the enclosure, no noise issues. Be sure to do your Tesla coil grounding correct to avoid RF noise in places you do not want it.

A good example of how bad the noise can be with a large powerful coil is seen on the camera interference in this video
/>
Over the years I have learned that a good Tesla coil enclosure is not so much about the layout on the inside, follow the few tips above and that is fine, what is most important is that you make it easy to handle, move and storage is not an issue from things sticking out here and there. Tesla coils spend 99% of their time in storage, so give that some thought. When a Tesla coil is running, no-one is near it enough to notice any "design flaws" on the enclosure anyway :)
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 GrantV

  • High Voltage Enthusiast
  • *
  • Posts: 26
  • Karma: +2/-0
    • View Profile
Re: Enclosure design considerations for a DRSSTC?
« Reply #5 on: January 25, 2021, 12:06:31 PM »
No need to shield the mmc or bridge, as long as the primary isn't mounted right on top of them.
Good to know, thank you. My coil is def not large (2.5KW) and the primary will be at least 4" from the top most part of the bridge and MMC.

Is there a reason you can't shield your driver as-is?
None at all, I have an old PC PSU case that I will put my driver into so that it is properly shielded.

It's also recommended to put some ferrite beads on the lines going in/coming out of the driver, especially on the wires going to your GDT(s).
Ah yes, I had forgotten about those! Thank you, I'll get those ordered now :-)

Driver enclosure, driver negative, rf ground, safety ground, are all tied together at a single point.
Just checking: By "safety ground" you are talking about mains/house ground right? and yes, I would def tie it all onto a single ground bus.



Offline GrantV

  • High Voltage Enthusiast
  • *
  • Posts: 26
  • Karma: +2/-0
    • View Profile
Re: Enclosure design considerations for a DRSSTC?
« Reply #6 on: January 25, 2021, 12:35:57 PM »
So it was more a worry about induction heating issues due to proximity and as long as the driver is just in a metal box in the bottom of the enclosure, no noise issues. Be sure to do your Tesla coil grounding correct to avoid RF noise in places you do not want it.
Agreed and thank you Mads.

Many many years ago when I built my SGTC, it was common practice to use 2 mains power line filters connected back to back. Is this still a good practice or is a single filter connected in reverse sufficient?

Talking about power line filters: Is it best to place my line filter into the circuit between my variac and the bridge? Or does it need to go into the line before the variac?
[Edit] Sorry, that was probably a stupid question. Keeping high frequency noise out of the variac is always best I guess.

Over the years I have learned that a good Tesla coil enclosure is not so much about the layout on the inside, follow the few tips above and that is fine, what is most important is that you make it easy to handle, move and storage is not an issue from things sticking out here and there. Tesla coils spend 99% of their time in storage, so give that some thought. When a Tesla coil is running, no-one is near it enough to notice any "design flaws" on the enclosure anyway :)
LOL thanks for this. You are of course right about it being mostly in storage and should therefore be part of the design consideration. I guess it can be quite easy to make the mistake of designing a perfectly beautiful coil which gets too easily damaged or breaks the first time you try to transport it to a teslathon  ::)
« Last Edit: January 25, 2021, 01:05:27 PM by GrantV »

High Voltage Forum

Re: Enclosure design considerations for a DRSSTC?
« Reply #6 on: January 25, 2021, 12:35:57 PM »

 


* Recent Topics and Posts

post Re: Resonant capacitors on Chinese ZVS drivers
[Capacitor Banks]
dreamth
Today at 04:56:30 PM
post Re: Light, laser and optics - Link collection
[Light, Lasers and Optics]
dreamth
Today at 04:41:06 PM
post Re: COHERENT transformerless 81mHz amplifier schematic ?
[Light, Lasers and Optics]
dreamth
Today at 03:18:19 PM
post Re: COHERENT transformerless 81mHz amplifier schematic ?
[Light, Lasers and Optics]
Da_Stier
Today at 02:40:56 PM
post Re: COHERENT transformerless 81mHz amplifier schematic ?
[Light, Lasers and Optics]
dreamth
Today at 01:48:05 PM
post Re: COHERENT transformerless 81mHz amplifier schematic ?
[Light, Lasers and Optics]
Da_Stier
Today at 01:18:44 PM
post Re: Project: FreakyDRSSTC MK1
[Dual Resonant Solid State Tesla coils (DRSSTC)]
GrantV
Today at 11:15:01 AM
post COHERENT transformerless 81mHz amplifier schematic ?
[Light, Lasers and Optics]
dreamth
Today at 10:42:41 AM
post Interrupter frequency?
[Dual Resonant Solid State Tesla coils (DRSSTC)]
GrantV
Today at 10:08:39 AM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
Today at 09:34:59 AM
post Re: TIG welder teardown. ESAB TIG Caddy 1500i.
[Electronic Circuits]
Bouaziz
Today at 09:34:05 AM
post Re: DRSSTC Performs only with 1cm Arcs - Troubleshooting
[Dual Resonant Solid State Tesla coils (DRSSTC)]
ChrisBlis
Today at 09:30:38 AM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
Today at 09:08:55 AM
post Re: Large coil experimenting with long on-times.
[Dual Resonant Solid State Tesla coils (DRSSTC)]
fh89
Today at 07:16:23 AM
post Re: DRSSTC Performs only with 1cm Arcs - Troubleshooting
[Dual Resonant Solid State Tesla coils (DRSSTC)]
davekni
Today at 05:08:32 AM
post Re: Project: FreakyDRSSTC MK1
[Dual Resonant Solid State Tesla coils (DRSSTC)]
davekni
Today at 04:47:32 AM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
March 03, 2021, 11:20:38 PM
post Re: Next Gen DRSSTC
[Dual Resonant Solid State Tesla coils (DRSSTC)]
AeraCura_
March 03, 2021, 11:15:32 PM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
Twospoons
March 03, 2021, 10:30:40 PM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
March 03, 2021, 10:03:26 PM
post Re: Need Help w/Build - Lightning Pulse Generator
[Laboratories, Equipment and Tools]
Mads Barnkob
March 03, 2021, 09:45:28 PM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
Twospoons
March 03, 2021, 09:44:17 PM
post First power on tests
[Dual Resonant Solid State Tesla coils (DRSSTC)]
GrantV
March 03, 2021, 06:26:23 PM
post Re: Search for opinions concerning the use or test of a yunbao / Ebay drsstc skp
[Dual Resonant Solid State Tesla coils (DRSSTC)]
GrantV
March 03, 2021, 05:54:58 PM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
March 03, 2021, 03:13:30 PM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
March 03, 2021, 01:18:22 PM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
March 03, 2021, 12:25:52 PM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
March 03, 2021, 12:24:40 PM
post Re: DRSSTC Performs only with 1cm Arcs - Troubleshooting
[Dual Resonant Solid State Tesla coils (DRSSTC)]
ChrisBlis
March 03, 2021, 10:43:20 AM
post Re: Search for opinions concerning the use or test of a yunbao / Ebay drsstc skp
[Dual Resonant Solid State Tesla coils (DRSSTC)]
GrantV
March 03, 2021, 09:05:02 AM
post Re: Help for people buying the "12-48 Volt 1800/2500 Watt ZVS induction Heater"
[Electronic Circuits]
davekni
March 03, 2021, 05:53:33 AM
post Re: Through-hole layout of UD2.7C universal driver
[Dual Resonant Solid State Tesla coils (DRSSTC)]
profdc9
March 03, 2021, 04:22:01 AM
post Re: Help for people buying the "12-48 Volt 1800/2500 Watt ZVS induction Heater"
[Electronic Circuits]
petespaco
March 03, 2021, 04:00:14 AM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
davekni
March 03, 2021, 01:21:15 AM
post Re: Just a noob with some HV concerns...
[Beginners]
AstRii
March 03, 2021, 12:36:05 AM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
March 03, 2021, 12:35:57 AM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
davekni
March 02, 2021, 11:40:16 PM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
March 02, 2021, 11:29:28 PM
post Re: DRSSTC Performs only with 1cm Arcs - Troubleshooting
[Dual Resonant Solid State Tesla coils (DRSSTC)]
davekni
March 02, 2021, 10:48:04 PM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
davekni
March 02, 2021, 10:33:13 PM
post Re: Baxandall converter strange output
[Transformer (Ferrite Core)]
dreamth
March 02, 2021, 10:20:22 PM
post Re: Help for people buying the "12-48 Volt 1800/2500 Watt ZVS induction Heater"
[Electronic Circuits]
davekni
March 02, 2021, 10:18:05 PM
post Re: Search for opinions concerning the use or test of a yunbao / Ebay drsstc skp
[Dual Resonant Solid State Tesla coils (DRSSTC)]
davekni
March 02, 2021, 09:38:45 PM
post Re: Through-hole layout of UD2.7C universal driver
[Dual Resonant Solid State Tesla coils (DRSSTC)]
Max
March 02, 2021, 08:54:33 PM
post Re: WTS [EU] Vici DM4070 LCR meter with SMD tweezers
[Sell / Buy / Trade]
Da_Stier
March 02, 2021, 08:53:31 PM
post Re: Through-hole layout of UD2.7C universal driver
[Dual Resonant Solid State Tesla coils (DRSSTC)]
profdc9
March 02, 2021, 05:04:44 PM
post Re: Search for opinions concerning the use or test of a yunbao / Ebay drsstc skp
[Dual Resonant Solid State Tesla coils (DRSSTC)]
GrantV
March 02, 2021, 03:16:25 PM
post Re: WTS [EU] Vici DM4070 LCR meter with SMD tweezers
[Sell / Buy / Trade]
AstRii
March 02, 2021, 09:41:31 AM
post Re: DRSSTC Performs only with 1cm Arcs - Troubleshooting
[Dual Resonant Solid State Tesla coils (DRSSTC)]
ChrisBlis
March 02, 2021, 08:26:30 AM
post Re: Help for people buying the "12-48 Volt 1800/2500 Watt ZVS induction Heater"
[Electronic Circuits]
hightemp1
March 02, 2021, 07:05:01 AM

Sitemap 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 
SimplePortal 2.3.6 © 2008-2014, SimplePortal