Author Topic: CM300 coil build questions  (Read 136 times)

Offline acobaugh

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CM300 coil build questions
« on: July 21, 2019, 05:32:28 AM »
Hey folks!

I've got the itch again to start back up on my first DRSSTC build. Now, this is not my first TC by any means - I've been building and improving my own tesla coils since about  2002. I've recently maxed out my latest design - an 8" SGTC running a pair of 12kV PTs in series/parallel, about 30A+ @280VAC input (see https://labs.cobaugh.io/hv/tesla/8inch-sgtc for full specs). The resonant frequency doesn't allow me to put the system fully in tune without off-axis induction with the current 0.03uF MMC. The whole system was intended to be run off a pole transformer eventually by reconfiguring the MMC for 0.12uF, or using a pair of GE industrial snubber caps, but I doubt that will happen as I've grown tired of hauling all of this heavy iron around when I want to run it outside (despite having a nice big workshop, the rafters even at 10ft are rather limiting for TC use at high power).

I'd like to reuse this secondary, primary, and topload for a CM300DY-24H full bridge drsstc, running up to 1000A (maybe more if folks think I could swing 1200A with this frequency). The secondary+topload have a measured Fres of around 73kHz.

For DC bus I have a pair of CDE 520C series 11,000uF 450VDC stud-mount capacitors, to be configured in a voltage doubler setup.

IGBTs were originally going to be 4x Mitsubishi CM300HA-24H single modules, as there was a time when the single modules were cheaper than the dual modules. Then I found a seller with CM300DY-24H at a very reasonable price, so I picked up 4. Right now I'm leaning towards the dual modules for the ease of bus layout, and generally better availability of replacements.

For the MMC, I think I have two options:
1) I use my existing 20s4p CD942C20P15K MMC and rearrange it so it's 5s16p for 0.480uF, 10kvdc, 216A RMS, 6912Apk.
2) I procure some of the Aerovox RBPS 2uF 1kvdc snubber caps, and set them up in 16s4p for 0.5uF, 16kvdc, 88A RMS, 3416Apk

Driver will be Gao's UD2.7C.

A couple of questions:
1) Is 73khz a low enough frequency to run these CM300s at, at up to 1000A peak (assuming phase lead and such)? Or should I wine a new secondary with thinner wire for a few more inches to get it down a bit? I'm probably also going to build a much larger skeleton topload, which should drop Fres even further.
2) Which MMC option would you run? It seems like some people (Gao, maybe ArcAttack?) run the RBPS snubbers without issue, but the thermals and RMS current capability don't look too good on paper with only 4 strings in parallel.

Offline Mads Barnkob

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Re: CM300 coil build questions
« Reply #1 on: July 27, 2019, 08:51:22 PM »
Welcome to HVF!

You have a solid plan and the HV experience to pull this off, no problems, only new terratory to you is phasing of signals, unstable feedback and EMI problems :)

Both your MMC options are viable, but there is no doubt that the 942C one, with its high RMS current capability, is superior to the RBPS, even though it has a higher voltage rating, once you do the math for a DRSSTC (or use some calculators: http://kaizerpowerelectronics.dk/calculators/mmc-calculator/ ) you will see that you often do not need that high voltage rating for a DRSSTC MMC compared to a SGTC.

For the IGBTs withstanding 1200A at 70kHz, you have to do the math :) http://kaizerpowerelectronics.dk/tesla-coils/drsstc-design-guide/igbts/

36 kHz    1300 A    Powerex CM300DY-24NF    Fabrício Franzoli
42 kHz    1200 A    Powerex CM300DY-24    Dzejwor on 4hv.org
70 kHz    750 A    CM300DY-24H    Hydron on 4hv.org
72 kHz    700 A    CM300DU-24NFH    Gao Guangyan

Looking at these recorded settings, you might be facing some serious switching losses and perhaps you water cool your way out of the problem, or use the single IGBT modules so you have much more surface to dissipate the heat on, if they have good enough specifications to do so.
http://www.kaizerpowerelectronics.dk - Tesla coils, high voltage, pulse power, audio and general electronics

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Re: CM300 coil build questions
« Reply #1 on: July 27, 2019, 08:51:22 PM »

 


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