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Goodchild

Wed Sept 22 2010, 04:03PM

Registered Member #2292 Joined: Fri Aug 14 2009, 05:33PM
Location: The Wild West AKA Arizona
Posts: 795

I'm starting this project thread for my newest project. The dead line for this project is The Winter Western Teslaton 2011, as I hope to be demoing it there with my other musical coils. This is the fifth DRSSTC I have built so far.

Well Ill start with some specs (as we all do with these project threads

):

Secondary:
12.75 x 45 inches
24 AWG double build magnet wire
1/16 epoxy coating

Primary LC:
10 turns 3/8 copper tube water cooled
0.5uF 16Kv MMC (940C 1uF 2kv caps)

Topload:
12 x 45 inch tube/ring toroid very similar to Finn's and Steve's

System Fo (With topload):
40KHz

Power electronics:
Full bridge CM600HA-24H
GDT gate drive (no high side gate drive junk

)
650VDC bus (for now, later on I plan to have a PFC boost convert for this system at 750VDC)

Controller:
Steve Ward's UD 2.0

Interrupter:
My custom digital regular/MIDI Interrupter

OK now for some photos!

Me standing next to the un-wound secondary + the bare bones CM600 H bridge
4994121246 63cbc1604a

Secondary end caps
4994810772 0555f944ca

Winding the secondary:
5005574199 346c298d58

Epoxy on secondary:
5012986743 1133c0732d

Well that's all I have for now, I will update my progress as the build progresses. Don't hold your breath it's a long processes

More build photos here:

ScotchTapeLord

Wed Sept 22 2010, 04:21PM

Registered Member #1875 Joined: Sun Dec 21 2008, 06:36PM
Location:
Posts: 635

That's a beautiful secondary. I'm working on a ~12" secondary with low Fres (26 gauge wire) that I'm eventually going to convert to solid state, but I could only get cardboard with dimensions like those. Where did you find PVC that wide?

Goodchild

Wed Sept 22 2010, 04:54PM

Registered Member #2292 Joined: Fri Aug 14 2009, 05:33PM
Location: The Wild West AKA Arizona
Posts: 795

I have a friend that got me this pipe at a local Irrigation supply. I did try Sono tube at one point, but it's just so much work to prep and never comes out the same as just strait PVC.

Jrz126

Wed Sept 22 2010, 05:35PM

Registered Member #242 Joined: Thu Feb 23 2006, 11:37PM
Location: Erie PA
Posts: 210

wow, that is a smooth secondary. I have a similar sized one made with Sonotube. Now I wish I would've used PVC.

How do you plan on water cooling the primary? I'm in the process of converting mine to a DRSSTC, and using 3/8 would make things a lot easier and cheaper.

Goodchild

Wed Sept 22 2010, 05:57PM

Registered Member #2292 Joined: Fri Aug 14 2009, 05:33PM
Location: The Wild West AKA Arizona
Posts: 795

Water cooling is easier than you mite think. I just got a small fountain pump, that will sit in a bucket of water next to the coil. I will pump water into one end of the primary tube and another tube will let the water flow back into the bucket. I will have some pics of this setup in a week or so when I build the primary.

Just wondering how much primary current do you plan on running?

Jrz126

Wed Sept 22 2010, 08:06PM

Registered Member #242 Joined: Thu Feb 23 2006, 11:37PM
Location: Erie PA
Posts: 210

That's how I figured it'd be done. Seems like the conductivity of water would be an issue though.

As for my primary current, haven't really figured it out yet. I'm using some Uber-igbts, (2500V, 1200 Arms). So I think I can run just about anything.

Coronafix

Wed Sept 22 2010, 11:14PM

Registered Member #160 Joined: Mon Feb 13 2006, 02:07AM
Location: Melbourne, Australia
Posts: 938

You might consider adding a old heat exchanger out of a fridge into your water cooling circuit. Some cpu fans would also greatly help.
Otherwise after a while, probably not very long, your pump will be pumping hot water back to the IGBTs.
Fantastic looking secondary.

Goodchild

Thu Sept 23 2010, 12:39AM

Registered Member #2292 Joined: Fri Aug 14 2009, 05:33PM
Location: The Wild West AKA Arizona
Posts: 795

Coronafix wrote ...

You might consider adding a old heat exchanger out of a fridge into your water cooling circuit. Some cpu fans would also greatly help.
Otherwise after a while, probably not very long, your pump will be pumping hot water back to the IGBTs.
Fantastic looking secondary.

Ive seen the same thing done with 1/4 primary and the same current (even more heat) and only used a bucket of water, and it ran with almost no heating of the water.

Dr. Drone

Thu Sept 23 2010, 04:24PM

Registered Member #290 Joined: Mon Mar 06 2006, 08:24PM
Location:
Posts: 1673

Goodchild

Thu Sept 23 2010, 05:10PM

Registered Member #2292 Joined: Fri Aug 14 2009, 05:33PM
Location: The Wild West AKA Arizona
Posts: 795

On top of running at 40KHz the system will also use phase lead so there will we almost no voltage spikes or ringing.

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