DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
HV Enthusiast, Tue May 30 2006, 01:17AMThis past week, we finished building the final build prototype of our commercial DRSSTC system, the miniBrute system. Two of these units will be extensively tested in the coming months and the third one will be sent out as a demo unit to a firm overseas. Stay tuned for actual arc photos once we fire these babies up. They will be officially unveiled to the Tesla community at the 2006 RATCB this year.
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
..., Tue May 30 2006, 03:06AM
Looks sweet
All of top 5 4hv posters get free ones, right
Lets see then fired up!
..., Tue May 30 2006, 03:06AM
Looks sweet
All of top 5 4hv posters get free ones, right
Lets see then fired up!
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
Mike, Tue May 30 2006, 04:07AM
I've never really thought post spamming would give you free stuff.
Anyways, those do look awesome and well built. I always saw those on your site and wondered if you had given up work on them or what.
Do you have any guesses as to how long period time they can be run safely or what the cost might be?
Mike
Mike, Tue May 30 2006, 04:07AM
I've never really thought post spamming would give you free stuff.
Anyways, those do look awesome and well built. I always saw those on your site and wondered if you had given up work on them or what.
Do you have any guesses as to how long period time they can be run safely or what the cost might be?
Mike
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
Hazmatt_(The Underdog), Tue May 30 2006, 06:18AM
I know you're probably already sold out, but what's the going cost of one?
Hazmatt_(The Underdog), Tue May 30 2006, 06:18AM
I know you're probably already sold out, but what's the going cost of one?
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
HV Enthusiast, Tue May 30 2006, 11:41AM
Thanks. We've built up several iterations of prototypes, mostly just "ugly" benchtop stuff, so these are the first form-fit-function units.
These are designed to be run continously as long as necessary, or at least until the thermal sensor trips. There is a pretty powerful cooling fan inside this unit and both a large heatsink (power electronics) and the MMC are within the flow of the fan, so it should remain quite cool, although we shall see how it runs for real.
As far as pricing and availability goes, not sure whats going on with that yet.
Tonite i plan on first light testing, so hopefully all goes as planned . . . keeping my fingers crossed . . .
HV Enthusiast, Tue May 30 2006, 11:41AM
Thanks. We've built up several iterations of prototypes, mostly just "ugly" benchtop stuff, so these are the first form-fit-function units.
These are designed to be run continously as long as necessary, or at least until the thermal sensor trips. There is a pretty powerful cooling fan inside this unit and both a large heatsink (power electronics) and the MMC are within the flow of the fan, so it should remain quite cool, although we shall see how it runs for real.
As far as pricing and availability goes, not sure whats going on with that yet.
Tonite i plan on first light testing, so hopefully all goes as planned . . . keeping my fingers crossed . . .
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
ragnar, Tue May 30 2006, 12:25PM
I hope you don't have to walk up to it and bend over the topload whilst you flick the "ON" switch
hehe
ragnar, Tue May 30 2006, 12:25PM
I hope you don't have to walk up to it and bend over the topload whilst you flick the "ON" switch
hehe
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
HV Enthusiast, Tue May 30 2006, 01:06PM
Darn, i knew i forgot something . . .
HV Enthusiast, Tue May 30 2006, 01:06PM
Darn, i knew i forgot something . . .
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
Self Defenestrate, Tue May 30 2006, 01:43PM
Don't make a remote controller available just yet, sell a few of the coils and advertise the controller seperate from the coil like this: "Tired of reaching under 100,000 volt arcs to turn off you tesla coil? Sick of electrocution and RF burns on you back? Then we have the innovation for you...." You could also make an Executive Style coil, with a polished redwood front and calender to schedule runs.
How's current draw out of the wall? Will you be able to run off a five amp line?
Self Defenestrate, Tue May 30 2006, 01:43PM
Don't make a remote controller available just yet, sell a few of the coils and advertise the controller seperate from the coil like this: "Tired of reaching under 100,000 volt arcs to turn off you tesla coil? Sick of electrocution and RF burns on you back? Then we have the innovation for you...." You could also make an Executive Style coil, with a polished redwood front and calender to schedule runs.
How's current draw out of the wall? Will you be able to run off a five amp line?
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
Marko, Tue May 30 2006, 02:05PM
That would be cruel.
But where is really the remote/interrupter?
Marko, Tue May 30 2006, 02:05PM
Don't make a remote controller available just yet, sell a few of the coils and advertise the controller seperate from the coil like this: "Tired of reaching under 100,000 volt arcs to turn off you tesla coil? Sick of electrocution and RF burns on you back? Then we have the innovation for you...." You could also make an Executive Style coil, with a polished redwood front and calender to schedule runs.
That would be cruel.
But where is really the remote/interrupter?
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
HV Enthusiast, Tue May 30 2006, 02:42PM
The remote controller plugs into the jack on the front of the panel. This prototype will still require an external variac for bridge power, but the final unit will use no variac, and use pulsewidth to control power output vs. voltage control.
HV Enthusiast, Tue May 30 2006, 02:42PM
The remote controller plugs into the jack on the front of the panel. This prototype will still require an external variac for bridge power, but the final unit will use no variac, and use pulsewidth to control power output vs. voltage control.
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
Avalanche, Tue May 30 2006, 04:16PM
Very nice, very professional looking! Don't think I've ever seen 3 identical coils pictured together
Just out of interest, how is the front panel made, with the text on it?
Avalanche, Tue May 30 2006, 04:16PM
Very nice, very professional looking! Don't think I've ever seen 3 identical coils pictured together
Just out of interest, how is the front panel made, with the text on it?
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
HV Enthusiast, Tue May 30 2006, 05:18PM
Thanks!
The front panels were made from an outfit called Front Panel Express. They are a German company and do excellent work. The panels themselves are anodized 3mm aluminum and the lettering is engraved and then painted.
HV Enthusiast, Tue May 30 2006, 05:18PM
Thanks!
The front panels were made from an outfit called Front Panel Express. They are a German company and do excellent work. The panels themselves are anodized 3mm aluminum and the lettering is engraved and then painted.
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
Steve Ward, Tue May 30 2006, 05:22PM
Very nice indeed. Are the toroids from John Freau (they look like the one i used to have).
If you could, can you try to document your stress testing? Id be curious to see what (if anything) causes it to fail.
Steve Ward, Tue May 30 2006, 05:22PM
Very nice indeed. Are the toroids from John Freau (they look like the one i used to have).
If you could, can you try to document your stress testing? Id be curious to see what (if anything) causes it to fail.
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
HV Enthusiast, Wed May 31 2006, 12:22AM
As Hannibal Smith always said, "I love it when a plan comes together . . . " Anyways, first light was a complete success with almost zero hitches. All the time spent planning, simulating, and designing paid off with a DRSSTC that fired up first time to 30+ inches with a supply rail of only 200 volts driving a half-bridge of IGBTs, of course the initial benchtop prototypes didn't hurt either . . .
Everything worked right off the bat. Current limiting worked, although was initially set for only 200A, and the bar graph peak current meter worked very well.
Only problem was primary to secondary arcing due to overcoupling, so i had to raise the secondary 1.5 inches to eliminate this. When I connected the strike rail to earth ground, i had a disastrous arc over to the secondary destroying it instantly. Damn! Anyways, a simple repair was in order, and the secondary was up and running again.
Increased current limit to 500A peak, and reached output arcs of 34 inches.
40 inches!!!!
Current limit was still kicking in at about 75% output, so i increased to about 650A peak current. DC supply voltage now at a full 380V (approx) and output arcs of 40 inches to a grounded strike target. Fantastic! Considering a 12" secondary, thats not too shabby.
Didn't get any photos tonite since i forgot to load my camera, but will get some tomorrow, along with a video or two.
Next order of business is to play with the tuning and look at the primary current to see exactly where i'm operating at. Also, probably bring out the spectrum analyzer if i feel up to it. Biggest problem will be determining the proper coupling and geometry of the strike rail, etc... looks like i'll be cutting that to pieces and re-adjusting quite a bit in the coming weeks.
I'm going to try for 48 inches. Not sure if its achievable with this set-up, but if i'm hitting 40 inches on the first light run without even tuning it, it may be possible . . .
Stay tuned ! ! ! !
HV Enthusiast, Wed May 31 2006, 12:22AM
As Hannibal Smith always said, "I love it when a plan comes together . . . " Anyways, first light was a complete success with almost zero hitches. All the time spent planning, simulating, and designing paid off with a DRSSTC that fired up first time to 30+ inches with a supply rail of only 200 volts driving a half-bridge of IGBTs, of course the initial benchtop prototypes didn't hurt either . . .
Everything worked right off the bat. Current limiting worked, although was initially set for only 200A, and the bar graph peak current meter worked very well.
Only problem was primary to secondary arcing due to overcoupling, so i had to raise the secondary 1.5 inches to eliminate this. When I connected the strike rail to earth ground, i had a disastrous arc over to the secondary destroying it instantly. Damn! Anyways, a simple repair was in order, and the secondary was up and running again.
Increased current limit to 500A peak, and reached output arcs of 34 inches.
40 inches!!!!
Current limit was still kicking in at about 75% output, so i increased to about 650A peak current. DC supply voltage now at a full 380V (approx) and output arcs of 40 inches to a grounded strike target. Fantastic! Considering a 12" secondary, thats not too shabby.
Didn't get any photos tonite since i forgot to load my camera, but will get some tomorrow, along with a video or two.
Next order of business is to play with the tuning and look at the primary current to see exactly where i'm operating at. Also, probably bring out the spectrum analyzer if i feel up to it. Biggest problem will be determining the proper coupling and geometry of the strike rail, etc... looks like i'll be cutting that to pieces and re-adjusting quite a bit in the coming weeks.
I'm going to try for 48 inches. Not sure if its achievable with this set-up, but if i'm hitting 40 inches on the first light run without even tuning it, it may be possible . . .
Stay tuned ! ! ! !
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
..., Wed May 31 2006, 12:42AM
wow, I think that 3.3x secondary length is the largest spark length/secondary hieght I have ever seen I can't imagine where you could fit 48" of spark 25"? coil...
..., Wed May 31 2006, 12:42AM
wow, I think that 3.3x secondary length is the largest spark length/secondary hieght I have ever seen
I can't imagine where you could fit 48" of spark 25"? coil...Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
HV Enthusiast, Wed May 31 2006, 01:05AM
Well, destroyed my secondary again. Nice arc from primary to secondary burnt right through the windings. I'll probably have to move the secondary up another 0.5 inch tomorrow. I did get a single 44 inch strike tonite from toroid to the ceiling, but then the circuit breaker tripped, so i called it quits. Tomorrow, i'll get some video and pics . . .
HV Enthusiast, Wed May 31 2006, 01:05AM
Well, destroyed my secondary again. Nice arc from primary to secondary burnt right through the windings. I'll probably have to move the secondary up another 0.5 inch tomorrow. I did get a single 44 inch strike tonite from toroid to the ceiling, but then the circuit breaker tripped, so i called it quits. Tomorrow, i'll get some video and pics . . .
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
Steve Ward, Wed May 31 2006, 07:25AM
Cool, my 11" tall coil did 37" max. My 22" coil did 80", so thats like 3.63X the secondary length. I think Steve Conner still has us beat at 4.something X secondary length. 40" from the 12" coil is still really great.
Maybe you should move to epoxy coating of the secondary winding? Its actually considerably easier than many layers of varnish, and seems to stand up to a lot of flash-over abuse. The arcs just spread out across the epoxy surface, rather than breaking a pin sized hole in the insulation and then causing burning and carbonization.
Also, from my experience, you can often get away with the strike rail sitting at the same height as the last primary turn (so long as the arcs are coming from the toroid). Its too bad that you already have 3 of them built up so nicely and now you need to modify the design.
Steve Ward, Wed May 31 2006, 07:25AM
Cool, my 11" tall coil did 37" max. My 22" coil did 80", so thats like 3.63X the secondary length. I think Steve Conner still has us beat at 4.something X secondary length. 40" from the 12" coil is still really great.
Maybe you should move to epoxy coating of the secondary winding? Its actually considerably easier than many layers of varnish, and seems to stand up to a lot of flash-over abuse. The arcs just spread out across the epoxy surface, rather than breaking a pin sized hole in the insulation and then causing burning and carbonization.
Also, from my experience, you can often get away with the strike rail sitting at the same height as the last primary turn (so long as the arcs are coming from the toroid). Its too bad that you already have 3 of them built up so nicely and now you need to modify the design.
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
Steve Conner, Wed May 31 2006, 09:19AM
60" from a 14" tall coil is my personal best.
It took over 3kW of power to do it though.
I used a similar geometry of strike rail and solenoid primary, and had very similar problems. I got serious flashovers from primary to secondary that eventually burnt clean through the secondary windings and stopped the coil working. I took a few turns off the top of the primary, and raised the secondary as far as I could. I guess I should rebuild the primary as a cone, but I couldn't be bothered, and it works fine now.
I found I could fix my frazzled secondary coil by soldering the wire carefully back together and wrapping the whole coil in electrical tape. This seemed to have much the same effect as Steve said epoxy coating does: the sparks stay dim and crawl over the tape, instead of forming bright arcs and burning things.
Why did you put a power switch on the front? I always like to be well out of the range of sparks and "flying silicon bits" when I throw the switch.
Steve Conner, Wed May 31 2006, 09:19AM
60" from a 14" tall coil is my personal best.
It took over 3kW of power to do it though.I used a similar geometry of strike rail and solenoid primary, and had very similar problems. I got serious flashovers from primary to secondary that eventually burnt clean through the secondary windings and stopped the coil working. I took a few turns off the top of the primary, and raised the secondary as far as I could. I guess I should rebuild the primary as a cone, but I couldn't be bothered, and it works fine now.
I found I could fix my frazzled secondary coil by soldering the wire carefully back together and wrapping the whole coil in electrical tape. This seemed to have much the same effect as Steve said epoxy coating does: the sparks stay dim and crawl over the tape, instead of forming bright arcs and burning things.
Why did you put a power switch on the front? I always like to be well out of the range of sparks and "flying silicon bits" when I throw the switch.
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
Marko, Wed May 31 2006, 09:31AM
Then my 18 inch secondary needs to do 2 meter arc to be just competing with you. d00d.
Yep, coupling seems pretty high to me, too.
I figured out that steve ward's DR1 has base of secondary beggining just about the top of (helical) primary.
I also use very similar coupling as EVR, it may be too high, I don't know.
Isn't the remote-interrupter switch enough?
Maybe he could sell the pwer supply cable with small box and 'kill switch' on the end
Marko, Wed May 31 2006, 09:31AM
Then my 18 inch secondary needs to do 2 meter arc to be just competing with you. d00d.
I used a similar geometry of strike rail and solenoid primary, and had very similar problems. I got serious flashovers from primary to secondary that eventually burnt clean through the secondary windings and stopped the coil working. I took a few turns off the top of the primary, and raised the secondary as far as I could. I guess I should rebuild the primary as a cone, but I couldn't be bothered, and it works fine now.
Yep, coupling seems pretty high to me, too.
I figured out that steve ward's DR1 has base of secondary beggining just about the top of (helical) primary.
I also use very similar coupling as EVR, it may be too high, I don't know.
Why did you put a power switch on the front? I always like to be well out of the range of sparks and "flying silicon bits" when I throw the switch.
Isn't the remote-interrupter switch enough?
Maybe he could sell the pwer supply cable with small box and 'kill switch' on the end
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
HV Enthusiast, Wed May 31 2006, 11:42AM
Thanks, good tip. I have been exploring different types of secondary coatings - these were done with acrylic coating, but i'm not happy with the results.
What type of epoxy have you had success with?
Will also have to move primary strike rail down, tonite i'll play with the distance. No biggy on modifying these. These are prototypes, so all this rework was anticipated. I'm sure when i'm done testing, these things will be beat to hell with duct tape holding pieces together, etc... But, then again, thats the whole fun of it!!!
The power switch on the front only turns on the control logic and cooling fan. Also, these are prototypes, so the only person going to operate them are myself.
For the final units, i plan on using a twinax cable (two conductor) and have a modulator input to the system and also a DC bus enable signal which will power the relays turning on the dc bus from the external modulator. That is one plan right now.
Thanks for the comments . . .
Dan
HV Enthusiast, Wed May 31 2006, 11:42AM
wrote ...
Maybe you should move to epoxy coating of the secondary winding? Its actually considerably easier than many layers of varnish, and seems to stand up to a lot of flash-over abuse. The arcs just spread out across the epoxy surface, rather than breaking a pin sized hole in the insulation and then causing burning and carbonization.
Also, from my experience, you can often get away with the strike rail sitting at the same height as the last primary turn (so long as the arcs are coming from the toroid). Its too bad that you already have 3 of them built up so nicely and now you need to modify the design.
Maybe you should move to epoxy coating of the secondary winding? Its actually considerably easier than many layers of varnish, and seems to stand up to a lot of flash-over abuse. The arcs just spread out across the epoxy surface, rather than breaking a pin sized hole in the insulation and then causing burning and carbonization.
Also, from my experience, you can often get away with the strike rail sitting at the same height as the last primary turn (so long as the arcs are coming from the toroid). Its too bad that you already have 3 of them built up so nicely and now you need to modify the design.
Thanks, good tip. I have been exploring different types of secondary coatings - these were done with acrylic coating, but i'm not happy with the results.
What type of epoxy have you had success with?
Will also have to move primary strike rail down, tonite i'll play with the distance. No biggy on modifying these. These are prototypes, so all this rework was anticipated. I'm sure when i'm done testing, these things will be beat to hell with duct tape holding pieces together, etc... But, then again, thats the whole fun of it!!!
wrote ...
. . . . power switch on front . . .
. . . . power switch on front . . .
The power switch on the front only turns on the control logic and cooling fan. Also, these are prototypes, so the only person going to operate them are myself.
For the final units, i plan on using a twinax cable (two conductor) and have a modulator input to the system and also a DC bus enable signal which will power the relays turning on the dc bus from the external modulator. That is one plan right now.
Thanks for the comments . . .
Dan
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
ragnar, Wed May 31 2006, 11:53AM
How do you stop the coil from striking the cord going to the interrupter?
Do you just give it a thick shield so it doesn't matter? =P
ragnar, Wed May 31 2006, 11:53AM
How do you stop the coil from striking the cord going to the interrupter?
Do you just give it a thick shield so it doesn't matter? =P
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
Dr. Drone, Wed May 31 2006, 03:59PM
Dr. Drone, Wed May 31 2006, 03:59PM
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
HV Enthusiast, Thu Jun 01 2006, 12:35PM
Thanks Chris and good tips. As far as the disks go, i'm okay at this time, although i do appreciate the offer. We'll keep you all posted!
Thanks again
Dan
HV Enthusiast, Thu Jun 01 2006, 12:35PM
wrote ...
Dan,
Nice coils indeed! I use Plexy ½ disc under the secondary to raise the secondary up. This way I can keep adding ½ inch increments until no flash over. The clear plexy looks good and makes a good insulator.
Again, Looking SWEEEEEEEEEEEEEEEEEEEEEET Sir!
I have a few extra 4 inch x 1/2 inch plexy disc if you want me to blast a few to you?
Rgs,
ch
Dan,
Nice coils indeed! I use Plexy ½ disc under the secondary to raise the secondary up. This way I can keep adding ½ inch increments until no flash over. The clear plexy looks good and makes a good insulator.
Again, Looking SWEEEEEEEEEEEEEEEEEEEEEET Sir!
I have a few extra 4 inch x 1/2 inch plexy disc if you want me to blast a few to you?
Rgs,
ch
Thanks Chris and good tips. As far as the disks go, i'm okay at this time, although i do appreciate the offer. We'll keep you all posted!
Thanks again
Dan
Re: DRSSTC III System - Final Prototypes and FIRST LIGHT!!!
HV Enthusiast, Sat Jun 03 2006, 11:24AM
VIDEO UPDATE:
Here is a first light video of my new commercial DRSSTC III system prototype. The video is at the bottom of the page located here:
http://www.drsstcbook.com
Specifications of the system so far:
Half-bridge
0.11uF Primary Capacitor
DC Bus Voltage = 380V
Maximum Arc Length: 44 inches
Enjoy!!!
Dan
HV Enthusiast, Sat Jun 03 2006, 11:24AM
VIDEO UPDATE:
Here is a first light video of my new commercial DRSSTC III system prototype. The video is at the bottom of the page located here:
http://www.drsstcbook.com
Specifications of the system so far:
Half-bridge
0.11uF Primary Capacitor
DC Bus Voltage = 380V
Maximum Arc Length: 44 inches
Enjoy!!!
Dan
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