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4hv.org :: Forums :: Tesla Coils
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13.56MHz CW coil, 250W target, class-E drive topology

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ragnar
Tue Jan 30 2007, 08:57PM
ragnar Registered Member #63 Joined: Thu Feb 09 2006, 06:18AM
Location:
Posts: 1425
The caps were from Bulgaria and cost me about USD$6.50 each, which I guess isn't bad -- but if they're not rated for transmitting power and the contacts melt, or the plates simply arc over, then I'm up the creek, aren't I? :)

I believe the guy has a lot of them, see here if you'd like to try some yourself:
http://cgi.ebay.com/Dual-Air-Variable-UNITRA-Capacitor-505-480pF-NOS-2pcs...
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...
Wed Jan 31 2007, 02:23AM
... Registered Member #56 Joined: Thu Feb 09 2006, 05:02AM
Location: Southern Califorina, USA
Posts: 2445
Nothing better than some cheep Bulgarian caps tongue

Too bad they arc over at like [voltage needed for breakout]-1 wink
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ragnar
Wed Jan 31 2007, 02:34AM
ragnar Registered Member #63 Joined: Thu Feb 09 2006, 06:18AM
Location:
Posts: 1425
After dumping 56,000uF of smoothing caps into that aircap (tuning C), I considered it a lost cause. I was able to replace it with 500pF of ceramics, since his value isn't as critical as the shunt capacitor.

Top trace on scope is Vout, bottom trace is Vds.

This is running at 7.75MHz, drawing about 3A at 24V. Much more satisfying than the 13.56MHz coil, because it actually works for longer than a few seconds, and I haven't heard any bubbling noises coming from the FET, yet.

1170210844 63 FT19970 678resonator

1170210844 63 FT19970 678ready 1170210844 63 FT19970 678breakout1

1170210844 63 FT19970 678breakout2 1170210844 63 FT19970 678breakout3

1170210844 63 FT19970 678breakout4 1170210844 63 FT19970 678scope1
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...
Wed Jan 31 2007, 04:45AM
... Registered Member #56 Joined: Thu Feb 09 2006, 05:02AM
Location: Southern Califorina, USA
Posts: 2445
Looks good!

Glad to hear about the fet tongue
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ragnar
Wed Jan 31 2007, 05:05AM
ragnar Registered Member #63 Joined: Thu Feb 09 2006, 06:18AM
Location:
Posts: 1425
I upped the input voltage to 60V... the result? Rippling, flaming, violent, silent white doom... that was until I lost the FET. I believe it was a thermal issue, and the drive isn't strong enough, so it droops when it's switching. The second aircap hasn't arced over, yet...


1170219950 63 FT19970 678flamingdoom1

1170219950 63 FT19970 678flamingdoom2

1170219950 63 FT19970 678flamingdoom3
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...
Wed Jan 31 2007, 08:45AM
... Registered Member #56 Joined: Thu Feb 09 2006, 05:02AM
Location: Southern Califorina, USA
Posts: 2445
muhahahah

Too bad the flaming white doom (FWD) is hungry, not only for power, but for not-quite pure silicon tongue

But BP is gonna put him on a diet cheesey
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WaveRider
Wed Jan 31 2007, 04:18PM
WaveRider Registered Member #29 Joined: Fri Feb 03 2006, 09:00AM
Location: Hasselt, Belgium
Posts: 500
Hi BP,
Is that "interference" that appears in your last photos caused by being close to the coil?

Sorry to hear about your FETs...

I have some simulations for you.. I'll try to post them when I get home this evening.... You may find them interesting (and even helpful wink )

Cheers!
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ragnar
Thu Feb 01 2007, 02:22AM
ragnar Registered Member #63 Joined: Thu Feb 09 2006, 06:18AM
Location:
Posts: 1425
WaveRider wrote ...

Hi BP,
Is that "interference" that appears in your last photos caused by being close to the coil?

hi Bill,
a distinct moire / interference pattern appears on the CCD depending on proximity to the coil... if I go closer still, you have more noise than you have image, closer still, the LCD blanks out altogether, closer still, and the lens/focus control circuitry goes nuts and all the internal motors stutter and jitter.

wrote ...
Sorry to hear about your FETs...
Me too, thankfully I've got plenty of spares, and I shouldn't lose any more if I can get the gatedrive right. I can use a second IXDD414 to contribute to the drive power. Would you recommend two independent primary windings, or paralleling the two outputs into the existing single winding?

wrote ...
I have some simulations for you.. I'll try to post them when I get home this evening.... You may find them interesting (and even helpful wink )
Aw, cheers! :)

I was slightly demoralised by the difficult nature of the 13.56MHz circuit, and having blown up three FETs already, so for a fix (and to better understand the behaviour/feel of the output network) I made the 7.75MHz coil. It would be wonderful to be able to approach 13.56MHz again with your insight. Thanks for following my progress.

Matt
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WaveRider
Thu Feb 01 2007, 04:07PM
WaveRider Registered Member #29 Joined: Fri Feb 03 2006, 09:00AM
Location: Hasselt, Belgium
Posts: 500
Hi Matt,
Here are the simulations I promised. They may or may not be applicable you your setup, but I tried to make some educated guesses about certain system parameters (e.g. arc-loaded resonator Q, primary-secondary coupling and resonant frequency. I used the IRF730 SPICE model for all simulations.

Three cases are studied:

  • 1. VDD=115V, 13.56MHz, Resonator loaded Q=10.
    2. VDD=40V, resonator Q=10, using Ls, Ctune for the 115V case
    3. VDD=40V, resonator Q=10, optimizing Ls, Ctune for 40V case


The characteristics on the IRF730 are not all that different from the 2SK2698 that I used in my 4.5MHz coil, so I expected the behaviour at 115V to be similar, so I tried it with no changes to the 2SK2698 matching network. Here are some pertinent voltage “measurements”:


1170345438 29 FT1630 Voltages115


The drain current:


1170345438 29 FT1630 Supplycurrent115


Next, I tried the same circuit, but now with a VDD of 40V (like your power supply).

Voltages:


1170345438 29 FT1630 Voltages40


The drain voltage curve has changed dramatically, indicating poor “switch-off” timing as a result of the shift in the DC load-line of the MOSFET transistor. The effective output impedance of the amplifier has changed, which has also changed the amplifier dynamics.

Furthermore, the input current has dropped off in a “superlinear” fashion:


1170345438 29 FT1630 Supplycurrent40


By modifying the series inductor (Ls) and the shunt (primary) tuning capacitor, we can match the coil better to the modified DC load-line and achieve something more like class-E operation.


1170345438 29 FT1630 Voltages40optimised


Given the better match (and power transfer), the drain current is seen to rise.


1170345438 29 FT1630 Supplycurrent40optimised


The SPICE listing for the Class-E amplifier model is
* This cicuit models the TC resonator and matching circuit in time domain
.INCLUDE irf730.cir

VIN	100	0	DC	40.0
LDD	100	1	25u IC=0

VGG	201	0	SIN(0.0 15.0 13.56meg 0 0)
RGG	201	200	2.2

XQ1     1       200    0       irf730

RDUM	1	0	100000
CDD	1	0	100p
*LS	1	2	2.5u
*For Q=10,20 VDD=115
*LS	1	2	0.800u
*For Q=10 VDD=40
LS	1	2	0.600u
CS	2	3	2700p
*For Q=10, VDD=115
*CP	3	1000	340p
*For Q=10, VDD=40
CP	3	1000	480p
*For Q=20
*CP	3	1000	280p

LP	3	1000	1u
VDUM	1000	0	0

LR	10	0	6.115u
CR	10	0	23.47p
*For Q of 10
RR	10	0	5000.

KLL	LP	LR	0.30

.OPTIONS NOPAGE RELTOL=1.0E-8
.END


I used a transient simulation with 0.02ns time step and 5us simulation time. See comments for lines to include (or comment out) for various Q settings and VDD (Vin) settings.

The transistor model is:

.SUBCKT irf730 1 2 3
**************************************
*      Model Generated by MODPEX     *
*Copyright(c) Symmetry Design Systems*
*         All Rights Reserved        *
*    UNPUBLISHED LICENSED SOFTWARE   *
*   Contains Proprietary Information *
*      Which is The Property of      *
*     SYMMETRY OR ITS LICENSORS      *
*Commercial Use or Resale Restricted *
*   by Symmetry License Agreement    *
**************************************
* Model generated on Apr  2, 99
* MODEL FORMAT: SPICE3
* Symmetry POWER MOS Model (Version 1.0)
* External Node Designations
* Node 1 -> Drain
* Node 2 -> Gate
* Node 3 -> Source
M1 9 7 8 8 MM L=100u W=100u
* Default values used in MM:
* The voltage-dependent capacitances are
* not included. Other default values are:
*   RS=0 RD=0 LD=0 CBD=0 CBS=0 CGBO=0
.MODEL MM NMOS LEVEL=1 IS=1e-32
+VTO=3.99 LAMBDA=0.000144225 KP=2.88036
+CGSO=6.42864e-06 CGDO=1e-11
RS 8 3 0.0001
D1 3 1 MD
.MODEL MD D IS=7.93539e-09 RS=0.020221 N=1.5 BV=400
+IBV=0.00025 EG=1.2 XTI=3.05954 TT=0
+CJO=5.57785e-10 VJ=5 M=0.688789 FC=0.5
RDS 3 1 1e+06
RD 9 1 0.485778
RG 2 7 2.63633
D2 4 5 MD1
* Default values used in MD1:
*   RS=0 EG=1.11 XTI=3.0 TT=0
*   BV=infinite IBV=1mA
.MODEL MD1 D IS=1e-32 N=50
+CJO=8.85779e-10 VJ=2.49436 M=0.9 FC=1e-08
D3 0 5 MD2
* Default values used in MD2:
*   EG=1.11 XTI=3.0 TT=0 CJO=0
*   BV=infinite IBV=1mA
.MODEL MD2 D IS=1e-10 N=0.510385 RS=3e-06
RL 5 10 1
FI2 7 9 VFI2 -1
VFI2 4 0 0
EV16 10 0 9 7 1
CAP 11 10 8.85779e-10
FI1 7 9 VFI1 -1
VFI1 11 6 0
RCAP 6 10 1
D4 0 6 MD3
* Default values used in MD3:
*   EG=1.11 XTI=3.0 TT=0 CJO=0
*   RS=0 BV=infinite IBV=1mA
.MODEL MD3 D IS=1e-10 N=0.510385
.ENDS irf730


Other comments worth including:

  • 1. The series cap in the matching network is mostly for DC blocking. As long as it has a fairly low reactance, tuning can be accomplished by modifying the series coil and the primary shunt capacitor.
    2. Start off with no or little capacitance in between the MOSFET drain and ground. At 13.56MHz, the transistor Cds should be sufficient. However, if instantaneous Vds is more than 300V, add 68-100pf and see what happens.
    3. The secret to good class-E is low matching circuit Q. This means tight primary-secondary coupling for good power transfer (contrary to what many long-streamer coilers use) and as low series inductive reactance as you can get away with. This also means keeping the load-line impedance close to the expected coil primary input impedance. Resonance in a loosely coupled high-Q primary will smoke your MOSFETs (I’ve tried this)!!!
    4. Higher VDD is your friend, if Qs are low and your MOSFET can tolerate it. This also helps reduce I²R losses in the primary (lower primary current).
    5. I can’t overemphasize enough the need to shield the coil at these frequencies. Inadvertent parasitic coupling and radiation looks like extra loading to your amplifier circuit…as well as generating loads of obnoxious RFI. If it interferes with your digital camera, imagine what might be doing to shortwave-listening grannies on the other side of Oz!! ;)


Anyway, looks great and I hope this helps..



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ragnar
Thu Feb 08 2007, 12:20AM
ragnar Registered Member #63 Joined: Thu Feb 09 2006, 06:18AM
Location:
Posts: 1425
Time is precious these days, sorry about the radio silence. I think one of the most important problems was my insufficient drive; here I have a new driver with a few revisions including:
- the removal of the pre-IXDD414 duty-squisher/stretcher,
- addition of a variable GDT-powered bias circuit on the MOSFET instead,
- I'll be using fixed caps instead of aircaps on the output network / flywheel,
- using TWO IXDD414s driving TWO primaries on the GDT,
- primary feed is now by coaxial cable, ideally into a cage.


Will tighten coupling and use a fixed primary for repeatability.

Matt
1170894006 63 FT19970 Revision1
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