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Re: [TCML] Findinding the facts of a 3 P unknown transformer 50:1, "black Box" and Charging inductor(s) design.



Hi Greg and Stefan,

The combination of resistors, capacitors, and spark gaps in a Terry filter provide a low-pass filter and protection from primary strikes. The resistors and MOV's provide rapid damping of energy from UHF/VHF or other over-voltage transients. But the protection comes at the expense of significant parts count and added power losses. This filter was designed primarily to protect fragile NST's, and it should provide similar protection for other fragile upstream components, such as charging inductors. However, Greg's approach is more cost-effective and efficient.

Until Greg's last post, I was unfamiliar with his current protection approaches. His L-diode protection scheme has the advantages of being robust, easier to construct, and significantly more efficient - and it has demonstrated its reliably in large systems. Stefan, I see no reason why a similar approach shouldn't work for your system as well. I certainly can't argue with success. :^)

Best wishes,

Bert


Teslalabor wrote:
Hi Greg & Bert,

very interesting! Regarding my 6-pulse rectifier, I now have a better
feeling :-) Concerning my other question, it really seems to be a good
idea, to use any form of protection circuit, for not killing the
reactor. Greg's concept of L-diode damped filter is completely new to me
but sounds very cool, whereas I also never have built a Terry Filter
before in my older (not DC resonant) systems. So the question is, should
I use a simple Terry Filter or this L-diode arrangement. A terry filter
doesn't have any L in it....

Regards,
Stefan


----- Original Message ----- From: "Greg Leyh" <lod@xxxxxxxxxxx>
To: <tesla@xxxxxxxxxx>
Sent: Tuesday, July 15, 2014 6:23 AM
Subject: Re: [TCML] Findinding the facts of a 3 P unknown transformer
50:1, "black Box" and Charging inductor(s) design.


Hi Bert, Stephan,

Yes, essentially what Bert said sums it up.  The air-core 9mH choke
keeps the HF hash off the reactor which, although an inductor itself,
has lots of internal uneven winding capacitance that doesn't handle RF
very well. And yeah, I swapped the positions of the cap and rotary a
few years after it was built.  Also, the 45nF filter cap is gone,
replaced by a reverse-biased 45kV diode stack.  the 9mH choke forms a
L-diode damped filter.  Electrum uses a similar arrangement.

Cheers,
Greg


------------------------------

Message: 2
Date: Sun, 13 Jul 2014 19:15:41 -0500
From: Bert Hickman <bert@xxxxxxxxxxxxxxxxxxxxx>
To: Tesla Coil Mailing List <tesla@xxxxxxxxxx>
Subject: Re: [TCML] Findinding the facts of a 3 P unknown transformer
50:1 "black Box" and Charging inductor(s) design.
Message-ID: <53C3212D.80400@xxxxxxxxxxxxxxxxxxxxx>
Content-Type: text/plain; charset=ISO-8859-1; format=flowed

Hi Stephan,

Teslalabor wrote:
> Hi Bert & all,
>
> as you know I'm also actually constructing a similar DC resonant
> charging system. At the moment the construction of the 400bps rotary
> (400bps @ 4000 1/min with very low dwell time) is in progress.
> Until it is finished, there are still 2 questions, I'm wondering >
about.
>
> First question is about the design of a properly rated 6-pulse
> rectifier. My system is powered by a 3-phase transformer, which >
delivers
> 9,44kV output between it's phases. So after 6-pulse rectifying I get
> 13,35kV DC for feeding the system, so far so good.
> My first try were 6 diode strings with each only 16 diodes in series,
> each 1kV / 1A. This 16kV strings died after short time during my >
initial
> halogen-dummy experiments, when increasing the voltage more and more.
> Then I build a new 6-pulse rectifier, constisting of 6 strings, this
> time each using 39 diodes in series, each 1kV/3A. So I now have >
strings
> each 39kV / 3A. Couldn't test it until now, because new rotary is
> still
> in progress.
> But I have the feeling 39kV is still to less, because I saw 6-pulse
> rectifyers, using 60kV per string and these were only powered by
MOTs.
> So, what are the important design parameters, when building a 6-pulse
> rectifier for a DC resonant charger? Are there special diodes, one
> should use? Im actually using 1N5408 1kV/3A Diodes. Do you think,
they
> will survive?
The 6-pulse rectifiers live in a relatively benign environment. The
total PIV rating of each stack must be at least 2xVdc (~26.7 kV), so
using almost 3XVdc (39 kV) should certainly provide adequate voltage
margin for your system. 60 kV strings on a MOT system is definitely
overkill. I haven't analyzed your system, so I don't know what the RMS
current is for your rectifier and dequeing diodes under various
conditions. However, converting from 1A to 3A rectifiers will provide
greater current margin.

>
> Second question. By studying Greg Leyh's amazing DC resonant charging
> systems, both the 40kW coil and also Electrum, I recognized, that he
> uses an aditional air coil inductor and a capacitor, to protect the
> charging reactor (and the DC supply?) from HF, going backwards. In
the
> case of the 40kW coil he uses a 9,5mH inductor combined with a
45nF > cap.
> Isn't the charging reactor itself blocking all of the HF, because of
> it's high inductance?
> Is this realy needed and if so, how critical are the values of L
and C
> of this protection circuit? Because I use a homemade reactor, I
want > to
> minimize the risk of killing it, it was a lot of work :-)
That's a good question for Greg to address. :^)

Remember that the design for the 40 kW coil was done way back in 1990-91
- long before the army of TCML experimenters arrived. Today, Greg might
swap the position of the tank cap and spark gap to prevent the RF that
appears across the tank cap from backing up into the chokes. In his
original design, a lower frequency filter (~8 kHz) was used to help
block TC operating frequency RF from backing up into the charging
chokes.

However, even if we swap the gap and tank cap, using a HF filter may
still be a good idea. But use a modern Terry filter (that shunts and
dissipates the transient's energy), since the TC's RF is now shunted by
the gap. But, even with the gap shunting the HV charger output, it still
generates tons of high-amplitude conducted (and radiated) VHF and UHF
"hash" every time it fires or reignites. Unfortunately, the high dv/dt
transients don't uniformly distribute themselves across the choke
winding. Because of inter-turn and inter-layer capacitances and winding
inductance of each turn, the transient voltage stresses become
concentrated across a relatively small number of turns that are
electrically closest to the gap. If not blocked, these have the
potential (NPI) to generate corona and partial discharge damage between
turns and even nearby winding layers in the choke. This can cause
premature failure of the choke's insulation system. Introducing a lossy
low-pass filter harmlessly bypasses (and dissipates) these transients
before they can reach the choke. Consider it as cheap insurance...  :^)

Bert



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