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Registered Member #1403
Joined: Tue Mar 18 2008, 06:05PM
Location: Denmark, Odense C
Posts: 1968
My vacation was almost over and I felt like building a Tesla coil before starting at my new job which means a lot of travelling.
Link to my site with all pictures:
Its made from things I had at hand, everything but the driver board is salvaged or reused components / materials.
Bridge 2x IXGN60N60C2D1 IGBTs in a half bridge configuration Bridge supply 0 – 210VAC through a variac, 6A rectifier bridge and 2x Aerovox 410uF 430V filtering capacitors in parallel. Primary coil Flat primary. Inner diameter 70 mm, Outer diameter 187.36 mm. 6 turns 1.78 mm copper wire (2,5 mm²), turn spacing 8 mm. Tapped at 4.8 turns. MMC 2 in series Cornell Dubilier (CDE) 942C20P15K-F capacitors for 0.075uF at 4000VDC rating. Secondary coil 50 mm diameter, 2000 mm long, 1430 windings, 0.127 mm enamelled copper wire. Resonant frequency Around 300 kHz. Topload 40 x 215 mm aluminium tape on a Styrofoam toroid. Input power 350BPS, 120uS ontime, 35 primary cycles, 280A limiter: 210VAC in at 2A, 420 Watt. Spark length Up to 370 mm long sparks.
13th August 2011 Optimize driver PCB, design bridge PCB, toner transfer to PCB.
14th August 2011 Etch PCBs, assemble bridge PCB completely, half done with driver assembly. materials for building a enclosure and base is found.
15th August 2011 Winding CTs for feedback and OCD, building enclosure and base, driver pcb assembled.
16th August 2011 Driver PCB fault finding and testing, enclosure and base building.
17th August 2011 Complete construction and ran first test, no first light.
28th August 2011 First light, phasing of feedback transformer was wrong.
3rd September 2011 24 cm sparks, running 250uS, 68 primary cycles, 120VAC in, 268A primary current. 250BPS.
Here is a scope shot of the primary current waveform. Tuning is clearly way off.
4th September 2011 I blew up the bridge from running with a too high current limit, properly about 350A primary current at 160VAC in.
Registered Member #1403
Joined: Tue Mar 18 2008, 06:05PM
Location: Denmark, Odense C
Posts: 1968
11st September 2011
Rebuilt the bridge with some larger IGBTs
16th September 2011
Additional tuning really sent the power usage down, along with the on time, it runs much better now. Here is a shot of it shooting streamers out to 340 mm, 70 uS on time, 260A peak, 300-400 BPS at 260VAC at 0.5A.
Registered Member #1403
Joined: Tue Mar 18 2008, 06:05PM
Location: Denmark, Odense C
Posts: 1968
Saz43 wrote ...
Mads Barnkob wrote ...
11st September 2011
Rebuilt the bridge with some larger IGBTs
I'm amazed at how neatly you've attached those crimp connectors to the ends of your magnet wire. How did you do that?
It is regular 2.5mm^2 copper wire, stripped from house installation wire. It is only soldered in the crimp connector, no crimping tools were used, which is also why they look so neat
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Kaizer DRSSTC II
