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My first DRSSTC: EVR MicroBrute

Move Thread LAN_403
Fiddy
Thu Dec 27 2012, 11:57AM Print
Fiddy Registered Member #8817 Joined: Mon Dec 17 2012, 05:16AM
Location: Australia
Posts: 110
G'day blokes,

Im on holidays :D So that means all projects will be in overdrive!

Working in induction heating as an electrician ive been keen to build my first tesla coil so I bought the Microbrute kit from Eastern Voltage Research.

Frontpage MicroBrute260x200

Kit arrived:

DRSSTC

Now this kit is a 110V job, and Australia being 240V i bought a 2kW 110V step down tranny.

01 12

The kit came with a plastic top load must be laced with aluminum foil, which doesn't look too bad but i really love the spun aluminum toroid's out there so i bought one 8" x 2.25". This will increase the secondary capacitance but i can tune the primary to suit.

7367 1

I also need a cooling fan to the heatsink cooling the 2 IGBT's so i bought a 6" Dayton rated at 239CFM.

60 3

Built the interrupter remote:

Remote

Made a winding jig and wound the secondary by hand (30AWG 10" length, 3.22" diameter)

Secondarycoil

Here's a enclosure idea im working on:

Layoutresize

PCBLayoutampFanresize


Wound the primary and wrapped the top load in aluminum duct tape.

Microbruteprimaryseconday


Got a 4" cooling fan until my 6" one arrives:

Coolingfan Zps45bd9db8


Finished the circuit board:

Pcbcomplete Zps3ae3f0a2


Here are my calculations for the new Top Load:

-----------------------------------------
Secondary
-----------------------------------------

===============
Standard Top Load
===============

3.22" x 10"

Capacitance = 5.792pF

Turns = 1000
Wire = 30 Gauge
Diameter = 3.22"
Length = 10"

Inducatance = 22.64mH


Resonant Frequency: 439.5khz

===========
New Top Load
===========

3.22" x 10"

Capacitance = 8.897pF

Turns = 1000
Wire = 30 Gauge
Diameter = 3.22"
Length = 10"

Inductance = 22.64mH

Resonant Frequency: 354.6kHz



-------------------------------------- ----
Primary
------------------------------------------

==================
Standard Primary Turns
==================

4" x 0.2424"

Capacitance = 0.075uF

Turns = 3
Wire = 12 Gauge
Diameter = 4"
Length = 0.2424" (0.0808" per turn)

Inductance = 1.917mH

Resonant Frequency: 419.7khz

===============
New Primary Turns
===============

4" x 0.29088"

Capacitance = 0.075uF

Turns = 3.6
Wire = 12 Gauge
Diameter = 4"
Length = 0.29088" (0.0808" per turn)

Inductance = 2.65uH

Resonant Frequency: 357khz


My first run:
Tesla1 Zps34ff625c

Installed the spun toroid:
Toroid Zps8c5186de

Some photos of it running:
Arcs1 Zpsa6b7bdbd
Arcs2 Zpsfd5819cb

I have ordered the enclosure for the unit, but it hasn't arrived yet.

Stay tuned for more progress,

Fiddy.
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Sigurthr
Fri Dec 28 2012, 03:32PM
Sigurthr Registered Member #4463 Joined: Wed Apr 18 2012, 08:08AM
Location: MI's Upper Peninsula
Posts: 597
Awesome work, Fiddy! I need to get one of these one day.

I can't remember, is this your first plunge into TCs or did you build a SSTC or SGTC before this?
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Fiddy
Fri Dec 28 2012, 03:48PM
Fiddy Registered Member #8817 Joined: Mon Dec 17 2012, 05:16AM
Location: Australia
Posts: 110
Theres a user name i know!

Yeah i did, a small audio modulated SSTC "plasma speaker"

Plasmaspeaker2
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Sigurthr
Sat Dec 29 2012, 02:35PM
Sigurthr Registered Member #4463 Joined: Wed Apr 18 2012, 08:08AM
Location: MI's Upper Peninsula
Posts: 597
Hehe, yup this is one of my more frequent haunts.

Ohh that's right, the cute blue one. I love small TCs, so awesome. The physical design aspects to your projects always amaze me. I can do great things with electronics but cases, stands, bases, etc are beyond me.
You're familiar enough to be safe then, that's good. HV high e-field RF tends to do things one would not expect.
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Fiddy
Sat Dec 29 2012, 02:39PM
Fiddy Registered Member #8817 Joined: Mon Dec 17 2012, 05:16AM
Location: Australia
Posts: 110
Shweet!

Hehe thanks, i the case came with this unit, i just assembled it.

Most of the time its just send a diagram to the plastic mob and you get what you want in the mail :D

Yeah funny that, it does crazy things at work on our 3MW induction furnace.
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