Sig's Universal SSTC Logic Controller Board and Deluxe SSTC Kit Sale Thread

[Sigurthr]

Sig's USSTCC - Universal Solid State Tesla Coil Controller!​

Hello everyone! Recently a venture years in the making has advanced to the point that I am now preparing to offer up for sale Professionally Fabricated PCB boards and accompanying electronic component bundles. I will update this thread as well as the TCBT (tesla coil build thread, in Geek's Corner) as things move forward. Currently the first production run of boards is being fabricated. The Test Batch passed all tests and the project is a GO!

A website has been set up to house all my projects/data/boards for sale, etc, and the boards ARE NOW AVAILABLE both there and here! Feel free to check it out: www.SigurthrEnterprises.com

My USSTCC will work with any half bridge or bridge based SSTC and has been tested for use with resonant frequencies between 100KHz and 1MHz.

It uses either antenna based feedback or secondary base current transformer based feedback by using one of EasternVoltageResearch's Pre-made Current Transformer boards or by making your own current transformer. CT feedback is recommended for >500KHz operation.

It features an expansion connector to allow for the use of fiber optic based interruption and PWM modulation. This allows the user to easily convert from normal CW operation to a pulsed or music playing (both midi and true mono audio) Plasma Speaker format. If desired the USSTCC can even be used as an intermediary gate driver board for specialized fixed-frequency Tesla Coils or half-bridge/full-bridge flybacks by feeding a logic level / TTL signal into the antenna input from your choice of square wave generator (from the basic 555 to even an Arduino).

Sig's Universal SSTC Logic Controller (USSTCC) and SSTC Kits: *FOR SALE NOW*

Updated Price List and Availability: 6/8/2014
-Board ONLY: $25 + S&H - 8 IN STOCK
-Board Kit (Board + Board Mounted Components + GDT Core): $50 + S&H - OUT OF STOCK.

Planned Future Options:
-Expanded Board Kit (Board + Board Mounted Components + GDT Core + Board Power Transformer): $60 + S&H *BEST DEAL*
-Deluxe Kit (Board + Board Components + Board Power Xformer + Half-Bridge Components): $130 + S&H
-Deluxe Kit - "On PCB" Version (Board + Board Components + Board Power Xformer + Half-Bridge Components + PCB Version Terminal Blocks): $135 + S&H

All Sale Options require the user to exercise basic knowledge of electronic components and electrical principles in the identification, mounting, and soldering of components to the circuit board.

Board Kit Expanded Bundle and both versions of the Deluxe Kit will NOT be stocked and must be pre-ordered. Deluxe Kits are NON-REFUNDABLE, NON-RETURNABLE, and CANNOT BE CANCELED AFTER ORDER CONFIRMATION IS RECEIVED. No returns or refunds will be accepted on boards which have been soldered to in any way.

Deluxe Kits are offered as a convenience to customers. It IS entirely possible to build the completed equivalent for less than I have to charge. Board Kits are sold with all components AT COST. The Expanded Board Kit includes a stepdown mains isolation 120Vac to 12Vac 2Amp Board Power Transformer sold AT LESS THAN COST.

I will make roughly $5 per sale, which will mostly goes towards packing materials and gas costs of driving to the post office.

220/240VAC versions are available upon special request. Pricing will vary.

Users must exercise caution when wiring the completed boards. Risk of injury or death is always present when working on electronics. Buyer/user assumes all responsibility for use of the products.

No Tesla Resonators, Heatsinks, mounting hardware, current transformers (CTs), or wiring is included in any options! All of these not included items are available for sale from EasternVoltageResearch. Seller is not affiliated with EasternVoltageResearch in any way.

Tesla Secondaries are also available Wound-To-Order from McWilliamsTech on eBay. His prices are far better than EVR, and I have personally used his secondaries. He lists many selectable sizes for sale and also takes custom order requests. http://www.ebay.com/itm/32123391828...eName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649 Seller is not affiliated with McWilliamsTech in any way.

http://imagizer.imageshack.us/v2/640x480q90/854/qzyx.jpg

Action shots:

With Advanced Expansion capabilities used: 4046PLL as audio modulator.









All three videos shot sequentially with no cool down time in between, running straight from mains on only passive cooling to the half-bridge.


Without advanced expansion capabilities used:

"The Stubby SSTC - 350W @ 430KHz"


350W @ 350KHz

​

VERSION 1.0 IMAGES. VERSION 1.1 Is Now In Production!
PCB Front:

PCB Back:

Credit goes to LPF User Fiddy for the layout and design of the PCB, without which none of this would be possible. Thank you my friend.

Data Files: UPDATED 1/5/14 !!
USSTCC Bill of Matierals: https://app.box.com/s/lp0wnwjqb3tvmpk8g2po
USSTCC Schematic: https://app.box.com/s/7kvqvvs0sx8504g2de4j
Half-Bridge Bill of Materials: https://app.box.com/s/2w9zbyq2vjx0t4d6iizi
Half-Bridge Schematic: https://app.box.com/s/zssa3gcd4b32sqsjau27

Sig's ATTiny85 Microcontroller Interrupter; Pre-programmed MCU Chips!​

Sig's ATTiny85 Interrupter has been finalized and I'll be able to offer pre-programmed ATTiny85 MCU chips for sale for those interested. . I'll order in more chips soon if there is interest.

Price; $10 for one chip. $5 for each additional chip. $4 shipping within Domestic US. International shipping available at cost.

OUT OF STOCK - WILL ORDER MORE UPON REQUEST.

Data files:
Bill of Materials: https://app.box.com/s/zn1vb0li8lxpviw0a9cn
Application schematic: https://app.box.com/s/bkv971vuest7jz8toeec
Code file: https://app.box.com/s/93dt6fso6wj3tvx13m7b

http://imagizer.imageshack.us/v2/640x480q90/713/3wi9.jpg​

 

[The Lightning Stalker]

I want the board only option when they come out.

 

[Sigurthr]

Just a quick update;

Boards are still in fabrication.

I have a limited number of pre-wound secondaries which will be available for sale.

Also, since transistor choice is dependent upon switching frequency I have a limited supply of matched transistors I can offer with the pre-wound secondaries for an additional (but small) price.

Lastly, I will help every single buyer of one of my boards with determining optimum primary and secondary design parameters. No more guesswork!

 

[Speedy78]

If those secondarys will support the huge e field im after may have to grab one too depending on the frequencies and transistors available.

 

[Sigurthr]

All of these will support a very large e-field. You can maximize e-field production by adding a large topload, which also makes the transistor choice a lot easier. Right now I only have three available: 500KHz, 750KHz, and a third one with an old topload I made that I need to test out before giving it the OK. IIRC the fres was somewhere around 666KHz. XD

The ideal secondary for pumping out a HUGE amount of power (>1.25kW) should resonate at 350KHz or lower. I can specify dimensions for those who wish do DIY, or put you in contact with someone who can sell you a pre-made one which will reach this frequency range when you add a large topload (again I have a source for those too). I might be able to handle all of the special ordering myself on a one-off basis for those who don't want to order from multiple places, but the lead time greatly increases, and I would have to pass along costs, as you'd expect.

The relationship between output power and frequency is not a limitation of my boards, but rather a limitation on the end user's half/full bridge. Not all inverter bridges are created equally, and how high of frequency you can push your transistors to has a lot to do with layout, construction, and parts used. This is why I offer my help in working out the parameters.

 

[The Lightning Stalker]

I was on Mouser searching for the core, and apparently it cross-referenced to the B64290L0674X038. Will
this core work, or does it absolutely have to be the other?

 

[Sigurthr]

I was on Mouser searching for the core, and apparently it cross-referenced to the B64290L0674X038. Will
this core work, or does it absolutely have to be the other?

That is the exact core I chose.

B64290L674X38 EPCOS | Mouser

DigiKey

Cheaper on digikey is all. Not sure why you'd ask if it would work, hehe.

But ya, these cores are the minimum size needed to get the required number of turns at the required wire gauge with enough core cross section area to not saturate at high speeds and currents. The T38 material allows for wide frequency range and low loss. Depending on your frequency and drive current you could get away with using a larger but lower grade core, but not sure why you would want to, especially since the cost is mostly based on size.

 

[The Lightning Stalker]

Okay, the Digi-Key part number was throwing me off. I am stuck ordering from Mouser right now because
Digi-Key didn't have the higher current tactile switches at a reasonable price. Those stupid Chinese pen
lasers use a switch that's only rated 50mA to switch hundreds of mA. Pretty soon the button is going all
soft and it makes poor contact.

 

[Sigurthr]

Update: OSHpark has received my first batch of boards from Fab and they will be shipped to me shortly. The final testing phase should begin the day after the boards make it to me.

 

[Sigurthr]

Update: Boards are back from Fab. Testing will begin shortly.

 

[Speedy78]

Testing better include pictures!

 

[Sigurthr]

Today was Testing Day!

I built my test board and just finished a rigorous testing schedule of said test board. After many hours of blood, sweat, and painstaking concentration I am happy to announce the USSTCC is a COMPLETE SUCCESS!

I ran the gamut on this board 100KHz to 1MHz, antenna and CT feedback, floating board ground and tied to RF ground, 14Vac to 24Vac input, ground strikes, sustained ground arcing, you name it. She's a real beauty.

Pics and Videos:

Alpha Testing the board:

https://www.youtube.com/watch?v=ki0I2u0teaQ

Long Duration testing the board:
200W CW 666KHz
30min warm up before filming began.

https://www.youtube.com/watch?v=QFoIBfOGhrU

Production run will be the next step!

 

[Sigurthr]

OP has been updated.

Updated Pricing to reflect updated vendor prices.

I fixed an error in the Half-Bridge BOM and Schematic. New Files Uploaded and Linked.

Added additional source for pre-wound and wound-to-order secondaries.

Suggested Free-Standing Half-Bridge Layout:
note: the MUR860s are mounted in the vertical axis above the FET pins, MUR860 wiring shown is for connection info only, make connections as short as possible between the shown points. The rest of the bridge wiring can be made as shown.

https://app.box.com/s/rpjg8jc4eiqose9or5xl


Free-Standing Bridge Example:
note: MUR1560s and Zeners not installed/shown.

http://img19.imageshack.us/img19/9453/ur1v.jpg

On-PCB Style Bridge Example:
note: MUR1560s not installed/shown.
note: MUR860s are heatsinked, which is optional.
note: minimal useable size bus caps are shown: CDE 600V 0.68uF.
note: snubber cap omitted due to bus cap choice.
note: no D1 Full-Wave Bridge Rectifier shown.

http://imageshack.us/a/img827/874/f4ms.jpg

http://imageshack.us/a/img594/8531/j7ra.jpg

http://imageshack.us/a/img839/7840/nvg5.jpg

Bridge Version Explanation:
-The free standing bridge features the best heatsinking capability and the lowest inductance wiring scheme available to the average electrical amateur. This bridge can, with the same components as the On-PCB version, run at much higher frequencies. In addition, due to the ability to use a much larger heatsink, far longer run times are attainable. The pictured free-standing bridge can run at 200W output CW-mode at 666KHz continuously with zero active cooling. I use this design for my 3kW coil, but on a heatsink roughly three times the size as pictured, and with forced air active cooling.

-The On-PCB style bridge has the convenience of being totally disconnectable without having to cut or desolder any wires. As such, the easily damaged FETs are easily replaced without any soldering necessary. Once could even mount them to far larger individual heatsinks and then rotate the bridge 90degrees so that the heatsink is now the base and the PCB is vertical. Also, because all connections are supported by the Pad-Per-Hole PCB there are no free-standing unsupported wires to solder to, which is difficult for the soldering novice. Likewise, the GDT can be firmly mounted with hot-glue or cable ties / zip line, and GDT wiring can be kept to a minimal, as there is no heatsink height to overcome. The price comes at stray inductance. Even with thick traces (roughly equal to 12-14ga wire) laid down with the Solder-Bridge technique there is more inductance to this bridge, which limits the upper frequency feasibility. I have tested this design to 1MHz, but there is a lot more loss, and FET failures may result. I advise using the Free-Standing Bridge above 500KHz to ensure long life of FETs. Also note that the On-PCB version has no room for the D1 Full-Wave Bridge Rectifier. This must be mounted separately and heatsinked as well, with heavy gauge and short wiring linking the output of the rectifier to the DC bus inputs at either side of the Bus Capacitors.

 

[The Lightning Stalker]

Let us know when you will be ready to take orders.

 

[Sigurthr]

I will keep you posted! I submitted the order for the first real production run a few hours ago. It should be starting fab by the end of the week. As soon as the boards are in hand and they're confirmed free of errors they'll be up for sale. I personally inspect every trace of every board to ensure quality.

 

[The Lightning Stalker]

I have the utmost confidence in you, Signature! :beer: