Tesla Coil Build Thread

[Sigurthr]

That's what I figured. It is pretty critical to solid operation, really. There's two main ways to easily lay out a DIY bridge, and I have examples of both sitting in front of me, hehe. Just a matter of doing the documentation.

Update: I've placed the DigiKey single BOM order for my test board. I've got the Mouser parts in stock already so no need to order them. I've reworked the BOM files to include Mouser part numbers and sorted the BOM by distributor for ease of ordering. I'm working on the bridge files now.

 

[Atomicrox]

Looking good so far. I wouldn't mind pre-paying, I'm sure others wouldn't mind either.

Would you consider including the bridge components? (specially caps and MOSFETs/IGBTs)
It'd be cool if you had an almost-complete-kit, missing only the big parts: resonator, box, transformer and bridge heatsink.

Good luck on the initial tests and keep us posted!

 

[Speedy78]

Yeah. I dont mind shooting a pre order your way to help work the kinks out.

 

[Atomicrox]

I do mind helping work the kinks out As in I don't know how to debug electronics properly, which is why I need the kit after all

 

[Speedy78]

I do mind helping work the kinks out As in I don't know how to debug electronics properly, which is why I need the kit after all

Same! If the kit tells me to test for this voltage on this pin and mine is wrong its time to order another kit and try again. <- My eletronics trouble shooting theory.

 

[The Lightning Stalker]

The schematic/BOM don't look like they have changed.

 

[Sigurthr]

Looking good so far. I wouldn't mind pre-paying, I'm sure others wouldn't mind either.

Would you consider including the bridge components? (specially caps and MOSFETs/IGBTs)
It'd be cool if you had an almost-complete-kit, missing only the big parts: resonator, box, transformer and bridge heatsink.

Good luck on the initial tests and keep us posted!

I was just working on a DigiKey BOM for a "Deluxe Kit" (bridge components, board components, + board) which is pretty much what you described. Initial Price Projection; $100. (the MOSFETs are $15ea). This is only worked out for 120VAC operation, those across the pond would need different bridge caps and bridge rectifier for the DC bus. Also, this is for a "free standing bridge design" which is very much preferred in terms of robustness and quality, but is not the most straight forward for a truly new coil builder. It direct solders connections to components, so you can't easily change out blown components. This is for a more confident builder. I also have an "On PCB" type bridge layout which uses terminal block connectors and a much easier to build Pad-per-Hole PCB. The cost is higher due to additional parts, but it allows for easily and quickly swapping out blown MOSFETS and easily detaching the GDT from the bridge. Great for the true beginner. I've tested this design running CW at 3kW on my large SSTC as well, it is solid.

Both versions of the bridge do not include heatsinks, and I'll not be selling any coliforms or completed secondaries. I can refer customers to EVR for those.

Same! If the kit tells me to test for this voltage on this pin and mine is wrong its time to order another kit and try again. <- My eletronics trouble shooting theory.

The nice thing about my design is that there's very little to test (without a scope) since there is very little to go wrong. If the chipsets didn't die from mishandling (and I've dropped mine on a carpet before and they survived!) and you've not done something like over-volt them or put the AC into the GDT output or antenna input, then the board will work just fine.

This is a major reason why I decided to put forth the extra effort to nail down the exact GDT core, power supply transformer, bridge components, etc.

The schematic/BOM don't look like they have changed.

I had to take down the old files to update them. New ones should be up now.

Here's new links. I haven't taken the old links down yet.

USSTCC Schematic: https://app.box.com/s/7kvqvvs0sx8504g2de4j
USSTCC BOM: https://app.box.com/s/lp0wnwjqb3tvmpk8g2po
Half-Bridge BOM: https://app.box.com/s/hbzsstw612ipl9j2cclz
Half-Bridge Schematic: https://app.box.com/s/5jexixwy3igh01wgdh4i

Note: I fixed an error in the quantity numbers for the On PCB section of the Bridge BOM.

 

[The Lightning Stalker]

Okay, thanks. The BOM is showing the updated part numbers. The schema does not appear to have
changed.

Thanks for the bridge schematic as well.

This work?

 

[Speedy78]

Those be some big ass caps. So there will be a separate PCB for the bridge? I'm a huge fan of solder things in holes instead of free standing.

 

[The Lightning Stalker]

I have some bigger ones too if these little ones won't work.

 

[Sigurthr]

Okay, thanks. The BOM is showing the updated part numbers. The scema does not appear to have
changed.

The only thing that changed on the schematic is the note about which core to use. My old core was obsolete and removed from digikey/mouser. Likewise, I found my DC BUs caps were obsolete and I had to hunt down the new version.


Sig's Universal SSTC Logic Controller and SSTC Kits: *Not Currently For Sale* (Coming Soon!)

Updated Price List:
-Board ONLY: $25 + S&H
-Board Kit (Board + Board Mounted Components + GDT Core): $50 + S&H
-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): $125 + S&H
-Deluxe Kit - "On PCB" Version (Board + Board Components + Board Power Xformer + Half-Bridge Components + PCB Version Terminal Blocks): $130 + S&H

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.

 

[Speedy78]

So is the bridge on a PCB as well?

 

[Sigurthr]

Okay, thanks. The BOM is showing the updated part numbers. The schema does not appear to have
changed.

Thanks for the bridge schematic as well.

This work? *pic*

Haha, ya those'll do just fine for the Bridge DC Bus / DC Blocking caps.

Those be some big ass caps. So there will be a separate PCB for the bridge? I'm a huge fan of solder things in holes instead of free standing.

The BEST bridge layout requires point to point construction for minimal leakage/parasitic/stray inductances, and allows for the best cooling by not restricting heatsink size or orientation, so that is always recommended.

Not a fabricated PCB, no. There's no reason to do that, it would be uneconomical for all. The "On PCB" version requires the buyer to source a "Pad-Per-Hole Copper Clad PCB" which is available many places. I get mine from RadioShack for less than $10 for a very large board. I will do a detailed write up with instructions and pictures of how to construct a viable and solid half bridge on one of these blank PCBs.

 

[Speedy78]

That works. Let us know when these are available. I would do the deluxe kit.

 

[Fiddy]

Can we design the bridge board together Sigurthur?

 

[Sigurthr]

Haha, a fab PCB bridge? Maybe if we find a place that can do more than 1oz Cu per layer. Idk if any standard traces will will handle >500W in CW SSTC operation.

In professional setting they put power traces on bottom layer and leave bottom mask off then wave solder the board so the trace gets built up will several mm thick of solder. I don't have a wave solder station, haha.

Plus, we'd have to beat EVR's price point of $40 per board and his handles CM 600s (but not 3KW CW, haha).