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Topics - Magneticitist

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1
Solid State Tesla Coils (SSTC) / 120VAC Mains Ramped Builds
« on: January 21, 2022, 03:00:04 AM »
Got a lot of useful information reading this website so for what it's worth here are some pics and a little info about a ramped build I thought worked out pretty good. ZakW posted a lot more info about a similar build which has gotten great results. I'll probably try to rebuild mine and jack it all up so here is the breakdown.

I saw good results from the Loneoceans RSSTC and one shown on SciTubeHD's youtube channel so I basically tried to wind some coils with similar dimensions and resonant frequency. I also tried some other staccato interrupters already out there but Gao's seemed to work the best for me. I've found it difficult to exceed 12 inch arcs on an SSTC without upping the coil size so the budget QCW mains ramped approach seems like a really good setup and who doesn't like sword sparks.

They are based on Steve Ward's SSTC 5 driver (https://www.stevehv.4hv.org/SSTC5/miniSSTCfnlsch.JPG) with a "staccato interrupter" in place of Steve's 555. I'm running FGA60N65SMD IGBT's on it and still using a 1:1 GDT but using a 15v regulator to power the gate drivers and this just makes things simpler.
Other changes are things like the DC blocking capacitor value at the driver outputs (which should probably be experimental, I think I have like a 2uF ceramic) and the addition of a 1uF DC blocking capacitor in series with the primary (a few .33uF 1200V MKP caps I had).
I had a fairly large T37 core so I used that to wind a single GDT for driving both halves of the bridge. It allowed me to fairly easily wind 5 twisted wires. I have a CT for the feedback with about 30 turns. To add PLL feedback I put a 5v driven CD4046 in between the hex inverter and the gate drivers.

Below are the two builds I've tried with the half bridge on the left and full bridge on the right. They are both using very similar coil dimensions of 36 AWG on 9cm tall by 8cm wide formers (and run about 400khz). A 32 AWG coil of slightly larger dimensions seemed to work well also. The one on the left has the staccato and logic transformer inside the box and the one on the right currently uses an external logic supply and gets the mains sync from a transformer inside my interrupter box. I plan to get a nice toroid for the full bridge and hopefully hit that 20 inches. They are both more or less identical builds but with one using the full bridge and PLL feedback.


This is is a big universal interrupter box I went ham with trying to put everything I could into it over time. The interrupter circuit is isolated from the RCA plug with an optocoupler and 9v battery which I found almost necessary without 'getting lucky' dodging interference. I did the mains sync like that because I figured I'd want to be able to run any other builds I make mains synced without having to make a new circuit each time. I'm using Gao Guangyan's circuit seen here https://www.loneoceans.com/labs/sstc3/schema_sstc3_staccato.jpg but with C4 modified for the full 60hz half wave (quieter thicker arcs due to adding and shutting off after the downward slope).


Bridge and driver board. I believe there is about 2uF worth of film caps across the bridge and I stacked what I had at the time.
There are 15v, 12v, and 5v regulators, the 12v just being for the fan. There is a janky heatsink I used which was just a couple alu plates from somewhere I put together so it has this fan on a 40C N.O. switch. At ~8ms and highest BPS it appears to pull around 5A from the wall with the current tuning. I noticed the arcs were decent enough without the PLL though.


Using the two UCC2732x gate drivers which seem to run the full bridge ok in this operation but it's possible at ~8ms on times at highest BPS they will start overheating eventually. If I run it hard for a while to the point I can feel the heatsink getting more than just warm (with fan blowing) then the output seems to drop a little probably indicating the drivers and switches don't like it. Nothing gets too warm at the lower break rates it typically runs so it all kind of works out. I get them from mouser and Ebay/Amazon or something like that will always give you fake ones so don't do it.


A pretty basic layout that hasn't punished me for it but hey I'm not recommending a slack build or anything. This is the 2nd time I made a full bridge "test layout" like that I ended up just keeping in a final build, the other being a DRSSTC which uses the same kind of bridge layout, but to be fair might be getting saved by the snubber. I usually test with an isolated DC supply first, then low voltage AC, then full mains. So far with various coil testing these IGBT's have held up so they are pretty trusty.


A few shots of some ~18 inch arcs. I have a piece of foil above set to 20 inches from the breakout point which I could not get it to strike no matter how clever my insults were. When I had it set to 18 inches it would strike it every now and then but who knows what slight variations could result given environmental changes etc. I was originally struggling to get it to hit 16 inches before just messing with the primary a little bit and randomly testing various phase angle adjustments.




Here's a 16 inch strike from the half bridge catching mainly the tail end of the arc. I was pretty liberal with the size of the boards so in reality the spark to coil ratio could look much better after condensing the box down and everything looks smaller. I tuned that half bridge, got it to strike 16in, then was too excited about it to mess with it any further lol.


When it comes to the longest arcs from such a build it seems like it becomes a battle of finding a running frequency which is not too high or low, as well as trying to get it to form arc channels which don't branch on their way out as actual swords. That is to say I've seen tuning which seemed better in phase and probably had more power in the arcs but due to a tendency to branch more, a different tuning which pulled less power might yield longer discharges. I've kept fairly high coupling with these something around normal SSTC range and tried to keep the primary just out of streaking. There seems to be a certain science to 'encouraging' discharges to form just right as that voltage in the secondary starts to skyrocket. Slight changes in the breakout point length can for example make a big difference. A stuttering output with popping and clicking may indicate this energy trying to go somewhere and ending up in primary discharges you might not see in the light, where it may otherwise find its way out a longer breakout point, or one which is oriented to the side for example. I think using mosfets and an even smaller coil maybe closer to 600khz could get either the same arcs or longer. That's about all the insight I can personally offer into it so if you made it this far reading thank you for your sacrifice.

2
For anyone who may be interested in small coils like me I made a single video showing the output of 3 different variations of what I've basically been calling a Tefatronix style circuit, which is sort of a simplified Skori driver. Tried to make timestamped links but it didn't work. These are really handy for using 30V DC supplies or so. I think I've seen a couple iterations on forums but there aren't many around the net it seems. Figured I would post something here before I put these coils away for a while.

Tefatronix circuit at http://tefatronix.g6.cz/display.php?page=sstc4&lang=en
is a really good baseline for this circuit to see how it works.
Skori and Tefatronix have the most impressive results I think and Skori has a lot of detailed explanation of his drivers on his webpage.
http://skory.gylcomp.hu/tesla-ml/index.htm
http://skory.gylcomp.hu/tesla/mini_tesla.html

You can see that it is self oscillating with secondary feedback using a 1:1 transformer or thereabouts to drive a push-pull stage. This means that you can more or less build a 'high power Slayer exciter' with just a small GDT and extra mosfet. I have been making these circuits for a while and find them to be a great way to get fun discharges from low voltages or pull ZVS-like arcs from small coils. Most of them had been thrown together only experimenting with the GDT and primary. With a dual resonant primary one can run at 12V and get inches of arcs. It is also common to see sword-like discharges from these circuits. These can be tuned to run continuous anywhere in the realm of 1v to 30V or so before pulling in excess of around 10A but it is all around better to run them interrupted where one may want to sacrifice running continuous for longer arcs. This is like an in-between circuit to play with interrupted arcs after building a Slayer Exciter but before going to a high voltage half bridge.


/>--
The first coil is the smallest I've made so far and it's just a bit tinier than Tefatronix's. I usually run this ungrounded but adding the ground slightly improves performance. I use a TL494 to interrupt all of these via a 12v regulator. There is some slight primary arcing where the topload is just too close.
This uses IRFZ44N mosfets (this circuit at 26V or so is reaching about the ceiling with these)
Secondary is 1 x 1.2 inches using 40 AWG wire
The GDT is about 9 turns bifilar
Primary is 5+5 interleaved windings and center tapped similar to Tefatronix' flat cable primary

--
@2:48
Second coil is a bit larger at about 2 inches tall and 1.7 inches wide also using 40 AWG. There are two chokes on the input allowing for a primary without a center tap. It seems increasing this secondary to a slightly larger size can also increase the output considerably.
It uses 3x 18650's to make a fully charged 12.6V battery which feeds a 35v max boost converter.
I set the max voltage on this to around 26V to avoid possibly damaging the 12v regulator and the mosfets.
Again using IRFZ44Ns and about a 9 turn transformer for feedback and gate driving. Everything could be made so much smaller than I have here but I'm not very good at condensing.
Primary is 2 turns of 12 AWG.
This was meant to be dual resonant but I damaged the first coil and left the capacitor. Still works.
It will run CW at around 12V for short periods but heats up the small heatsink quickly without a fan.
This circuit taught me that with just the right tuning (which I only saw for a little while before being unable to reproduce it) a dual resonant SSTC of this size can produce something like 3 inch discharges at only 12-13v on the bus. That had ultimately destroyed the small series capacitor I was using and I settled for this more reasonable output. It's not easy to get Skori's results at 12-18V but, possible of course.

--
@5:03
Third coil is the largest iteration I've made of this circuit but it also gives me the longest discharges at about the 30V-50V intended max input voltage. I've ran it up to about 60V before it started having trouble but was able to pull 6 inch arcs at 50V and have had it tuned just right to where it could barely stretch out 6 inches at a high duty cycle low bps @30VDC.
It uses IRFP250 mosfets and an IRFZ44N for interrupting
The transformer is a small 1:1 of probably 25-30 turns I pulled from some board
Currently about 8000uF on the bus
Circuit is dual choke fed with a 4 turn primary and incrementally tuned series capacitor with an additional parallel 5nF or so. It is currently tuned to where the breakouts are longest at 30V-50V but could still tune it for pretty good arcs at around 15V-24V.

I think this kind of arrangement allowing for a higher voltage bus ceiling is a good in-between circuit
where one can get more than puny arcs at under 50V which is what may be close to the ceiling of a 'safe' or more commonly attainable DC supply voltage.

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