Author Topic: Ebay Bipolar Tesla Coil Rebuild  (Read 110 times)

Offline Razerwire

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Ebay Bipolar Tesla Coil Rebuild
« on: June 28, 2022, 09:42:52 AM »
A bit of quick background.. I have had many Tesla coils, that I have either built or bought, either home-built or Amazon specials. Anyways, I've had my eye on this BPSSTC on ebay and bought one once I worked out a good price... $180+$30 shipped. Man, I got screwed. Arrived all busted up with cracked acrylics and detached wires inside, scratches on everything. Seller was worthless and I settled on a $50 partial refund and glued the acrylics back together and went through ALL of the electronics, resoldered the wires that came loose etc. Most all of it was well built. 5 1/2" × 1 1/2" one piece aluminum toroid on each end with 6cm threaded rods going up to 1" solid stainless steel balls with copper wire breakouts. Secondary wound on acrylic tube is 21cm long with a 6 1/2cm O.D. ITS UGLY NOW BUT ITS ALL THERE I thought.  While going through the inverter/electronics one thing that stood out as shoddy was the GDT. It was sloppily wound with 8 turns each of very small solid wire. 1:1:1. Not twisted together and overlapping in places with no effort made to evenly space any of the wraps. This is a half bridge unit with the following component rundown: iron power xfmr, 10VA 120V IN 17V OUT. 2x24v fans, Avago fiber optic interrupter  RX. The ugly green core GDT 1" Dia, 3/4" wide. 4x green low esr electrolytic caps for the bus 120uf 450v. 2x TC4422 DIP 8, 9A driver ICs. CD74HC132E  Quad high speed CMOS logic NAND IC W/Schmidtt triggers. 2x RIFA PHE 450  630-  100nJBBD DC blocking caps. 1x MKP 0.33uF cap between the RIFAs^. 7805 and 7815 voltage regulators. Finally 2x GP50B60PD1 IGBTs.   So I added thermal grease to the IGBTs because there was nothing.... and fired it up... the output was highly disappointing. Instead of the 30cm arc advertised I was seeing 8cm MAX. So I decided to rewind the GDT trifilar with the same number of turns (8) and scoped it after. It was better than what came but still not perfect... I added a baby food jar lid spaced 1/4" with washers to each end toroid for more toploading and finally re made the primary which had only 2 wraps originally + the single loop of the feedback antenna wrapped on the primary coil form. The stock primary wire was like this silk wrapped very finely stranded wire that had ripped insulation and just looked pathetic. I put 3 turns of silicone insulated fine stranded #12 AWG on. Now I had my 2nd power up, with much improvement. Now I was making 10-12cm arcs. STILL not 30cm! So finally since I live in USA land of 120v mains I removed the full wave rectifier chip and installed a full wave voltage doubling rectifier. Tried it again... this time playing music. And WOW good improvement (still not 30cm though!) It was SCREAMING the notes beautifully for 25-30seconds before suddenly, *blip* , the output dies quickly and quietly. Released some nasty smoke and blew 2 fuses on the PCB... Both IGBTs died. My question is.... From here what other prudent mods would you suggest? I have a commercial  GDT on its way from coil craft and I ordered from IXYS: IXXH110N65CH ×4 IGBT. AND 4x IXXK110N65B4H1. As well as two 250v 1000uf electrolytics for the voltage doubler.  What more can I do to get the output increase of 30 cm? Remember this is a self tuning BIPOLAR SSTC, Thanks guys for all your input, I will post pictures if I'm able, of the coil in question... or at least what it should have looked like.
-Razerwire-  Shocker Coil and Converter LLC

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Ebay Bipolar Tesla Coil Rebuild
« on: June 28, 2022, 09:42:52 AM »

 


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