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1. 6 How does a Tesla coil work eere 7 Notes about COMPONENtS sssesesesesesseseseseseseenenenenenenen 5 Want to learn MoOre sesesesesessssesesesessssrsrseseseeserssesssesesesesesseseses 20 Step 0 Preparation eerie eere ee eee eese etn tn tne tnenatnets 21 Step Let s Start 23 Step 2 Gate Drive Transformeer eese 26 Step 3 Mounting the Heatsink esee 27 Step 4 Interrupter Board eese 28 Step 5 Interrupter Controls eese 39 Step 6 Double check Your Boards 30 Step 7 Test the Interrupter eese 3l Step 8 Interrupter Chassis eese 32 Step 9 Low power testing ennt 33 Step 10 Test for Startup Pulses esses 35 Step I Assemble the Main Chassis 4 Step 12 Primary Assembly sss 43 Step 3 Secondary Assembly eese 45 Step 14 Putting Together the Primary and Secondary 46 Step 15 Final Checks eere 48 Step 16 Pre operating Warnings eese 49
2. emele marc weill Stephan H Wissel jon c mortimer Nigel Nathan Mark Pearse Steve Watson Attila Kr lik Griebenow Andreas Georg Zmugg Mick Fielding CISR Deakin University Stefano Pento Sean Smith Gavin Maxwell Sweet Pea Bronte Roberts Koori Wong Allie Paterson Andrew Relf HangFire Kjetil Lio John Hutchinson Nicolas Chauvin Alan R Parker Noel Keating Remy MAGNAC Vegard Stenhjem Hagen Christopher Kay Chalk Simon Holmes Court Jens Rosenfeld Jon Russell Philip Davidson Riley Lu Ponsonby Computer Club Timbo Newbs Grant Lindsay Jim Moretti Romanoff DavidPapp com David Rioux Jon Newlands Nobody confuse Aaron ODIN Jensen Eddy Wilbers Tesla Toni Eric VanWyk Timothy Roach Jennifer Moores Marcellino Juan Quezada Michael Una Ed Schnurr Chris Howard T A Valdes Erik Cubbage Michael Dewberry Kurt Kurasaki Andrew LeTourneau Carl Witty Matthew S Phillips Ludwig Bradley Feder Jeff Howbert Jeff Coffin Dave Rivera Chuck Pint Craig Allen Len Shustek Stephen Jacobs Christopher Kelly rudiemcska Derek Graham Szydtowski Tim Henning Craig Calkins Barry Grall Gerhard Spangenberg Mark Boenke j4cbo Bill Riess Zane Faught Emmanuel Hernandez Corey Runge Andy Miller Rich Mills Chip Crell Walter Murphy E Horikawa Master Norberto Christine amp JT Ellert Dan Stewart Morgan Sandercock Jose R Cordero Ladner Joey Bruce Odelberg Samuel Lawrence Foundation Mark Rowe Dick Bell Jas
3. firm that the fiber emits light If it does the interrupter is functioning and the control board is faulty C D 4 Low power system testing We will now test the main chassis and interrupter together at low power When probing anything on the board clip the ground lead to the back of the voltage regulator like in the picture below Plug the 19V adapter into the DC power jack on the driver board We are only doing low voltge testing at this stage so DO NOT PLUG IN THE IEC CORD Do the LEDs light up g p NO Measure the outputs of the 5V regulator and and 5V regulator with a multimeter If they are they correct voltage you have a poorly soldered LED or a damaged LED YES 2 Confirm that the 19 power jack is properly sol dered 3 Remove all socketed ICs on the board Measure the resistance between the rail in question and ground It should be a high value If not check for solder bridges between the rails and ground 4 With the ICs removed measure the 5V and I5V rails with a multimeter If they are now the correct value you have a damaged or backwards IC Reinstall the ICs taking care to note the location of pin and measure the rails after each IC is installed The IC that causes the rails to vanish is the culprit 5 If none of the above resolve the problem replace the voltage regulator s in question Use a voltmeter to measure 14 of the 74HCT 4 and 74HCT74 Confirm tha
4. 19V adapter If this happens it s again is a problem of geometry Move the cords away from the region where the spark might strike them Move out the breakout point so that the sparks have a lon ger path to curve back and hit the primary 3 Watch out for device latchup Occasionally noise picked up by poorly shielded MIDI cables or an interrupter too close to the coil will cause the optical transmit ter on the interrupter to latch high This tells the Tesla coil to stay on continuously which causes the average current draw of the coil to become extremely high in a matter of tens of milliseconds In this case the fast acting fuse will blow to protect the main control board You will typically hear a high pitched whine when the coil latches up followed by a flash of green light from the blowing fuse as in the picture to the left If latch up happens frequently move your interrupter and MIDI cable further away from the coil You may want to replace the MIDI cable with a well shielded one of good quality if it s a recurring problem Sometimes the fuse may not blow fast enough to save the bridge in which case you will need to replace the IGBTs 4 Avoid excessive ground strikes e While it may be fun to watch white hot ground strikes these arcs also carry significantly more current that regular stream ers This in turn translates into increased inverter current which generally makes things run hotter on the driver e Stop
5. BEFORE PLUGGING IT INTO AN OUT LET 5 Ensure that the power cable is on the opposite side of the breakout point so there s no risk of a spark hitting the power cable Ensure that your MIDI interrupter is the full distance that the optical fiber allows it to be from the coil 6 Standing away from the coil plug the other end of the IEC cable into the power outlet THE COIL IS NOW ENERGIZED DO NOT onel esla User Manual v1 3 6 Power test with MIDI Input If the power test in fixed frequency mode works then con tinue to test with a MIDI input As before power up the Tesla coil by following these steps in the exact order they are written A good tool for debugging is a virtual MIDI keyboard For Windows computers download V M K 1 6 available at http www hitsquad com smm programs VMKXP N D 4 U You will also need MIDIEditor available at http midieditor sourceforge net MIDIEditor is an open source program for playing and editing MIDI files Plug the USB to MIDI adapter into a free USB port Due to driver limitations you should use the same USB port every time if it doesn t work try another USB port 2 Open MIDIEditor 3 to Midi gt MIDI settings and select USB2 0 MIDI in the list under Send Output To 4 Plug the OUT cable of the MIDI adapter into the inter rupter 5 Power the logic on the driver board with the 19V adapter Turn the interr
6. G26 wire An LC circuit can have an inductor and capacitor in series or parallel Here we are using series LC circuits like this C AC source L Consider what happens when you don t drive the circuit as sume that the AC source in the above figure is replaced by a wire but start out with the capacitor charged The capaci tor wants to discharge so charge flows around the circuit through the inductor to the other plate In che process a magnetic field builds up inside the inductor When the charge on each plate of the capacitor is zero current stops flowing But at this point the inductor has energy stored up in a magnetic field which tends to oppose change The magnetic field collapses inducing a continuing current in the same direction thereby recharging the capacitor and restart ing the cycle in the opposite direction The resonant frequency of an LC circuit or the frequency at one esla User Manual v1 3 6 which the energy cycles between the capacitor and inductor as described above is 1 2nvLC Driving the circuit at its resonant frequency adds energy during each cycle By providing a succession of well timed pushes we can build up to extremely high voltages In the Tesla coil a spark breaks out and discharges the circuit once the voltage is high enough D DRSSIC The oneTesla 10 coil employs a double resonant topol ogy hence the name double resonant solid state Tesla coil or DRSSTC In a DRSS
7. VOLTAGE warning warning label sticker on the front plate of the chassis in the marked area DO NOT OMIT THE WARNING LABEL It s important that the Tesla coil is marked as a high voltage device 3 Align the chassis front and back pieces correctly with the IEC jack and primary screw terminal respectively Completely assemble the chassis with the board inside WITHOUT GLUE There s only one right way to put the sides together so make sure that you have them in the correct orientation before applying glue The warning label and oneTesla logos on the side pieces should be on the outside of the box 4 Use four 6 32 bolts 6 32 nuts and 1 4 standoffs to attach the main circuit board to the bottom plate in the onel esla User Manual v1 3 6 Par dais of phe haro Primary Assembly The challenge in winding the primary is getting the turns tight and even We designed laser cut clips to hold the wire to the acrylic former for a nice clean look Roughly measure enough AWG 14 wire for six turns on the former plus about a foot of extra length on each Step 12 end Li 2 Tape the wire to the primary about a foot from the Put dabs of end glue here 3 Wind six turns around the former as tightly as pos sible and keep it tight until you tape down the other end 4 Tightly twist together the leads coming off the primary all the way down their length Use some heat shrink tubing or electrical tape to secure the lea
8. adapter blinking If not you have a configuration problem on your computer Try the usual restarting the program unplugging the adapter etc If the OUT LED is blinking check to make sure that the values of the resistors and direction of the 134148 diode on the optoisolator section of the interrupter board are correct Check your soldering one esla User Manual v1 3 6 Coil appears to work fine but One possibility is a tuning issue Check the primary and secondary assemblies for any physi the IGBTs unexpectedly fail cal damage then use the capacitance setting on your multimeter to check the value of the or heat up excessively primary capacitor If it is not close to 0 068uF you will need a replacement Another possibility is a gate drive issue With a signal generator supplying a 250kHz sine wave at the feedback input of the 74 14 use an oscilloscope to observe the waveforms between the gate and emitter of each IGBT You should see a 30 volt peak to peak square wave If there is ringing check to make sure your gate resistors are not shorted out and are within 5 of 6 8 ohms If the gate resistors are fine then your has too much leakage inductance and you should rewind it tighter and with shorter more tightly twisted leads If the edges of the square wave look significantly rounded off then there is excessive damping resistance on the gate causing the IGBTs to spend too much time in their linear region
9. best on certain notes An unfortunate side effect is that on nonoptimal conditions the coil may flash over Rather than for example disable nonoptimal notes we leave them enabled for flexibility It is up to you the user to ensure that these features are used wisely Q C D 4 U Curing flashover e Adjust the breakout point and improve the surroundings so the coil sits on a ground plane You want the spark discharge to have an easy path between the breakout point and ground If there s no single easy path for the sparks to take discharge in undesirable places such as between the secondary and primary will happen more often e Avoid playing low notes The coil most often flashes over on low notes be cause of their long pulse widths e Each time your coil flashes over it degrades the insulation on both the sec ondary and the primary If flashover is persistent it s necessary to re varnish the secondary with a few coats of polyurethane e Watch carefully where flashover takes place Sometimes the arc will track along the primary former and down a clip Rounding the edges of the clips or removing them entirely may help e Ensure that your secondary is centered in the primary HIGH VOLTAGE dm Step 19 continued onel esla User Manual v1 3 6 2 Watch out for arcing to the primary or power cords Arcing to the primary coil or any power cords should be avoided particularly the cables of the
10. coil damage The radiated electric field has a tendency to temporarily cause nearby capacitive touchscreens and laptop touch pads to misbehave This is normal and will not perma nently damage your electronics If this happens just move further away from the coil TURN OFF COMPUTERS in the vicinity of the coil to prevent potential data loss in case they re poorly shielded This probably won t happen but don t take risks Breakout point opposite coil cabling from the spark Nothing unnecessary plugged into the outlet large flat surface to ensure good grounding No unnecessary items around the coil Sufficient distance 3m between coil Cabling between and interrupter interrupter and MIDI source is short to prevent noise pickup rre enfer ORAA PAIE one esla User Manual v1 3 6 Breakout Point Placement Positioning of the breakout point can significantly affect coil performance and reliability Follow the diagram on this page as a guide If performance is low try moving the breakout point further in If the secondary flashes over trying moving the breakout point out a little Make sure the breakout point does not protrude fram the other side APPROACH IT OR OPEN THE CHASSIS Power test in fixed frequen 7 Slowly turn up the power on the interrupter Sparks should fly As you turn the power up you should get a Cy mode nice clean ton
11. onel esla User Manual v1 3 6 4 Install Fl the fuse holder and fuse The fuse holder is composed of two identical fuse clips Install these in the board Note that the ends with the bent tabs should be on the outside to allow the fuse to slide in It s a good idea to install the clips with a fuse inserted to make sure the spacing and direction is correct 5 Install 4 pin sockets for and IC2 Match the notch on the socket to the notch on the board Don t solder the ICs directly to the board 6 Install 8 pin sockets for IC3 IC4 Match the notch on the socket to the notch on the board Don t solder the ICs directly to the board 7 Install ICS and IC6 voltage regulators Be sure not to confuse the two IC5 the LM7815 is the 15 volt regula tor and IC6 the LM7805 is the 5 volt regulator Don t install them backwards The tab of the voltage regulator need to match the stripe on the board Step 1 continued 18 Install the IC s in their sockets ICI is the SN 74HCT 14 IC2 is the SN74HCT74 1C3 and 4 are the UCC3232x gate drivers for now you can just install them in either socket but you may have to swap their positions 21 There are three thick power traces that carry later a lot of current on the back of the board Tin them 19 Install the current transformer Cut a few inches of coat them in a thick layer of solder but don t cover AW Gl4 wire and strip the ends Put it through the cu
12. overload and destroy the driver immediately necessitating a re placement of the bridge Make sure the cooling fan is plugged into the fan header on the board and that it runs when you plug in the 19V plug Never run the Tesla coil without the cooling fan Proper environment for operation ENSURE THAT THE TESLA COIL IS POSI TIONED IN SUCH AWAY THAT THE SPARKS DO NOT STRIKE ANYTHING They should dis charge into the air There should be nothing within two feet of the breakout point PEOPLE WITH PACEMAKERS SHOULD NOT BE IN THE VICINITY OF THE COIL BE AWARE THAT THE COIL IS VERY LOUD If you are indoors ear protection may be necessary Al ways turn up the power of the coil slowly Make sure you your MIDI source and the interrupter at least 10 feet away from the Tesla coil This is the minimum safe distance for people and equipment If you are using a laptop as a MIDI source MAKE SURE IT IS NOT PLUGGED IN The RF returning through mains ground will be injected back into the laptop often causing problems If you are using a MIDI keyboard bat tery or USB powered keyboards are preferable ONLY RUN THE TESLA COIL ON A LARGE FLAT SURFACE The tuning of the Tesla coil is very sensitive to its surroundings In its stock configuration it is tuned to operate properly on a large table or on the floor If you run the coil on a small surface or an insulat ing surface you may suffer from reduced performance or cause
13. that the toggle switches are in the right ori entation in the chassis and affixed securely With the battery attached and the second toggle switch in the Fixed posi tion check that the light in the optical transmitter turns on when the power switch is in the ON position and turns off when the switch is in the OFF position The light should not turn on at all when the second toggle switch is in the MIDI position unless there is a MIDI input 2 Peel the protective paper off the acrylic parts 3 Carefully assemble the sides of the chassis without put ting any strain on the optical transmitter 4 Usea small amount of hot glue at the corners of the chassis to hold it together C D 4 N one l esla User Manual v1 3 6 Interrupter testing Testing and debugging the driver board relies on a functional interrupter so we wil debug it first This is a low power test only DO NOT PLUG THE TESLA COIL INTO AC POWER IN THIS STEP Connect a 9V battery to the interrupter Put the toggle switches in the OFF and Fixed positions respectively Gently insert the fiber cable into the transmitter on the in terrupter and and receiver on the main board Do not push the fiber in too hard There is a delicate glass lens inside the transmitter and receiver that will break if you push the fiber in too hard Plug the 19V wall adapter into the main driver bord This is a low power test only so DO NOT PLUG THE IEC CAB
14. the iron against both the pad and the component lead The idea is that the iron heats up the surfaces that you want the solder to wet to and the solder flows onto those surfaces by itself without touching the iron inside which makes removing improperly soldered com ponents rather difficult Get it right the first time 6 Once your solder has wet to both the lead and the pad remove the iron Generally don t apply heat to the pad for too long because it can become weak and fall off the board Inspect the joint Is it sticking well to both surfaces Soldering tips he order in which you install the components doesn t matter but it s generally easier to start with the parts with the shortest leads first 7 If the joint is satisfactory trim the lead with flush cutters A bit of masking tape can hold components to the board while you solder e We highly recommend investing in a good iron Weller irons are probably the best but comparably good ones can be found for around 40 Invest in a good iron early It will pay off in saved time and avoided frustration e Some of the pads are octagonal These pads connect to power planes on the board and as such are trickier to solder because of the high thermal mass of the planes 8 If you make a mistake remove excess solder using A little patience and maybe gently feeding extra solder solder wick The holes in our boards are plated on the at the joint or inc
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16. Its terminals are labelled collector gate and emitter as a C E holdover from vacuum tubes before the era of transistors A simplified model of an IGBT is normally open switch that closes when a positive gate voltage V is applied In the following diagram of a half bridge S and S2 represent the IGBTs They alternately turn on and off which switches the polarity of Vbus 2 across Lprimary and Cprimary the primary inductor and capacitor The oneTesla 10 coil runs off a bus voltage of 340VDC 31 Cbus Vbus Lprimary Cprimary 32 On the control board we get the bus voltage from rectfied and doubled line voltage We ll go into detail about that por tion of the circuitry later Zero Current Switching When the IGBTs are fully on the switches closed they are nearly perfect conductors When they are fully off the switches fully open they are nearly perfect insulators When they are in transition between fully open and fully closed or vice versa however they behave like resistors Re call that the amount of power dissipated in a circuit is P VI If we try to switch the IGBT while the current through the circuit is large then it will heat up a lot We have to time the switching of the IGBTs to the natural zero crossings of the primary LC circuit On the oneTesla board we achieve zero current switch ing by sensing the primary current and using control logic to ensure the transistors switch at the
17. LE INTO THE BOARD Flip the toggle switch on the interrupter to the On position The interrupter should now be emitting pulses Does the green LED next to the fiber receiver light up YES 3 If there is no light disconnect the fiber from the transmitter end and examine whether the LED in the transmitter emits light If it does you either have a damaged cable check for kinks or obstructions in the cable or a damaged fiber transmitter 4 If the fiber transmitter does not emit light check for poor solder connections on the interrupter board In particular the crystal is sensitive to bad solder joints Make sure pin 23 of the ATMega328 is not shorted to ground Sweep the power knob from minimum to maximum while playing a note Does the green LED fade and brighten cor respondingly YES NO Check the power knob potentiometer and confirm all solder joints are intact in particular excessive strain on the wires connected to this potentiometer may dam age the solder connections 2 Make sure there are no solder bridges between pin 23 of the ATMega328 and the 5V rail J Flip the MIDI Fixed switch to MIDI then turn the in terrupter off and back on If the LED lights up you have the switch wired backwards to fix this simply rotate the switch 180 degress in the chassis At this point you are ready to test the control circuitry on the driver board 2 Disconnect the fiber from the receiver end and con
18. Smith H Fred Oakley Keith Huss Steven Mullis Bill Porter Seth Lewis Greg Rudisel d3c4f Conrad Farnsworth Matthew Strider Jones Amar Shabbir Jeff Picolla Sparr Tim Bitson Clint Sare Jerry Wingenroth Dale Sulak David Christal Brad Schuller Adam Brookman Pascal Helou Laen Sunil Gupta Resonance Research Ryan Peterson c d wrestler Jim amp Paula Kirk Greg Peek Cecil Casey Eric Hall Derek Geyer Mikey Dave Kleeberg Michael F Peacock Jeff Lake John Young Monty Goodson lan McMahon David Dressner donbert pezmanlou n8 bit Bruce Webster Scott E Sanders Scott McFarlane Gary M Raleigh NC Jason Fisher Graham Bergey Arnim Sommer Mel Gannon James Ross Harrison Yuri Mathews Fraser Reid Malcolm Fleury Azalea Dambergs Richard Giltech Gilmore Steve Kurzeja Chris Lin Raz Schreiber Michael D Blanchard ePop Trevor Lewis Eric Wood Jon Nebenfuhr Larry Schoeneman James Gregory Einstein s Workshop Jon Reese Dr Richard Grimmett Rob Wittner Roy Wolman MiTE Asia william prewitt Gregory Lewis Eric L Smith Aaron Cartterfield Jerry Horn Trevor Johns ktern American McGee Artlav Matej Rebersek John Paul Pretsch Pierre Gaudet Christopher Heard Dmitry Akimov Sandro Grundmann Elke Schick Ewan Richards Kai Uwe Kuehnel Traci Whitehead Jonny Alex Ross Asmund Gravem Todd Holden morbid Nathan Ward Althalitus Nathan Licciardo Kean Maizels Harry Sasha Rudan ernie janosikm Clement Hathawa
19. Step 17 Fixed Frequency Testing esse 50 Step 18 MIDI Testing cernere eene terne 5 Step 19 What to Watch Out 52 Step 20 Reliability Tips eese 54 Step 21 Fine Tuning eres eee eee ee eee ee tentent 55 Step 22 Service and Repair eese 56 Need help Ask questions and get help on the online forum at http onetesla com forum Need replacement parts Get components from our online store at http onetesla com or your favorite electronics supplier like Digi Key at http digikey com Stay tuned for updates Follow the blog at http onetesla com blog Note We try our best to keep all images and instructions consistent with the latest revision of the oneTesla hardware but the photos in this manual and on our website are not always identical to the components you will receive in your kit They will however maintain the same functionality This document is licensed under the GNU Free documentation license That means that you can improve and redistribute it as long as you propagate the license For more information see http www gnu org copyleft fdl html one esla User Manual v1 3 6 IMPORTANT SAFETY WARNINGS ELECTRICAL SAFETY WARNING HIGH VOLTAGE AND HIGH FREQUENCY OUTPUT The Tesla coil output is over a quarter m
20. TC the circuit driving the secondary LC circuit is another LC circuit tuned to the same resonant frequency In the following diagram LI and L2 are the pri mary and secondary inductors respectively They are weakly coupled linking around one tenth of their magnetic fields Csecondary C primary Rwindings 4 L primary L secondary There are several reasons why Tesla coils do not employ a magnetic core First of all the voltages in the Tesla coil are so high that the core would quickly saturate meaning it would no longer be magnetizable past a certain point Also most materials pose a resistance and heat up in a magnetic field that switches rapidly as is the case in the coil The high voltage the coil produces also has the potential to arc to the core But most importantly it s critical that the primary and secondary coils be loosely coupled so the secondary is not loaded down by the primary Half Bridge How do we go about exciting the primary We use a DC voltage source and apply the voltage in alternating directions across the primary m Streamer discharge happens here 340V 1 A f pplied to Primary ov i V He LU voltage The switches that we use to apply a DC voltage in alternat ing directions across the primary are IGBTs short for insu lated gate bipolar transistors An IGBT is a transistor capable of controlling very high voltages and currents This is its schematic symbol s
21. an use a tire inner tube that s close to 8 major diameter across the whole toroid 2 minor diameter a cross section of the tube and cover it in aluminum tape Hold the inner tube in place with a cardboard disc with a hole in it 5 Attach the primary wires to the primary screw ter minals through the hole in the back of the chassis You Step 14 continued will need to lift up the lid of the chassis to tighten the terminals with a screwdriver 6 Verify that you have a good ground connec tion DO NOT SKIP THIS STEP ALSO DO THIS CHECK EVERY TIME YOU MOVE THE SECONDARY OR TOROID An ungrounded Tesla coil runs poorly and can damage the board Use a multimeter to probe between the ground prong of the IEC port the middle prong and the metal toroid There should be 2500 More than that means that you have a bad connection whch you need to fix H VOLTAGE E X gt NA Je P av ba as 1 Ek Special instructions for external grounding If you do not have a grounded outlet you need to externally ground the coil To externally ground the coil run a wire from the bottom of the secondary to a ground point close to the coil A good ground point could be a stake in the ground a water pipe or a large metal sheet We highly recommend running your coil on a coun terpoise a sheet of aluminum foil metal window screen or chicken wire at least 4 feet in diameter that s also
22. are probing work with one hand in your pocket This prevents you from inadvertently touching a grounded object with your other hand when probing something that is potentially high voltage which could cause a short circuit across your chest IMPORTANT SAFETY WARNINGS Adult Supervision Required Users under 18 should only use this kit under the supervision of an experienced adult ADULT SUPERVISION REQUIRED Pacemaker Warning Persons with electronic medical implants such as pacemakers should not be near the Tesla coil during operation EMI from the coil may interfere with the pacemaker s function Ozone Warning The high temperature of the Tesla coil stream ers causes the gases that make up air to form other compounds including ozone which can often be smelled when the coil is in operation and nitrogen oxides Keep the Tesla coil work area well venti lated to prevent the buildup of irritating gases such as ozone and nitrogen oxides which become toxic if concentrated Fire Hazard The arcs from the Tesla coil can set flammable objects on fire Keep all flammable objects away from the Tesla coil while it is in operation Ear Protection Recommended The Tesla coil output is loud ear protection is rec ommended Eye Glasses Required Always wear eye protection while soldering Power semiconductors may overheat and fail vio lently causing a shrapnel hazard Wear safety glasses when working on the board while it is
23. ceiver outputs 5V or OV depending on the signal from the interrupter R2 and R3 form a resistor network that ensure that the coil can be tickled into op eration by just the interrupter signal on startup in absence of a feedback waveform When the coil is just starting up there is no feedback signal but the interrupter signal makes one esla User Manual v1 3 6 it through to the UCCs When the coil is in operation the feedback signal dominates the top of the signal pathway The inverted interrupter signal and the square wave from the squared primary current signal are then fed into a D type flip flop which performs logic that determines when the gate drivers recieve a signal They are only turned on when there is a zero crossing as well as a signal from the inter rupter The D flip flop behaves according to the following truth table FUNCTION TABLE In our circuit PRE and D are pulled high The inverted inter rupter signal which is fed into CLR sets Q high when the interrupter is ON When the interrupter turns off Q stays high until the next falling edge of CLK which is synchronized with the zero crossings of the primary current upon which it switches low The inverting gate driver turns on when IN is high and EN is low The noninverting gate driver turns on when IN is high and EN is high Interrupter The oneTesla interrupter is a microcontroller based device that converts an incoming stream of MIDI c
24. coil is a learning experience Usually a damaged coil can be repaired with just a handful of components available from any electronic parts supplier or our online store at http onetesla com Conceptually the components on the coil fall into two cat egories Semiconductor devices including e FGA60N65SMD IGBTs e MUR460 diodes e UCC37321 2 Gate Drive ICs e 7 4HCTI4 and 74HCT74 e 134148 signal diodes e Optical receiver Indicator LEDs e LM78xx voltage regulators These components are most likely to fail and are the first suspects in case of a failure 2 Passive devices resistors capacitors transformers These components are exceedingly unlikely to fail Electronics often fail in unpredictable ways so we re not going to give you a step by step flowchart to follow Instead this step will comprise of some handy general tips that will help you fix your coil Remember that you can always ask for help on the online forum at http onetesla com forum 60 The IGBTs are by far the most failure prone components IGBT s often fail short if you measure across pins 2 and 3 of the IGBT in diode test mode on a multimeter posi tive lead on pin 2 it should read open If not the IGBT is damaged and should be replaced When replacing IGBT s always replace both at the same time A blown fuse will often be associated with damaged IGBT s or damaged MUR460 diodes Test the MUR460 s with a multimeter to confirm that they are not shor
25. correct times We ll describe this logic circuitry in a following section Gate Driving The IGBTs are far from ideal switches We want them to switch fast to minimize the time during which they are resis tive and dissipate power The issue with switching gates fast is that they have significant internal capacitance and it takes a lot of charge to fill up that capacitance and achieve the turn on voltage across the gate the voltage of a capacitor is given by V Q C Ji i Se To charge C in as short a time as possible we want to use a short high current pulse Gate drive ICs are designed to do exactly this We use UCC3732x ICs which can source up to 9A for brief pulses The logic circuitry preceeding the gate drivers isn t even close to being able to source enough current to turn the gates on fast so the gate drivers are es sential components Lastly we need to isolate the gate drivers from the IGBTs using a gate drive transformers GDT Each IGBT needs gate voltage to be applied between its gate and emitter to turn on This is easy on the low side bottom IGBT its one esla User Manual v1 3 6 emitter is always at ground meaning its gate only needs to Rectifier amp Doubler be brought up to 15V Things are not so easy with the high side top IGBT because its emitter is referenced to the col lector of the low side IBGT a node which swings between 0 and Vbus 2 which in our ca
26. derstand more of what s going on we need to introduce resonant circuits Resonant Circuits A resonant circuit is like a tuning fork it has a very strong amplitude response at one particular frequency called the resonant or natural frequency In the case of the tuning fork the tines vibrate strongly when excited at a frequency determined by its dimensions and the material properties A resonant circuit achieves the highest voltages when driven at its natural frequency which is determined by the value of its components Resonant circuits use capacitors and inductors and therefore are also known as LC circuits They are also known as tank circuits because of the energy storage elements present Capacitors store energy in the form of an electric field between two plates separated by an insulator known as a dielectric The size of the capacitor is dependent upon the size of the plates the distance between them and the prop erties of the dielectric Interestingly the topload on the Tesla Coil acts like a one plate capacitor with the ground plane surrounding the coil acting as the opposing plate The capaci tance of the topload is determined by its dimensions and its proximity to other objects Inductors store energy in the form of a magnetic field around a wire or in the middle of a loop of wire The prima ry inductor in the oneTesla 10 coil is six turns of AWGI4 wire and the secondary is approximately 1800 turns of AW
27. dison Mario P Alexandre Joseph Cortese Randy Main Rob Winters Main Light Industries Jim Tolley TheXenocide Gregg Ken Sweeney Richard Wolff Jim Stratigos Matt Shabet Jareth Hein Nathan Taube Guy Marsden Tim Moore Nick Stock Marcus Eubanks Ryan Wenner Douglas B Fletcher Wally Kissel Peter Casper Will Ernst Eden Brandeis Techniplex The Stein family from Downers Grove Barry Brian Wheeler Dr Richard Boulanger Justin Capogna John Borleis 111 Andrew Creighton Jeremy Alliger d andruczyk Eric R Schroeder Clement T Cole amp Margaret E Marshall Nathan Hangen Andrew J Welker Clockwork Feathers Richard Brull Gary Ricard Bhusan Gupta Lee White Peter W Piechocniski Donby Mathieu Michael Wacht David Friedlander Holm Steven Collier Alex Orion Kiwerski Jeremy Faircloth The Jon Atwood John Penny Tox Charles Alvis Bradley C Howes Ron Beck Ward Shelley Doug Hill David Judd Dove Dan Mozgai Steve Fish Matthew Shurboff James Fulton Tom Zelick man Aaron Rosenthal Raygun Ballet John Lewis Tom McKeone Freeside Atlanta David R Tabb Michael D Kellner Tyler Madison Caleb Cotter Ben THomas Steve Goldstein Marco Alpert Dave Hall Paul Camann Krellmusician Kerry Hammil WireKAT Tadei Christopher Strider Cook Steve Mueller Dr Sam Jaxsam Artemus Jules Rodin Handy Gelbard David panicopticon David F Bishop Peter Dyer Duane Zobrist thebrianmanley Ali Hassan Enrico Ros Rafael Matt Was
28. ds right where they come off the primary 5 When the windings are sufficiently secured with pieces of tape slide the clips over the windings like hair pins Space them evenly around the former They break easily so be careful 6 Use a dab of hot glue at the top and the bottom of each clip to hold it in place When all the clips are in place take off the tape for a clean look Glue the circu lar base plate onto the former as well 7 Strip a quarter inch of insulation off the ends of the wire Crimp spade terminals to the ends of the wire using a crimp tool if you have one or large pliers You can also solder the terminals on onel esla User Manual v1 3 6 Y Secondary Assembly Thank us we ve saved you hours of tedious work manu C ally winding 2000 turns of 36 gauge wire without a single qd crossed turn There are a few inches of loose wire coming off of U each end of the secondary Gently sand off the enamel at the end If the lead breaks while you are doing this gently peel off more You should see exposed copper when you are finished 2 Solder the end of the lead to a ring terminal 3 Put the ring terminal over a 1 4 20 bolt Put the bolt through a secondary end cap so that the ring is clamped between the bolt and the plastic Use a small amount of hot glue to attach the bolt to the cap 4 Use a small amount of hot glue to put on the sec ondary end cap 5 Repeat on the other end of the
29. during each switching cycle and dissipate more power than they should Check the soldering of the GDT IGBTs and gate resistors for poor joints and confirm that the values of the gate resistors are 6 8 ohms If the peak to peak voltage is less than 30V then there is an issue in the gate drive cir cuitry Check the 15V logic rail If it is correct then probe the outputs of the UCCs It is likely that one of both of the gate driver chips have sustained damage and will need to be replaced Coil does not respond at all One possible cause is that the interrupter is low on batteries Because the microcontroller is to interrupter input but inter capable of running down to 3 3V there are situations where the interrupter operates but the rupter appears to be working transmitter LED is not bright enough to trigger the optical receiver In these cases replace the battery Operating your Tesla coil I Watch out for flashover and surface tracking on the secondary Flashover is the phenomenon where an arc forms between the primary and secondary Surface tracking on the secondary is where an arc forms between two points on the secondary Both of these events are extremely harmful In addition to possibly destroying your secondary or your bridge they also severely degrade the insulation on the secondary and primary wires Why do these events occur Well oneTesla is optimized for performance on a large flat ground plane and performs
30. e and steadily increasing spark length Power up the Tesla coil by following these steps in the exact 8 If the coil doesn t work don t panic Unplug the IEC ca order they are written The purpose of these steps is to en ble from the power source wait 5 minutes before touch sure that if something is wrong with the Tesla coil s construc ing the board and proceed to step 18 troubleshooting tion you minimize the risk of being near it when it is energized and malfunctioning Ensure that you have read and con tinue to follow all the pre operating warnings Due to the self resonant nature of the driver there is inherently a 5076 chance the Tesla coil will not produce output the first time In that case Step 16 Put the toggle switch on the interrupter box to Fixed mode and turn on the interrupter 2 Look at the fiber transmitter on the interrupter Turn the power knob and observe the light changing in brightness reverse the positions of the Turn the power knob so that the light is as dim as it gets You may want to mark the direction of increasing power UCC3 322 IC and the UCC37321 IC on the case with a marker and re test the Tesla coil This should 3 Turn off the interrupter Connect the main board and the be the first step you take if your Tesla interrupter via the fiber optic cable coil does not work 4 With the other end disconnected plug the IEC cable to the main board CONNECT THE IEC CABLE TO THE BOARD
31. e but electrically resistive After any errors found are fixed unplug the board and wait five minutes Prior to further working on the board mea sure the bus voltage you can do this by using a multimeter on the 1 000 0 setting to measure across the far ends of D3 and D4 afterwards and confirm that it is ZERO VOLTS Step 10a Test For Startup Pulses no scope Set the mode switch on the interrupter to FIXED mode power on the interrupter turn the POWER knob to maxi mum and connect the interrupter to the driver board via fiber optic cable DO NOT ENERGIZE THE BOARD BY PLUGGING IT INTO AN AC POWER SOURCE WITH THE IEC CABLE This is a low power test only The next steps should be done in a quiet room Plug the 19V adapter into the driver board Listen to the gate drive trans former GDT and verify that there is a faint buzzing noise If you cannot hear the GDT buzz Ensure that you re in a quiet environment The buzz ing is quite faint 2 Make sure all ICs are seated properly 3 Make sure the fiber cable is installed correctly in both the interrupter and the control board 4 Make sure all solder joints are good in particular e R4and R5 e Pins I2 and 13 of the 74 4 IC e Pins 2 3 4 5 and 6 of the 74HCT74 IC e Pins 2 3 7 and 8 of the UCC3732x gate drive ICs e The three pins of the optical receiver 5 Make sure the GDT is properly wound and installed and none of the GDT leads are sho
32. energized Only power up the board when it is fully enclosed inside the chassis RF Warning Keep sentitive electronics away from the Tesla coil at all times Use the entire length of the included fiber optic cable to distance your com puter from the Tesla coil Observe Good Workspace Practices Keep your workspace neat and orderly Always obey common sense e Do not continue work if at any point you feel uncom fortable with the hazards Always work with a clear mind Do not work when you are tired Use caution when soldering lead is hazardous and the iron is extremely hot onel esla User Manual v1 3 6 Overview Toroid Secondary coil Primary Primary former former clip a Primary coil 4 Main chassis DANGER HIGH VOLTAGE UO m MIDI fixed frequency mode selection switch Power adjustment knob Pitch pulse frequency adjustment knob Optical transmiter MIDI input jack screw terminals for Current Gate drive Primary leads ff transformer transformer CDE primary capacitor Gate drive ICs Logic ILS n E i TIITTT Te c E _ Bus Voltage _ me BR capacitors regulators Optical receiver Ground lead to base of secondary 4 Power Protection IGBTs and DC power jack indication fuse heatsink poe AEE LEDs one esla User Manual v1 3 6 How do
33. ent Fiber out jack Step 5 Interrupter knobs amp switches In addition to the board mounted components we will need to install a couple of off board controls two 10 potentiometers and two toggle switches Using flush cutters separate the ribbon cable into three 3 wire strands and one two wire strand Separate about an inch of each strand at the ends Strip half an inch of insulation off the ends of the ribbon cable Solder one end of each ribbon cable into the board and the other end to a poteniometer or toggle switch Pn PW _ Pint F Pin PWRI _ Pini SW 0 Mount the potentiometers and toggle switches to the top plate of the chassis Match the toggle switches to the labels on the chassis Potentiometer POWER Potentiometer 2 FREQUENCY Toggle Switch ON OFF Toggle Switch 2 MIDI FIXED Solder the battery connector to the underside of the circuit board The red lead goes into the BATT pad and the black lead goes into the BATT pad 5 Mount the circuit board to the bottom plate of the chas sis using four nylon standoffs and 8 M3 screws Pobenbometer amp Potentiometer 2 POWER FREQUENCY Pins 1 23 Pins 4 3 Toggle switch I ONIOFF onel esla User Manual v1 3 6 Double check your boards At this point the electronics should be completely assembled O Scrutinize your boards and look for the following U e Check that all components are so
34. errupter board with the components in the that the notch on the IC lines up with the notch on the list to the right Use the picture as a reference board 3 Insert the optocoupler into the socket ensuring that the dot on the IC lines up with the notch on the board Install RI through R6 2 Install capacitors through C4 Step 4 3 Install the 28 pin socket for the ATMEGA328 Match the notch on the socket to the notch on the silkscreen Don t solder the IC directly to the board 4 Install the 6 pin socket for the optocoupler Match the notch on the socket to the notch on the board Don t solder the IC directly to the board 5 Install IC3 the 5V voltage regulator Carefully bend it backwards and use a 4 40 bolt and nut to secure it to the board 6 Install Yl the 16MHz crystal 7 Install the 2x3 programming header for the AT DI IN4148 MEGA Don t attach anything else to the pins ATMEGA328P PU microcon 8 Install DI the IN4148 diode and LEDI the power troller indicator LED 4N25 optocoupler LM7805 voltage regulator 9 Install JI the power jack if it is included It is not nec 1 6MHz crystal essary if you connect the battery TT E header CI C2 luF 10 Install the MIDI in jack 2 5mmx5 5mm power jack P MIDt in jack 1 Install che fiber out jack CAREFUL This compo nent is delicate Use a 4 40 bolt and nut to secure it to the board immediately after installation to prev
35. es the Tesla coil work The Tesla coil is well known for producing extremely high voltages In this section we ll explain how the one Tesla 10 coil can reach voltages over a quarter million volts using coupled resonant circuits We ll build up from the fundamen tals to give you a thorough explanation of what s going on Current Magnetic Fields and Induction Let s start with the basics of electromagnetism One of Max well s equations Ampere s law tells us that current flowing through a wire creates a magnetic field around it B LA If we want to use this magentic field to our adavantage as we do in an electromagnet we coil the wire The magnetic fields from the individual turns add together in the center RLF A constant current makes a static magnetic field What happens with we put a changing current through the wire Another of Maxwell s equations Faraday s law of induction tells us that a magnetic field changing in time induces a volt age across the wire proportional to the rate of change of the magnetic field dB Vinaucea NA dt If the current is abruptly shut off Faraday s law tellls us that there will be a sharp spike of voltage If an oscillating current flows through the coil it induces an oscillating magnetic field inside it This in turn induces a voltage across the coil which tends to oppose the driving current Intuitively the mag netic field is stubborn induc
36. externally grounded This gives the sparks a convenient place to jump to right underneath the coil If you have a GFCI external grounding may be neces sary If the GFCI on the outlet repeatedly trips you will need to disconnect the internal ground and ground to a stake or water pipe as specified above No 2 prong to 3 prong adapters allowed If you re unsure of whether the wiring in your building was done properly for instance if you re in an old build ing use a ground tester to confirm that your outlet is grounded one esla User Manual v1 3 6 Pre Operating Warnings We are now ready to power test the coil Before we do so we want to do some final checks Reference this step be v fore every time you run the coil Follow this list and the diagram on the following page Proper Tesla coil setup weed Make sure all mechanical components are sturdily U mounted e MAKE SURE THE TESLA COIL IS PROPERLY GROUNDED Follow the instructions in step 14 to check whether your outlet is properly grounded A grounded outlet is preferred but if one is not available use an external ground Use a multimeter to ensure that there is at most 5000 between the toroid and the ground prong of the power plug Improper grounding results in damage to the coil Using a counterpoise is an excellent idea e Make sure the secondary is vertical and centered in the primary DO NOT RUN THE COIL WITHOUT THE SECONDARY IN PLACE This will
37. g easy The voltage regulators and IGBTs should be inserted into the board so that the metal tab of the component aligns with the band on the board Band on Back of the the board voltage regulator Match the notches or markings of the IC and the socket The pins of ICs are numbered sequen tially starting from the one to the left of the notch then circling counterclockwise around the chip onel esla User Manual v1 3 6 Optical transmitters and receivers The optical transmitter and receiver are probably the two most delicate electronic components The transmitter has two terminals power and ground and a blue casing The receiver has a black casing and three terminals power ground and output voltage Secure them with a 4 40 bolt before soldering them in Headers amp Jumpers Mounting Hole Photodetector P Positioning Foot This cross section is taken from the data sheet of the receiver Since the fiber sits right against the lens never push it in too hard Also if you need to cut the optical fiber use a sharp ra zor blade and keep the cut as close to a neat 90 degree angle as possible Headers should be installed with the long ends sticking up out of the board Jumpers slide right over them x EA r pocta Want to learn more If you want to find out more about any component look for its data sheet online Data sheets usually have all you need and more He
38. here match D YES NO Confirm that the fiber cable is installed correctly at both ends 2 Check for shorts from this pin to 5V or ground In particular this pin is adjacent to the 5V and ground connections for the optical receiver so this is a likely cause 3 If there are no shorts the optical receiver has been damaged Replace it Reinstall the 74HCT 14 Inspect the output of the optical receiver if it has vanished replace the 74HCT 14 Probe pin 3 of the 74HCT 14 Does the waveform there match N YES NO Check soldering of R4 and the IC socket Make sure the IC is seated properly Make sure pin 13 of the IC is not bridged to any adjacent pins Asa last resort replace the IC Proceed to the next page Test For Startup Pulses with scope Probe ee 4 of the 74HCT74 ae read 5V Does 12 of the 74HCT 14 match waveform M Y YES NO Make sure the IC is seated properly V 2 Make sure pin 13 of the IC is not bridged to any adja cent pins 3 Asalast resort replace the IC Make sure the IC is seated properly 2 Make sure the socket is properly soldered 3 Asalast resort replace the IC Does pin of the 74HCT74 match waveform M YES NO Does pin of the 74HCT 4 match waveform F 17 YES l Make sure the IC is seated properly 2 Make sure the socket is properly soldered Check the soldering of R5 and the socket 3 Asa last resort replace the IC 2 Make sure
39. illion volts of high frequency electricity at currents of up to tens of milliamperes NEVER TOUCH THE OUTPUT OF THE TESLA COIL At best you will get a nasty burn at worst you ll get a po tentially life theatening shock PRIMARY VOLTAGE AND CURRENT WARNING Though lower in voltage the approximately 2 0VDC on the primary side of the coil can be even more dangerous than the sparks The primary carries up to hundreds of am peres of current for short periods of time For reference just lOmA across your heart is enough to kill you NEVER SERVICE THE BOARD WHILE IT IS POWERED ON ALWAYS WAIT AT LEAST FIVE MINUTES AFTER THE BOARD IS POWERED OFF FOR CAPACITORS TO DISCHARGE BEFORE SERVICING To safely work with electrical hazards observe the following rules Always be in control of the power source Have the plug within your reach at all times Perform power testing hands off This means that the board should be enclosed in the chassis when it is powered and you should not service it when it is energized Wait 5 minutes after unplugging the board for capacitors to discharge before servicing the board e Don t wear jewelry that could accidentally come into contact with circuitry and cause short circuits e Never work on something dangerous when you re alone f you feel tired or uncomfortable at any point take a break and come back to your work later e f you have any hesitation about the nature of the high voltage circuits you
40. ing a voltage that opposes any change to the field Transformers A transformer takes advantage of the law of induction to step AC voltages up or down lt consists of two coils of wire around a core The core is soft iron or ferrite materials which are easily magnetized and demagnetized Magnetic field lines Primary side Secondary side An oscillating current in the primary winding establishes an oscillating magnetic field in the core The core concentrates the field ensuring that most of it passes through the second ary As the magnetic field oscillates it induces an oscillating current in the secondary coil The voltage across each turn of wire is the same so the total voltage across the coils is proportional to the number of turns NM No Wo oV Because energy is conserved the current on the side of the transformer with the higher voltage is smaller by the same proportion The Tesla coil is a very souped up transformer Let s briefly consider what would happen if it were a perfect transformer The primary winding has six turns and the secondary has about 1800 turns The primary is driven with 340 volts so the secondary will have 340V x 300 102kV across it That s alot But not quite a quarter million Additionally becuase the Tesla coil is air cored and the coils are positioned rela tively far apart only a small fraction of the magnetic field produced by the primary is actually interlinked with the secondary To un
41. iodes DI and D2 matching the band on the diode to D3 D4 MUR460 the band on the board to ensure correct polarity power diode LEDI Red LED 6 Install power diodes D3 and D4 matching the band on the diode LED2 Blue LED to the band on the board to ensure correct polarity 7 Install the three LEDs matching the flat side of the LED to the flat side of the symbol on the board to ensure correct polarity The red jack LED is the 15 indicator the blue LED is the 5V indicator and the green LED is the interrupter signal indicator receiver 8 Install JI the 2 5x5 5mm DC jack Note that the holes in the board are large and you need to fill them in with solder J4 2 terminal out put block 9 Install J2 the fiber receiver CAREFUL This component is delicate 2 pin header Use a 4 40 bolt and nut to secure it to the board before soldering fuse the leads XI 3 pin fan 10 Install the 3 pin fan header header 1 Install J3 the IEC power plug Use 6 32 bolts and nuts to secure this power plug to the board to prevent excessive stress when plug ging and unplugging the cord 2 Install J4 a 2 terminal block that you will later attach primary wires to 3 Install JPl two pin header If you are using the 19V DC power supply provided by us slide a jumper over the pins This is because the power supply is floating If you are using your own grounded power supply do not connect the pins together
42. ldered in properly aje and that there are no solder bridges Look closely If you re 7 unsure of the quality of the joints pass over them again with a good soldering iron to reflow them Poor soldering will invariably lead to difficult to trace problems Confirm that diodes DI D2 D3 and D4 are installed with the correct polarity Confirm all electrolytic capacitors are installed with the Clean up messy joints Re correct polarity move blobs of solder using sol der wick and make sure that Confirm the LEDs are installed with the correct polarity you re not shorting terminals together Confirm the LM7805 and LM7815 voltage regulators are not installed backwards or switched Confirm that the 74HCTI4 AND 74HCT74 are in the at correct socket and in the correct direction Confirm that the UCC37321 and UCC37322 and all other ICs are inserted in the sockets in the correct direc tion Component not flush Confirm the OOK I 2W bleeder resistors RIO RI Fix it are installed properly e Confirm all of the resistor values are correct Interrupter chassis You will need a small amount of hot glue superglue or epoxy to put the chassis together Hot glue is preferable because it C doesn t damage the acrylic like superglue does and if you make U a mistake or need to fix the circuitry it s relatively easy to pull 42 the chassis apart and scrape off the old glue U First check
43. of the traces in the power section are intact A bridge failure during operation may excessive currents to flow through the traces on the board possibly damaging them Check that the IGBTs are properly insulated from the heat sink with sil pad by metering be tween the heatsink and pin 2 collector of each IGBT Step 18 Coil underperforms and e Stop operating Turning up the pulsewidth further will not rectify this problem or outputs noisy sparks As Check the coil s grounding There should be no more than 5000 between the toroid and the you turn up the power you ground prong of the IEC cable if you are using a grounded outlet Use a ground tester to make should get steadily increasing sure your outlet is properly grounded Put the coil on a grounded counterpoise an aluminum spark length and a clean tone foil chicken wire metal window screen circle at least 4 feet in diameter from the coil Check for poor soldering on the driver board Try reflowing all solder joints this kind of error is often caused by a bad solder joint picking up noise Your coil might be out of tune See the corresponding fix listed under problem 5 Laptop interrupter or MIDI Increase distance between the device and the coil keyboard latches up often Use cables with better shielding Use a ground tester to make sure that the outlet you are using to power the coil is properly grounded No output in MIDI mode Is the OUT LED on the MIDI
44. ofarads So for example 154 means 15 x 10 picofarads or 15 x 10 x IO F2 15 x 10 F 150nF The one film capacitor we use is the primary tank capacitor which is specified for high voltage use S9 PRY a oo Cx CES There s a huge variety of capacitor types We use three different varieties on the oneTesla board ceramic capacitors electrolytic capacitors and a film capacitor Electrolytic capacitors are polar You will damage the component if you install it backwards so be sure to match the positive side of the capacitor to the sign on the board the side of the electrolytic capacitor with a stripe is typically negative observe the polarity markings on the board this is a ceramic capacitor which is nonpolarized Electrolytic capacitors have a safety vent at the top which rup tures when the capacitor is con nected backwards Don t re use blown capacitors onel esla User Manual v1 3 6 Diodes All diodes are directional and must be installed in the correct orientation the band on the diode should match the stripe on the board Here s a signal diode It s much smaller than the power diode because it rectifying relatively low power signals This kind of diode has its polarity marked by a black band which needs to line up the diode with the band on the board Here are power diodes which rectify the AC from mains They re big becau
45. oid straining your eyes CE 0109 9 The first two T g thir band is a multiplier correspond to numbers ad he fouth band is tolerance 140x000 E cos 10000 10 Resistors of different power handling capabilities are dramatically different Potentiometers are variable resistors sizes This one is a 5 Watt resistor like Turning the knob changes the position of a sliding contact along a resistive path The resistance between the first and third con tacts is always the same but the resistance between the first and second contacts changes as you rotate the knob We use a potentiometer to modulate the power of the Tesla coil on the interrupter board RI on the one Tesla control board It s large and made of ceramic so that it can withstand high heat Ths value of the resistor is printed on the body lt 4 This is 1 4 Watt resistor which is used for most applications o Capacitors Ceramic capacitors are the small capacitors we provide you They are often used as decoupling capacitors across the power pin of an IC to short out high frequency voltage spikes as well as to buffer the power rails The value of the ceramic capacitors is printed on the casing using two or three numbers If there are only two numbers that is the value in picofarads If there are three numbers multiply the first two numbers by 10 raised to the power of the third to get the capacitance in pic
46. om capacitor The voltage across the load is the sum of the voltages on each capacitor Curent transformer Yi Protection diodes Optical reciever Logic As mentioned previously control logic is necessary to sense the primary current and prevent turning on and off the IG BTs while there is current through them Let s step through the above schematic from left to right Note that the part numbers in the schematic don t correspond to those on the board but we use them here just for explanatory purposes Refer to the Eagle files available at http onetesla com downloads for the full schematic The current transformer steps down the primary current to a safe level to use on the logic section of the board is a 5W resistor that loads down the transformer and limits the current DI starts conducting when the signal exceeds 5 V D type flip flap IIGBTs Inverting gate drive IC k 5 9 TT LELI a Gale drive Bus caps lransformes Noninverting gate drive IC which is the rail voltage plus the forward voltage drop of the diode effectively preventing the signal from exceeding 5 7V D2 starts conducting when the signal is 0 7V Together DI and D2 are protection diodes that clip the signal and pre vent damage to the logic ICs if the signal from the current transformer is too high Next Gl and G2 are inverters which square up the signal for subsequent ICs The optical re
47. ommands into a stream of pulses for the Tesla coil These pulses turn the en tire coil on or off thereby controlling both power throughput and allowing for music playback The MIDI commands are received through the MIDI input jack As per MIDI specifications the 4N25 optoisolator provides the isolation necessary to eliminate ground loops When the microcontroller receives a note on command it begins output a stream of pulses at the note s frequency The lengths of these pulses are specified by a lookup table in the firmware The interrupter uses separate MIDI channels to play multiple notes at once in order to play back two chan nels the software simply generates pulse trains correspond ing to each channel and then performs the OR logic function on the pulse trains before outputting them Maximum pulse width limitation ensures that the resulting stream does not have excessively long pulses Power control linearly scales the pulse widths based on the position of the potentiometer While this does not give linear spark length it has the advantage of predictably scaling the power consumption of the coil a feature that would be lost if the scaling curves were tweaked for linear spark growth So how does it make music Sound is a pressure wave Its pitch is determined by the fre quency of the wave We can make sound in a variety of ways conventional speakers vibrate a membrane and Tesla coils use the expansion and contraction of ai
48. on Sanphy Paul Blackborow Jeremy Hammer John McCoy Parts and Crafts Sam Schneider Mr Borodiansky Gregory wooby6 Mitch Fiddy Fidler Julian Ringel Marcus Leif Jason DTB Hunter Christian Phil Davies Noel B TheOnlyZby Marcel Smeets Warry Arcangelo Argento Eirik Mikkelsen Pal yvind Reichelt Scherrer Beat Vincent v d Mark aka Dayokun John Harrison Ahaxz Kristian Lord Tesla and ruler of middle earth Ben Attfield tommy t Thomas Uddmar Richard Proctor Fidi amp Dad Dr Marc Eberhard James Bailey Peter Cramp Donald D Parker Tristan Graham Nicholas J Atkins Gogar Marc Gunter Tom Callaghan Jose Roberto Lopez Chuck Fogh Maarten Lens FitzGerald Lane Erwin Erkinger Mark Walton Tim Shaw Cooper Chan Bradley Clay 2Lt Rhys Alasdair Hexter Paul Marchant Geoffrey Ward Floris St phane Boillon Jens Wiechers Admiral Aaron Ravens dale Martin Decurtins Andrew Robert Barnbrook mafro Aaron Clauson Ronald Frahm elsombrereroLoco Guenther Friesinger paraflows Simonis Stuart Griffiths pen sone for eksperimentell informatikk Yukihisa Okada James Heaver John Tumbach James Dantow Cam Farnell David Tragger Hypocrite Productions Inc Parable WhiteStatic Philip Chalk Daniel Carmichael N4EWT Michael Casselli Jon Jackson Julia Takarada Chris Laura and Quinn Smith Brian Davis Rick Rubio GT amp D William Griffith Ken Purcell Daniel Goldman Alison Tisza Brian Glogower xthulu T Alva E
49. onelesla Musical 10 Coil User Manual v1 3 6 May 2014 Heidi Baumgartner and Bayley Wang onel esla User Manual v1 3 6 2 elcome to the world of high voltage Singing lightning wireless energy high frequency resonators and beautiful sparks fascinate us too That s why we made one Tesla We want the fun of musical Tesla coils to be available to all pas sionate hobbyists and not just experts in power electronics We want to remove the barriers between what you dream of and what you can build one Tesla is the smallest most powerful Tesla coil kit you can find How well it works though is contingent upon the quality of your workmanship You will probably need a few tries to get it right so be patient ask for help when you need it and ensure that you have replacement parts Solder carefully crimp well keep wires neat maintain a clean workspace and have a criti cal attitude Follow the instructions closely and you ll likely get yourself some beautiful arcs and sparks Read and understand the entire manual before begin ning It s important that you understand how the Tesla coil works in order to build it right and handle it safely Ensure that you are comfortable working with hazards You should not construct this kit without supervision if you are under 18 Table of Contents WIN CONS CLIN E Dek 2 Safety WaArningS scsccsssssscsesssscsessessssessesssssssesssssssesssssceesensssseces 4 GU ge
50. r the holes of components that are not yet installed rent transformer and place the ends into solder pads P and P2 like the following picture Solder it in 20 Install the tank capaci tor the large white CDE film capacitor ri TEEEATE DM 22290 Tu ar PILAT rE EN Ha LI Li Fi c ram ka Lad m a LI E m LEI A d ira Hapi eg Fs oi By the end of step 1 your board should look like this with the addition of ICs inserted into the sockets onel esla User Manual v1 3 6 Gate drive transformer The gate drive transformer isolates the IGBTs from the gate drivers It s important to maximize coupling here so twist the CY wires together tightly and then wind them on the core tightly It s also VERY IMPORTANT that the wires have the correct phasing the coil will not work if you don t insert the wires qd into the board in the right configuration U Twist three strands of thin wire together tightly You can do it by hand but it goes much faster if you use a hand drill clamp the wire in the chuck hold the other end and turn the drill 2 Wind up to 12 turns of the twisted wire tightly around the toroidal core Leave a few inches of extra wire at each end Note that the ferrite toroid in your kit is gray and slightly larger than the toroid in the photos here That s why it needs fewer t
51. r due to heating from plasma The secondary s resonant frequency is about 230kHz far above the audio range We can use bursts of sparks that are firing away at 230kHz to create pressure waves at the audio frequency A burst of sparks fires at every peak of the audio signal The rapid firing of the sparks is faster than your eye can resolve so it looks continuous but in reality the spark is forming and extinguishing at intervals of the audio frequency This modulation technique is known as pulse density modu lation PDM or pulse repetition modulation PRM Current in the primary keeps increasing while the bridge is being driven It s important to make the bursts short enough so that the IGBTs don t overheat Within a single cycle the current on the primary can reach up to hundreds of amps for a short time Due to thermal reasons the maximum duty cycle of the bridge is approximately 1076 The interrupt er s firmware has a lookup table of frequencies and on times which are determined empirically by varying the pulse width and watching the spark performance ce 300KHz r3 E F M E i TERE a ms QOOHz Secondi Voltage Interrupter Signal Ims QO0Hz onel esla User Manual v1 3 6 Some Notes about Electronic Components Resistors The value of a resistor can be read from its color bands Or you can measure the resis tance with a multimeter and av
52. re are some links to the data sheets of components that there are most often questions about 74HCT74 D type flip flop http www nxp com documents data_sheet 4HC HCT74 pdf UCC3732x gate drivers http www ti com lit ds symlink ucc3 732 pdf LM78xx voltage regulators http www fairchildsemi com ds LM LM7805 pdf FGH60N60 IGBT http www fairchildsemi com ds FG FGH60N60SMD pdf Optical receiver http i fiberoptics com pdf ifd95 pdf Optical transmitter http i fiberoptics com pdf if e96edatasheet pdf onel esla User Manual v1 3 6 Preparation 1 Before you begin you will need e atemperature controlled 20W 30 soldering iron and solder fety gl 4 satety glasses luca U CN Vv i small pliers flush cutters wire strippers crimp tool or large pliers screwdriver electrical tape hot glue gun or superglue solder wick or solder sucker e multimeter 4l bes s g 1 WE 4 Bend the leads of the component slightly so that it Stays in place A quick review of how to solder Assemble your tools put on safety goggles and turn on the iron 2 Neatly bend the component leads to fit into the holes in the board either with your fingers or small pli ers 3 Insert the component into the board and ensure it lies flush Make sure you have the right component in the right place 5 Flip over the board Place the tip of
53. reasing iron temperature slightly goes a long way on these pads one esla User Manual v1 3 6 Let s start soldering We begin by populating the main circuit board Each component s num RI 0 IKO SW ber and value is printed on the board You can also use the tables to the 00 right as a reference IOKO Install Note that it is a large rectangular ceramic SW resis R4 R5 R7 tor 5600 marked 4700 lt on the board but either value is fine a RS RIO RII 100KQ 1 2W 2 Install R2 through RI I ENSURE THAT R10 AND R11 ARE IN STALLED PROPERLY These are 1 2W 100 bleeder resistors which drain the large capacitors C14 and CI5 when the unit is powered off Failure to install RIO and RII properly will result in the capacitors storing energy for extended periods of time and a board that is unsafe to service The two 2W resistors are slightly larger than the one 1 4W 100 resistor in the kit Step 1 eg x fames amm YL r m m 114 E HIO i i a i j A Fi a EET z LM7815 LM7805 QI Q2 FGA60N60SMD IGBTs 3 7 T CET CN i zc 7 1 hee f ES x 1 A 3 Install ceramic capacitors Cl and C4 4 Install C2 C3 and C5 through C16 Note that C5 C7 C15 and DI D2 IN4148 signal C16 are all electrolytic capacitors and the polarity matters diode 5 Install signal d
54. rted to anything If no soldering errors are found Replace the 4HCT 4 and 74HCT74 ICs Retest the board 2 Replace the UCC3732x gate drive ICs Retest the board 3 Replace the optical receiver Retest the board Note itisexceedinglyunlikelythatabrand newcomponent is defective Itis strongly advisedtocheckforother errors first one esla User Manual v1 3 6 Step 10b Test For Startup Pulses with scope If you don t have an oscilloscope or if the test without a scope has been sucessful so far you can skip this step You may want to refer back here to do more in depth trouble shooting later Power on the interrupter and turn the pulsewidth knob to maximum Connect the interrupter to a MIDI source refer to Step 7 for details on how and connect the interrupter to the driver board via fiber optic cable Plug the 19V adapter into the driver board Play a note and probe pin 7 of the UCC3732x gate ICs Does the waveform there mat NO VES i The startup pulses are present Proceed to Step 11 Probe pins 2 and 3 of the UCC3732x gate drive ICs Does KIS waveform there match OYE s Y Check for shorts from pins 7 and 8 to ground 2 If there are no shorts replace the Check the soldering of each socket 2 Confirm each IC is seated properly If there are no visible soldering errors remove all ICs from Probe the center pin of the optical receiver Does the wave form t
55. se is 70V This means we need to bring the gate of the high side IGBT up to Vbus 2 15V to turn it on Vbus The half bridge in oneTesla is driven by a doubling rectifier as shown in the diagram above This rectifier alternately charges each capacitor on alternating half cycles of the AC input Vous 2 resulting in twice the source voltage across the load Gate needs to be at Vousl2 15 Da primary Lprimary Emitter of the low side IGBT is at Veusi2 On the positive portion of the cycle the top diode conducts and charges the top capacitor Fortunately there is a simple way around this We can drive the primary of a 1 1 1 transformer with the bipolar drive signal derived from a push pull pair of UCCs More specifically we drive the primary of the transformer with the difference of the outputs of an inverting and non in verting gate driver This ensures that half the time this signal is positive and half the time this signal is negative Due to transformer action the voltage across each secondary of the GDT is guaranteed to replicate the voltage across the primary no matter where we connect the ends This means we can simply connect a secondary across the gate and emit ter of each IGBT and guarantee that Vge will always swing between 0 and 15 regardless of the emitter s potential On the negative portion of the cycle the bottom diode con ducts and charges the bott
56. se they handle a lot of cur rent Their polarity is marked by a silver band on Light Emitting Diodes LEDs On the oneTesla board LEDs are used as power indications and inter rupter signal indicators LEDs only work when installed in the correct direction There are three ways to determine the negative side of an LED locating the flat portion of the die identifying the shorter of the two leads or looking closely at the internal structure of the LED anode 4 P 189 shape inside match the flat side on cathode the LED to the flat line on the board flat portion on the die lead is shorter Integrated Circuits ICs There are a variety of ICs on the oneTesla board The 74 series chips are logic The UCC chips are gate drivers On the inter rupter there s a 6 pin optocoupler and an ATmega microcontroller The main board also has IGBTs and voltage regulators DON T SOLDER ICs DIRECTLY TO THE BOARDS Solder on a socket with the correct number of pins and insert the IC into the socket Keep the notch on the socket aligned with the socket on the board and keep the notch on the IC aligned with the notch on the socket Some chips don t have notches but rather a single dot on the appropriate side Align the notch on the socket to the notch on the board The voltage regulators and IG BTs are in three legged verti cal package in order to en hance thermal properties and make heatsinkin
57. secondary 6 Use a multimeter to check the resistance between the two bolts It should read about 300 ohms If it reads significantly more or jumps between values check your connections 7 You should do whatever is necessary to attach the secondary wire to the bolt If it s easier for you to wind the fine wire around the bolt directly then do that onel esla User Manual v1 3 6 Putting together the primary and secondary together the whole assembly is proper grounding of the secondary First we re going to make a good ground connection on the circuit board Solder a wire 5 long to the back tab of the IEC port Crimp or solder a spade terminal to the other end of the wire Sr The most important thing to pay attention to when putting q Step F Back tah gf IEC port p 2 Put the primary assembly over the secondary assem bly like in the photo below 3 Place the top plate of the chassis on the stack as well with the bolt going through the hole in the middle of the plate Use a wing nut to clamp down the spade terminal the photo shows a ring terminal either is fine just be sure to make good contact at A When the assembly is complete put the top lid on the chassis Don t glue it down 4 Place the metal toroid on top of the secondary with the bolt going through the hole in the toroid Secure it using a wing nut Note if you do not have a metal toroid you c
58. serman Dimitri Diakopoulos lint Dewey Electronics Corp Rustcycle Steven R Bible Craig The Coder Dunn mOnk Carlos Villarreal Brent Busch Dave Feldt Alan Ford js0000 Ruben Ray Ghanbari Adam Elliott Lauren O John Boreczky John Haller Bert Zelten Chad ckeck Keck Bob Oldfather Jonathan Ly Bonner Boys Kelley Bergmann Daryl Spitzer Jeffrey Pride Neel Bishop Thomas Ochs Ira Burton John Kent Terry L McFadden Mark Huntley Jennifer McDonnell Eiso Vaandrager Matthias Lange Mr S Schober Emma Dlsm Fab to Lab Nicholas Booth Carlos Rubio Ricote sirneggles Michael Ommundson mikenz lan Walker Choo Chun Yew Makharinsky Dirk Bergen Mr one I esla User Manual v1 3 6 Henry loic James Baker lan Barnes Stewart Greenhill Matt Lloyd Jonty Wareing Tim Reynolds Adriaan Swanepoel Lee Brooks Stefan Gustavson Samuel Chaabane StealthPhotography Ward Wouts Robert Hercz Dan Heggs Emil Karlsson Chris Davidson ghostwheel Mark Loit Michel Gallant Matt Mazzola Craig Becker John L Driggers Erik Broman James Hale Daniel R Shepard Bill Tyler Tyler Labs Moleque de Ideias Jason Miller George Klinger Nick Tuttle Devon S Tyler Staudinger Peter Easton ungood James and Anna Claire Korenman Richard Senegor Chris Farrow Nathaniel Burge Chris Derossi Gary Sparky Shigenaka Charles Butkus Jim Kleinmeyer Jay Summet Sam Posten Orion Beach Bill Culverhouse Adam Perkins Jim
59. sure all component values are correct Make sure there are no stray bits of wire stuck between pins Test For Startup Pulses with scope C UCC37322 Input startup F 74HCT 4 Pin startup Z4HCT 14 pin 3 startup one esla User Manual v1 3 6 Test For Startup Pulses with scope SCOTIA L MAKE pin 2 men m C O 74HCT74 pin 6 ma Primary current oscillation Main chassis assembly correct orientation 5 Use small dabs of glue in the corners to assemble the qu As when assembling the interrupter chassis you will need a chassis A little glue goes a long way DON T GLUE ON small amount of hot glue epoxy or superglue Hot glue is by THE TOP V far the best option because it s sturdy enough to hold the O chassis together but it s still possible to take apart the chas sis if you made a mistake or need to go fix the circuitry later 6 Use long 4 40 bolts to attach the cooling fan to the back Put its power cable through the hole under the fan and connect it to the jack on the board Peel the protective paper off the acrylic parts The UL chassis has two sides with vent holes a front plate with holes for the optocoupler power jack and IEC jack a back plate with a fan grille a bottom plate to which you screw the board and a top plate The rest of the laser cut parts are for the primary and secondary assembly and the interrupter chassis Don t omit the 2 Place the DANGER HIGH
60. t the voltage of the pins is 5V Also confirm that pin of the optical receiver is 5V Are all the voltages 5V YES NO Check the soldering of pins 7 and 14 on the socket 2 Make sure the IC is seated properly Use a voltmeter to measure pins and 8 of the UCC3732x gate drive ICs Again the ground lead of your multimeter should be touching the back tab of one of the the voltage regulators Do they measure 15V 5 D C O e OV C D 4 one esla User Manual v1 3 6 YES NO Check the soldering of pins 1 4 7 and 8 on the socket 2 Make sure the IC is seated properly Disconnect the 19 adapter Plug an IEC power cord into the AC jack on the board and plug it into a wall outlet Nothing should happen Do the bus capacitors C15 and C16 get hot WARNING Do not touch the tops WARNING Board is energized Proceed with extreme caution A If the capacitors get hot immediately unplug the IEC power cord Wait five minutes and then check the polarity of the bus capcitors Does the fuse blow Unplug the board and wait 5 minutes for the capaci tors to discharge Examine the board primarily the right hand side which contains the power components for shorts or solder bridges Also confirm the capaci tors are installed with the correct polarity 2 Ensure that you properly insulated the backs of the IGBTs form the heat sink using sil pad which is ther mally conductiv
61. ted If the IGBT s and diodes are confirmed working it is help ful to re run steps 9 and 10 This will isolate any damaged semiconductors in the control circuitry After replacing a failed bridge do not immediately power test lest the remaining systems as you would in a freshly built coil often a failed bridge leads to cascading failures in the logic circuitry these failures could then damage the new bridge causing an endless cycle of self propagating failures Passives almost never fail The exception is the tank ca pacitor extended runs have a nonzero chance of over heating it and damaging the internal structures This often manifests itself as a reduction in capacitance and a sub sequent loss of performance if you see a sudden loss of performance the tank capacitor might be suspect how ever other components are far more likely to fail first Very rarely the low side IGBT fails open This will mani fest itself as a sudden decrease in performance often accompanied by an unstable spark In this case the fuse will not blow Thanks to all those who made oneTesla happen On Dec 25 2012 we launched a Kickstarter campaign Within a week we reached 84576 of our goal selling 600 kits We had so much demand that we had to stop adding more rewards despite being only a quarter of the way into our campaign 929 backers helped make oneTesla what it is David Gaipa Peyton Wendy Rowe John Arrasjid Jay Gilligan Alfred DiBlasi
62. the IC is seated properly 3 Asa last resort replace the IC Does pin 3 of the 74HCT74 match waveform E YES NO Do pins 2 3 and 4 of the 74HCT74 match the waveforms F Y 1 and J YES NO Make sure the IC is seated properly 2 Make sure the socket is properly soldered 3 As a last resort replace the IC Check the soldering of the socket around that pin 2 Make sure the IC is properly seated 3 Asa last resort replace the IC Does pin 6 of the 74HCT74 match waveform O continued on the next page Reinstall the 74HCT74 IC 2 Probe pins 4 and 12 of the 74HCT I4 If the waveform has vanished replace the 74HCT74 IC one esla User Manual v1 3 6 Ob continued D 5t Test For Startup Pulses with scope YES NO Make sure the is seated properly 2 Make sure pin 6 is not bridged to any adjacent pins 3 Replace the 4HCT74 Reinstall the UCC37322 IC Probe pins 2 and 3 of the IC If there are waveforms there check the seating of the IC If the IC is properly seated replace the IC There should now be the correct waveforms on pins 7 and 8 of the IC 4 Repeat the above 3 steps with the UCC37321 IC a UJ If there is still no output double check to make sure the above steps have been followed Make sure no components have been damaged during the troubleshooting process sometimes this can happen if your probe strays and shorts components on the board Make
63. turning up the pulse width e Ensure that there s nothing for the sparks to hit 5 Avoid excessively long runs e Avoid excessively long runs In general one Tesla is tolerant of long runs the default interrupter settings run the inverter at conserva tive peak currents and the bulky heatsink and active cooling help keep the power components cool However long runs will result in an overall greater chance of failure We recommend 3 minute songs with 3 minutes of time between songs e Don t let the secondary get too hot Because the secondary is wound with fine wire it has several hundred ohms of resistance which dissipates quite a lot of power 6 Be aware of how loud your coil is e Recognize that a coil suddenly starting to operate can startle people Always start at low power and gradually turn it up This helps you identify problems with the coil and fix them before running at full power too Don t annoy your neighbors with a coil at 7 Be aware of ozone buildup strange hours of the night Ozone is an irritating gas with a has a pungent smell a little bit like the air before a thunderstorm If you smell ozone stop operating for a while until it dissipates Ensure you re in a well ventilated area Step 20 one esla User Manual v1 3 6 Coil Service amp Repair As carefully as you build your coil and as conservatively as you run it sometimes you will run into problems Build ing and maintaining your Tesla
64. upter off and set the pulsewidth knob to minimum With the other end disconnected plug the IEC cable to the main board CONNECT THE IEC CABLE TO THE BOARD BEFORE PLUGGING IT INTO AN OUT LET Ensure that the power cable is on the opposite side of the breakout point so there s no risk of a spark hitting the power cable Ensure that your MIDI interrupter is the full distance that the optical fiber allows it to be from the coil Standing away from the coil plug the other end of the IEC cable into the power outlet THE COIL IS NOW ENERGIZED DO NOT APPROACH IT OR OPEN THE CHASSIS Turn the interrupter on Go to File gt Open in MIDIEditor and open a song of your choice Click the Play button You should see small sparks com ing from the breakout point and faintly hear the music Slowly turn up the power on the interrupter Sparks should fly and music should play If the coil doesn t work don t panic Unplug the IEC cable from the power source wait 5 minutes before touching the board and proceed to step 18 troubleshooting Tesla coil troubleshooting Fuse blows immediately On a brand new board check for solder bridges across the IGBTs and voltage doubler diodes upon insertion of IEC cable check the polarity of the bus capacitors and check the phasing of the GDT This often indicates a damaged bridge Use a multimeter to confirm that both IGBT s and doubler diodes are intact Then check that all
65. urns than in the picture 3 Mark one end of the twisted bundle with a marker Then separate the wires 4 Twist each color pair together a few turns close to where they come off the toroid Trim the leads so that the GDT is relatively flush to the board 5 Install the transformer in the board making sure that the marked ends are on the inside of the row of four through holes The other side doesn t matter UNMARKED MARKED MARKED UNMARKED Step 3 Mounting the heat sink We want good thermal conduction between the IGBT and the heat sink but no electrical conduction Clean the backs of the IGBTS and the heat sink with some rubbing alcohol You want thermal conduction to be as good as possible so it s important that the sur faces be clean 2 If you have thermal compound place a small amount of thermal compound on the back of the IGBTs and on the heat sink around the holes The thermal compound fills in the portions where the IGBT is not completely flat It sometimes helps to spread it out with a flat object like a credit card It is not strictly necessary addition to thermal compound 3 Put a 4 40 bolt through the hole in each IGBT and sil pad 4 Screw the IGBTs to the heatsink 5 Solder the IGBT and heatsink assembly into the board ETT onel esla User Manual v1 3 6 straining it Interrupter board 12 Insert the ATMEGA328 into the socket ensuring Populate the int
66. y Shane Colton Ethan Langevin Ahmed Amer Brian Del Vecchio Ed Young Allan Seward Thomas Sedlacek Eric Hoffstetter Harvey Olifson Geoff Hahn Frank Kurka Owen Marshall Joe Balint Kyle Watson Jonathan Samuel Ward miroslav gordan Alice Steinke David John Oglesby Richard Butterfoss Glenn Howlett Timothy Stoller Jason Lim George Brown ralph pearson Emil Girardin Matthew Shapiro Candice Rebel A Studios Eric Albert Kristen Coyne Tim Howe David N Faust Richard Zak cthulhuwtf Jeremy Ashley Andrew alexi menace2chicago toni Bret Burnett Matt Stultz Michael Sanchez Jim Frankland Paul Alioshin Curtis Matt Kusak Lauri Dahl ellery buntel David VanHoose Randall Roman Daniel J Gonzalez Elizabeth Scott R Vittum John Trataris James Graves Kenneth Jonsson CHARLES Z GUAN Sam Reed Anders Hovden Andrew Nicholls Remi Dahl Finjord Hans Peter Hemmer Cindy Filler James Gan Jack Ryan Marin Kilyovski Christian Dannie Storgaard Carey Adams Carlos Andujar Tibor Horvath Thomas Steinbrenner Gavin Lambert Daniel J Lewis Audrey Horst Alex Willisson Tieg Zaharia c o Kickstarter Jon Ferguson Chris Jennings Patrick Gonzaga Richard DeFeo Kent Gustavson Henry Steingieser Gary McFarlen Marc Jacques Lyle Dingus Jason Axelson Andrew Radin Robert Wolfe John Leonardo Contarino Marek Belski James Fennessy Chris Makarsky Chris Tran Andrew Seidl Ben Ramsdell Spencer Lambert Michael Allen Jules Agee C O Pacific

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