TCL Series Solid State Tesla Coil
TCL Series Solid State Tesla Coil
TCL Series Solid State Tesla Coil
CAUTION Do not operate without a load as serious damage to output transformer may occur
This versatile project in the above photo shows how to convert a readily available television flyback
transformer into a high frequency, high voltage generator operating from a 12-volt or battery source.
Assembled device is excellent for powering all kinds of gas display pieces from plasma balls to even an
every day light bulb. The PTG3 PLASMA TORNADO GENERATOR Project shows how to actually
build a plasma tornado with some very fascinating and unique properties.
The project as shown may be used to create ozone, corona and brush discharge, electric pyrotechnics
including a small Jacob’s ladder.
Easy to build circuit costing under $50.00 with parts readily available. Those that are special including a
printed circuit board may be obtained through www.amazing1.com Flyback will require some rework
that involves disassembly and the addition of a 10-turn coil. Small hand and soldering tools are
required. .
Circuit theory
Output is a result of a resonating action of the secondary coil occurring around 50 to 100 KHZ. Under
these “tuned” open circuited conditions the transformer requires considerable power and produces high
voltage discharges that would quickly breakdown the insulation if left on for any period of time.
Immersion in an oil bath for this type of operation should be considered as it can help limit overheating
and eventual breakdown Oil filling is not necessary if operated as directed.
Fig 17-1 shows the transformer [T1] primary being driven by two Mosfets [Q1, 2] in a push pull
configuration. This approach utilizes the full core potential of the flyback and reduces electrical strain on
the Mosfets as they run very cool even at 5 to 6 amps input. A driver circuit [I1] generates
complementary outputs 180 degrees out of phase with built-in dead time. The frequency is made
variable by control pot [R4] and range adjust trimmer pot [R3]. This adjustment allows a wide range of
frequency, driving T1 out of the resonant mode where it can power a voltage multiplier making a
variable high volt DC source.
Capacitor [C2] and R3, 4 determines the operating frequency. Resistors [R2] set the upper frequency
limit. Resistor [R1] sets the switching dead time for reliable operation. Resistor [R9] and capacitor [C1]
provides decoupling between the Mosfets and driver I1. Resistor R6, 7 eliminate parasitic oscillation
from occurring on the gates of Q1 and Q2. Resistor R8 and C5 form a snubber network to control the
energy generated by the leakage inductance of T1. The Mosfets would quickly breakdown as a result of
high voltage spikes if it were not for this network. C3 and C4 bypass any of the high frequencies
appearing at the primary center point of T1. Resistors R5A&B control the operating current from
peaking when tuned to a high Q resonant load
Power requirement for the unit is 12-14 VDC at a max of 5-7 amps occurring when tuned to the
resonant frequency of T1. It is suggested that the entire T1 flyback assembly be immersed in
transformer oil if full output operation is anticipated over a period of time. The oil bath both cools and
provides added insulation to the high voltages developed. Not necessary for normal operation.
Assembly
1. Layout and identify all parts and pieces and check against parts list.
2. Assemble T1 ferrite transformer per fig 17-3. Measure the inductance if you have an LCR meter for
verifying to the values given. If you purchase the kit this part will be fully prepped.
3. Fabricate MTGBKT mounting bracket fig 17-4 and CHANNEL /COVER combination as shown fig
17-5
6. Mount a 3.5” plastic cap CAP2 to CHANNEL using two screws nuts and small flat washers
SW2/NU1/WA1. Note the four holes for the two tyewraps to secure T1 in place via the primary section
shown in fig 6. Note the ground return lead of T1 being routed thru a small hole beneath channel and
returning thru another hole to connect to common ground point.
7. Final assemble as shown and insert 4” x 3 1/2” PVC tube [EN1] as shown fig 17-7.
8. Verify all wiring with schematic. Use ohmmeter to check that the drain tabs of Q1
and Q2 are insulated from the metal chassis. Check for solder joints, shorts etc.
9. If you decide you require oil filling, CAP2 will need to be replaced with an actual PVC flat cap fitting
intended for 3” (actually 3.5” OD) schedule 40 PVC tube. These parts are available thru most local
hardware stores. Final seal using PVC cement and primer as directed on container. Note that oil
filling is only needed for light loads where output voltage will be excessively high.
Test steps
10. Setup
11. If you have a scope you may short the output of T1 to ground and note the test patterns included on
fig 17-1. This verifies operation. Note that the transformer is designed to allow proper switching of the
Mosfets even with output shorted. Open output can cause overload to Q1,2 and damage to T1
Note steps 12 and 13 are not necessary for use with the enclosed experiments when operated
as shown
12. Insert (EN1) 4" enclosure tube into bottom cap [CAP1]. Use PVC plumber
cement to seal these pieces, as they must not leak the transformer oil. Do this only after
correct circuit performance has been verified, as you cannot service T1 without hack
sawing the enclosure apart!
13. Fill with oil to top of T1. It is not necessary to seal the top cap, if the unit is
always operated in its upright position. Note steps 12 and 13 are not necessary for use with the
enclosed experiments when operated as shown
14. Proceed to conduct the experiments as shown fig 17-7 and 17-8. Experiment using pieces of steel
wool, needles, fluorescent and gas filled lamps and observe how different materials react to the high
frequency energy. CAUTIUON: Obtain some potassium nitrate and sprinkle on to some steel wool.
Note the pyrotechnic display. Danger: Do not use chlorates or perchlorates
R3 5 kohm trimpot
*R50, 51 *1 ohm10 Watt parallel resistors These are necessary for open circuit or light loads where
resonant rise in voltage can damage the transformer. Not necessay when operating as a
jacob’s ladder or igniting larger gas filled vessels. These can be shorted out for momentary
operation but will void warrantee if transformer fails
R9 10 ohm 1/2 watt resistor (br-blk-blk)
R8 15 ohm 3 watt resistor (br-grn-blk)
R4 10 k 17 mm potentiometer
PCTCL Printed circuit board or perforated circuit board .1X.1 grid PCVARG
SW1 2 6-32X1/2" Nylon screws
- 12in +
Control R4
FS1
S1
Twist leads of
R50, 51
Note these R50
resistors will
get hot after
long operating R51
times. Position
accordingly.
1. Remove the "U" bolt and one of the core halves. Some units may require chipping away the binding material with a
pointed object until the cores will come apart using moderate force.
2. Form a bobbin from a piece of plastic or card board tubing as shown of a length that allows core pieces to touch one
another.
3. Bifilar (parallel) wind two different color #18magnet wire or 20-22 litz for 10 turns of these double windings leaving 8"
leads. Note the different colors will help identifying the lead ends.
4. scotch tape the face of each core half so that when reassembled there will be two pieces separating each side of the
cores. These should produce a 10-20 mil gap at each junction.
5. Place the coil wound in step 3 onto the cores as shown and tape tightly into place.
6. Most flybacks units have a base with connection terminals intended for the original circuitry. Identify the secondary return
lead on the base and carefully isolate. Usually any one will work but it is suggested to use an ohmmeter and attempt to use
the highest resistive combination. If you remove the base you must carefully attach an external wire to this point and strain
relieve with some silicon rubber. Verify other leads are not shorted together and secure with a dab of silicon rubber.
OUTPUT LEAD
T1
"A" TO DRAIN OF Q1
JOIN "B&C"TO
CONNECT TO VC+
Gap between
core halves
Use scotch tape.
"D" TO DRAIN OF Q2
#18 solid magnet wire can be used
Tape hv output lead
however high frequency LITZ wire
in place after
will give a slight improvement. You
attaching and
can make this wire by obtaining 6
soldering to thin wire
pieces of #26 magnet wire and twist
output of coil
together as a single wire.
Grd
USE WR4
HV RETURN TO GROUND
Note that most fly backs are similar and will work. Some may have a built
in diode in the output lead section of the secondary coil. This can be
removed if the potting material is rubber; if epoxy "good luck"! get a
replacement
Fig 17-4 Mounting bracket fabrication MATERIAL: .063 SHEET ALUMINUM
1
24
1
Ø2
Holes shown are positioned without dimensions to
HOLE FOR COMMON
allow for use of alternate components than those
GROUNDING LUG
1 shown. Trial fit before drilling holes.
Ø2
FUSE HOLE HOLE FOR S1 HOLE FOR FEED
THRU WIRES TO T1
3 5
3 Ø8 Ø32
Ø8
HOLES FOR TABS OF
MOSFETS Q1 AND Q2
HOLE FOR INPUT HOLE FOR
LEADS BUSHING R3 CONTROL
FRONT PANEL VIEW INNER PANEL VIEW
3
1 8
38 1 1
24 2
5
Ø32
1
24
MATING HOLES FOR
SECURING TO CHANNEL
SIDE VIEW VIEW LOOKING DOWN INTO CIRCUIT
Fig 17-5 Fabrication of plastic channel and cover MATERIAL: .063 LEXAN-BLACK FOR LOOKS!
283
1
2
End view showing bend downs
Cover to fit as shown reduced view
3
Ø16
5
Ø32
Mating holes for securing
4 holes for tye wraps
mounting bracket
to secure T1 transformer.
Locate as required
1
22 1
12
3
8
Side view showing 116" holes for securing cover
7
NOTE ON FLYBACK
Flybacks may vary in size and shape from the one shown in this
Fig 17-6 Isometric view of total assembly drawing. The important thing to watch is that the high voltage out
put lead is clear of all objects and positioned so it comes out from
the top.
Also check that the hv coil is clear of nearby leads and wires
OUTPUT WIRE
SW1 NYLON SCREW
MTGBKT
NU1
MICA
SW2/NU1/WA1
COMMON CAP2
GROUND
Q1,2 MOUNTING
POINT
SCHEME
BU1
A
CHANNEL
FS1 BC
TYEWRAP
ASSBLY D
FROM FIG 1
BU2
Insert a thin piece of plastic sheeting to insulate the circuit board connection
points from shorting to the metal mounting bracket
R4
Use a plastic tubing extension on shaft of
control to avoid annoying shocks and
burns from electromagnetic field pickup
FIG 17-7 Isometric view of FIG 17-8 Poor mans plasma globe!
ARC
JACOB's ladder project
Plasma arc starts at bottom of ladder and
travels up the ladder elements where it
expands and eventually extinguishes. Arc
quickly reforms at the bottom and repeats
itself.
Adjust bottom of ladder spacing so that arc
reliability starts but yet does not remain
stationary. Adjust top of ladder so that arc
travels up to desired length before extinguishes
and repeating. It may take patience and
perseverance to get it right!!
1. Shape two 1/8" brass rods as shown.
2. Drill two 1/8" holes about 1/2" deep
into EN1 enclosure as shown. SOLDER OR
3. Connect output lead of T1 to one rod CRIMP
and ground lead to other. Solder or
crimp for a positive secure connection.
4. Adjust bottom separation to 1/8" .
Separation between rods increases to
about 1 to 2" at top end. Fine tune T1 1. Carefully solder a piece of thin buss wire to the
spacing for best effect center terminal of light bulb. This is usually lead and
solders easily. Caution to not over heat.
EN1
FROM FIG 17-6
GROUND 2. Connect output lead from T1 to this lead. Bulb
LEAD should be secured to top of EN1 via a small bracket or
other suitable means. Use a non conductive material.
3. Use a 5" clear 100 watt "DECOR" lamp preferably
one made by Sylvania or GE as these seem to work the
best. Experiment with other bulbs as you may get
some interesting results.
4. Do not leave this display on for long periods as high
frequency energy may quickly puncture the thin glass
This setup should draw under
2 amps and maybe left on envelope of these bulbs
5. Do not allow unit to draw more than 4
amps...6amps max for 20-30 seconds.
PTG Series Amazing plasma tornado generator
This project provides a very simple yet quite spectacular display of various forms of electrical plasma.
The medium used is safe ordinary rarefied air pumped down to a rough vacuum of approximately ½
mm (Torr). The plasma display takes on various forms from a well-defined multi vortex swirling tornado
to a column of orange saucer shaped disks. Hand proximity to the container produces an interactive
mechanism where the can be controlled both in position, movement and intensity.
Low cost construction shows the use of a 1-gallon glass pickle jar as the plasma display vessel. A wide
mouthed jar is preferred with a brass cap that will allow soldering the necessary pumping down fittings
to. The electrical input is supplied by the high frequency high voltage Tesla project described in
chapter 17. You will need access to a vacuum pump usually found in most high school science labs
that will pump down the above-mentioned value. A pumped down jar is available from amazing1.com.
Properly processed the display will last up to a year.
Theory of operation
An evacuated glass container is sealed and pumped down to .5 to 2 Torrs of pressure. A metal cap
seals the container and serves as an electrode for charging the remaining thin gas mixture. The voltage
applied to the cap is at a potential of 10 to 20 thousand volts and is at a high frequency of
approximately 25 KHZ. The capacitive effect of the thin gas causes current to flow creating the plasma
discharges. One may visualize the device in the following manner: a capacitor is formed by the
conductive gas inside the container forming one plate, the glass envelope being the insulating dielectric
and the outer air serving as the other plate. Any conducting object brought near the container now only
enhances this effect and appears to draw the plasma arc to the point of contact.
The vacuum will vary along with the physical parameters of the container and can be adjusted to
enhance the type of discharge desired. A pressure where the plasma discharges are most defined may
be critical. Increases will create a broken wispy effect where a further decrease will broaden the
discharge and eventually form striations as a series of weird orange disks. Any weird effects are
possible changing pressures power frequencies and voltage.
The effect of where conduction of a gas peaks at a certain pressure is known as the TOWNSEND
EFFECT and becomes an important factor in the design of vacuum systems where medium to high
voltages are encountered. The device as described does not use any gas other than the
existing-atmosphere rarefied by evacuation. Other colors and effects are limitless when the builder
chooses to charge the unit with other gases or combinations of pressures etc.
Project description
The described device is intended for display purposes, conversation pieces, novelty decorations,
special effects, as well as an educational science fair project demonstrating plasma controlled
electrically and magnetically. Special materials treated by a controlled plasma beam can also be
realized.
Plasma is often considered to be the fourth state of matter. It consists of atoms that are ionized and
demonstrates peculiar effects unlike the other 3 forms of matter.
Columns of pinkish and purplish plasma are attracted to external influences such as fingers and other
objects when placed on or near the display container. These columns of plasma light span the entire
length of the display container dancing and writhing with a tornado type effect. Balls of plasma and
fingers are created and controlled by simply touching the container. This effect cannot be effectively or
justifiably described in words and can only be appreciated when actually observed.
The device consists of a low powered high frequency high voltage producing the necessary parameters
for obtaining the described plasma effect. This generator utilizes conventional electrified circuitry
consisting of a transistor switching the ferrite core of a high voltage resonant transformer (similar to a
TV flyback). Power for the transistors is obtained from a simple step down transformer and rectifier
combination.
Assembly instructions
This project will require a properly working Tesla driver as described in chapter 17.
Obtain a 1 gallon pickle jar or equivalent with a brass or tin plated metal cap for the display container as
shown on fig 20-1. The display container must have provision for depressurizing and then being
permanently sealed. Again this metal cover of a pickle jar makes an excellent choice as a piece of
copper capillary can be directly soldered to it forming a good vacuum tight seal and allowing pinching
off for sealing. Should the display container require re-pumping, the pinched capillary may be easily
reopened for reconnection to the vacuum system.
The display container may be mounted on a suitable stand that houses the generator beneath
resembling a water cooler or used as shown in the figure. Refer to the drawing figures for final
assembly and pump down instructions.
PV2
PV3
PV1
DISPLAY
1. You will need a roughing pump good for pulling a vacuum below
100 millitorr, a Pirani gauge and a bleed off valve PV3.
2. Connect output of power supply to metal base section. Verify proper isolation from any conducting objects
as this point must support the high voltage and high frequency energy for this setup.
3. Slide copper capillary into appropriate section of vacuum hose.
4. Allow to pump down to limit of system -should be below 100 millitorrs.
5. Bleedoff to .5 torr and apply power noting rarefied air glowing a purplish pink.
6. Disconnect from vacuum system and pinch off section of rubber hose as shown.
7. Connect power supply output now to copper tube on cap and reapply power noting a well defined tornado
shaped discharge extending the full length of jar. Display is visible under normal lighting but should be quite
spectacular in the dark.
NOTE: Display may vary with temperature, proximity to other objects, grounding and of course pressure of air
inside. Many display variations are possible and experimentation is suggested.
Fig 20-2 Plasma tornado jar setup Connection is made to
copper tube via clip or
tight wire twist.
Jar is sealed via a small washer pinching the
folded rubber hose. This method provides an
excellent temporary seal that is easily removed
for repumping etc.
Hold a fluorescent lamp near the jar and note it lighting!! This demonstrates the radiative effects
of the energized plasma and provides an interesting science project.
If you are fortunate enough to have access to a vacuum pump, experiments with different
pressures can yield some real interesting results.
Adjust power control knob for maximum display. Note sharp peak in adjustment.
Do not leave on for extended periods of time until you check for heating of supply and jar.