Fiddys Tiny Tesla & TS Build/Feedback

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Fiddys Tiny Tesla & TS Build/Feedback

Postby Fiddy » Tue Mar 17, 2015 8:55 pm

G'day,

Heres my thoughts and feedback on the Tiny Tesla and TS


  • I received a a extra set of TS bleed resistors
  • I had a left over 1N4148 diode from the SD card interrupter.
  • I wanted to add alumina oxide thermal pads like i did previous to the Onetesla but the IGBT's are too close together on both the TS and Tiny Tesla.
  • On the TS I added heat shrink to the primary stand-off posts that connect the primary winding to the driver board.
  • My TS kit didn't come with M3 washers to space out the stand-off posts so the driver board had clearance of the IGBTs. I used M3 nuts instead.
  • There is no LED indication on either boards, im planning on adding a DC bus LED and/or logic level LED down the track, having 15V/5V/3.3V may be a dilemma, i will probably choose one. Depends how head room for current there is on those tiny regulator chips.
  • When following the manual in order, some components are harder to install based on the order installation.
  • The TO-92 regulators dont have right foot print/lead spacing on the board, the center through hole on the board is offset to the 2 outside through holes but on the regulator pins they are all in a straight line which is painful.
  • On the small electrolytic capacitors they have the wrong lead spacing which makes the stick up off the board and are lest stable.
  • The hardware for Tiny Tesla wasn't listed individually which presented some confusing when building both kits.
  • The boards lead spacings for the control transformer is off on one side, i had to fight to get the last leg in and it went in on an angle on both the TS and Tiny Tesla.
  • Winding the primary directly onto the secondary isnt good practice in my book, i dont know the coupling co-efficient they are going for but im definitely going to varnish the whole secondary and kapton tape the base where the primary is to be wound.
  • Will be adding MUR1560 ultra fast diodes across the IGBTs for protection against reverse voltages from the primary for robustness. im not real keen on the 1.5KE510CA's as seen on the schematic.


Anyway here we go:

Kits Arrived nicely packed.
Image

Finished Interrupter
Image

Varnishing the secondarys.
Image

99% complete
Image
Pico SGTC
Nano SSTC
Audio Modulated SSTC
Audio Modulated Bipolar SSTC
TinyTesla SSTC
Onetesla TS DRSSTC
OneTesla DRSSTC
EVR MicroBrute DRSSTC
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Fiddy
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Re: Fiddys Tiny Tesla & TS Build/Feedback

Postby KarlFlick » Tue Mar 17, 2015 10:17 pm

1) Love your varnish jig. I was dreaming up the same kind of thing using lego gears to get a slow, unattended rotation.

2) Cool cones on top. Are they functional, or mostly for looks?

3) What's the test tube rack? Different colored gas glow or something?
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Re: Fiddys Tiny Tesla & TS Build/Feedback

Postby Fiddy » Tue Mar 17, 2015 10:31 pm

KarlFlick wrote:1) Love your varnish jig. I was dreaming up the same kind of thing using lego gears to get a slow, unattended rotation.

2) Cool cones on top. Are they functional, or mostly for looks?

3) What's the test tube rack? Different colored gas glow or something?



Haha thanks, its the made from free left over wood from a local timber yard :-) that would be nice ive seen some use pedal systems to control a drill motor.

They serve as a breakout point an look cool for vertical sparks, heres one in operation on my EVR DRSSTC

Watch on youtube.com


You guessed it, different gases glow different colors :-)

Image
Pico SGTC
Nano SSTC
Audio Modulated SSTC
Audio Modulated Bipolar SSTC
TinyTesla SSTC
Onetesla TS DRSSTC
OneTesla DRSSTC
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Re: Fiddys Tiny Tesla & TS Build/Feedback

Postby alexp » Wed Mar 18, 2015 5:24 am

Hi Fiddy,

Thanks for identifying the 'Missing Parts' . When I inquired, I was told they were 'not required' ??
I just ordered some from Newark .. at 50 cents each, that's cheap Insurance.

[quote="Fiddy"]G'day,

[*]Will be adding MUR1560 ultra fast diodes across the IGBTs for protection against reverse voltages from the primary for robustness. im not real keen on the 1.5KE510CA's as seen on the schematic.[/list]
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Re: Fiddys Tiny Tesla & TS Build/Feedback

Postby SystemsGuy » Wed Mar 18, 2015 11:19 am

Would y'all mind posting the part numbers? I'm happy to add to my next mouser order - cheap insurance is good! :)
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Re: Fiddys Tiny Tesla & TS Build/Feedback

Postby Fiddy » Wed Mar 18, 2015 2:23 pm

SystemsGuy wrote:Would y'all mind posting the part numbers? I'm happy to add to my next mouser order - cheap insurance is good! :)


Im going to use MUR1560 ultra fast diodes. Im not real keen on the 1.5KE510CA's as seen on the schematic.
Pico SGTC
Nano SSTC
Audio Modulated SSTC
Audio Modulated Bipolar SSTC
TinyTesla SSTC
Onetesla TS DRSSTC
OneTesla DRSSTC
EVR MicroBrute DRSSTC
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Re: Fiddys Tiny Tesla & TS Build/Feedback

Postby Fiddy » Wed Mar 18, 2015 4:43 pm

Made a JavaTC load file for the tiny tesla, note the coupling data.

Download JavaTC here: http://www.classictesla.com/java/javatc/javatc.zip

go into the file directory and open JavaTC\script\JTC_load.js with notepad, delete what is there then paste the whole content of the attached notpad file into it then save.

Then clock load sample coil on JavaTC to load it in
Attachments
Tinytesla JavaTC Load FIile.zip
(1.03 KiB) Downloaded 645 times
Pico SGTC
Nano SSTC
Audio Modulated SSTC
Audio Modulated Bipolar SSTC
TinyTesla SSTC
Onetesla TS DRSSTC
OneTesla DRSSTC
EVR MicroBrute DRSSTC
User avatar
Fiddy
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Posts: 89
Joined: Tue Jan 15, 2013 6:31 pm
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Re: Fiddys Tiny Tesla & TS Build/Feedback

Postby Fiddy » Wed Mar 18, 2015 5:18 pm

Heres my winding/varnishing jig in action:

Watch on youtube.com
Pico SGTC
Nano SSTC
Audio Modulated SSTC
Audio Modulated Bipolar SSTC
TinyTesla SSTC
Onetesla TS DRSSTC
OneTesla DRSSTC
EVR MicroBrute DRSSTC
User avatar
Fiddy
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Re: Fiddys Tiny Tesla & TS Build/Feedback

Postby Fiddy » Thu Mar 19, 2015 12:47 am

I soldered in my Anti-parallel diodes today!

Added kapton tape underneath them to insulate from the other solder pads.

Image

Dont mix the anode/cathode up!
Image

Image

Heres the mark up on the schematic:

Image
Pico SGTC
Nano SSTC
Audio Modulated SSTC
Audio Modulated Bipolar SSTC
TinyTesla SSTC
Onetesla TS DRSSTC
OneTesla DRSSTC
EVR MicroBrute DRSSTC
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Fiddy
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Re: Fiddys Tiny Tesla & TS Build/Feedback

Postby Fiddy » Thu Mar 19, 2015 10:54 pm

Had bad luck today guys with the TS secondary, i had coated it with many layers of polyurethane over many days.

Went to run it today and i could see tiny sparks from the breakout with the minimum pulsewidth but then i saw just a thin stream of smoke rise, so i stopped to check the coil and found my secondary had arc'd inside the former almost all the way down.

I had cleaned the inside of the former previous, and checked the winding resistance before I ran, it was at ~780 ohms previous to running now its ~800ohm with the burn marks on the secondary, there's' no burning on the secondary at all.

Image

Pretty peeved that it failed on the inside :(
Pico SGTC
Nano SSTC
Audio Modulated SSTC
Audio Modulated Bipolar SSTC
TinyTesla SSTC
Onetesla TS DRSSTC
OneTesla DRSSTC
EVR MicroBrute DRSSTC
User avatar
Fiddy
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Posts: 89
Joined: Tue Jan 15, 2013 6:31 pm
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