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Solid State Tesla Coil
by Michael Chen on September 25, 2011 Table of Contents Solid State Tesla Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro: Solid State Tesla Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 1: Tesla Coil Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 2: Secondary Coil (Part 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 3: Secondary Coil (Part 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 4: Secondary Coil (Part 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Step 5: Secondary Coil (Part 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 2 3 4 6 7

Step 6: Toroid (Part 1 out of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Step 7: Toroid (Part 2 out of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 8: Toroid (Part 3 out of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Step 9: Toroid (Part 4 out of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Step 10: Primary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Step 11: Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Step 12: Test it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Step 13: Links and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

http://www.instructables.com/id/Solid-State-Tesla-Coil/

I take no credit for the original design. The Primary : The primary is powered by the control circuitry and it generates the magnetic field that the secondary uses to create the high voltage. It has several advantages over the more common spark gap tesla coil. One side is connected to ground. It is the few turns of thick wire at the base of the secondary coil. based on Steve Ward's design. I'm still posting the instructable. which is a cool effect. the secondary coil.Intro: Solid State Tesla Coil A solid state Tesla coil is one of the kinds of Tesla coils available. the topload. I will show you how to make a solid state Tesla coil. orange cylinder. The Secondary : The secondary is the long. The Topload : The topload is the metallic object at the top of the secondary coil. Step 1: Tesla Coil Parts A Solid State Tesla coil is made by four main parts: the primary coil. so bear in mind this design is far from perfect. although caution should still be applied. yet they can still achieve a respectable output. Try at your own risks. which is Steve Ward's. Results may vary. They can also be made to play music through its spark.com/id/Solid-State-Tesla-Coil/ . as some of the techniques I used may be interesting to some. It provides a capacitance to the Tesla coil. In the following instructable. as well as several helpful tips and hints that will come handy during its construction. Examples of this trick can be seen by searching for musical tesla coil or singing tesla coil. They are less louder than conventional Tesla coils. It is actually a white PVC pipe covered by a lot of enameled wire. If you like this instructable. with some small modifications "here and there.instructables. http://www. and the control circuitry. I accidentally burnt both of the Mosfets. They are also more friendly to nearby electronic apparatus." While fiddling with the antenna. high voltage comes through the other side. The Control Circuitry : The circuits that make the tesla coil work at the correct frequency and duty cycle. please rate it and vote my instructable for the contest.

I used a 4 in. http://www. Sandpaper (120grit. PVC pipes will come with a non-straight edge. The external diameter of the pipe should be 4.com/id/Solid-State-Tesla-Coil/ .5 in. A 4 in. PVC pipe. the flange can be removed for the next step. (11. Measuring tape 3. Flange 2. Irregular edge chopped off.5 in. PVC Pipe (It's outer diameter is actually 4. Hacksaw Image Notes 1. leaving a nice straight edge in the pipe's end.Step 2: Secondary Coil (Part 1 of 4) First. Irregular. case. To straighten it out. If a 4 in. outer diameter. which is the diameter required.48 cm). non-straight edge Image Notes 1. although anything around it works just as fine) 4. Usually. Image Notes 1. Now. the irregular edge is cut. with a hacksaw. In my. using the flange's border as a nice. 4 in. the coil former must be prepared. specially if it is a leftover. PVC pipe sizes are not the outside diameter size.5 in. The coil former is the hollow tube in which the enameled wire will be wrapped. so be wary. The irregular side must be slightly past the flange's edge(picture 2). One can observe the irregular side cut off on picture 3. outer diameter. PVC pipe has a 4.5 in. one must use any non conductive hollow cylinder with a 4.) 2. place the pipe inside the flange (see picture). Then.instructables. PVC pipe cannot be obtained. straight guide.

Finished piece. Position the right edge of the flange 21 inches (or what you require depending on the flange) from the pipe's end. the secondary former must be cut to the appropriate size. In my case. each flange had a height of 2 inches. + 2 in. Nice. the former must be able to accommodate two flanges. confirm measurements before continuing. = 21 in. but the principle remains the same. 17 inches must be available. clean. so: 17 in. From one end of the winding section to the other end of the winding section. Be wary. Image Notes 1. In addition. + 2 in. but yours may vary.2. Image Notes 1. Image Notes 1. as the specific height of the flange may vary according to where you buy it. http://www. Place the flange so that the required number of inches are in between the flange's edge and the pipe's end and then cut the pipe using the technique described in the previous step.com/id/Solid-State-Tesla-Coil/ . My flange's height is two inches.instructables. straight edge Step 3: Secondary Coil (Part 2 of 4) Now.

com/id/Solid-State-Tesla-Coil/ . Cut in the right side of the flange. http://www.Image Notes 1.instructables.

Getting glue on the outside of the flange will not decrease performance. might. Depending on the specific PVC cement you use. Sorry for the fuzzy pictures.Image Notes 1. Regardless of the PVC cement instructions. it might have negative dielectric properties (it may hurt performance). place the flange above a disposable surface. Flange http://www. Disposable surface 2. Image Notes 1. a perfect seal is not needed.instructables. PVC cement 3. To do this.com/id/Solid-State-Tesla-Coil/ . After placing the glue on the flange. place the pipe inside the flange. do not cover the pipe's surface with glue. specifically on the winding area. Besides that. but getting it on the pipe. and cover only the interior surface of the flange with glue. pushing the extra glue downwards towards your disposable surface. Secondary with only one flange (not glued yet) Step 4: Secondary Coil (Part 3 of 4) The next step is to glue one flange to the pipe.

you break the wire midway. The materials are. If for any reason. For a note. but try not to make a bad job in here. This can range from a small. There is no quick way and easy way to wind the secondary without a lathe or similar acting jig. Metal expands during summer and contracts during winter. check the links at the end of this instructable. or place some electrical tape sticky side up to hold the first turns. etc) to hold the last few turns. I recommend you to (before starting the Tesla).com/id/Solid-State-Tesla-Coil/ . Image Notes 1. You will need slightly less than 3/4 of a pound. but not necessarily needed. assuming perfect winding (which probably will not happen) is 0. You can use electrical tape to hold the wire if you are stopping halfway through the coil for any reason. the pipe. have something to hold the wire that permits it to spin freely. of course. My wire-holding jig. you could end with an unusable pile of twisted wire by summer. it is best to start over. For maximum quality (and slowest time). hot glue. Varnishing the secondary coil after winding is extremely recommended. and time. The exact weight. First. Attention If the difference between summer and winter temperatures is large in your region. not by length. One overlapped turn will not ruin the entire coil. http://www. The secondary coil presented below is a compromise between speed and quality.instructables. lots of it. mine is not varnished. Pipe Step 5: Secondary Coil (Part 4 of 4) The final step of this subsection is to wind the secondary.4. as well as overlapping turns. It is extremely important to avoid spaces between wires. When you finish. add a bit of glue(epoxy. but they can be winded by hand. it will be worth it. 30 AWG enameled wire. or almost 1/4 of a kilogram. eager kid to some books and a stick. you may either glue a few turns of wire with super glue. varnishing the secondary is a must. try to break a small section with your hands for you to know what is the maximum force you can apply without breaking it. an idea does help) Enameled wire is sold by weight. If not varnished. (Although not exact.246 kg. To start winding it.

Tape (optional) 3.Image Notes 1.com/id/Solid-State-Tesla-Coil/ .instructables. Want to stop? Use tape! http://www. Pipe (with flange already glued) Image Notes 1. Enameled wire (30 AWG) 2.

com/id/Solid-State-Tesla-Coil/ .instructables. http://www.Image Notes 1. More windings. First few windings Image Notes 1.

Wire http://www. you should glue it as described in one of my links at the end of the instructable. Using the pliers. wire.5 x 34.Image Notes 1. Aluminum duct 2. and a second flange. having it in the outside would be detrimental to the Tesla coil. Tadaa! A finished secondary coil. First.com/id/Solid-State-Tesla-Coil/ . cut a piece of wire whose length is slightly larger than the aluminum duct. bend the wire to bring the two edges of the aluminum duct as close as possible. I had to use a wire. Make sure the wire is inside the toroid.5 Toroid for the 'Phoenix' . a plier. The missing slice can then be covered using either aluminum tape or scraps of aluminum duct. Wire 2. Since I could not find this material.instructables. Pliers Image Notes 1. if you can find a piece of tube with a diameter just smaller than you aluminum duct's diameter. Step 6: Toroid (Part 1 out of 4) To make the toroid. cut the aluminum ducting so that it can do exactly a full revolution to the flange. It will still be okay as long as the wire remains in the inside of the toroid. titled A new 8. Then. Ideally. you will need aluminum duct. Image Notes 1.

glue the toroid to the flange using hot glue. going around the circumference.com/id/Solid-State-Tesla-Coil/ . Depending on how you are going to connect the Tesla secondary to the toroid. Avoid using any other glues without checking flammability first. Gluing the toroid http://www. Please see the next step for further clarification.instructables. Image Notes 1. Use the plier to bring the edges of the toroid closer. Paste the toroid to the flange well. A Flange 4.3. Hot Glue Image Notes 1. you can glue the remaining notch in the ducting either now or later in the process. Image Notes 1. Wire Image Notes 1. As close as you can Step 7: Toroid (Part 2 out of 4) Now.

Screw. use hot glue to close the notch that remained in the toroid if you have not done so already. Remove it with sandpaper before connecting. nut. just glue the secondary cable to the outside of the toroid. Toroid glued Step 8: Toroid (Part 3 out of 4) Before continuing. remember the secondary cable has an enamel coating. Some of you may ask: How did the cable got from the outside to the inside of the pipe? The way I used was to drill a small 1/16" hole through the pipe. the way to connect the secondary to the tesla coil has to be thought out.instructables. arcs good enough for me. I drilled a hole through the flange and the aluminum ducting. If you have either conductive glue or aluminum tape (glue preferred).Image Notes 1. 2. After finishing this step. Screw head is inside here. you can skip away this step. 3. and used nuts to hold it . Screw and nut http://www. This is not ideal. See pictures for an explanation. I consider 17 in. I inserted a screw through the aluminum ducting from the inside of the aluminum duct towards the flange. I decided to make a screwed connection. If using conductive glue. In all cases. undefined 4. Image Notes 1. Nevertheless. Then. Image Notes 1. and secondary cable. Bear in mind that drilling a hole limits the maximum arc length of the Tesla coil to the separation between this hole and the base of the secondary.com/id/Solid-State-Tesla-Coil/ . Afterwards. Notch already glued. any greater would arc inside. but it works good enough. I placed the toroid over the secondary and attached the wire to it. Being too cheap to buy these.

use it.com/id/Solid-State-Tesla-Coil/ . Toroid (top section unglued) 2. If not. then one can reduce the number of turns until the MOSFETs start getting warm. Secondary Step 10: Primary The primary of a Tesla coil is made by another coil of wire. Hold it temporarily with tape. if you have too many turns. If the number of turns is too low. the MOSFETs will blow up eventually. I have decided to not place a fixed one so that experiments using different breakout points can be made. and hot glue the flange to the pipe. The number of turns affects how much current passes through the circuit (see next step for the circuit). http://www. If you can obtain a pie pan that fits in the toroid's inner circumference. but the hotter the MOSFETs will get. Ten turns is a good starting point. on the other hand. Important Solid state Tesla coils require a breakout point to work properly.Step 9: Toroid (Part 4 out of 4) The final step in the tesla coil construction is to fill the top hole of the toroid with aluminum. Just wind a ~16 AWG wire ten times around the lower part of the secondary. The less turns. take a pie pan and cut a circle that can fit in the toroid.instructables. For example. the longer the arcs. as the precise number of turns may be adjusted later on if deemed necessary. Top section (already glued) 2. but never run the tesla coil without a breakout point. the performance will be sub-par to what is achievable. Then. Image Notes 1. a screwdriver placed on top of the toroid is commonly used. Pie Pan Image Notes 1. place the cut pie pan on top of the toroid and glue it with hot glue. it only requires ten or less turns of a thick wire (16AWG or thicker). A breakout point is a pointy object that protrudes from the toroid. Fortunately. Place the toroid in its final position on top of the secondary.

bear this in mind when working. If any of the authors would want their links or respective information taken down.hvtesla. you will get the Tesla Coil working. printed circuit board. This is why I recommend Steve's Design if possible. Be sure to discharge them before fiddling with the circuit. -The bottom part of the secondary goes to ground. A disadvantage from my spinoff is that there is no isolation. The Mosfets must have a big heatsink.5 Toroid for the 'Phoenix'" http://www.capturedlightning. point to point. To the Tesla Coil Primary Step 12: Test it Connect everything and plug it in.4hv. though. \ In this instructable. Use what you can find. read below: -Sometimes one needs to connect the primary the other way around. 12 VAC 3. please tell so.Step 11: Control Circuitry I strongly recommend you to employ Steve Ward's design. I made my own variation of his circuit. 2. If it doesn't. Image Notes 1. I will not teach you to make a circuit out of a schematic. For example. A dedicated ground is ideal. but do not use a breadboard (Protoboard).htm Disclaimer: I am in no way associated. So.5 x 34. I could not find locally the UCC37322 or UCC37321.com/toroid_2. sometimes you will not be able to find some components. veroboard.But. The Tesla Coil has capacitors that will remain charged after you turn it off. Unfortunately. Mains ground works out at this power level. (Scroll to the bottom of his page for his final design). with any of the authors linked. Step 13: Links and References Useful links.. see if swapping the connectors solves the problem.com/id/Solid-State-Tesla-Coil/ . and double check that they are discharged before poking anything. but do not have sensitive stuff plugged nearby. See the schematic below.org/SSTCindex. in any way. Antenna and Interrupter 4. I did not take any photos of this before the MOSFETS died.html Steve Ward: "Solid State Tesla Coils" http://stevehv. if you can't read them you should try simpler projects first. there is too much parasitic capacitance.instructables.. better methods (although more time consuming).htm "A new 8. Hopefully. and references Stephen Kludge: "How to build the perfect secondary coil" http://www. and adjust primary turns accordingly. . You may build this circuit in a strip board. Bonus: Add some salt to the breakout point and the streamers will be orange instead of blue. etc.org/hot-streamer/stk/tc/coilbld. http://www.

:) Same goes for resistors.. but perhaps I need to re-read the rest of the article.25 W is required. While this is not important for the low voltage parts of the circuit.Related Instructables How To Build A Spark Gap Tesla Tesla's Coil (SGTC) by Candlestick: Xellers Wireless Electricity by Mr. this is the start-up stage. I. Apol Audio Modulated Solid State Tesla Coil (video) by Xellers Tesla Coils for Dummies (Photos) by Xellers Build and Code a MONSTER Musical Tesla How To Build A Coil with a Vacuum Tube Microcontroller Tesla Coil by (VTTC) by TheHomebrewGuru Xellers Comments 1 comments Add Comment Feb 7. amplitude. 0. it performs such-and-such function. this is the output stage.instructables. etc? Is your schematic a "singing" coil? If so.com/id/Solid-State-Tesla-Coil/ . I can't figure out what the antenna does.e. 5:01 PM REPLY florinandrei says: Great instructable re: the mechanical part. say. What is the "interrupter"? Is it some kind of signal you need to apply? What's the frequency. yadda-yadda. Please indicate the wattage where it's important. It would help to add a few words about the main parts of the circuit. Thanks! http://www. if more than. What is it? What does it do? Various capacitors don't have the max voltage indicated. I'd imagine it's kind of a big deal when it comes to the output stage. The electronic part needs a bit more pampering. its function is to feed the primary. where does the audio signal go? The main IC (the one that feeds the MOSFETs) is not labeled. 2012.