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BipolarTeslaCoils:
Experimenter’sGuide
K.R.Scott
Copyright2016
PREFACE
Thistextisnotmeanttobeadetailedengineeringdocumentonhighvoltagedevices.Itiswrittenfor
educationalandinformationalpurposesonly.Thereisnohighlevelmath,theoryoranalysis.Thecontentsareacollectionofempiricalexperiencefrommakinghighvoltageequipmentovertheyears.Thereisanenormousamountofinformationonlineandinbooksforthosewhowantthereallytechnicalstuff.Whenbuildingthesedevices,youcanonlycalculateenoughdetailtogetyouintotheballpark,andthenitisalittletrialanderror,goodengineeringpractice,testing,fixingandre-testing.Thisisnotanindepthstudy;itisbasicnutsandbolts.Iamaretired(semi-retired)engineer,andforme,itisaboutthe”funfactor”,solet’sletourcuriositygowild,havesomefunandbesafe.
Regards,K.R.Scott
HighVoltageExperimenterSeries
Willow-TechPublishing
©Copyright2016K.R.Scott
©Copyright2016Allrightsreserved.Nopartofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinanyform,orbyanymeans,electronic,mechanical,photocopied,recorded,orotherwise,withoutthepriorwrittenpermissionofthecopyrightowner.
DISCLAIMER
Theauthorandpublisherhavemadereasonableefforttopresentthisinformationasclear,conciseandaccurateaspossible.However,theycannotbeheldresponsiblefortheuseormiss-useofthismaterial.Wearenotliableforanydamagesincluding(butnotlimitedto)personalinjury,propertydamageorlegaldisputesarisingfromtheuseofinformationcontainedinthisbook.
DONOTUSETESLACOILSAROUNDPACEMAKERS,INSULINPUMPS,ORHEARINGAIDS.
BipolarTeslaCoilsoldbyCENCO1920s
IpurchasedthiscoilonEbay.
Withtheexceptionofcleaning,itisinverygoodshape.IusedtheTeslaCADprogramtocalculatethecapacitorvalue,Iwiredituptoasparkgapanda9kV/30maneontransformeranditworkedgreatafter95years!Mainproblemwasdustonthecoilwhichcameoffwithapaintbrush.Dustonasecondarycoilwillreduceoutput.Theresidualelectrostaticchargeonthesecondaryattractsdust.
CencoBipolarTeslaCoil
BipolarTeslacoiloperatein½wavemodewhereasthetypicalverticalconfiguredcoilswiththebottomendofthecoilgrounded,operateinthe¼wavemode.The¼WaveTeslaCoilhasthesecondarycoilgroundedandisslightlymoresensitivetotuningandcouplingthanaBipolarTeslaCoil.OnBipolarCoilsthecouplingisinthecenterareaofthesecondarywithlessproblemofracingsparkstypicallycausedbytootightcouplinginthe¼wavecoiland/orinsulationbreakdown.A¼wavecoilcanbemoredangerousasinsomeconfigurations,ifthereisashort,oraconductivespark(racingsparks)60Hzcurrentcanbecarriedonthesecondary’shighfrequencycurrent(lessisolationbetweenprimaryandsecondary).Thereisoneincidentinthe1910s,whenthishappenedtoastageperformerandhewaselectrocuted.ABipolarTeslacoilsomewhatactslikeanisolationtransformerasthesecondaryisnotgroundedandisinsulatedfromtheprimarycoil.ThebipolarTeslaCoilwillgivebetterperformancethanthe¼wavecoilandthedischargesaremoreimpressive.YoucanforcetheBipolarCoiltooperateinthe¼wavemodebygroundingoneend.AdescriptionofaHVdischargewandfordrawingsparksinthisconfigurationisinthelastsectionofthisbook.
Fig.BisthecircuitthatIprefer,asthesparkgapactsasbothanoperatingsparkgapandasasafetygap.Thecapacitorseeemstorunalittlecoolerandislesslikelytofail.Onethingthatcanbedone,especiallywithdoorknobtypeceramiccapacitors,istoaddacoupleoffenderwashersseperatedbyanutoneachendofthecaptoactasaheatsink.Capacitorscanalsobepottedinparaffinforextrainsulationandtheparaffinabsorbsalotofheatbeforeitwillmeltandactsasaheatsink.Youcanalsotrydifferentcombinationsofparaffinandcanolaoil.Beeswaxworksverywell.Manyoftheoldhighvoltagecoilsanddeviceswhereinsulatedusingamixtureofbeeswaxandrosin.Beeswaxandlinseedoilwillmakeakindofselfhealinginsulationgel.Tryvarousmixturesmeltedtogethertogettheconsistancyyouwant.CanolaoilisusedasabaseingrediantforsomeHVinsulatingoils.Itisoneofthenon-toxicreplacementforPCBs.(PolychlorinatedBiphenyls)Verytoxicandisstillfoundinoldtransformers,especiallypolepigsandoilfilledcapacitorsbuiltbefore1979.
OneofTesla’sexperimentalcoilsetups.
G–Electricalpowersource
P–PrimaryDriveTransformer
S–SecondaryDriveTransformer
A,B–SparkGapElectrodes
M–Sheetmicaconfiguredclosetoelectrodestopromoteairflow.
C,C–LeydenJars(Selectedforequalcapacitancevalue”
a,b-Sparkgapcloselyadjusted.
K,K-HighVoltage/HighFrequencysecondarycoiloutput.
ThisisaschematicofElihuThomson’s(1853-1937)DisruptiveDischargeCoilbasedonTesla’spatent#454,662.Drivetransformer:15-20kV.Compressedairquenchedsparkgap.Primary:15-20turnsheavycopperwire.Secondary:150turnsfinewireiswoundonaglasscylinder.Thecoilswhereemergedinatankofboiledlinseedoil.Thiscoilproduced150kV.SomeofThomson’slatercoilsproducedsparksover60incheslong.
SPARKGAPS
Asparkgapwillarcinsteadofsparkingifthecurrentgoingthroughit,istohighi.e.usingaMOT(MicrowaveOvenTransformer–typically2,500volt@500maor5,000voltsDC(whenusingthediodeandcapacitorvoltagemultiplierthatwasinthemicrowaveoven.APoleLinetransformers(PolePig)wiredbackwardswillincinerateasmallorpoorlymadesparkgaps.IfyouaregoingtousethismuchenergytodrivetheTeslacoilyouneedtousearotarysparkgapormulti-gap.Inthiscase,theelectrodesneedtobetungstenandaircooled.Note:Thesetypesoftransformersaremoredangerousthanneonsignoroilignitiontransformers.Whenanaccidentalcontactoccurs,thereisaveryhighprobabilityofelectrocutionorattheleaseverybadburns.Otherhazardswithsparkgapsareacoustic/electricalnoise,hardUVlight,shockhazards,fireandtheproductionoflargequantitiesofOzoneandNitrogenOxides.Ozonehasaverypungentsmell.Youneedgoodventilationandoutsideair.
SOMEGENERALOBSERVATIONSABOUTSPARKGAPS
Multi-gapsarebetterthanasinglegap.
Rotarygapsarethebestperforminggaps.
Gapelectrodematerialsandgeometryeffectperformance.
Bestelectrodematerialistungsten.Thoriatedtungstenandspotweldingelectrodesalessexpensive.
SparkGapsneedtobecooled.
Airblastquenchingworkswellandifdrynitrogenisused,theyworkevenbetter.
Youcanquenchasparkgapwithstrongrareearthmagnets.N–Spolesacrossthespark.
SparkGapscontinuallyburnopen(widergap)andwillneedtobeadjusted
NeveradjustSparkGapwithpowerplugpluggedinandnevertrustaswitchtobeoffastheycanshortinternally.
Alwaysdischargethetankcapacitor–leavegroundstraponasthecapscanregenerateacharge!
Donotstareatthegapinoperation–hardUVcanburnretina(weldersburn–fellslikesandinyoureyeswherethereisnone).
Asinglestaticparkgapneedstobeadjustedaswideaspossiblebutstillworkreliably.
Seriesgapsareadjustedclosertogether.
SAFETY
ThebestTeslaCoilsafetywrite-uponlinehasbeencreatedbyseveralcoilersandisavailableasanhtmdocumentat:
http://www.pupman.com/safety.htm
“pupman.com”isagreatsiteforinformationandhasbeeninusefromtheearlydaysoftheinternet.
Youcansignupat:
http://[email protected]
Therearehundredsofcoilersthatcontributetothissite.Lotsofstufffromthereallygreatcoilers.
Someofthegeneralsafetyissuesareasfollows:
Electrocutionhazard,especiallyfromthehighthevoltagedrivecircuit,sparkgap,primarycoil.
Alsobeawarethatifthereisashortorgroundfaultthatthethelowerfrequency60Hzcurrentcanbecarriedthroughthesecondarycoilalongwiththehighfrequencyhighvoltagecurrent.TherewasastageperformerthatdidanactwithalargeTeslacoilthatwaselectrocutedintheearly1900sthisway.ThereisalsoonecaseonrecordofasmallchildthatwaselectrocutedfromanunattendedTeslaCoilinthefather’sbasementworkshop.Nevertrustaswitch,ALWAYSunplugthecoilandputashortingwireacrossthecapacitor(s).ThedischargesfromthecoilcancauseburnsfromheatandinsomecasesRFburns.Dischargescancausefirewhencombustiblematerialsarepresentandanexplosionifcombustiblefumesareinthearealikeacetone,cleaningsolvents,PVCglue.IhavewitnessedoneexplosionofaPVCsecondarycoilthatwasputtogetherwithPVCglueandtheresidualvaporswhereignitedinsidethecoilform(voiceofexperience).ThehighvoltagedischargesfromthesparkgapandcoilterminalwillcreatehardUVlight,ozoneandnitrogenoxides.Theozonewillirritatethethroatandsinusesandthenitrogenoxidescanproducenitricacidwhencombinedwithmoistureinthelungsandcanproducechemicallyinducedpneumonia.TheUVlightcanburntheretinaandcause“weldersburn”Properventilationandeyeprotectionisneeded.TheintenseRFradiationproducedbytheTeslacoilcandamagesensitiveelectronicequipment,especiallyTVremotecontrols,cellphone,iPods,etc.
NoisehazardsfromsparkgapandHVdischarges,especiallyrotarysparkgaps.Youcanbestartledbyashockfromtheelectrostaticchargethatcanremainonsurfaceofsecondarycoil,(especiallyifitisalargecoilwithalotofsurfacearea)aftertheTeslaCoilhasbeenturnedoff.
DriveTransformer:NeonType9kV/30ma
SecondaryCoilwinding2.4”x10”#26AWG520Turns
PrimaryCoil:3.5”DiameterTunes@11-1/2Turns
Capacitor:2ea1000pF/20kVinparallel=2000pF
DualStaticSparkGap(SteelandBrass)
ThecalculationswheremadeusingTeslaCAD
forthisparticularBipolarTeslaCoilareasfollows:
Createdby:RichardChapman
http://www.richardsplace.net/tesladownload.htm
Note:ThisprogramwillworkwithWindows10
Donotusewirediametersfromcommercialwirecharts.Wind/countturnsfor1inchanddivideby#turnstogetgoodwirediameter.Example:#26AWGis52Turns/inchdividedintoone=0.01923.Setthespacingbetweenturnsto:“0”.
Calculationsforcapacitorvalueforlinematching.
TeslaMapisanotherpopularCADprogram.
http://www.teslamap.com/download.html
Secondarycoil:2.4”x9”470Turns#26AWG
PrimaryCoil:Tunesat11Turns
Capacitor:2ea.1000pF/20kVTotalCapacitance2000pF
Tested/operatedwith9kV/30maneontransformer.
Baseishardwooddrawerfront.
Theelectrodesaremadefrombrazingrod,threadedwith8-32threadswiththreadedbrassballsontheends.Therodswheregroundtoapointwithabeltsanderononeendandthenthreaded.Thiswayyoucanhavepointedorsphericalelectrodes.Thesecondarycoilsupportsarefromendsofanewwoodentoiletpaperdispenser.Thereisashortbrasstubeinadrilledholethatgoestothecoilelectrodeends.
Brazingrodsinavarietyofdiametersaresoldbythepoundatanyweldingsupply.Thebrassballswherepurchasedfrom:http://www.grandbrass.com/
SecondaryCoil:1.875”x10”#26AWG520Turns
PrimaryCoil:4.5”DiameterTunesat8-1/2Turns
Capacitor:1200pF/20kVCeramic
DriveTransformer:5KV/10maOpenFrameNeon
Baseishardwoodtrayturnedupsidedown
SparkGapBrassandSteelAngle
bracketsandstainlessmachinescrews
SecondaryCoil:1.875”x11”#26AWG
Primary:CoaxCableShieldsbraid&Centerconductorused.
Tunedat:10-1/2Turns
Capacitor:1000pF/25kV-NAVYMica/Ceramic
DriveTransformers:2ea3.5KVWiredfor7kV
LineFilterused(rightsideofunit)
SparkGap:Brassandsteel
Baseisanewhardwoodcuttingboard+4RubberFeet.
SecondaryCoil:1.875”x10”#26AWG
PrimaryCoil:CoaxCableTunesat10Turns
Capacitor:1300pF/18kVCeramicDoorKnobType
Transformer:5kV/10kV/10maOpenFrameNeon
SparkGap:BrassandSteel
Base:HarwoodDrawerFace
4Turnedlegs.
Secondary:2.4”x8”420Turns#26AWG
Primary:#12AWGTunesat:11Turns
Capacitor:1200pF/20KV
DriveTransformer:5kV/10ma
SparkGap:SteelandBrass
Box:Madeinmywoodshop.
SecondaryCoil:2.4”x7.5”#26AWG400Turns
Primary:Tunes@11Turns
Capacitor:2ea690pF/20kVTotalCap=1380pF
SparkGap:SteelandBrasswith12VMuffinFan
Baseissmallfinishedshelf.
Secondary:2.4”x9”#26AWG470Turns
Primary:3.5:ODTunes@11Turns
Capacitors2ea690pF/20kVTotalCap:1380pF
DriveTransformerAutoIgnitionCoil
SparkGapBrassandSteel
Theignitioncoilisdrivenusingalightdimmer
anda2ea1uF/350VMotor“RUN”Capacitors
DONOTUSEMOTORSTARTCAPS!
SecondaryCoil:1.875”x12”#26AWG625Turns
PrimaryCoil:Tunes@10Turns
Capacitor:2000pF/30kV
DriveTransformer:7.5kV/30ma
SparkGapStainlessSteel
RemoteON/OFFSwitch
Base:hardwoodDrawerfrontandturnedlegs
SecondaryCoil:1.875x12”#26AWG625Turns
PrimaryCoil:Tunes@10-1/2Turns
Capacitor:2000pF/30kV
DriveTransformer5.0kV/10maOpenframetype.
SparkGap:Stainlesssteel
BaseisrepurposedwoodKleenexbox.
Secondarysupport:Redoak@T-Paperholderends.
Terminals:Brazingrodand1.2”brassballs.
BipolarTwinTeslaCoilConfiguration
SecondaryCoils:2.4”x8”#26AWG420Turns
Primary:TVCoaxCableTunes@10Turns
Note:Primarycoilsarereversewound.
Capacitor:2ea690pF/20kvTotalCap:1380pF
Base:RepurposedJewelryBox.
SparkGap:Brassandsteel.
TopLoadTerminalsare:Brassdoorknobs.
SecondaryCoil:3.5”x30”#26AWG,1,560Turns.
Primary4.5”DiameterTunes@11-1/2Turns
Capacitor:0.02uF/15kV
SeriesSparkGap4ea.SparkPlugs&12VMuffinFan.
HousingConsoleTable,Reinforcedwithwood.
Variac(autotransformer),ON/OFFToggleSwitch
Drawerknobremoved&replacedwithredjeweledindicatorlamp.
Two5kVDriveTransformersTotal:10kV.
Electrodessolidgauge#10AWG/brassballs/crimpterminals.
Hotmeltglueworkswellforinsulatingwireconnectionsandhardware.
DrillintowoodwithaForstnerdrillbit,usewasherwithscrew.
MusicalBipolarTeslaCoil
RegionalMuseumJohnsonCityTennessee
http://roadsideamerica.com/tip/44988
http://www.pictorialism.com/tesla.html
Locatedin:BigBearLake,CA
HVDischarges
Dischargesthroughclearlightbulb.
Dischargesriseincenterduetoheatedions/air.
1930
KinraideCoilEarly1900s
HerculesTesla-ThomsonElectrotherapyUnit1907
Bipolarcoilsecondaryisgrounded(centerelectrode).
RotarySparkGap.
1915
1918
1930sPopularScience
Gaiffe’sBipolarResonatorusedinelectrotherapyearly1900s.ManufacturedbyAdolpheGaiffeinParis
1891BipolarTeslaCoilpresentedtoLordKelvinin1897ThistypeinventedbyNikolaTeslain1891
25Watts@110VDCInput
ElectricalExperimenterJuly,1919
FreeDownloadArchivehttp://www.electricalexperimenter.com/
COILWINDING
ThesmallcoilwinderthatIuseisfabricatedfromanoldmechanicalfilmwinder,threadedrodstock,andtwoplasticfunnels.Itworksverywell.Itisfastandeasytocontrol.IgetbettercontrolusingamechanicalcrankthanIdidfromamotorizedwinder.
Afewhintsoncoilwinding.
Wherethincottonglovesand/orwashyourhandsbeforewindingthecoil.Avoidgettingoilandsaltfromyourhandsonthewire.Useanew3-4”paintbrushtokeepdustofthecoil.(Especiallybeforecoating)Sandthecoilformwithfinesandpaperandcleanwithalcoholbeforewinding.NoSteelWool!Theareawherecoiliswoundneedstobewarm–donotwindcoilincoldworkshopasthewirewillexpandandloosenthecoilwhenitiswarmedup.Coatthecoilwithseveralthincoatsofinsulatingspray.Thebest,mostcosteffectivespraythatIhavefoundisRust-OleumCrystalClearEnamel,itisaverygoodinsulatoranditdriesquickly.Thebesttechniqueistohaveafixturewherethe
coilcanbeslowlyrotated–amicrowaveovenmotorworkswell–thiswillreduceruns.Donotusedatafromwirechartsfor#ofturns/diameterorwire–handwindandinchfor#ofturns.Example#26AWGis52Turns/inch,1/52=0/01923Diameter.Usethis#TeslaCAD.
DischargeWand
Note:Thewireexitsthewandattopforsafety.
MaterialPVCElectricalConduit.
TerryFilterforprotectingdrivertransformerandhomeelectricalsystem
http://www.hvtesla.com/terry.html
ExceptionallywellmadeTerryFiltermadeforalargeTeslaCoil.
http://ian.macky.net/tesla.html
KEEPTHESEDEVICESAWAYFROMCHILDREN,PETSANDINDIVIDUALSNOTFAMILUREWITHHIGHVOLTAGESAFETY.IFYOUAREINEXPERIENCEDINWORKINGWITHTHETYPESOFDEVICESDESCRIBEDINTHISMANUAL,PLEASESEEKHELPFROMAPERSONWHOKNOWSHOWTOSAFELYWORKWITHHIGHVOLTAGEDEVICES.PLEASESEETHEWEBLINKSLISTEDATTHEENDOFTHISMANUALFORADDITIONALINFORMATION.More people are killed each year by low voltage than by high voltages. Themost commonelectrocutionhazardis110and220voltsAC.Theamountofcurrentthatpassesthroughthebodydetermines the physiological damage. If electrical contact is made to a person whose skinresistanceisloworbysufficientlylargecontactarea,enoughcurrentcanpassthroughthebodytocauseburns,damagetonerves,musclesordeath.Youcanbecomepartoftheelectricalcircuit,evenwhenungroundedandstillbeelectrocuted.Highvoltagescanpenetrateinsulationmaterials,orjumpthrutheairtofindapathtoanunwaryexperimenter’sbody.Itisnotadvisabletoworkalone. Capacitors can hold a lethal charge for several days and can partially recharge due todielectric retention after discharging and shock the experimenter. Electrolytic capacitors canexplodeviolently if thevoltage rating is exceeded;ACcurrent is applied (shorted rectifier)orhookedupbackwards.Capacitors thataredischarged through lowresistance loadsuchas lowresistance,wires(smalldiameterwire,coilsresisters,etc.)cancauseanexplosionandsprayhotmetal and sparks. High voltage can cause fires and/or explosions if combustible vapors arepresent.Electricaldischargesunderfluidssuchasoilcancausethefluidtoexpandwithexplosiveforce.Discharges in a vacuumcanproduceX-raysunder some circumstances.Ozone (O3) isproducedinelectricaldischargesandcanreachtoxiclevelsifventilationisnotadequate.BeawarethatTesla,OdinCoilsandsparksgapsproduceelectricalinterferencewithTVandradios.Youneed to shield both the power line feed and airwaves from this. Use RF line filtering and agroundedFaradaycage.
CHECKOUT:http://pupman.com/safety.htm
See:“Skineffect”onwebsite:http://en.wikipedia.org/wiki//Teslacoil
TESLACOILDESIGNBOOKS
TheUltimateTeslaCoilDesignandConstructionGuidebyMitchTilbury2007
UnderstandingTeslaCoilsandBeyondbyBrentTurner2013
DRSSTC:BuildingtheModernDayTeslaCoilbyDanielMcCauly2006
TheTeslaHighFrequencyCoil:It’sConstructionandUses1912
VintageTeslaCoilandHighVoltageBooks-GreatInfo…
ThesebooksareavailableasFREEdownloadsinpdfformatfrom:
https://books.google.com/
https://archive.org/details/googlebooks
https://www.gutenberg.org/
https://openlibrary.org/books
TheInventionsandwritingsofNikolaTeslabyThomasCommerfordMartin504Pages1894TheTeslaHighFrequencyCoil:ItsConstructionandUsesbyGeorgeF.Huller160Pages1910CurrentsofHighPotentialofHighandOtherFrequenciesbyWilliamBenhamSnow,M.D.302Pages1911HighFrequencyApparatus,Design:ConstructionandPracticalApplicationbyThomasStanleyCurtis269Pages1920ExperimentalHighFrequencyApparatus:ConstructionofInductionCoilsandTransformersbyThomasStanleyCurtis269Pages1920High-FrequencyCurrentsbyFredrickFinchStrongM.D.301Pages183Illustrations1908HighVoltagePhysicsbyL.Jacob,M.Sc.105Pages1930sTheInductionCoilinPracticalWorkIncludingRoentgenXRaysbyLewisWright192Pages1897TheInductoriumorInductionCoilsbyHenryNoad,Ph.D.135PagesRuhmkorffInductionCoils:ThereConstruction,OperationandApplicationwith
ChaptersonTeslaCoil,InductionCoilsandRoentgenRadiographybyH.S.Norrie208Pages1896
OldMagazinesources
https://archive.org/details/magazine_rack?sort=titleSorterhttps://en.wikipedia.org/wiki/List_of_online_magazineshttp://www.electricalexperimenter.com/http://www.americanradiohistory.com/Electrical-Experimenter.htmhttp://www.americanradiohistory.com/Popular-Electronics-Guide.htmhttp://www.popsci.com/archiveshttps://books.google.com/books/about/Popular_Mechanics.html?id=49gDAAAAMBAJhttps://archive.org/details/TheAmateurScientisthttp://www.electrotherapymuseum.com/Oneoftheverybestsourcesofinfo,photographs,videosandhistoricalstuffonhighvoltagedevices.
Projectsplanshttp://www.teslastuff.com/
http://www.amazing1.com/
http://www.instructables.com/
http://makezine.com/
LinkstoBipolarCoilProjects
http://www.electrotherapymuseum.com/
http://tesla-coil-builder.com/double_cone_bipolar_tesla_coil.htm
http://lateralscience.blogspot.co.uk/2012/07/main-page.html
http://ydjj.blogspot.com/2011/10/my-bipolar-tesla-coil.html
http://www.teslasociety.com/teslacoil.htm
http://thehappyheathen.com/?p=50
http://thehappyheathen.com/?tag=tesla-coils
https://www.museumofdiscovery.org/experience/world-record-musical-bi-polar-tesla-coil
http://teslaweb.freeservers.com/tesla1.htm
http://www.roadsideamerica.com/tip/44988
http://tesla-coil-builder.com/FlatSpiralSecondaryLongitudinal.htm
http://tesladownunder.com/Tesla_coils_intro.htm
http://www.lateralscience.co.uk/tesla/index.html
http://kenscoil.com/tesla-coils/
PARTS
http://www.amazing1.com/tesla-coils.html
http://www.easternvoltageresearch.com/faq.html
http://www.teslastuff.com/
http://www.grandbrass.com/
http://prosites-llcwccd.homestead.com/