Eastern Voltage Research microBrute DRSSTC Tesla Coil KiT, Instruction Manual

Page 1: ...2011 Eastern Voltage Research LLC microBrute DRSSTC Instruction Manual m mi ic cr ro oB Br ru ut te e D DR RS SS ST TC C K Ki it t I In ns st tr ru uc ct ti io on n M Ma an nu ua al l E Ea as st te e...

Page 2: ...T IS INTENDED FOR USE FOR INDIVIDUALS OVER 18 YEARS OF AGE WITH THE PROPER KNOWLEDGE AND EXPERIENCE AS WELL AS FAMILIARITY WITH LINE VOLTAGE POWER CIRCUITS BY BUILDING USING OR OPERATING THIS KIT YOU...

Page 3: ...STC Instruction Manual SAFETY AND EQUIPMENT HAZARDS PLEASE BE SURE TO READ AND UNDERSTAND ALL SAFETY AND EQUIPMENT RELATED HAZARDS AND WARNINGS BEFORE BUILDING AND OPERATING YOUR KIT THE PURPOSE OF TH...

Page 4: ...tage Research LLC microBrute DRSSTC Instruction Manual PACEMAKER WARNING THIS DEVICE WHEN CONNECTED TO A RESONATOR WILL PRODUCT ELECTRICAL AND MAGNETIC FIELDS EXPOSURE TO THIS FIELD SHOULD BE LIMITED...

Page 5: ...te DRSSTC Instruction Manual MODULATOR WARNING USE ONLY THE microBRUTE MODULATOR FOR CONTROLLING THIS DRSSTC THIS MODULATOR IS SPECIALLY DESIGNED FOR THIS DRSSTC AND HOOKING UP A DIFFERENT MODULATOR I...

Page 6: ...e manner may result in serious injury or death POWER SEMICONDUCTOR HAZARD This is a solid state power device Components may fail explosively at any time and eject high velocity projectiles EYE PROTECT...

Page 7: ...MENT The electronic kit you purchased utilizes line voltages 115VAC and also contains circuitry that produces output voltages in excess of 400VDC Normally consumer electronics equipment are safely enc...

Page 8: ...are grounded objects nearby that could complete a circuit path in the event you make accidental contact with live voltage Avoid wearing any kind of jewelry or other articles that could accidentally c...

Page 9: ...of the fan Always allow the cooling fan to continue running even after power is removed until the heatsink and board components are properly cooled down SAFETY GUIDELINES ELECTROMAGNETIC FIELD OUTPUT...

Page 10: ...l safe Please read this manual in its entirety before building testing or operating your kit Circuit Description The microBrute DRSSTC is a relatively simple second generation DRSSTC system comprised...

Page 11: ...l the DRSSTC a handheld modulator is connected via RCA connector J1 This provides a low frequency pulse signal which turns the DRSSTC ON and OFF at a nominal frequency of 100Hz with a very low duty cy...

Page 12: ...flat to the board and the leads are bent on the backside of the board to prevent the part from falling out before soldering The part is then soldered securely to the board and the remaining lead lengt...

Page 13: ...R101 R102 1 10k Potentiometer R23 Note 120k may be substituted for R43 R44 CAPACITORS 13 0 1uF Ceramic Capacitor C1 C3 C4 C5 C7 C9 C13 C15 C16 C18 C23 C25 C26 marked 104 or BC104 1 1000pF Ceramic Cap...

Page 14: ...er Inverting UCC37321 U5 1 15V Linear Regulator LM7815 U6 1 5V Linear Regulator LM7815 or LM340T5 U7 1 LM311 Voltage Comparator U21 1 555 Timer U22 MISCELLANEOUS 2 8DIP IC Socket for use with U4 U5 7...

Page 15: ...RSSTC Instruction Manual 1 Fuse 5A F41 REQUIRED NOT SUPPLIED A R Thermal Grease A R Two Part Epoxy or similar adhesive A R 1 Aluminum Tape Available at Hardware Stores A R Sand Paper Small Piece 1 Eye...

Page 16: ...microBrute DRSSTC Tesla Coil Kit November 2019 Rev 5 16 Copyright 2011 Eastern Voltage Research LLC microBrute DRSSTC Instruction Manual microBrute DRSSTC Component Layout Diagram...

Page 17: ...s Also please be sure to take us seriously when we say that good soldering is the key to the proper operation of your circuit Use a 25W soldering pencil with a clean sharp tip DO NOT USE a high power...

Page 18: ...04 or 104 18 Install C3 0 1uF capacitor marking BC104 or 104 19 Install C4 0 1uF capacitor marking BC104 or 104 20 Install C5 0 1uF capacitor marking BC104 or 104 21 Install C7 0 1uF capacitor marking...

Page 19: ...olytic capacitor Install this capacitor into the board ensuring the positive side of the capacitor installs in the hole that is marked positive on the PCB layout 38 Install C24 10uF 50V electrolytic c...

Page 20: ...9 Install CR3 1N5819 diode The cathode band on the diode must match that shown on the silkscreen 50 Install CR4 1N5819 diode The cathode band on the diode must match that shown on the silkscreen 51 In...

Page 21: ...kwards of that shown on the silkscreen Failure to do this will result in improper operation of your miniBrute DRSSTC 65 Install VR45 1 5KE33CA diode This device is bi directional therefore can be orie...

Page 22: ...e silkscreen 73 Install D1 Blue LED The short lead of the diode is the cathode and will install into the square pad on the PCB board 74 Install D2 Blue LED The short lead of the diode is the cathode a...

Page 23: ...nd inserting the IC as you would in direct soldering of the chip Note that one end of the IC is marked by a dot notch or band this end MUST be oriented as shown on the PCB layout 83 Install U6 LM7815...

Page 24: ...gate transformer as shown in the instructions below Visibly check to ensure the windings of the transformer connect to the board as shown below Failure to connect the windings properly will result in...

Page 25: ...d to use thermal grease not supplied in between the heatsink and the IGBT to ensure proper heat transfer IMPORTANT Ensure notch location is oriented as shown in the figure below 97 Attach Q42 IXGN60N6...

Page 26: ...are provided so you can insert a rod through them if desired to make winding easier as shown in the example winding jig shown below Homemade Secondary Winding Jig 101 Using the figure below wind the s...

Page 27: ...t unwind and also allows you to take rests if needed Once you are completed tape off the end of the winding and finally add a few extra turns For finishing the coil you have the option of leaving it...

Page 28: ...ing the included 12 AWG wire wind the primary coil as shown in the figure above The primary coil can then be secured in place using masking or electrical tape not supplied or two part epoxy not suppli...

Page 29: ...hard rubber or plastic material to accomplish When complete you will have an almost completely smooth aluminum toroid 106 Roll up some aluminum tape pieces much as you would with masking tape to attac...

Page 30: ...croBrute DRSSTC Instruction Manual 108 Connect AC power cord and fuse block to the board as shown in the figure below DO NOT connect the primary coil to the PCB board at this time 109 Install Fuse 1A...

Page 31: ...microBrute DRSSTC Tesla Coil Kit November 2019 Rev 5 31 Copyright 2011 Eastern Voltage Research LLC microBrute DRSSTC Instruction Manual...

Page 32: ...serted correctly After you are sure that everything seems to be properly installed move on to the set up and testing section Set up and Testing Okay so lets begin MODULATOR WARNING DO NOT USE ANY OTHE...

Page 33: ...LM7805 Pin 3 Output 5V 0 5V U4 UCC37322 Pin 1 Pin 8 Vcc 15V 0 5V U5 UCC37321 Pin 1 Pin 8 Vcc 15V 0 5V U1 SN74HC14 Pin 14 Vcc 5V 0 5V U2 SN74HC74 Pin 14 Vcc 5V 0 5V U3 SN74HC08 Pin 14 Vcc 5V 0 5V U21 L...

Page 34: ...toroid This should be a 1 inch long conductive wire which is taped to the toroid via aluminum tape The break out point should be installed the side of the toroid OPPOSITE of the control electronics 1...

Page 35: ...the microBrute DRSSTC with Resonator Power applied Please review the following warnings before proceeding The Output Arc of the Tesla Coil is at high voltage potential and extremely hot Never attempt...

Page 36: ...al on the PC board This is done by simply reversing the direction that the primary wire enters and exits both current transformers as is shown in the figures below Reverse the polarity as shown above...

Page 37: ...e ready to start final testing and tuning of the microBrute Tesla coil The following instructions procedure shows the proper power up and power off sequences recommended for the microBrute DRSSTC For...

Page 38: ...um output Both PW and PRF settings on the handheld controller should never exceed 50 during the tuning process The tuning process is described as follows Repeat this process until maximum output arc i...

Page 39: ...process then Congratulations Your microBrute DRSSTC Tesla Coil is now completed and operational Additional Operational Suggestions from our Customers a Shortening of the RCA modulator cable to six 6 f...

Page 40: ...have good electrical contact between wraps Some aluminum tape has a plastic backing which prevents this electrical contact Use a multimeter to ensure you have electrical continuity around the entire...

Page 41: ...and away from the primary coil A grounded strike target can also be positioned to ensure that output arcs are attracted to the target and not downwards toward the primary coil f Always ensure the toro...

Page 42: ...rn Voltage Research LLC microBrute DRSSTC Instruction Manual Terms and Conditions of Sale Before opening or assemblying your kit please read and review the latest Terms and Conditions of Sale on our w...

Page 43: ...roBrute DRSSTC Tesla Coil Kit November 2019 Rev 5 43 Copyright 2011 Eastern Voltage Research LLC microBrute DRSSTC Instruction Manual Military Dash Number Identification M39014 01 xxxx Ceramic Capacit...

Page 44: ...roBrute DRSSTC Tesla Coil Kit November 2019 Rev 5 44 Copyright 2011 Eastern Voltage Research LLC microBrute DRSSTC Instruction Manual Military Dash Number Identification M39014 02 xxxx Ceramic Capacit...