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TRANSFORMERS

   In order to charge the capacitor bank enough to fire the gap each cycle, you will need a source of high voltage. Since a minimum of 4kV is required to fire the spark gap reliably, electrical outlets (120V-240V) are ruled out. Since it is unlikely you own your own high voltage generator or dynamo, step-up transformers are your best option.

   Step-up transformers operate similar to a Tesla Coil (in fact, a Tesla Coil is a type of transformer): a low AC voltage is applied to a primary coil, which creates a alternating magnetic field that induces a higher voltage in a secondary coil via electromagnetic induction. For Tesla Coil use, usually 4kV to 20kV are used, however it is possible to use voltages even higher (100kV  x-ray transformers have been used). Unlike a Tesla Coil, though, most transformers do not require a resonant capacitor or drive circuit (flyback transformers and ignition coils are among the exceptions). Most transformers have four terminals: two primary coil inputs ("positive" and "negative") and two secondary coil outputs. Some transformers have only three terminals, in which case the missing terminal is the other secondary output, and is generally connected internally to the iron core or metallic case. Below is a list of the most common transformers used to power Tesla Coils, along with their specifications and other important details:

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Neon sign transformer (NST):

  • 3kV-15kV

  • 10mA-60mA (although rare, 120mA models also exist)

  • More expensive ($50-$200)

  • Found in two forms: solid state (plastic, lightweight, small, 

      practically useless in a Tesla Coil) and 60Hz/50Hz (heavy,

      metallic, usable in a coil, and are the type this site refers to).

  • Internally current limited by magnetic shunts within the transformer core, which, with some effort, can be removed to allow more current (for more on this, check out this YouTube video).

  • Single units are commonly used in smaller coils, while a bank of paralleled (phased) NST's can drive even large coils (for a demo on NST phasing, click here).

  • Lower output currents allow for easier gap quenching, meaning a static gap can be used with fewer issues.

  • Although an excellent option, NST's are more prone to secondary failure

Microwave oven transformer (MOT):

  • 1.8kV-2.3kV

  • Over 1A when unballasted

  • Most models available to buy are salvaged/used and are quite affordable ($20)

  • Most units have only three terminals (the missing fourth terminal is the other secondary output, and is internally wired to the metal body).

  • Non-current limited (although ballasting isn't always needed). A popular ballasting option is to connect one or more MOT's (with the secondary shorted) primary(s) in series with the primary of the main MOT. This limits to power to 1-2kW (8-17A at 120V), but generally causes a lot of heating in the ballast MOT and the Tesla coil output may be severely decreased.

  • Since 2kV isn't usually enough to fire a spark gap, 2-4 MOT's are usually connected with secondaries in series and primaries in parallel to yield 4-8kV (some coilers have even connected eight or more MOT's successfully). To make a dual MOT bank, electrically connect the metal bodies of two transformers, ground the bodies using the ground terminal on a wall socket (the rounded, third prong which some appliances don't have) or the earth directly, and use the two wire terminals as outputs. If no voltage (or excessively low voltage) results, switch the connections on one of the transformer's primary winding. This essentially gives you a 4kV center-grounded transformer with two 2kV outputs that are 180 degrees out of phase (i.e. when one terminal hits +2kV, the other hits -2kV, giving you 4kV between them. This prevents the individual units from facing the full 4kV, which could potentially damage them). With any bank over two MOT's, it is smart to submerge the transformers in oil or wax to help prevent voltage breakdown, interwinding arcing, etc. (even a dual MOT bank can benefit from oil submersion). 

  • The high currents produce by MOT's make static gap quenching more difficult, so rotary gaps are preferred in MOT coils.

  • Most commonly used in medium to large coils.

Oil/gas burner ignition transformer (OBIT):

  • 10kV-14kV (although harder to find, models as low as 6kV are available)

  • 20mA-40mA

  • Relatively cheap (usually $30 or more)

  • Internally current limited

  • Single transformers may be used in small coils. However, OBIT's can be paralleled in the same manner as NST's to get more current. Paralleled OBIT banks, like NST banks, can power almost any coil.

  • Relatively low currents allow single units to work with a static gap.

Flyback (television) transformers (FBT):

  • 10kV-40kV

  • Approximately 5mA-30mA

  • Units have several terminal pins. To power a flyback transformer, a drive circuit (ZVS drivers are the most popular for Tesla Coil use) is need, which can easily be bought online for under $40. Although most flyback transformers have built-in primary coils, a DIY primary coil is usually wrapped around the exposed ferrite core (shown in the image at right). The secondary coil has one end coming out the transformer top (the long, thick, red wire in picture at right) while the other end is one of the pins (you may test for continuity with a multimeter or find which pin pulls an arc from the other secondary wire to determine which pin is correct).

  • Flyback transformers operate at relatively high frequencies (usually over 20kHz). At frequencies this high, the primary capacitor will simply act like a short, and not function correctly in a resonant circuit. To overcome this, the current must be rectified (converted to DC, usually by placing a diode or diode array in series with the output). Many flyback transformers have a built-in rectifier diode, however, so this is generally not an issue.

  • Generally used in small to medium coils. While more difficult, it is theoretically possible to parallel several flyback transformers to get enough power to drive a larger coil.

  • The low currents and high frequencies associated with flyback transformers allow them to be easily run with a static gap. As power and voltage increase, though, a rotary gap might become the better option.

Distribution transformers (pole pigs):

  • 3kV-35kV

  • 200mA to over 3A (without a ballast)

  • Non-current limited. Requires a ballast (otherwise it will trip almost any size breaker).

  • Very expensive ($500+) and hard to find

  • Usually used as step-down transformers, stepping down the high voltage from powerlines to be used in homes. For Tesla Coil use, simply input the mains voltage into the secondary (usually found on the unit's side as two to three metal terminals), and high voltage comes out the primary (the large bushings found at the top of the unit).

  • Most often used in large coils, but can be used with any coil size (especially if ballasted).

  • The high output currents mean a rotary gap is nearly essential (heavily quenched static gaps may still be used).

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   Other transformer models can/have been used in Tesla Coils (such as bombarding, x-ray, plate, or potential transformers), but, due to their rare or hard to implement nature (x-ray transformers, which can run up to 150kV, are a good example), they will be omitted from discussion.

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T volt

BALLASTS AND CONTROLS

   Many transformers used in medium to large coils (esp. distribution, microwave oven, and potential transformers) will draw so much power when turned on, that they will trip the circuit breaker (if no breaker is present, damage to the unit and/or your home wiring could result). This is where a ballast comes in handy. A ballast (in electronics) is something that limits the amount of current that can enter a circuit. Listed below are the three main types of ballasts, as well as some general information on each:

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Resistive ballasts:

  • Utilize electrical resistance (provided by a resistor) to limit current

  • Usually connected in series with the transformer primary (input)

  • Less efficient (usually lose energy as heat, dropping the current/voltage to the transformer as they get hotter, and generally reduce coil output)

  • Examples include high-power (1kW or more) heaters and incandescent light bulbs

Capacitive ballasts:

  • Use capacitor(s) to limit current

  • Generally connected in series with the transformer secondary (output)

  • Somewhat harder or more costly to implement (requires some impedance/reactance calculating)

Inductive ballasts:

  • Use a large inductor to limit current

  • Don't usually heat up nearly as much as resistive ballasts, and are considered the best option

  • Examples include other transformers (usually with the secondary(s) shorted of even removed), output-shorted arc welders, and home-wound, iron-core coils.

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Controlz/ballast

   While large arc welders are a definite favorite (by adjusting the power or amp settings on it, one can limit the power to a rather specific level), using that spare 2kW space heater will still yield admirable results. The limit on what can be used as a ballast is almost limitless: any high-power appliance, tool, etc. will work (however, any sensitive, internal electronics might be fried by the electromagnetic fields produced by an operating coil). Just be ABSOLUTELY certain that the wires used to connect the primary side of the transformer can handle the current being put into them without burning up (when in doubt, always go with the lower, thicker gauge).

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   Many people desire the ability to control the size, intensity, and sound characteristics of their Tesla Coil's arcs, as well as monitor the circuit. The classic solution: the variable autotransformer (or Variac). Variacs control the voltage entering the coil (which controls the arc length and, to some degree, the intensity) and/or the rotary spark gap's motor (which alters the motor speed, and thus arc BPS and sound pitch). Most Variacs also have a voltmeter built in, so the input voltage to the coil can be monitored. Dimmers and motor speed controllers are also good options for controlling the coil or its rotary gap (if used). One of the easiest options for power control is the liquid rheostat (sometimes called a scariac). A form of variable resistor, this device works in series with the power supply's input. Two electrodes are submerged in a partially conductive solution (water mixed with a small amount of lye, baking soda, or washing soda). As the electrodes become further submersed and/or closer together,  more current is allowed to flow into the coil. The liquid solution absorbs any heat produced relatively well, allowing it to be used with large, high-power coils. Click here for an excellent, high quality YouTube tutorial on how to build your own "Scariac".

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TRANSFORMER PROTECTION

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   When used in a Tesla Coil, a transformer experiences enormous stress from high frequencies, feedback, high voltage spikes, etc. There are two main components that help extend the life of a transformer operating in a Tesla Coil: the safety gap and the Terry filter (at left, you can see a combination of the two). The first is the easiest to make and highly effective. If you could pick only one safety feature to have, this should be it. A safety gap is just an ordinary spark gap in parallel with transformer's output and set to fire just over the voltage the transformer supplies. This is to cancel out any harmful overvoltage spikes that may harm your transformer. To set your safety gap, simply keep widening the gap in tiny increments until the transformer can't arc across it when turned on (I say it like this because once an arc is struck from a transformer, it can generally be pulled to a distance longer than the voltage can originally jump).

    A Terry filter is basically a Tesla Coil-suitable high frequency blockade. This prevents any HF interference from entering the transformer, and ultimately the mains outlet. For more on the Terry filter, click here

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