envproduction·api/api-origin/v1·backendcommongnd.org·checking…buildde577045
[ driver tree · DRSSTC · gate-drive add-on · schematic shown; no board photo published ]

oneTesla dead time add-on: Donna Whisnant's 74LS123 circuit

74LS123 one-shot → SG3525 · adjustable dead time into the UCC37322s · 2015 to 16

She names the failure this fixes. The oneTesla v1 kit driver has no dead time between its gate pulses, so the two IGBTs overlap and die early. Her add-on inserts an adjustable gap. The title block is signed Donna Whisnant / Dewtronics, “oneTesla PWM Dead-Time Driver”, Rev 1.0, 14 December 2016, KiCad. The handle `dewhisna` on GitHub is hers.

The sheet is split in two, and each half says whose circuit it is. The upper half is labelled “Original oneTesla Circuit”. It has a CST206-3A current transformer at 1T:300T, a 1 kΩ 5 W burden, a 74HCT14 chain, a 74HC74, and UCC37322 and UCC37321 onto the gate-drive transformer through 6.8 Ω to each IGBT. Two crosses marked “Cut Here” show exactly where to break it, and a note on the ‘21 reads “Replace with UCC37322 !!”. The lower half is hers: a 74LS123 dual one-shot forming the sync pulse into an SG3525. Its three trimmers are labelled on the sheet: Sync Pulse Width (20 k), Free-Running Frequency (2 k) and Dead-Time (100 Ω). OutA and OutB are wired back to “UCC37322 #1 Pin 2” and “#2 Pin 2”.

The setting-up procedure is printed on the drawing. Turn the dead-time pot until the wanted gap appears between OutA and OutB. Set the free-running frequency about 5 % below the primary’s resonance. Then widen the sync pulse until the SG3525 locks to the current-sense signal. A table gives the 74LS123 timings: 220 pF/330 Ω = 50 ns, 220 pF/470 Ω = 74 ns, 470 pF/330 Ω = 108 ns, with a warning that its inputs need at least 40 ns.

The repository also has the earlier working notes. A pencil sheet dated 31 May 2015, headed “oneTesla Musical Tesla Coil · SG3525 Driver”, carries the numbers she was aiming at (“@286 kHz maxDead = 794 ns, minDead = 266 ns”) and the later marginal note “both are now 27322 non-inv!”. The repository states no licence, and no photograph of a built board is published. The two sheets are all there is.

Schematics and photos

Sources

This is the card from the driver tree, written from what the builder published. Send corrections through the forum.