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CTU tabletop SSTC with a CD4046 PLL driver: Marek Novotný

half bridge · PLL-driven (CD4046) · university commission · 2021 to 2024

Commissioned rather than self-started. Czech Technical University in Prague asked Marek Novotný, who had just finished a working DRSSTC, for a tabletop SSTC small enough for an 80×30×30 cm shelf with no airflow. It was to sit in PlasmaLab at the faculty of nuclear sciences and physical engineering. He documented it in a multi-year build log on his own site, UHVLab, including months of failure before it worked. A borrowed UD2.7 board couldn't drive the gates cleanly at the small coil's 660 kHz. After four different gate-drive-transformer cores he gave up on that frequency and rewound for 391 kHz. Next he built his own antenna-feedback half-bridge driver, but antenna feedback was too noisy and position-sensitive. So he switched to a CD4046 phase-locked loop, building from a schematic he found on Jakub Tejišćák's site, and he credits both by name. With a PLL the drive frequency can be modulated directly by audio, so a $3 Bluetooth receiver board feeds music straight into the VCO input. First sparks: ~10 cm at 120 VAC. Three years later a transistor failure exposed a destructive bug. An LTSpice check showed that the under-voltage/over-temperature lockout left one IGBT's gate charge with nowhere to discharge, over 14 kW of simulated peak loss on the stuck switch. He fixed it with a GDT winding dedicated to dumping residual gate charge to ground. Separately he found that the CD4046's output phase could be fine-tuned with its R1 center-frequency resistor, a trick from a third credited source, Tefatronix. Final spec: half bridge of IRFP460s, CD4046 PLL, 481 kHz, three selectable power modes (50 Hz / 100 Hz / CW) reaching 1 kW, and roughly 10 cm sparks from the secondary in CW mode.

Schematics and photos

Sources

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