gate driver PCB for half bridge

4 months ago

Profile:Dual isolated gate driver for Radiant Half Bridge Circuit, designed by "Master Ivo". Can be used as a impulsed series resonant primary for a Tesla coil, as Nikola Tesla intended it to be. More info can be found on my channel:[https://www.youtube.com/c/masterivo](youtube) Needs symmetrical power supply, and dual channel square wave generator with out of phase 49% duty signals.

Open source license: Public Domain

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Description

Dual isolated gate driver for Radiant Half Bridge Circuit, designed by "Master Ivo".

Can be used as a impulsed series resonant primary for a Tesla coil, as Nikola Tesla intended it to be.

More info can be found on my channel:https://www.youtube.com/c/masterivo and specifically this video: https://youtu.be/c2_rKc7sHGk (describes this circuit)

Needs symmetrical power supply, and dual channel square wave generator with out of phase 49% duty signals. L1=L2=L3 are all bifilar pancake coils, made from 12,5m X 1.5mm2 or 10m X 2.5mm2 (prefered) speakerwire (pure copper), 10

L1 creates impulses during 1% dead time L2 is series resonant. L2 is the primary, L3 is parallel resonant and is the secondary L1 is close coupled to L3. L3 is loose coupled to L2, L2 is fliiped over (counter wound).

21-1-21 Updated BOM (caps!) part links are added in "custum attributes">"supplier part" direct link to BOM: http://magstar.eu/wp-content/uploads/2021/01/BOM_gate-driver-for-half-bridge_2021-01-21.csv

MUR8100EG diodes need active COOLING (from 12V fans on heatsinks)!!! https://www.reichelt.de/de/en/heat-sink-38mm-9-9-k-w-black-anodised-fk-225-sa-l1-p228035.html?search=fk+225+sa-&&r=1 (diode cooling body)

website with additional info: magstar.eu

Documents

smd 1.27 to dip8 tht

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smd 1.27 to dip8 tht V1.1

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BOM

ID Name Designator Footprint Quantity
1 Metal oxide resistor 1 W, 5%, 10 Ohm R2,R1,R3,R4 R_AXIAL-0.4 4
2 5x20 RHOS Fuse clip/seat 630mA U5 FUSE-TH_5X20RHOSFUSECLIP/SEAT 1
3 100(0)uf 50V elco C9,C25 CAP-D3.0XF5 2
4 47u 50V elco C18,C1 CAP-D3.0XF5 2
5 680uF 10V elco C6,C19 CAP-D3.0XF5 2
6 1EDI60I12AF U1,U4 DIP8 2
7 C3M0065090D Q2,Q1 TO-247AC-3_L15.8-W5.0-P5.46-L 2
8 78L05 U3,U2 TO-92-3_L4.8-W3.7-P2.54-R 2
9 390 ohm R6 R_AXIAL-0.4 1
10 204-10SURD/S530-A3 LED1 LED-3MM/2.54 1
11 MUR8100EG D3,D1 TO-220-2 2
12 MKS2 4,7µ 50V C20,C12 RAD-0.2 2
13 wima 22n 63V or 100nF 50V multi layer ceramic C2,C5 RAD-0.2 2
14 Wima MKS-02 220 nF 63V C7,C4 RAD-0.1 2
15 1μF C3X7R 50V C10,C8,C11,C3 RAD-0.2 4
16 X7R-5 100N Multi-layer ceramic capacitor 100N, 10% C24,C21,C23,C15,C16,C17 RAD-0.2 6
17 Header-Male-2.54_1x1 P6,P5,P16,P1,P2,P11 HDR-1X2/5.08/1.0MM 6
18 Header-Male-2.54_1x1 P10,P9,P4,P3 HDR-1X1/2.54 4
19 1N4007 D2 DO-41_BD2.4-L4.7-P8.70-D0.9-RD 1
20 Inductor, axial, Ferrite, 10 µH L1,L2 R_AXIAL-0.6 2

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Mike Weatherl

(unofficial) addendum for future makers:



 • MGJ1D121505MPC (obvious if looking at PCB, but absent in BOM earlier drafts); on Mouser there are 2 variants (MGJ...-R7 & MGJ...-R13); both are equivalent, just different reel types for mass-manufacturing tooling


 • for #6 (1EDI60I12AF), solder SMD chip to a "SOIC-8 to DIP-8 adapter" chip, for through-hole pins (such as this or this). Then the assembly fits into a "DIP-8 IC Socket" (such as this or this)


 • heatsinks for #7 and #11: search for 'TO-247' & 'TO-220' heatsinks, probably 'vertical fin' extruded type, but mounting can be tricky - one option is to use screw-terminals mounted to PCB, and then MOSFET/blocking diode inserted into screw terminal, for heatsink placement flexibility. Finally, something like dual 40x40x10mm 12v fans to cool the blocking diodes


 • I finally got some high quality Loctite/Multicore 63/37 Solder, and it makes a HUGE difference compared to the cheap stuff I'd been burning up boards/tips with lol. highly recommended, if you find yourself needing to step up your solder game like I did, for this beauty!

2021-02-04 10:57:43
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MasterIvo

@Mike Weatherl  I'll start updating the BOM the next fey days, updating the cap info.
Also: I have moved the 12V fans to the cooling body's of the impulse blocking diodes (in series with the mosfets) as they need the most cooling. The Mosfets keep cool with only a cooling body without fan.

2021-01-21 02:56:29
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