Plasmasonic 1.0 Tesla Coil

Spun Aluminum Toroids - Exquisite Beauty

Our Plasmasonic systems use only the highest quality aluminum spun toroids as toploads. We believe that the topload of any Tesla coil system is what makes a Tesla coil, well . . . "a Tesla coil," and therefore believe that only the finest toroids possible should adorn the top of these devices.

You may have noticed that one of the more common methods Tesla coil builders are using to cut costs is to create toroids out of tubing and plastic disks giving them a skeleton-like appearance. Although functionally this works, we believe it detracts from the true essence of the overall design and appearance of a high power Tesla Coil.

Professional Handheld MIDI Controller - Advanced Features

Included with every Plasmasonic Musical Tesla coil system is our professional handheld MIDI controller. This controller utilizes a high quality custom EMI shielded enclosure with an amazing silkscreen legend utilizing a classic military avionics control panel scheme and layout. Each handheld controller accepts a standard MIDI input and can be operated in both standard pulse and musical MIDI operating modes. Each controller can be set to one of eight MIDI channels and can be custom programmed to each user's individual tastes and requirements. The handheld controller has a fiber optic output which connects to the main Tesla coil unit. Using fiber optic communication provides a virtually 100% noise immune connection between the handheld controller and the main Tesla coil system providing flawless operation under virtually any condition.

Tesla Coil Advanced Controller - The "Brains" of the Plasmasonic

Our microprocessor controlled Tesla coil controller is the "brains" behind each and every Plasmasonic system. Our controllers accept a fiber optic input from our handheld MIDI controllers and control the output bridges of our Plasmasonic systems using advanced logic and feedback circuits. There are also several layers of protection embedded in these controllers including overcurrent and undervoltage detection. Onboard LED annunciators inform the end user to the status of the system and if faults are occuring.

Additionally, each advanced controller is enclosed in an EMI shielded, handsomely designed enclosure with all adjustment knobs accessible from the outside of the enclosure for easy access.

US Manufactured Power and PCB Subassemblies

Each subassembly in our Plasmasonic systems are designed and built using printed wiring board (PCB) technology and manufactured using advanced automation processes in a PCB fabrication facility here in the United States. This ensures high quality construction and reduces the probability of a failed connection or incorrectly installed component. Unlike our competitors who use mostly "point-to-point" wiring for all components, our components are all integrated into PCB subassemblies and connected via connectorized and harnessed cables.

Safety Features and Discharge Circuits - High Reliability

Safety is paramount in any Plasmasonic Musical Tesla Coil system. We ensure that each system has several layers of safety designed and incorporated into them. Management of the capacitive energy storage of the DC bus circuit is one example. Each Plasmasonic system includes both an active and a secondary backup discharge system to ensure that the DC bus circuit is discharged upon removal of power. You will not find this dual layered safety feature in any of our competitors' Tesla coils.

Also, our larger Plasmasonic systems also employ warning indicators and buzzers as well as external interlock and E-STOP capabilities.

High Current Laminated Busbar - Highest Performance

If the advanced controller is the "brains" of the Plasmasonic, the half-bridge or full-bridge circuit is the "brawn" of the circuit. Because these bridge circuits switch upwards of 750A of peak current, low inductance connections between the high current IGBT transistors is crucial to ensure the Tesla coil will have a long operational life with high reliability. All of our high current bridge circuits are connected using custom 6oz. copper, 4-layer laminated bus boards. This ensures extremely high coupling between positive and negative conductors and minimizes inductance. Our competitors are still using point-to-point wiring which is prone to inducing large spikes on the transistors as well as operating less efficiently which reduces overall life of the power bridge circuits.

Primary Capacitor - Superior Thermal Management

The primary capacitor is the main resonant component in any Tesla coil and is subjective to enormous peak currents which leads to considerable heating of the capacitors that make up a primary capacitor. Because of this, we utilize 6 oz. copper laminated FR-4 with integrated cooling holes which provide 360 degree cooling airflow coverage for maximum thermal performance resulting in lower capacitor temperatures and increased reliability.

Competitors mount capacitors generally to single sheets of HDPE, which is the same material that kitchen cutting boards are made of. This poor mounting method results in much less airflow coverage for each capacitor and results in higher capacitor temperatures ultimately leading to decreased component lifetime and reduced reliability.

Intuitive Controls and Annunciators - User Friendly

High power Plasmasonic systems have a number of controls and annunciators which are controlled by an onboard computer processor which provides safety feedback and other related controls including:
•Warning Timer - Indicator and Audible Buzzer
•DC Bus Charging Indicator
•Ready Indicator
•Key Lock-out
•External Safety Interlock circuit

No Surplus or Used Components - Highest Quality

Eastern Voltage Research uses only new components, purchased from authorized distributors, here in the United States for each and every item in our Plasmasonic systems. In order for our competitors to offer low pricing on their products, they use second-hand and surplus components, many of them from China or Malaysia, for their Tesla coil systems. The problem with surplus components, is that there is never any way to determine how the components were previously operated and what their history was, and how much life is remaining in them. We believe that to provide the highest reliability and longest lasting systems to our customers, that only new components be used in our products.

EMI / EMC for Conducted and Radiated Emissions

The engineers at Eastern Voltage Research have extensive knowledge in the design of EMI filters for conducted emissions as well as the control of radiated emissions. As an option, we can provide filtering for both differential and common mode conducted emissions and meet both commercial and military EMI conducted emissions specifications for your Tesla Coil. We can also provide detailed information on how to effectively control radiated emissions.

Eastern Voltage Research also had all the necessary equipment to fully characterize the conducted emissions of your Tesla Coil, if required, including LISN networks and RF spectrum analyzers.

Custom Professionally Manufactured Magnetics

All of the magnetics in our Plasmasonic systems are custom designed by engineers here at Eastern Voltage Research and fabricated at magnetic manufacturing companies across the United States. This includes the secondary coils, current transformers, gate transformers, and EMI / RFI chokes and filters.

Our magnetics are fabricated using state-of-the-art computerized winding machines which ensure a high quality, consistent product each and every time they are produced. Although acceptable for the amateur, hand wound magnetics, especially in the area of secondary coils leads to large variations that can lead to reduced performance and reliability in the long run.

Advanced Computer Controlled Sequencing

Control and power sequencing of our Plasmasonic systems is performed either through the use of microprocessor based circuits or in the case of our larger systems, Programmable Logic Controllers (PLCs). These advanced control circuits control the following functions:
•Start-up and sequencing of power relays
•Warning LED, buzzers, and other annunciators
•Cooling fan management
•DC Bus inrush current control
•External safety interlocks and E-STOP circuits