Re: Hookup Wire

["Tesla list" <tesla-at-pupman-dot-com>]

Original poster: "Mark Broker by way of Terry Fritz <teslalist-at-qwest-dot-net>" <mbroker-at-thegeekgroup-dot-org>

I would tend to agree with Dan.  For small coils, or even larger coils with 
a high surge impedance, smaller gage wire ought to work just fine.  I 
suppose the acid test is to run the coil wide open for a few minutes and 
test the wires immediately after shutdown.  If the wires are warm, use 
larger wire.  Or, use multiple thinner parallel wires, a la Litz.

I've found that car audio installation shops are some of the best sources 
of hookup wire.  8 and 4AWG audio power cables (MonsterCable, StingRay, 
etc) are just as flexible as quality welding cable, have a very heavy 
insulation with a high standoff (which I discovered by accident :0 ) and is 
usually free for short lengths.  Most shops will save the 2 or 3 feet that 
they billed the customer, but didn't use, and throw it in a "clippings" 
box.  If you're lucky, you may even find some nice 0AWG :)  At one store 
alone I walked away with about 6 pieces of 4 foot long pieces.  You'll have 
to either buy the rather expensive large connectors (perhaps US$.75 each 
for 8WG), or make your own from some copper tubing or copper unions.  A 
propane torch makes excellent work of silver-soldering it onto the wire 
(use ample flux before inserting the wire into the connector - think 
plumbing), and a vice grip makes a suitable heat sink to keep the 
insulation from melting.

Regards,

Mark Broker
Chief Engineer, The Geek Group


On Wed, 19 Mar 2003 08:10:30 -0700, Tesla list <tesla-at-pupman-dot-com> wrote:

>Original poster: "Mccauley, Daniel H by way of Terry Fritz 
><teslalist-at-qwest-dot-net>" <daniel.h.mccauley-at-lmco-dot-com>
>
>
>Suggesting no less than 4 AWG for a 12/30 or 12/60 coil is absurd.  12 AWG
>stranded wire is perfectly acceptable for this
>application.  I use 14 AWG stranded HV wire on my 15/60 NST with excellent
>results.  Also, when initially running my 3.5kW
>portable tesla coil (using PT transformer), I used 12 AWG solid wire to
>connect all components on my primary circuit.
>I then changed to 6 AWG stranded wire (found in the local electric shop's
>garbage) for all my connections.  No noticeable
>difference was really seen in performance even at 3.5kW and my output is
>excellent given the input power.
>
>4 AWG or less may be the way to go for coils over 10kW, but for a small
>12/30 or 12/60 powered coil, thats just silly.
>
>The Captain
>
>
> >From the gap through the caps and the return should be no less than 4 AWG
>fine stranded welding cable to handle the large peak high frequency
>currents.  A local welding shop can supply this and also crimp on the copper
>lugs for you with their special crimping machine.  Keep these wires up in
>the air and not near any grounded parts.  If you have to go near a part then
>feed the cable through some clear plastic tubing.
>
>
> > One of my friends is making his first coil, and he wants to know what
>type
> > of wire to use for all the HV hookups (form NST to capacitor, capacitor
>to
> > primary, ect.)  He is probably going to use a 12/30 or 12/60 NST.  Any
> > recommendations are welcome.
>