Instructables

Step 4: PCB Boost Converter 500V

Picture of PCB Boost Converter 500V
Basic Regulated Boost Converter 500V PCB.jpg
If you have the resources I strongly suggest the you make this Printed circuit Board Boost converter instead of the protoboard one.

This circuit only takes up 1 5/8" x 1 1/4" x 1" and can operate from 8.4V to 31.2V and output maximum of 500V safely.

I strongly recommend using at least a 12V Battery.

This Version's Size can also be reduced to 1 5/8" x 1 1/4" x 3/8" if the Inductor is placed away from your circuit, as it is in most coilguns for convince. Shown in Picture Below.

DANGER HIGH VOLTAGE
This device can put out lethal voltages and the capacitors you charge can store lethal charges for hours, Wear Electrician gloves while operating and take all safety precautions

Specifications:
Project Cost:
- $20 + Shipping Mouser
- $5 + Shipping Coilcraft PCV-2-394-05L (Follow the link and type in the part number to buy)
->=$15 + Shipping MPJA
- Average Total Cost with Shipping
-- <$50--

Input Voltage: 8.4V to 31.2V
Output Voltage Range: 100V to 500V
Output Power:

- TEST 1-12V Input 48W max +-20% Charged 290J Capacitor Bank in 6s
- TEST 2 - 12V Input 45W max +-20% Charged 1160J Capacitor Bank in 26s
- 24V Input TBD

Output Power Measured with 1-2 12V 34Ah Lead Acid Batteries for a Virtually Constant Voltage Source
Each test was done 5 times, the best of which is shown.

The Major limitation of how much power can be drawn from your batteries is the Battery Packs ESR

---For Best results used high current rated batteries or Batteries meant for Power RC Devices---NiCd are the best(with the exception of Li-poly)
For The Following Batteries an Estimated Maximum Power can be drawn
ESR = Equivalent Series Resistance = Internal Resistance

Alkaline can be used, but I strongly recommend Rechargeable high current rated batteries.
Lower Voltages May be used, but expect a Lower Power Output.

NiCD/NiMH
12V AAA ESR = 350-400mOhm 28-30W
12V AA ESR = 150-300mOhm 31-34W
24V AAA ESR = 700-800mOhm 60-80W
24V AA ESR = 300-600mOhm 75-85W

Warning-Drawing too much current from your batteries may reduce there capacity, life, and cause your batteries to overheat, monitor your battery Temperature when testing.
 
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SuperFungus4 years ago
I mean this in the most constructive way possible and it's not really a criticism because I'm sure you were working with less than ideal tools.  However, I have to say that the soldering job on that PCB, while no doubt functional, is atrocious.  It may seem stupid but it is much easier to track down and rework problems on neatly done boards. Are pins or traces shorted on that board? I assume not because it works but really I can't tell by looking at it. Anyways just some unsolicited but hard won advice from someone who has put together a board sloppily and regretted it later.  Great project thanks for the post!
rwilsford07 (author)  SuperFungus4 years ago
I agree