Author Topic: Portable dual ZVS flybacks in series for HV bug zapper  (Read 164 times)

Offline sfazio

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Portable dual ZVS flybacks in series for HV bug zapper
« on: July 21, 2020, 08:15:07 AM »


This is my latest experiment, a bug zapper you hold kind of like a chain saw using a reacher/grabber with pointed electrodes mounted on the front. It uses two identical transformers (guess how many TVs I had to take apart before I found a match) with their primaries in parallel and their outputs in series.

Precautions were taken to isolate each transformer since they are mounted so closely together. The base has two layers, a Lexan first layer and an aluminum base with relief holes to prevent arcing. The electrodes are aluminum knitting needles and are replaceable. To prevent overheating, heat sinks were pressed around each electrode and act as an arc breaker to protect the plastic grabber arms. The position of the electrodes can be changed via the grabber hardware, switching from horizontal to vertical. The electrodes are brought together by the grabber trigger, and have an adjustable minimum distance via a screw that limits the trigger's travel, that way they never touch.

Four 26650 high drain 5000mAh lithium batteries were used for the power supply. They produce 16V in total with a very low output impedance - that voltage doesn't sag even under very heavy loads. They are protected by a 30A 4s battery management system (which sometimes trips if you draw big arcs!). The thumb trigger switch activates a 40A relay and starts the 12V regulator to drive the FET gates. The FETs I used are IRFP250s, the gates have fast schottky rectifier diodes in a TO-220 package. The capacitor is a big 12uF motor run capacitor. The primaries of the transformers are simply wired in parallel, no intermediate transformer trickery. I tried that and couldn't achieve good results, I also used like half of my magnet wire. Plus, I just didn't have space, it was all too compact. Anyway, the transformer in parallel deal works great, especially since the transformers are matched and they both have the same load on the secondary, so no hiccups driving them in parallel. Both are wired using 6+6 turns in the same direction

Some insights from the oscilloscope: when the trigger switch turns on, the gates are quickly brought up and the circuit begins to oscillate faintly before the 20-30mS delay of the relay making contact. The operating frequency is 12kHz and pretty audible until the arc is drawn and the oscillator bumps up to about 20kHz for the xfmrs to transmit more power. The standby current is about 3A and rockets to about 28-30A on a full arc. Sometimes the bms will kick off, indicating that the 30A mark was passed. Shorter arcs draw less current. The capacitor has a lot of current sloshing through it, enough to melt the wires it was salvaged with, so I put beefier wires on its spade terminals.

Everything is portable, so in my video I mounted a go pro for some POV action and we take it out for a spin, roasting/vaporizing a hot dog, and trying to light up my lab with a pickle.

Thanks,
Hope I added something of value to the forum

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Portable dual ZVS flybacks in series for HV bug zapper
« on: July 21, 2020, 08:15:07 AM »

 


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