Diy Wire Zapper

[johan]

For those DIY enthusiasts that want to build a simple NR-R Wire Welder / Zapper, here's a schematic and some info:



B.O.M (all components available from any electronic store):

R1 - 100 Ohm 5W Resistor
R2 - 1k Ohm 1/4W Resistor
R3 - 3k3 1/4W Resistor
C1 & C2 - 4700uF 50V Electrolytic Capacitor (if you use 48V, get 63V rated Capacitors
LED1 - Any standard 3mm or 5mm LED
Q1 - MCR106 or C106B Thyristor (see pic insert on schematic for pin-outs)
SW1 - Any SPDT (Single Pole Double Throw) Switch
P1 & P2 - Input connection from any 24V or 48V DC PSU (power supply)
P3 & P4 - Output to wires to be welded (use Croc-clips with insulation sheath)

Use:

Place SW1 in CHARGE position until LED1 lights up bright
Connect NR & R wires each on a seperate Croc-clip (doesn't matter which one connects to P3 or P4)
Overlap NR wire with R wire about 1mm and let them physically touch each other
Flick SW1 over to ZAP
You will hear a Zap noise and even observe a spark - that's absolutely normal
Your NR-R wires should now be securely welded together
Repeat for the other side R-NR

Note:

You can increase the values of C1 & C2 if you want a "deeper" penetration of weld.
Any questions, let me know.

 

[thekeeperza]

Awesome @johanct!!

Do you get a board of some sort that this can be easily built on?

 

[johan]

Awesome @johanct!!

Do you get a board of some sort that this can be easily built on?

No, but I can do a quick layout if you want to DIY pcb (apologies for slow response but my f%$# 4M Telkom line is worse than a dial-up for a couple of days now).

 

[thekeeperza]

No, but I can do a quick layout if you want to DIY pcb (apologies for slow response but my f%$# 4M Telkom line is worse than a dial-up for a couple of days now).

That would be cool. I can get hold of a PCB etching kit

 

[johan]

That would be cool. I can get hold of a PCB etching kit

I will do - you don't need pcb etching kit, just a plastic container (I will post a DIY pcb etching) as soon as my dsl line is fixed.

 

[thekeeperza]

Thanks @johanct

 

[johan]

@thekeeperza , here's a screen shot of pcb layout (pcb size: 57 x 49mm) seen from component side. With such a simple single layer layout, its faster to just rout the copper cladding than to etch it. Let me know if you want a 1:1 scale pdf of tracks only.

 

[CraftyZA]

The resistor and led is a nice way to allow for a slow drain if you do not use the charge. I did the same in my audio psu. Nasty effect fhen you short the cap output.

 

[thekeeperza]

@johanct that is great. Please send me the scale pdf.

 

[johan]

@thekeeperza refer attached (scale 1:1). Note: Double check C1 & C2 pin pitch and diameter, manufacturers use different sizes. In case yours differ from size on layout, let me know and I will change accordingly.

 

[thekeeperza]

Awesome thanks @johanct.

 

[thekeeperza]

@johanct wrt the power supply what should I be looking for? I have seen 12VDC and 24VDC ranging from 0.3A to 8A.
So in essence, confused I am.

 

[johan]

Don't need anything bigger than 5W - go for 24Vmin up to 48Vmax - if you don't come right give shout.

 

[thekeeperza]

Great thanks @johanct will see what I can find

Sent from my SM-N900 using Tapatalk

 

[thekeeperza]

Got some components today. Forgot the invoice at work so the cost is vague. I think about R250ish but I will confirm tomorrow. I must measure the caps to check if they will fit that PCB layout @johan.
I will try to get a PCB ready asap.

 

[shabbar]

What is this wire zapper ?

 

[devdev]

It lets rapid coil fiends weld their own Resistance/Non-Resistance wire for coiling @shabbar

 

[thekeeperza]

PCB and print-n-peel acquired. Hopefully tomorrow I can get a board etched.

 

[devdev]

This is looking very exciting @thekeeperza. It's gonna be quite a technical project which looks really interesting. Just don't think etching PCB's is within my range of skills.

How big is the finished product going to be approximately?

 

[thekeeperza]

pcb size: 57 x 49mm

I am going to work on a enclosure for this over the weekend so not to sure on the final size but won't be much bigger than the pcb. Height I am guessing around 60mm as the caps are 40mm tall.

 

[ShaneW]

Nice project...

 

[devdev]

Yeah this looks sick and I am very interested to see how the finished product looks @thekeeperza
Still don't really have a real need for NR/R wires just yet, but so interested in having a rig which zaps things

 

[thekeeperza]

Could always use it on colleagues or the like - but you didn't hear that from me

 

[Gazzacpt]

Could always use it on colleagues or the like - but you didn't hear that from me

We use to play catch with charged caps when I was in manufacturing and development. The programmers never learned their lesson.

Sent from my GT-I9190 using Tapatalk

 

[johan]

On varsity I had a 5,6uF/400V cap on my desk shaped in the form of a wired donkey - usually charged up straight from the mains 220V socket. Everybody will ask what it is and I will explain its a donkey, but be careful it bites, don't touch. Off coarse everybody will touch it. Caused many a good laugh . According to my room mate (I wasn't there) a certain one-time only visitor literally wets his pants when the cap discharged in his hands.