Hands-on with hobby-grade arc generator modules

These minuscule modules provide a safe and accessible way to dive into fundamentals for arc simulation and testing circuit behavior. The post Hands-on with hobby-grade arc generator modules appeared first on EDN.

Electronics Aug 20, 2025 0 3 Add to Reading List

Hands-on with hobby-grade arc generator modules

Arc generator modules may be small in scale, but they offer big opportunities for hands-on exploration in electronics. Whether you are experimenting with arc simulation, testing circuit behavior under fault conditions, or simply curious about high-voltage phenomena, these minuscule modules provide a safe and accessible way to dive into the fundamentals.

This blog will present hands-on tips and tricks for working with hobby-grade arc generator modules and circuits—ideal for curious minds and budding engineers eager to explore high-voltage experimentation.

There are several methods for generating electric arcs. However, this post will focus on how to achieve extra-high voltage levels using simple electronic circuits. The spotlight is on a widely available, budget-friendly arc generator module kit designed for DIY enthusiasts. It’s an accessible way to dive into high-voltage experimentation without breaking the bank.

Take a look at the kit below, along with its key technical specs to help you understand what it offers.

Input voltage: 3.7 V to 4.2 V DC
Input current: < 2 A
Output voltage: ~15 kV
Output current: ≤ 0.4 A
Ignition distance (high voltage bipolar): ≤ 0.5 cm

Figure 1 This compact arc generator kit delivers around 15-kV output using only a handful of components. Source: Author

This is arguably one of the elementary and most accessible kits for electronics enthusiasts looking to explore high-voltage applications. The module requires minimal setup skills, with no circuit-level adjustments needed. While the power output is not exceptionally high, even a minor mishap can result in serious electrical burns. That said, with proper safety precautions in place, the system can produce stunningly high-frequency arcs.

Now, let’s take a look at the schematic diagram to understand how the circuit works.

Figure 2 The schematic diagram demonstrates how the kit produces high voltage through a minimal circuit design. Source: Author

Examining its internal electronics reveals a single-transistor oscillator at the heart of the circuit. This simple yet effective configuration allows high-voltage generation from standard battery cells.

Functionally, it acts as a step-up (booster) transformer system, where a feedback loop controls the switching of a power transistor. The secret to high-voltage output lies in the transformer’s winding setup. It uses two primary coils—main and feedback—alongside a secondary winding that can produce voltages soaring into the kilovolt range.

The diode’s most critical function in this oscillator circuit is to block the reverse voltage pulse generated by the transformer’s collapsing magnetic field. This action is essential for two reasons; it prevents damage to the transistor and ensures a clean transition to the “off” state.

Next is another compact high-voltage boost module (sometimes labelled as XKT203-33) capable of generating up to 30 kV. Specifically engineered for pest control applications, it finds use in devices aimed at eliminating mosquitoes, cockroaches, and other small insects. Despite its impressive output, the module operates efficiently with minimal power input, making it ideal for battery-powered or low-power systems.

The image below presents the aforesaid module alongside its internal schematic for reference. A closer look at the available schematic highlights the use of proprietary components, with a Delon voltage doubler circuit strategically placed at the output stage to deliver the required 30 kV.

Figure 3 The 30-kV module achieves high-voltage generation through an elegantly minimal design. Source: Author

Interestingly, a closer look at two seemingly popular kV generator modules shows that even humble jellybean components can handle the task. Still, integrating custom parts might elevate performance and efficiency.

But before jumping to conclusions, consider this alternative design idea for building your own kV generator module, an approach many have explored with intriguing results. Let’s take a quick look.

Figure 4 The blueprint shows how to generate high-voltage output using an automotive ignition coil. Source: Author

This approach simply utilizes a universal automotive ignition coil to produce high-voltage output, as depicted in the self-explanatory diagram above.

At its core, an ignition coil consists of three main components: a primary winding, a secondary winding, and a laminated iron core. Secondary winding contains significantly more turns of wire than the primary, creating a turn ratio that directly influences the voltage increase. There is a fairly typical range for the ignition coil turns ratio, usually between possibly 50:1 to 200:1, with 100:1 probably being the most common.

Just to add, in an inductive ignition system, the primary winding is typically energized with 12 V or 24 V. When this current is suddenly interrupted, a high-voltage EMF is induced in the secondary winding—often reaching 20 kV to 40 kV—more than enough to jump across a spark gap.

To break it down further, a single switching action by a transistor (BJT/IGBT/MOSFET) initiates the ignition process by allowing current to flow through the ignition coil’s primary winding. The current charges the primary coil, storing energy in its magnetic field. When the transistor turns off and interrupts the current, the magnetic field begins to collapse.

In response, the coil resists the sudden change, causing a rapid rise in voltage across the secondary winding, ultimately generating the high-voltage spark needed for ignition. It’s enough to ionize the air to create a spark.

Back to the subject matter, when driving the ignition coil through either an IGBT or a MOSFET, try experimenting with appropriate square wave pulses. Start with low frequencies around 150 to 350 Hz and duty cycles between 25% and 45% (just to get a feel for the response).

Heads up! Touching the high voltage from the ignition coil will definitely sting. It won’t kill you, but it will make you regret it.

That wraps up this post. I have got plenty more practical tips and insights lined up, so expect fresh content soon. This is just one piece of a much larger puzzle.

Finally, please note that this article is intended purely for informational and educational purposes. It does not promote, endorse, or commercially affiliate with any product, brand, or service mentioned. No sponsorships, no hidden agendas—just straight-up knowledge for curious minds.

T. K. Hareendran is a self-taught electronics enthusiast with a strong passion for innovative circuit design and hands-on technology. He develops both experimental and practical electronic projects, documenting and sharing his work to support fellow tinkerers and learners. Beyond the workbench, he dedicates time to technical writing and hardware evaluations to contribute meaningfully to the maker community.