Introduction
As a companion to the Lighting Controller presented in Project 62,
this strobe can be used for the strobe head unit. Although the circuit
presented is somewhat incomplete (in terms of all component values,
suggested xenon flash tubes, etc), the basic principles will allow you
to create a unit that will work well and reliably. One of the problems
is that I can't predict what xenon flash tubes you will be able to
obtain, so some guidelines are given for tube selection, and
determination of the amount of capacitance needed.
Note that the description given here is meant only as a guideline.
Xenon tubes can have widely differing characteristics, depending on
their intended usage, and some may not work properly in this
application. You must accept all responsibility for your actions if you
decide to build this strobe flash. ESP has taken all reasonable
precautions against publishing errors in this article, but it is still
only a guideline.
*** EXTREME HAZARD WARNING ***
This system connects directly to, and operates at, mains voltages or above. It is potentially lethal.
Always be aware that the entire strobe circuit is LIVE and take all the
necessary precautions during construction to ensure safe operation. Never
work on the circuit while it is plugged into the mains outlet, and
remember that capacitors can hold a charge for a long time. Make sure
that all caps are fully discharged before attempting to work on the
circuit. |
Since the circuit operates at greater than mains potential and is not
isolated by a transformer, it is extremely dangerous. The DC operating
potential is about 340V, and there is more than enough stored charge to
kill you many times over (although in my experience, once is usually
sufficient). This is not meant to be funny - this is truly serious
stuff. In addition, the circuitry usually is directly mains (line)
powered, with no isolation. Discharge all capacitors before working on
any flash system.
STROBE LIGHTS CAN CAUSE EPILEPTIC FITS AND DISORIENTATION
This can happen even with people who are not epileptic as such.
Many countries have laws governing the use of strobe lights in public
places, and effects such as nausea, vomiting and epilepsy have been
directly linked to the excessive use of strobes at the right (wrong?)
flash rate. Use of this or any such circuit is entirely at your own
risk.
More information on strobes, flashes and related topics is available at Sam's Strobe FAQ This is suggested reading for anyone wanting to know more about the subject.
The largest strobe I ever made used a 1000J tube, and I flashed it at
about 80J / flash. This was a very powerful strobe, and had to be
limited at higher frequencies (above 12Hz) to prevent the tube from
going into meltdown. The following is NOT a description of that unit.
Description
A xenon flash tube is a triggered gas discharge device. A voltage may
be impressed across the tube and it will not conduct until the xenon
gas is ionised by an external high voltage (typically 3 to 5kV). Once
triggered, the gas becomes a very low impedance, and discharges the
storage capacitors in about 1ms (this varies considerably, but this
figure is fine for basic calculations).
During discharge, the xenon gas emits broad spectrum white light,
which is at nearly the same colour temperature of daylight. For this
reason, xenon flash tubes are now the universal choice for photographic
flashes, since there is very little colour change when using normal
daylight film. None of this has anything to do with a strobe - I just
thought I'd include it for interest's sake.
Figure 1 shows the basic flash (strobe) circuit. The mains is
rectified directly (using a voltage doubler circuit for 120V supplies)
via a current limiting resistor, and the capacitor bank is connected
directly across the flash tube. The trigger circuit charges a small
capacitance via another limiting resistor. When the SCR is triggered,
the capacitor discharges through the primary of the trigger transformer,
and a high voltage pulse is developed which is applied to the trigger
electrode of the flash tube.
The xenon gas becomes conductive, and the capacitor bank is
discharged until the voltage is insufficient to maintain conduction in
the tube, which then extinguishes. The capacitors charge up again ready
for the next flash.
Download
Skema Xenon Strobe Light
Figure 1 - Basic Flash Unit
Keep the wires from the storage capacitor (C3) to the tube short
(less than 100mm total if possible). The trigger transformer must be as
close to the tube as you can get it - HV insulated cable could be used,
but the results are unpredictable.
How it Works
The mains (switched by SW1) is supplied to the rectifier via current
limiting resistor R1 (for flash tubes above 100 Joules, I suggest that
this resistor be at least 10W). Diodes D1-D4 should be rated at 1000V,
and at least 2.5A (i.e. do not use 1N4007 or similar). At a pinch, 3 x
1N4007 in parallel for each diode should work out ok. The terminals
marked SWA and SWN are 'Switched Active' and 'Switched Neutral'
respectively, and are for connection to the transformer supply for the
trigger circuit. The fuse (F1) is shown as 1A, which will be fine for
240V units up to about 200W - a slow blow fuse is suggested. Do not use a
fuse rated at more than a couple of amps over the maximum power
rating. Calculate the minimum fuse value thus ...
I = P / V where I is current, V is supply voltage and P is maximum power (see below)
The SCR can be almost any medium current device your local
electronics supplier has handy, as long as it is rated at a minimum of
400V. A C122E, SC141D or BT137-500 would all do nicely - says he boldly,
after looking in a local supplier's cattle dog (for the non-Australians
out there, this is common slang for a catalogue

).
The link shown between the junction of D2 and D4 must be inserted for
operation at 120V, and omitted for 240V operation. This link converts
the bridge into a full-wave voltage doubler, and this is needed at the
lower mains voltage to obtain the 340V DC needed by the flash tube.
Do not install the link for 240V operation!
All capacitors should be rated at a minimum of 350V (preferably
450V). The storage capacitor can be a standard electrolytic, but its
life will be limited due to the high discharge current. You might be
able to get hold of a few disposable cameras and nab the capacitors from
these (they probably won't last very long either, but they're cheap

).
To obtain flash tubes, try your local electronics suppliers, or for
larger (i.e. more powerful) tubes you might be better off dealing with a
photographic supplier. Remember to get the correct trigger transformer
to suit the tube, and make sure that the tube you select is designed for
operation at about 300V - some require a very much higher voltage and
will not work properly (if at all) at lower voltages.
Trigger Circuit
The triggering circuit uses R4 to charge C4 with a time constant of
about 10ms. When the SCR is fired (via opto isolator CR2), C4 is
discharged with the primary of TR1 in the discharge path. This generates
a high voltage at the secondary, triggering X1, the xenon flash tube.
No appreciable voltage is generated as the capacitor charges due to the
relatively slow charge rate of the capacitor.
Flash Intensity and Capacitance
It is very important that you select the storage capacitor (C3) and
its associated limiting resistor to suit the flash tube. The following
section shows how the capacitance and resistance may be calculated.
The flash intensity is measured in Joules (Watt / Seconds). The
energy storage (in Joules) of a capacitor is determined with the formula
...
Energy (Joules) = 1/2(CV²) where C is capacitance in Farads and V is voltage
A typical strobe might use a 200uF capacitor charged to 340V, which gives about 11 Joules per flash, thus ...
Energy = 1/2 (200 E-6 * 340²) = 1/2 (23.12) = 11.5 J
It is actually less than this, since the entire stored charge in the
capacitor is not used, but this errs on the side of caution. This is
important, since we don't want to melt the tube or subject it to any
more mechanical shock than it was designed for. Assume a maximum flash
rate of 15 f/s, each with a duration of 1ms (meaning effective power is
actually nearly 11,000W per flash!). A passable guideline is ...
Total Energy (Joules) = 0.5J per 10uF (at 340V)
We can now calculate the average dissipation of the tube ...
Dissipation (Watts) = f/s * E where f/s is flashes per second, E is energy in Joules
For our example, the tube will have a continuous dissipation of 172W ...
Dissipation (Watts) = 15 * 11.5 = 172.5W
This means that the tube should have an average power rating of 200W
(or 200 Joules), or its maximum rating will be exceeded. To be able to
flash at the maximum power at higher flash rates is not generally
necessary, so we can limit the power simply by increasing the value of
the input limiting resistor. This will increase the life of the tube,
and ensure that its safe working temperature is not exceeded. Where you
really do need to operate at maximum intensity at the higher rates,
consider using forced air cooling for the tube (and the limiting
resistor - this will get
HOT!)
Resistance
R3 limits the current into C3, the storage capacitor. The value of
the storage capacitor must be selected to suit the flash tube (see
above). The value of R3 is dependent on the maximum flash rate and the
value of C3. At a typical value of 100 ohms it will need to be rated at
about 100W for normal use. With a 220uF cap this has a charge time
constant of 22ms, allowing up to a 20Hz flash rate with only a slightly
reduced voltage, but at this frequency the resistor will be dissipating
close to 275W!! That was not a misprint - even at a 10Hz flash rate
dissipation is over 100W.
Calculate the resistor using the following guidelines ....
R = 0.02 / C where R is the resistance and C is the capacitance (0.02 is 20ms)
P = (1200 * f/s) / R where f/s is the maximum flash rate per second
The above equations are approximate only, but will provide a passably
accurate result. Needless to say I take no responsibility if your flash
tube melts and the resistors explode.
 | Warning
- The current limiting resistor (R3) may need to be increased from the
calculated value to ensure that the xenon tube extinguishes after it is
flashed. All tubes have a 'holding' current, and if the resistor can
supply more than this minimum current, the arc will not quench. If the
arc is maintained, R3 will get very hot indeed, as will the tube.
Sustained operation with a continuous arc will destroy one or both
components. |
An Example
You can get a 100 Joule tube, and want to flash at 15Hz maximum. At
the tube rating, this will allow a maximum of 100/15 = 6.6 Joules per
flash (say 6.5). This requires a capacitance of 130uF based on the
guideline above. The resistance should be 150 Ohms at 120W, although you
will almost certainly get away with a 100W rating.
Trigger Circuit
The strobe circuit is not much use by itself. A fully isolated
trigger is also required, and the safety aspect cannot be
over-emphasised. Using an opto-isolated triac trigger is the safest
possible method, but great care is needed to ensure that the intrinsic
isolation afforded by the opto is not compromised - do not run any
tracks between the pins, and ensure that a minimum clearance / creepage
distance of 6mm is maintained between the mains connected wiring and the
"safe" terminals.
To allow the strobe to function as a standalone unit, an internal
oscillator can be used. A 555 timer is ideal for this, and can be
disabled to allow remote (10V DC) trigger control. Figure 2 shows a
suitable oscillator and the connection for the MOC3020 opto-isolator for
the remote trigger. The oscillator is very similar to that used in the
Lighting Controller, and has a frequency range from 1.25 f/s up to 19
f/s, with a positive going pulse duration of about 1.8ms. This circuit
will need a small transformer power supply (as shown) for simplicity and
safety.
This also allows you to work on the oscillator circuit (after the
mains is disconnected!). The circuit also shows the remote connection
(EXT), which can be used to connect the strobe to the lighting panel.
Any suitable connector may be used for this (e.g. a phone jack, Canon
XLR, DIN, etc). Use of a dual 7.5 V winding is suggested, and no
regulator is required. This will give about 10V DC to power the
oscillator. Capacitors in this circuit need only be rated at between 15V
and 25V (i.e. whatever you can get cheaply.
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Skema Xenon Strobe Light
Figure 2 - Remote and Internal Isolated Trigger Circuit
Note that the arrangement shown for the oscillator is critical in one
respect. The output pulse (which triggers the opto coupler and hence
the SCR) must be of very short duration. With the values shown, it is
about 20us, and this should normally be quite alright. You can reduce
the on time by reducing the value of R9 (1k as shown). The minimum
suggested value is 100 ohms, giving a pulse duration of 2us. The pulse
must be gone by the time the trigger transformer current falls to zero,
otherwise the MOC3020 and SCR may/will not be able to turn off.
It is critically important that the entire oscillator circuit
(including the pot used to control the internal oscillator) is properly
insulated to prevent accidental contact with the mains. The pot, remote
input connector, the bodies of all or any switch and all exposed
metalwork (including the strobe reflector) must be connected to safety
earth via a 3-core mains cable.
This latter point cannot be stressed enough!
The strobe circuit is dangerous, and the internal wiring can kill you on
contact. Given the opportunity it WILL kill you on contact! Every
safety precaution must be taken to ensure that you do not cause injury
or death to yourself or anyone else.