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[Ideas For Design]
Use Throwaway Camera Parts For A High-Voltage Flash Unit

Elio Mazzocca  |   ED Online ID #10083  |   April 14, 2005


Parts of a throwaway camera's flash unit can be salvaged to build a 280-V capacitor charger for a flash unit that uses six or nine batteries (see the figure). Camera shops usually will give them away for free. The flash capacitor, output rectifier, and transformer are easily de-soldered for use in the new circuit.

Many circuits are available for such flash units. But the transformers are hard to get or can only be obtained in large quantities, and they work at just one voltage. Because the units in disposable cameras are designed for blocking oscillators with a 1.5-V supply, they have very low primary inductance, and peak primary current can easily exceed 2 A. But because the switching frequency will be very high, they can't be used in a blocking oscillator at high voltage without an expensive high-speed, low-saturation transistor or MOSFET. The switching transistor in the flash units can't be used with a 6-V battery because they only have a 25-V breakdown rating.

In the circuit shown, a low-cost Darlington transistor is driven by a 5-ms on-time astable oscillator formed with an NE555 timer, preventing transformer saturation. This reduces peak currents, and the 1.6-kHz frequency reduces transistor overheating. Low peak currents also will prolong rechargeable battery lifetimes.

Capacitor voltage regulation is achieved with a 280-V "zener diode" made with two reverse-biased 1N914 diodes operating in voltage breakdown. During zener operation, the NE555 is stopped by transistor Q2 being driven into saturation by the zener current. Charging will resume once some charge has leaked from output capacitor C1.

These 100-V diodes will typically have a 140-V breakdown, but some have been measured at 170 V. The total capacitor voltage should not exceed the 300-V rating of the flash capacitor used. A lower voltage also will prolong lamp and capacitor lifetimes.

Resistor R5 and capacitor C4 must be included to limit the current peak that's produced when the diodes break down. Otherwise, transistor Q2 will be destroyed. The astable oscillator directly drives the switching transistor, with turn-off voltage drive provided by the transformer secondary.

The maximum reverse voltage is limited by the forward voltage of D1. It also provides a charging path for the charging current. No heatsinking for the switching transistor is necessary because the peak and average currents are low. An LED indicates when the capacitor voltage is reached. With a 45-second charging time, average current is approximately 40 mA.


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    Reader Comments

    Tim, There are 2 parts that look like transformers. One has 3 legs and a wire out of the top that attaches to the metal reflector by the strobe; the other has 4 legs that are connected to the diode, the light, a transistor... and the fourth is connected indirectly to the transistor too. I admit that i know little about electrical circuitry, but i really want to know how to do this. I've built the stun guns before, but this is more complicated to me. Which Transformer do i desolder (Little or Big = 3 leg+wire or 4 leg). Which legs do i solder together, and where in the world do i reconnect the transformer?

    Thanks I appreciate any help I can get, Mark

    P.S.The Capacitor is a 330v120uF Nichicon. What would happen if i use this instead of the mylar 250 Cap? I don't want to do this wrong and BLOW UP a capacitor in my face.

    Mark -October 21, 2006

    Interesting article. Too bad the schematic is unusable.

    penguinpete -October 06, 2006

    i dont think you can put up any pics or stuff like that on this site.

    tim -October 06, 2006

    i dont think you can put up any pics or stuff like that on this site.

    tim -October 06, 2006

    hi, got your message parker what do you mean an article ? this flash really, really flashes and fast so all those other ideas on making a flash out of camera flash circuit boards can be thrown away cause this one works. and can also make a stungun circuit too. its the same exact circuit as a real stungun only its miniature sized.

    tim -October 06, 2006

    Tim, you should make an article. (Hope you return to the site to see this mesage)

    And Make one with which the figure is in working order. I'm getting a black image as well.

    parker -October 04, 2006   (Article Rating: )

    theres a more simple way to make a really fast strobe light out of camera guts.all you have to do is replace the cap with a mylar 250 volt cap , use a 9 volt battery, and use the same trigger tranformer only take the 2 legs desolder then put both legs together and solder to the transformer side of the output diode.and watch how fast this animal flashes.

    tim -October 01, 2006

    i think it nice is presentation,but what happened to the figures...

    messay -July 24, 2006

    it seems nice but i can't find a full idea from it.

    mesujohn -July 24, 2006

    send 1500w inveter circuit thanks sanjay malik

    sanjay malik -January 16, 2006

    Can't read the figure.

    Anonymous -December 27, 2005   (Article Rating: )

    I guess I need to mark this a 5 out of 5, since I used the same method to shut off a similar circuit. I chose to use a zener rather than rely on reverse breakdown of 1n914, but if they don't degrade or shift greatly with time/temp then it should work fine and be a lot less expensive.

    I can suss out the circuit from the description. However, for everyone else you need to correct the schematic as it is munged up.

    I suggest the gentle reader use the timing given to calculate necessary values. 5mS on time, 1.6KHz frequency. You can use one of the online Java calculators if you don't want to get your fingers dirty on a calculator or pencil and paper. Output of the 555 drives Q1, an NPN transistor, primary of coil from V+ to the collector of that transistor.

    Rectified output of the secondary goes to a smoothing capacitor, and to two series connected 1n914 diodes, connected so reverse biased. Additional series resistor, then connected to Q2 base (NPN). Q2 base to ground is a small capacitor. Emitter of Q2 to ground. Collector of Q2 is connected to pin 4 of 555, and a pull-up resistor from there to V+.

    I left out a bunch of stuff: current limit resistor from 555 pin 3 to Q1 base, misc etc. But maybe reading the principles of operation twice will help you suss out the circuit.

    Steve Greenfield -November 10, 2005   (Article Rating: )

    This seems like an interesting project..Shame i cant view the image..Any chance of the image being updated? P L E A S E...

    Anonymous -November 09, 2005   (Article Rating: )

    Would be more useful if figure1 showed more than components on black background

    NewZealand -October 24, 2005   (Article Rating: )

    can not see anything else than components on black background;useless at the moment...

    Anonymous -September 14, 2005

    Figure is useless-just a black area with a few component names visible. No circuit shown. These faults ruin an otherwise interesting article showing how to use scrap parts to make something useful

    Pedr williams -September 10, 2005

    Picture still bad. Can't read it all.

    J Eckrich -August 31, 2005

    What's wrong with the figure? I just get a black background with a few white lines. Please can someone fix this?

    Anonymous -August 04, 2005

    excellent idea to drive re-cycling solutions

    Morris Novello -May 22, 2005   (Article Rating: )

    good article

    Rich Shurgalla -April 23, 2005   (Article Rating: )

    Interesting use for other wise trash parts. I love the recycling ;-)

    Anonymous -April 22, 2005   (Article Rating: )

    Great stuff !!!

    Al Shurgalla -April 21, 2005   (Article Rating: )

    xszzxzxz

    umut -April 15, 2005   (Article Rating: )

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