1000W xenon arc lamp built into DIY searchlight housing--- make money online

in this video I'm going to show what I

built that thousand watt xenon arc lamp

into I built it into a sort of

searchlight housing and this is the

power supply for the unit I took a

hundred amp arc welder which is

basically a constant current supply and

kind of reworked it just in minor ways

and built it into this box and I added

ampere and voltmeter gauges to the front

so I can keep track of what's going on

and the only control on this power

supply as a single knob which controls

the current setting the open circuit

voltage is about 80 volts 70 or 80 volts

and when it's running the arc lamp the

voltage is about 20 volts so 50 amps at

20 volts is the lamps rating the arc

welder was originally a Forney either

available on eBay it was about $100 110

or twenty dollars and I've never

actually used it for welding so I can't

tell you how good it is for that there's

the front of it there Arctic inverter

and it's yeah so it's an inverter a

constant current supply it's a little

cramped in there but you can kind of see

the basic idea under this this is just a

duct to move some air through some heat

sinks that are under here there's a

bunch of fats or switching transistors

or something and it pulses power through

this large transformer and then from the

transformer goes through a inductor to

smooth out the pulses coming through the

transformer and then I also added that

large bank of capacitors there that when

I first took this thing up to the arc

lamp kind of as is the arc the lamp

visibly flickered and it wasn't a

flicker at 60 Hertz it was like a a wild

arc like it was it had a lot of high

frequency in it which is exactly what it

had the switching frequencies 20

kilohertz or something like that so the

cats actually worked very well and I

just put a whole Bank them together so

that's a huge amount of energy storage

there I also changed the inductor this

this was the original inductor

and it has about eight or nine turns on

this toroid ferrite coil and I added a

few turns but I think this part may

actually have to be changed because this

wire is insulated and it gets pretty hot

when it's got 50 amps going through it

for a while so I may have to change that

or add a fan or something the box itself

is just a rack mount computer case or

something that I got at the surplus

store and the meters are off eBay

they're old analog meters but they're

actually new production from China just

one cooling fan at the moment and I used

the original welding cable actually

these cables came from a battery battery

box for a car like a jump starter type

battery and the actual jacks and the

cables are welding cables so here's the

actual lamp housing I'll show you inside

and you can see the arc lamp in a minute

the first time I talked about this

starter circuit so starting in our clamp

is actually fairly difficult you need a

a very high power low voltage supply 50

amps at 20 volts but then you also need

a starting a pulse of about twenty to

thirty kilovolts and you have to build

this such that the two power supplies

don't interact with each other and

that's achieved through this starting

circuit so the reason the starting

circuit is placed right on the side of

the lamp housing is that that thirty

kilovolts is kind of hard to contain so

the shorter the distance of wire between

the starting circuit and lamp the better

so in this case I just mounted it right

on the side and the heart of the

starting circuit is this automotive

ignition coil which produces you know 10

kilovolts maybe or something like that

and it stores up energy in this high

voltage capacitor and then fires through

this spark gap and after after firing

through the spark cap there's a pulse

that goes through this toroidal

transformer that I wound myself so

there's about four or five turns of

high-voltage wire

from the ignition coil circuit and then

there's about eight turns of high

current wire coming from the power

supply to the arc lamp so this does a

couple things one it steps up the

voltage even higher because there's you

know two to one or three to one turns

ratio on that transformer and it also

electrically isolates the ignition coil

circuit from the high power lamp drive

circuit the ignition coil is driven by a

standard household dimmer I just cracked

open the box and this is what it looks

like inside it's your basic Triax

circuit and it fires the ignition coil

straight off of 120 volts AC and it uses

this motor starting cap as a current

Lipnick device this works way better

than any 12 volt supply I've built for

ignition coils and has the benefit that

you don't need a 12 volt transformer or

something in there so that's cool this

capacitor is to try to prevent the high

voltage thirty kilovolts starting pulse

from going back down the line to the

high current supply I already blew up

one of those welders maybe not because

of this reason I had some other problems

with that circuit but this capacitor

goes across the line so that a spike

coming back from the starting circuit

hopefully won't make it in in its thirty

kilovolts apply so here's a view inside

the lamp housing I've got it set up with

the anode in the back I'm not exactly

sure if there's a convention or not but

I did it that way because the focal

length of that parabolic reflector

worked out better if the animoves in the

back so that's how I have it set up and

I made this phenolic plastic insulator

there so that both sides of the lamp are

insulated from the metal housing I

thought that would be important because

the thirty kilovolts starting pulse

might be an issue if one side of the

lamp was connected directly to the

housing and it also took pains to

make sure that there is no clothes metal

even though it looks kind of clothes is

actually a fair bit of space

okay so let's fire this thing up first

step when I turn on there's a cooling

fan mounted on the back of the housing

so I'm going to start that up and you

may not be able to hear me so I'm just

going to turn it off now

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