580exii posibile probleme
TRANSCRIPT
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PreliminaryResearchReportonCanon580EXIIFlashFailuresByJimClark&TimAmbrose,ResearchandDevelopment
LPADesignBackground:SincethelaunchofitsPocketWizardMiniTT1andFlexTT5modelsinearly2009,LPADesign(A.K.A.
PocketWizard)hasbeenreceivingperiodiccallsandreportsfromcustomerswhoareusingtheirCanon
580EXIIflasheswiththePocketWizardControlTLradiosandexpressingconcernthatperhapstheirflash
mayhavebeendamagedbyusingaPocketWizardradiotriggerwithit.
Asofthetimeofthisreport(Jan,2011),thereareabout120140PocketWizardcustomerswhohave
reportedhavingoneormore580EXIIflashesdamagedwithcommonsymptomsoverthepast18+
months.
Ifthefailuremodewasrelatedtoourproduct,thiswouldworkouttolessthan0.5%ofour
MiniTT1/FlexTT5radio
units
which
were
connected
to
aflash
that
failed
and
less
than
1%
of
the
580EX
II
flashesthatwereconnectedweredamaged.
LPADesignhasconductedaseriousindepthinvestigationforseveralmonthsaswecontinuetocollect
dataandevidenceofthespecificsofthefailuremode. Inadditionwehavejuststartedtheoutside
researchassistanceofanalyticalchemistryprofessorGiuseppePetrucciattheUniversityofVermont.
Research:Thesymptomofthefailureisthatthe580EXIIwillnolongeroutputcontrolledamountsoflight. Itwill
onlyoutputfullpowerdumps. Thisfullpowerdumpwillhappenevenonapreflash,thereforeleaving
nostoredenergywithinthecapacitorleftforamainflashexposure.
ThetestingquicklyrevealedthatanIGBT(transistor)withintheflashisdamaged. Thispartismadeby
Renesas(part#RJP4301).
TheIGBTisusedtoturnofftheflowofcurrentthroughtheflashtubewhenthedesiredamountoflight
hasbeenreached. ThisIGBTisalsousedtocontrol(modulate)thebrightnessofthelightwheninHSS
(HighSpeedSync)withthehelpofafiberopticcablefeedingalightsensorwithinthemainbody.
AlthoughLPADesignhasbeenabletoidentifythesymptomoftheproblem,LPADesignhasnotbeen
abletotracethecauseoftheproblemtoourPocketWizardproductsandwehavenoknowledgeofthe
incidenceratesofthisproblemarisingindependentlywithoutPocketWizard,i.e.somenumberof580EX
IIflasheslikelyfailwithoutPocketWizardControlTLradiosinteractingwiththem.Wereceivedreports
ofthis
IGBT
failure
in
all
spectrums
of
use.
It
spans
multiple
different
Canon
camera
models,
below
XSyncandaboveinHSS(moreofteninHSS),TTLormanualmodesandonanyversionoffirmwarethat
thePocketWizardMiniTT1andFlexTT5havehadinpublicrelease. Evenbrandnewflashescouldfail.
Wehaveruledoutheatbuildupasacausesinceseveralhavefailedwithinthefirstdozenshotsafter
beingpulledoutofthecamerabag. Thisisallbasedonverbaldescriptionsfromcustomers.
ItalsohasfailedasmanytimeswithaPocketWizardAC5RFSoftShieldasithasfailedwithoutusingthe
AC5. SothereappearstobenochangeinoccurrencewhenusingtheAC5orAC7.
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Wepurch
otherco
MostsigOnecom
replacem
Theseco
discharge
Repaired
periods
Soitbeca
Eventuall
andsoot
place.
Replacem
failwitho
Belowar
asedmanyo
moneleme
ificantobseontheme
ent.
dcommont
fromoneor
unitsthatha
henuseddir
mecleartha
wefoundt
builduparou
entofthefl
rwithouta
exampleso
fthefailedfl
tsbetween
vations:asthatALLf
hemewasth
moreendso
eonlytheI
ectlyonaCa
ttheIGBTw
attheflash
ndthe
ends
shheadssol
ocketWizard
the580EXII
ashesfrome
heunitstha
ailedflashu
atALLfailed
ftheflashtu
BTreplaced
oncamera
snttheonly
ead(tube/r
fthe
flash
tu
edthefailur
radio.
flashheads
ndusersso
failed.
itshavehad
unitshavevi
betotheme
willfrequen
ithoutaPo
failurecom
flector)was
be.Sparks
a
eproblems
hatwereca
ecouldtake
theIGBTda
iblesignsof
talreflector.
lyfailagain
ketWizardr
onentwithi
alsobadand
ndelectrical
ndtheflash
singIGBTfai
themapart
agedandn
electricalarc
ithinrelativ
dioinvolved
thesystem.
showedvisi
arcingwere
scouldnol
lurestorepe
ndstudyth
eded
ing/electric
elyshorttim
.
lesignsofa
pparentlyt
ngerbemad
at
l
sh
king
eto
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Figure1:
oxidizatio
Figure2:
possible
Figure3:
housingi
Flashtubee
nofmetalre
Flashtubee
xidizationof
Inmoresev
nearthetu
dshowingb
flectornear
dwithtrigg
metalreflec
recasesthe
e.
lacksootbe
ubberends
rringshowi
ornearrubb
flashtubegl
indtubeon
al.
gblacksoot
erendseal.
ssischarred
rubbermoun
behindtube
inaringaro
t. Alsoshow
onrubberm
undwheret
spossible
ount. Alsos
emetalrefl
ows
ctor
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Figure4:
Figure5:
Anotherexa
xampleofd
mpleofsoot
amagefrom
andelectrica
eflectortot
ldamageat
iggerringaf
ndofflasht
erelectrical
ube.
arcing
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ElectricalWecaptu
Forrefer
theIGBT
Belowis
Figure6:
AnalysisofFredfailuree
nce,IGBTcu
mitterlead.
nexampleo
Inthemiddl
ailureModeentsaswell
rrentissens
fafailurewe
ofaHighSp
:asgoodwor
dbymeasur
havecaptur
eedSyncpul
ingunitsto
ingvoltagea
d
setrain,the
erifythepro
crossa0.01
IGBTfailsan
blemusinga
hm1%resis
shortsColle
noscilloscop
torinlinewi
ctortoEmitt
e.
th
er.
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Figure7:
sparkjum
Closeupvie
pedtother
ofIGBTele
flectorandt
ctricalsignal
henintothe
. Notethat
collectoroft
theIGBTgat
heIGBT.
wasturnin offwhenth
e
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MakingtInmanyc
frontedg
infeedba
Weare
s
thenegat
Figure8:
Note:To
eflashmorases(butno
eofthehous
cktothesen
eingthat
thi
iveflashtub
Shortcurren
traceisthe
pronetofaall)weares
ingorithas
sor.
sfiber
optic
cathodeov
tspikesonI
controllineg
ilure:eeingthatth
kink/pinch
ablecan
ma
rtothetrig
BTemitterc
oingtothet
efiberoptic
inthefiberl
ethe
flash
erringofth
ausedbyarci
iggercoildri
cablehaseit
inewhichmi
oresensitiv
tube.
ingtoreflect
vercircuit.
erpulledba
ghtbecausin
to
having
a
orortrigger
cksomefro
gsomeredu
sparkarc
fro
ing.
the
ction
m
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Figure9:
Notethat
circuits.(
Intheory
fireatth
thatcaus
Tofurthe
withthet
aselimin
SameasFig
thearcpuls
appensafte
thisfigure9
momentth
dthearcing
rconfirmtha
riggerringa
tionofthec
re8(zoome
tothetrigg
rarcnotbef
showsthatt
tiscircleda
.
tthisisinfac
dsawasign
ircledpulseo
in)Shortcu
rringinthis
rewhichind
eflashesele
ove. Thisal
tarcingtoth
ificantreduc
nthedriver
rrentspikes
casepropag
icatesthatt
ctricalcontr
oindicatest
etriggerrin
ionincurren
ircuitline(t
nIGBTemit
atesbackwar
econtrolsi
lcircuitsdid
hatitsnota
,weplaced
tringingon
ptrace).
tercausedb
dsthrought
naldidnotc
notcauseth
CPUfirmwar
47Kohmre
hecircledev
arcing.
etriggercoi
usethearci
etriggercoil
edriveneve
sistorinseri
entaboveas
l
g.)
to
nt
s
well
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Figure10
the580E
Notethat
Thisflash
: Typicaltrac
XIIonagoo
thecurrent
hasagoodp
eshowinga
workingfla
rofiledoes
ositioningof
reflash(wh
hthatdoes
othaveany
thefiberopt
ileusingaPo
otdamageI
spikesinthe
icandnosig
cketWizard
GBTs.
middleofth
sofkinksor
iniTT1/Fle
eIGBTONpe
bendsinthe
xTT5)totrig
riods.
fiber.
er
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FlashTubAnothers
extendin
Onetheo
metalrefl
Manually
shortene
Wehave
Figure11
theflash
eAlignmentignificantob
intotherefl
ryisthatthis
ectorthe
sh
movingthef
didincreas
oundthatw
: NOTE:the
ube.
:servationist
ectoraremo
tubetrigger
rtestthereb
lashtubesh
therateat
ecannotget
ealedglassc
atflashesth
repronetof
ringposition
enabling
ar
wnonbotto
hicharcing
theIGBTtof
oversarere
athavethe
ailagain.
ing(topima
cingto
happ
mimagetot
ccurred. (H
ailifthefron
ovedfromt
lashtubeali
e)makesth
nmuch
easi
herightsuch
oweveritdid
tglasscover
heheadass
nedwithth
sparkgapdi
er.
thatthespa
notcauseth
isnotinplac
mbliesfore
triggerring
stancestoth
rkgapwas
eIGBTtofai
e.
sierviewing
e
l)
of
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OzonefrOzoneis
(source
Inaseale
electrical
shorterdi
Ozoneca
generate
separate
HighSpe
discharge
Intheory
Thehead
thathold
LPADesi
damaget
Tofurthe
didcause
Sointhe
Withthes
(Model#
Pictureso
mUVandEleneratedby
ikipedia)
dcontainer(
breakdown
stances.
begenerat
inthepres
byaglasst
dSyncmod
inaheadth
thisgenerat
assemblyon
theflashtub
ntheorizedt
heIGBT.
rtestthisth
IGBTstofail.
rythebest
etheoriesin
106M)
The
fthetestset
ectricalfieldusingUVlig
suchasseale
oltageofair
dinthepre
nceofrapid
beishowco
(HSS)ofthe
thasamisal
shigherand
the580EXII
einplace. T
hatozonebu
ory,werem
Withthegl
aytohelpp
mind,LPAD
model106
upareonth
s:t,highvolta
dflashhead)
suchthatarc
enceofUVf
repeatedele
mmercial/i
580EXIIgen
ignedtubea
higherlevels
asaglassco
eozonehas
ildupinthe
vedtheglas
sscoverre
eventozone
signrented
readsOzon
followingp
es(1020KV
ozonecanb
ing(electrica
romflashtu
ctricaldischa
dustrialozo
eratesaloto
longwithim
ofozoneth
veroverthe
nowhereto
flashheadis
sfrontcover
oved,weca
buildupist
anOzoneGa
as
low
as
1
ge(Figs12,
)oranelectr
uilduptoda
ldischarge)
es. Howeve
rge. Pulsed
egenerator
frepeatingp
roperfeedb
tcantesca
frontandar
go.
causingthe
fromaflash
tgettheIG
ventilateth
sAnalyzerfr
ppb(10
par
13).
icspark(cor
ngerouslevel
anhappen
ritsfarmor
ighvoltage
swork.
ulsesofelec
ackfromthe
etheheada
ubberizedse
ailureevent
headassem
BTtofail.
eheadasse
mOzoneSo
sper
billion)
na).
sandreduce
ucheasiera
likelytobe
lectricalcha
tricalarc/
fiberopticc
ssembly.
alonbothen
thatultimat
lythattypic
bly.
lutions.
.
the
t
rge
ble.
ds
ely
lly
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Figure12
Ozonega
Figure13
:This580EXI
scouldbesa
: OzoneSolu
Ihadthegla
mpledviath
tionsGasan
scoverrem
frontofthe
lyzermodel
vedfromth
housingthro
106M
einternalfla
ughtheplas
hheadasse
ticFresnelle
blysothat
s.
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OzoneAOurfirstt
sealsthe
theflash
Weconfir
700mlpe
holeinth
Nextwe
theflash
(HSSmod
TheOzon
upofozo
readinga
Figure14
nalysisoftestwastoc
lashtubehe
iaanOCE3
medthat
Oz
rminute. In
efarbackof
ovedthe58
ofirespecifi
e). ACanon
eanalyzerh
nevs.time.
teraveragin
:
e580EXIIFnfirmweco
adassembly
cabletofire
onewas
star
ordertoena
theflashhea
0EXIIflasht
cally80pops
CPE4batter
savoltageo
heOzonea
gforeach10
lash:lddetectOz
insidethefla
t1secondi
ingto
be
de
leairtobe
dnearthepi
beoffthec
at1.5secon
packhadto
utputportth
alyzertakes
secondperi
one.Todot
shhead. We
tervalsfora
ected.The
rawnfromt
vot/hinge.
amerarunni
dintervalsat
beusedtoe
atwasconn
samplesofa
d.
isweremov
thensetthe
bout40seco
zoneanalyz
eflashhead
gviaitsow
maximump
nablefiring
ctedtoano
irevery10s
edtheglass
camerathat
nds.
ersamples
ai
,wehadto
opticaltrig
owerat1/80
hisfast.
scilloscopet
condsando
overplatet
wasconnec
rat
arate
of
rillatinyair
erinput. W
00thshutter
showtheb
tputsanew
at
edto
vent
set
peed
ild
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Ascanbe
triggerin
isusedas
efficient
Shownb
Figure15
controls
possible
Sincethe
energyth
flashhea
Ourtheo
IIiswhat
Tofurthe
(seeFigur
seeninthe
hasamuch
thetrigger.
SStimingco
low(fig15)
: Showingfu
stem. Ther
henusingt
lightoutput
atwas
delive
washalfas
eticalconclu
causesmost
rconfirmthi
e16onfollo
copetraces
asterbuildu
Thislowerra
ntrolsystem
rethetwoli
llpowerHSS
dtracesho
ePocketWiz
henusingt
redby
the
fl
muchwhen
sionisthatt
oftheozone
,wealsofire
wingpage)
howninFig
ofOzonein
teofozone
usedbythe
htpulseout
lightoutput
stheshorte
ardFlexTT5
ePocketWi
shtube
was
singthePoc
erapidfirin
buildupand
dalongseri
re14,theC
sidetheflas
uildupislike
ocketWizar
putsasmeas
rom580EXII
firingtime
sthetriggeri
ardradiowa
thesame
bu
ketWizardFl
ofthe10KV
notthebrigh
sofnonHS
nonnatives
headthan
lyrelatedto
ControlTLs
uredbyaTh
whenfired
utbrighter
ingsystem.
sbrighterbu
tthe
resultin
exTT5.
triggercircu
tnessofthe
fullpowerli
ystemusing
henthePoc
themuchm
stem.
orLabsDET3
iaCanonsn
aximumout
thalfthedu
gozone
buil
itrepeatedly
lightoutput.
ghtpulsesfo
heirownop
ketWizardFl
reenergy
6Alightsens
ativeoptical
putthatis
ation,theto
upinside
th
insidethe5
rcompariso
ical
xTT5
or.
tal
0EX
.
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Figure16
buildup
brightnes
Testmod
Canonsn
theIGBT
systemm
However
ringarou
lightemit
fullpowe
HSSpulse
Wearep
muchthe
triggerri
research
: Whenfirin
asnearlyzer
sofCanons
einFlexTT5
ativepulsed
ail.Wehad
ighthaveinc
thetestsdid
dtheflasht
tedbythefl
rnonHSSfla
has
only
asi
eparingtor
ozonewillc
gtotherefl
rinthefield
theflashusi
o. However
nativeoptica
irmware5.2
urationand
thoughtthat
reasedthec
nothavetha
ubewerelik
shsincealo
shpulseisfa
nglefiring
of
ntestsatth
angetheele
ctormetalh
ofozoneand
ngonlyafull
henwetrie
llytriggered
2(neverap
rightnessof
perhapsthe
ancesofaf
toutcome.
lythemore
gerduratio
brighteran
thetrigger
ri
University
ctricalbreak
ousing. Che
willbeassis
powerdum
dtoduplicat
SS(1/8000t
blicrelease)
theiroptical
brighterligh
ilureevent.
efoundtha
significantca
HSSpulseh
yetgenerat
ngon
the
fla
fVermont(
ownofairs
istryprofes
tingustofur
innonHSS
etheexactsh)theozone
wastotest
ETTLsystem
outputcapa
tthe10KVe
useoftheoz
asmanymor
esnearlyzer
shtube
at
th
VM)inthec
uchthatane
sorGiusepp
therourrese
(belowXSyn
amepulsed
uildupwas
urtheoryth
mightbeles
bilityofthe
lectricalpuls
oneformatio
efiringsoft
oozone. Thi
ebeginning
omingweek
lectricalspar
Petrucciof
archandthe
c)theozone
rationand
uchgreater
atduplicatin
pronetoha
ocketWizar
sfromthet
nandnotth
etriggerrin
sfullpower
fthe
light
o
tofindout
kwilljumpf
VMisa
ories.
.
g
ving
igger
eUV
. A
on
tput.
ow
om
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PreflashBoost:PocketWizardintroducedbackinAprilof2009afirmwarefeaturethatenablesabrighterpreflashtobe
selectedbytheuser. Thedefaultwastohavethebrighterpreflashenabled.
InSeptemberof2010aspartofourongoingresearchintothisIGBTfailureproblemin580EXIIflashes,
wetried
atest
where
we
changed
the
default
of
the
preflash
to
be
disabled.
After5monthsofcollectingdatasincedefaultingtopreflashboostOFF,wehavefoundtherewasno
changeinreportedfailureratesince. Infact,thepreflashboostwasconfirmedtobedisabledinmostof
ourrecentreports.
OurcurrentconclusionsofaristhatthePreflashBoostfeatureisnotrelatedtothe580EXIIsIGBT
failure.
AnimportantthingtonoteisthatCanonspreflashisashortformofHSS. Itisjusta400uslongHSS
pulse.So
apreflash
can
generate
aquantity
of
the
high
voltage
pulses
similar
to
the
HSS
main
flash
mode. SoevenifauserisshootingatorbelowXSyncwithnonHSSexposures,thepreflashmaystill
begeneratingozone.
Furthertestswillbeneededtodetermineifpreflashesalonecouldgenerateenoughozonetocausethe
failureevenifwedisableanymainexposurelightoutput.
Othertesting:Weconductedmanyexperimentsaroundheat,static,andotherfactors.
UsinganESDgenerator,wedischarged11,00020,000voltsintomanyplacesona580EXIIbothalone
andmountedonaFlexTT5withandwithouttheAC5. Noissueswerenoted. The580EXIIandFlexTT5
arebothCEmarkedproductswhichmeanstheymustbeabletohandleacertainlevelofESDtoqualify
forsaleinEuropeancountries.
Heattestsoverlongperiods,torturetestsofhundredsoftriggersinvariousconfigurations,and
electricalshorttestsontheshoepinswereconducted.
NoneofthesetestsyieldedanyrepeatablefailuremodesorconclusivedataaroundIGBTfailure.
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Asparto
designed.
people.
thefailur
occurred
TheCano
Figure17
reflector
theoretic
Therubb
theresearc
Thenewest
hilewehav
wasactuall
rightafterini
n430EXIIFl
:The
430EX
I
hanusedin
llyforextra
rendseal&
T
effortswea
430EXIIflas
ehadasingl
relatedtoa
tialpurchase
shHeadAss
Ihas
3times
the580EXII.
ventingand
mountused
he430EXIId
lsowantedt
fromCano
failurerepo
nIGBTorifi
,itmayhave
embly:
moreair
gap
Additionally
learancefro
onthe580E
esnotdam
reviewafe
isonethati
rt,theflash
hadanyrel
beenaman
spacebetwe
acutoutwa
melectrical
IIiselimina
geIGBTs.
otherflash
sworkingex
asnotsent
tiontoozon
ufacturingde
enthe
trigg
saddeddire
rcing.
edonthe4
esandlook
tremelywell
tousandwe
e. Sincethis
fect.
rring
wire
a
tlybelowth
0EXII.
thowthey
andreliable
couldnotco
onefailure
dthe
metal
flashtube
ere
or
nfirm
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Figure18
flashuse
The430E
Ithas
bec
improve
models.
Theolder
thatthef
togetacc
opticalfe
problems
: The430EX
.
IIwasdesi
omeLPA
De
entofthed
Canon580Elashtubeish
identallyalig
edbacksens
.
IIdoesnotu
nedandstar
ignstheory
signonthes
flashdoes
eldinpositio
nedinthew
rinthe580E
easealede
tedshipping
hatdesign
p
eelementst
aveahead
ndirectlyby
ongposition
Xisverydiff
dcaptohol
beforePocke
roblemswith
preventfail
esignthatis
aprintedcir
byhandass
rentandma
theflashtu
tWizardCon
the
580EX
II
uresofasim
somewhatsi
uitboardan
mblyworke
ybelesssus
beinpositio
trolTLprodu
were
realize
ilarnatureo
milartothe
dhasnowa
rsatafactor
ceptibletoh
likethe580
tsexisted.
dand
neede
futureflash
80EXII,exc
fortheflash
. Also,the
ndassembl
EXII
d
pt
tube
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Conclusions:(ThePerfectStorm)Itappearsthatsomecombinationofelementscomestogethertocreatetheriskandincreased
probabilityofanIGBTfailurewithinthe580EXII.
Sealedflashtubeassembly(internalzoomcarriageassembly) Misalignmentoftheflashtubewithinthereflectorsuchthatarcingismoreprobable Reducedopticalfeedbackviathefiberopticsensecableintheflashhead Dryerairwhereozonecanbegeneratedmoreeasily ElectricaldischargethroughthereflectoratamomentwhentheIGBTisturnedoff
Byreviewingheavilyused430EXIIflashes(Canonsnewest)andseeingnosignsatallofarcingwithinthe
reflectororontheflashtube,wehavetheorizedthatpossible580EXIIdesignissueswerecorrectedby
identifyingthesameproblemsdiscussedinthisdocumentandchangingthedesigntominimizethe
potentialfordamageonthenewer430EXIIflash.
PocketWizardmarketsandencouragespeopletogetoutandusehighspeedsync(HSS). Wemakeit
easierthaneverbeforeforlargernumbersofflashestobeusedinthesemodessinceoursystemdoes
nothavelimitationsinbrightsunlightconditionscomparedtoopticallytriggeredCanonflashes.
WebelievethatHSSflashmodeismorepronetohavefailurebutisnotarequirementoffailureto
happen. SomecombinationofTTLPreflashandorHSSmainflashseemstoberequired.
OurControlTLfirmwarecontrolsthebrightnessinfora580EXIIinHSSmodetonomorethanwhatis
permittedbytheCanon40D,50D,7DseriescameraswhichhavetheshortestHSSpulsedurations(when
flashisontopofthecamera)andthereforehavethehighestnativepermittedpowerrequestlevels.
Thesecamerashavetheshortestbladetraveltimesfortheirshutters.
OurPreflashboostmodedoesnotincreasethechancesofafailuresinceequalnumbersofpeoplehave
hadafailurewithitdisabledashavehaditenabled. OurAC5andAC7shieldingproductswerenoteven
usedinabout50%ofthereportedfailuresanddidnotevenexistwhenfirstreportsoffailuresstarted.
SowhilePocketWizardproductsdonotappeartocausethefailure,throughaggressivemarketingof
remoteHSSfeaturesofCanonsflasheswemaybeaccidentallycontributingtotherateinwhichfailures
happen.
Researchwillcontinueintryingtofindsolutions(ifany)toreducingtheriskoffailuresonthe580EXII.