SHRIRAM SPARK

THINK DIFFERENT

POWER SAVING LED LAMP FROM SCRAP

Are you confused on how to give a fresh new life to a broken CFL bulb, read on you’ll get the answer to this question here.

In this post i’m sharing a LED lamp circuit which can be mounted in a broken CFL bulb and can be  converted into a LED based power saving light. This is just a LED lamp circuit that can be operated from the mains voltage. A string of five LED is driven using a capacitive transformerless power supply. In the circuit 0.47uF/400V Polyester capacitor C1 reduces the mains voltage. R3 is a bleeder resistor which drains the stored charge from C1 when the AC input is switched OFF. Resistors R1 and R2 limits the inrush of current when the circuit is switched ON. Diodes D1 to D4 forms a bridge rectifier that rectifies the reduced AC voltage and C2 acts as a filter capacitor. Finally Zener diode D5 provides regulation and the LEDs are driven.

Here are some of the pictures of the LED lamp.

led

DSC01770

Components used :

  • 120 Ohm 1/2 Watt resistors [2]
  • 470k Ohm 1/4 Watt resistor [1]
  • 0.47uF, 400 V Polyster capacitor
  • IN4007 Diodes [4]
  • 47uF, 25V electrolytic capacitor
  • 16-18V 1W Zener diode [1]
  • Hi power LED’s. [ Here i have used 1W circular LED’s ]

DSC01784

The circuit board arrangement which i have built.

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After assembling the Circuit board in the CFL bulb casing.

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The LED arrangement on a laminate sheet.

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The completely assembled, finished LED light.

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My smart LED lamp in action.

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Another close view of the illuminating LED’s.

Procedure

1. Carefully remove the broken glass pieces of the CFL bulb.

2. Open the assembly carefully

3. Remove electronics and discard

4. Assemble the circuit in dot matrix PC or on a 1mm laminate sheet.

5. Cut a round laminate sheet with (scissor)

6. Mark the position of the 5 round holes on the sheet

7. Drill the holes to suit the LEDs to flush fit in the six holes

8. Use a dab of adhesive to keep the LED assembly in position

9. Close the assembly

10. Ensure the internal wiring does not touch each other

11. Now test on 230Volt AC Your nice compact table lamp / puja room lamp / passage lamp is ready for use.

For any queries related to this post, ask your questions in the comments section below.

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  17. Mr Shriram can u help me build an led emergency light of 20 to 25 high bright leds fed by a 6v,5Ah battery and can be operated manually and that will glow for about 6-7 hrs

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  21. There are only 5 LED used. Can I use more, say for example 10?

    • If you are using 1W LED’s as I have used then you can use only 5-7 LED’s at the max, but you can use 10 normal 5mm LED’s in this circuit.

  22. hai super project. am golng to try it now

  23. Does this circuit provides full illumination? Do LEDs require heat sink?

  24. Hi, shriram, the power saving lamp of five 1w LED is very clear. Colud you show me how to modify the circuit if number of LED increase to 9 or 10 LED s. what is the calculation for the out put current and the Voltage for R1,R2 and C1 and its resistor.
    thanks for your kind concideration.

  25. Hi,
    I made the 2 nos. 5w LED bulb circuit as suggested by you. It worked well for some time, then one of the bulb went off. When checked I found the one of the Resistor 120 ohm was not showing continuity. I replaced with a new one. It start workning but few few hours again it wnet off. I checked the resistor, but it was ok. What is wrong now. Pl advice how to check the circuit.The other one is still working.

    • There should be a misconnection in the internal circuit, so check the circuit output and check whether you are getting sufficient voltage drop to light up all the LED’s, Since you told the other one is working fine, compare the output voltages of both and verify.
      Contact me back if you haven’t rectified the mistake.

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  29. This circuit can only supply a maximum current of roughly 27mA. A 1W white LED is rated at 300mA in full capacity. Simply say, the 1W LED which is many many times more expensive than a regular 5mm 20mA LED is a waste in this circuit.

    It’s more economical to use 5 regular 20mA LED in series with a 50-100 ohm resistor than the five 1W LED suggested. The light intensity generated by both should be comparable.

    • Yes you are right, we can settle with a 5mm 20mA LED itself, in fact my first prototype contains 5 of the normal [5mm,20mA] LED’s, and the brightness is definitely comparable. But I just went on with the 1W LED since I had them in my parts bin.

  30. Does this circuit provides full
    illumination? Do LEDs require heat
    sink?
     Reply

  31. Hi I wanted to know If you can guide making a LED lamp using the Electronic circuit of the CFL, In this case we are just using the Lamp holder, rest every thing is new.

  32. Sir i have made the circuit at home as you directed in your post. i tested on domestic power supply i think its 220v AC; as soon as i switched on the 470k ohm 1/4 watt resistor blown away but the led illuminated till the resister completely caught fire. Please tell me what is the reason for this.

    • Be very careful while handling circuits working with the mains, I think the capacitor should have malfunctioned. I recommend you to check the circuit thoroughly and then proceed to switch ON the mains, the problem most likely would be improper connection or capacitor malfunction. Again BE REALLY CAUTIOUS WHILE HANDLING CIRCUITS OPERATING WITH MAINS VOLTAGE

  33. Hi Sriram. The light Ive made working good. But the amount of light is not up to the mark. Could you put a circuit for 10 nos of 1 watt Led.

  34. can i change the input polarity ? or i have to maintain the ac positive negative as shown on pics

    • The Input AC supply doesn’t have polarity here, you can hook it up anyway you want…CAUTION:Please be careful while handling the AC supply voltages.

  35. i am not getting 0.47uf 400v capacitor in open market,plz guide me to any online sale website

    • Ask for a polyster capacitor with the nearest values, anything almost close like 0.5uF or a little lesser than mentioned would do fine…I think you will have to search for the capacitor online then, I have not much experience purchasing components online. If you are from Bangalore, Chennai, Hyderabad, Delhi, Mumbai then you will be getting it for sure. Contact me back if you still don’t get the component

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