Electronic halogen transformer

Electronic Halogen Transformer is a substitute for traditional line transformer for

halogen bulbs. (It can of course be used also for non-halogen bulbs and other types of
resistive loads who do not mind RF current.) It works on the principle of switching
power supply. Unlike conventional switching power supply, it does not have
secondary rectifier, because the bulb does not need necessarily the DC voltage. It also
has no smoothing electrolyte after network bridge. 100Hz ripple because the bulb
does not matter. Just by reducing ef. voltage by about 30%. Due to the absence of
electrolyte the thermistor is not necessary and it also solves problems with power
factor (which is nearly 1). Circuit is designed as a halfbridge with MOSFETs and
driving circuit IR2153, which is equipped with a floating upper MOSFET driver and
own RC oscillator. Circuit operates at a frequency of about 50kHz. At the primary of
the pulse transformer, the effective voltage is approximately 107V, according to the
calculation:
Uef = (Uvst-2) . 0,5 . √(t-2.deadtime)/t
Where Uvst is input line voltage, deadtime in IR2153 is always 1,2us and t is a
period, in case of 50kHz it is 20us. After substituting:
U = (230-2) . 0,5 . √(20-2.1,2)/20 = 106,9V.
The voltage reduces by 2V at diode bridge, divides by 2 at the capacitive divider
made of capacitors 1u/250V and finally the effective value is reduced due to
deadtime.
Transformer Tr1 is a pulse transformer ona a ferrite core (EE or EI) and can be
obtained from computer switchnig power supplies such as AT or ATX. The core
should have a cross section of about 90 - 140mm2. Number of turns will probably
need to be adjusted depending on the bulb. When calculating the transformation rate,
we assume that at the primary is the effective Voltage 107V (in case of 230V line
input). Transformer from AT or ATX usually has 40 turns on primary. Primary is
divided into 2 parts, 20 turns each, one is under the secondary and one above it. This
method of winding is used to reduce magnetic leakage. When adjusting the
transformer you will need to unwind the upper half of the original primary and whole
secondary. Then replace the secondary, which will have approximately 2.4 to 3V per
turn. For 12V bulb i recommend 4 turns (can be about 4-5). Required voltage we
choose 11,5 V (for halogen bulbs the voltage is usualy selected with reserve).
Transformation ratio is calculated: 107V / 11.5 V = 9.304 . At the secondary we have
4t, so primary must have 9.304 . 4t = 37t . Because in the bottom half of the
remaining primary remains original 20z, we wind top layer 37t - 20t = 17t . If you
can find out what the original number of turns was on the secondary, it will be much
easier. If you find that some of the secondaries has 4 turns, then just simply unwind 3
turns from the top of the primary and you're done :). A similar procedure would be
even 24V bulb, except that the secondary we chose 8-10 turns.
With MOSFETs STP9NK50Z or IRF840 without heatsink this electronic
transformer can be used for output to about 80-100W. Similarly, it would be with
STP10NK60Z, STP11NK50Z or STP9NC60FP. For more power, use the heatsink
and / or more powerful MOSFETs, such as IRFP460, IRFP460LC, STP15NK50ZFP,
STW20NK50Z, STP25NM50N, STB25NM50N-1 or 2SK2837. They should have a
voltage Uds 500-650V. Leads to the bulb should not be too long, because there is RF
voltage and it could cause interference and voltage drop due to their inductance.
Output voltage can't be measured using multimeter.

Warning ! Almost all parts of the circuit are electrically connected to the
mains. In case of poor design of TR1, the mains voltage can be present at the
output.

The schematic diagram of electronic halogen transformer

Experimental board
Testing it with the bulb 24V 75W as a load
Different transformers from ATX PC supplies applicable for our purposes. This small
top left is not the best :). Secondary are arranged differently. Sometimes it is 2x 7t
and 2x 3t, sometimes merged into 4-3-3-4t. These windings provide voltages 5V and
12V. Some transformers have even secondaries directly for 3.3 V output, then they
have extra 2x 2t.
Tr1 output at the scope. On the left you can see the 100Hz component and 50kHz
component on the right..

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