Help upgrading CFL circuit? Want to drive cfl's up to 25w.


I have built this circuit, it can drive cfl's up to 15w, how do i modify it so that it can drive cfl's up to 25w? 
I am using D313 for his project as the D882 didn't gave me the results i needed. Using 12v battery.

Here is the original instructable link

(This question is optional)
Do u think the transformer i made for this circuit can be used for the famous Jeanna's light (Joule's Thief). If yes then how it would connect on the circuit? I will be making two or three more transformers like this. Do u think it needs modifications for its working like number of turns for the primary, secondary and feedback, different wire gauge?

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Clarkdale44 (author) 3 years ago

Just to let you know that it is not my circuit, i just followed through the Instructable of the person who made this. Its link is above.

Anyway you said i should use capacitor in series with cfl, let me know what is the value of capacitor i should use?

The cap is only needed if you design a quite powerful transformer that is able to feed a let's say 20W flouro but want to use a small 8W lamp on it.

Basically just to llimit the available current so the lamp won't get too hot.

If you use quite thin wire on the secondary you have a good chance the current won't go too high anyway - simply test your setup with a big lamp and if it works but a small lamp on the same setup get's hot you add tha cap.

Start with something in the 470nF range and if the lamp refuses to work take a higher value until it works. If the lamp still heats up use a lower value like 220nF for example.

In a perfectly adjusted setup the input power used should only be slightly higher than the rating for the lamp.

So if you use a 11W lamp but your circuit draws close to 3A when running it uses to much.

Smae story if it is the other way around, if a 11W lamp only draws 500mA it won't reach full brigtness or might even only glow at the ends of the tube.

Clarkdale44 (author)  Downunder35m3 years ago

Thanks for your reply, i appreciate.

I did and experiment yesterday and added more turns on the secondary about 100 more making total 350. It ran at first without giving any more power or brightness in the cfl then transformer started giving strange noises and sparks, turned it off and since then its not running anymore. When i connect the power all that is happening is the transistor is getting extremely hot within 5 seconds.

I suspect you shortend the transformer or blew the transistor.

You might want to consider a ZVS circuit with two little mosfets instead.

If your primary was not properly insulated and the voltage too high for it there would have been arcs between the windings, maybe the sound you heard.

Clarkdale44 (author)  Downunder35m3 years ago

Yeah, you suspected it right. I will take this ZVS circuit into consideration.

I am also interested in this Jeanna's Light (Joule Thief) Not sure if i can use this transformer for the same purpose, i mean the windings are the same, all i have to do is connect the windings accordingly , i am gonna try using 2N3055. The idea is that this one seems more energy efficient.

Can you tell me what should be the primary and secondary gauge margins? I mean if i were to use 30 awg wire for the primary what gauge of wire i should use for the secondary?

Can't really give you recommendations on the wire :(

I take what I have available at hand but for HV only the thinnest wire possible.

Clarkdale44 (author)  Downunder35m3 years ago


Well i need your advise again...

Like you already know the issue was my transformer was shorted, So yesterday i winded it again and just as i was about to make it permanent on pcb, i thought i should check it one last time and then this happened. Just as i turned it on my transformer started giving weird noises and CFL went down from bright to low and then completely off at the same time my transistor was damn hot. I have no idea why it happened, i mean i have already tested it before for 30 minutes and it was running fine and everything was cool, i have big heatsink installed on the transistor. Still when it was working during that 30 minutes, heatsink was safe to touch, but now it might even melt solder.

I tried different transistor, capacitor, resistor but the transistor is still getting hot.

Just to let to know, when i was packing it all up, i saw one of the high voltage wire was touching the heatsink of the transistor, do u think this has anything to do with the issue?

Also i used D313 transistor, also tried with TIP41C

If you feed back HV to the transistor it really won't like it.
The weird noises, if the transformer is not getting hot is either vibrations of the wires due to low frequency or arcing between the layers of the HV wiring due to poor insulation.
If you magnet wire is not coated properly or the coating is damaged (salvadged wire from trnasformers or similar) you componsate by sealing the transformer with resin or wax.

A little vacuum pump and suitable container is advised as ohterwise you will trap air and in the air pockets still get arcs.

Clarkdale44 (author)  Downunder35m3 years ago

Well, i rewinded the transformer, the third attempt, and it is working again. I guess in the end transformer was shorted due to HV secondary was touching transistor heatsink. This time i made sure that i there is proper insulation between every layer not just secondary. I am gonna put everything back together in pcb today. Breadboard testing was successful and cfl was able to light up about 60% bright. Gonna need a bigger heatsink though. Also it can drive cfl's up to 20W.

My next project would be making Jeanna's Light. My last two attempt of making it was a complete failure and mess. I tried rewinding toroid again and again but it didn't even blink. Then i found out the toroid i was using was a iron power made, and cfl's requires ferrite made toroid. Well i don't have toroid of such material but i am gonna use transformer. I also have ferrite core from a flyback transformer, do u think i can use that for this project?

In most power supplies you can find suitable round cores as the input filters.

Flyback works too, depends on the size you have in mind.

For your CLF project you might want to consider a ZVS circuit to reduce the wasted power on the transistor.

Although the overheating could be due to a missing filter too, have you tried a RC filter parallel to the primiry of the coil?

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