Introduction: Transformerless Smd5730 Led Lamp/TUBE (Ac220-240)(uk-in)

EDIT: SINCE IMAGES AREN'T GETTING EMBEDDED; HERE'S A PDF LINK:

updated pdf for this instructable

NOTE: PLEASE REFER THE PDF AS IT CONTAINS IMPORTANT UPDATED INFORMATION REGARDING RESISTOR R3.
THE UPDATE IS NOT PUBLISHED ON INSTRUCTABLES PAGE

Well this is my first instructable.

As the title states, its an led lamp that employs a transformer-less driver circuit and utilizes the led smd5730.
THIS TUTORIAL WILL PRODUCE AN LED PANEL/TUBE HAVING HIGH WATTAGE(~45W-48W) AND HIGH LUMINOSITY(BRIGHTNESS)(~4800LUMENS-5200LUMENS)
About the smd5730:
v=2.8-3.4v
A=~150mA
LUX(brightness)=~50-55lumens

*NOTE: THIS IS FOR IN/UK MAINS(220-240V AC)

DO NOT TOUCH ANY PART OF THIS CIRCUIT WHILE IT IS CONNECTED TO AC MAINS

THIS IS A NON ISOLATED CIRCUIT AND CAN GIVE YOU A LETHAL SHOCK IF TOUCHED WHILE CONNECTED TO THE AC MAINS.

Step 1: PARTS

PARTS:

  1. SOLDERING IRON
  2. SOLDER
  3. SOLDER PASTE(OPTIONAL IF YOU CAN & ARE READY TO SOLDER ~96 SMD-LED USING A SOLDERING IRON AND SOLDER WIRE.)
  4. HOT AIR GUN(BLOWER)/OVEN(OPTIONAL)
  5. LED SMD5730 (AT LEAST 96) (AVAILABLE FOR CHEAP ON ALIEXPRESS)
  6. COPPER CLAD PCB ( 4PCS 6" x 1") & (1PC 3" x 1")
  7. MASKING/KAPTON TAPE (3MM WIDTH) can use any water resistant tape having width of 3mm. (COMMONLY USED ITEM IN NAIL ART)
  8. CHEAP NAIL ENAMEL (ANY COLOR :-D)
  9. FERRIC CHLORIDE/(ACETIC VINEGAR+HYDROGEN PEROXIDE)(HAVEN'T TRIED THE 2ND ONE YET)
  10. CAPACITOR 1 x 1.8uF400V NON-POLAR
  11. CAPACITOR 1 x 47uF160V ELECTROLYTIC
  12. RESISTOR 2 x 560K 0.5W/1W
  13. RESISTOR 1 x 24ohm 1W / 100ohm(OR NEAREST AVAILABLE VALUE)1W
  14. DIODE 4 x 1N4007
  15. MULTI-STRAND WIRES
  16. TWO WIRE CABLE WITH A 2-PIN PLUG ON ONE END( TO CONNECT TO MAINS)

Step 2: A: PCB PREPARATION(LED PANEL)


SCHEMATIC

YOU CAN MAKE AS MANY OF THESE AS YOU LIKE( WE'LL BE USING FOUR IN THIS CASE)

  1. TAKE A PIECE OF 6" x 1" COPPER CLAD
  2. TAPE THE PCB WITH KAPTON AS SHOWN.(START WITH VERTICAL COLUMNS AND THEN THE HORIZONTAL ONES.)
  3. CAREFULLY COAT THE EXPOSED COPPER WITH NAIL ENAMEL.
  4. NOW CAREFULLY PEEL OFF THE KAPTON AND SET ASIDE TO DRY.THIS WILL GIVE U A PCB WITH EXPOSED TRACKS READY TO BE ETCHED.
  5. NOW PREPARE A ETCHING SOLUTION OF YOUR CHOICE (I USE FERRIC CHLORIDE) AND DIP IN THE PCB TO BE ETCHED.
  6. ONCE ETCHED YOU WILL GET A PCB WITH ONLY ENAMEL COATED SECTIONS OF COPPER.
  7. NOW SCRUB OFF THE ENAMEL COATING WITH A MILD SOAP(ENAMEL IS A BIT TOUGH TO SCRUB SO USE A METAL SCRUB BUT USE IT GENTLY)
  8. NOW DRILL TWO HOLES (1-2mm). ONE AT THE TOP-LEFT CORNER AND THE OTHER AT THE BOTTOM RIGHT CORNER.

NOTE: LARGE SPACING IS TO ENSURE ADEQUATE HEAT DISSIPATION.

Step 3: B: PCB PREPARATION(LED DRIVER)

SCHEMATIC:

  1. REPEAT STEPS 2-7 OF {A: PCB PREPARATION(LED PANEL)} ON THE 3" x 1" COPPER CLAD BOARD USING THE BELOW DESIGN.

Step 4: C: COMPONENT MOUNTING AND SOLDERING(LED PANEL)

    1. TAKE EACH OF THE EARLIER PREPARED LED PANEL PCB AND APPLY VERY SMALL AMOUNTS OF SOLDER PASTE TO THE SIDE EDGES OF EACH OF THE COPPER SEGMENTS AS SHOWN BELOW.
    2. NOW PLACE LED CHIPS ON THE PCB AS SHOWN BELOW(NOTE THE POLARITY)

    Begin Soldering:

    1. using hot air gun
    2. using an oven
    3. using soldering iron(takes too long)

    WELL I DIDN'T HAVE 1 & 2, AND 3 WAS GONNA TAKE TOO LONG.

    SO HERE'S WHAT I DID:

    • TOOK A THICK BOTTOMED IRON VESSEL
    • PUT IN SOME PEBBLES TO FORM A LAYER AT THE BOTTOM
    • PUT IT ON THE GAS AT FULL FLAME FOR AROUND A MINUTE
    • TURNED THE FLAME LOW AND PLACED THE PCB'S ON THE PEBBLES.
    • PUT ON THE LID AND WATCHED WHILE I WAIT.(GLASS LID)
    • AS SOON AS THE PASTE BEGAN TO MELT I TURNED OFF THE FLAME.
    • ONE ALL LED WERE SOLDERED I PUT A LITTLE WATER ON THE PEBBLES AROUND THE PCB'S TO PREVENT OVERHEATING.
    • DONE. IN ~5MINS ALL 96 LED SOLDERED.

    EACH PANE HAS AN OUTPUT ~12 W,1200-1320 LUMENS

    NOTE:

    LARGE SPACING IS TO ENSURE ADEQUATE HEAT DISSIPATION.
    DUE TO HIGH OUTPUT CAPABILITY, SMD5730 TENDS TO DISSIPATE QUITE SOME HEAT.

    Step 5: D: COMPONENT MOUNTING AND SOLDERING(LED DRIVER)

    1. REFER TO THE BELOW IMAGE AND DRILL THE NECESSARY THROUGH HOLES IN THE EARLIER PREPARED PCB(LED DRIVER) FOR COMPONENT PLACEMENT AND SOLDERING.
    2. REFERRING TO ABOVE IMAGE INSERT THE THROUGH HOLE COMPONENTS AND SOLDER THEM IN PLACE.
    3. CUT OFF THE EXTRA LEADS OF THE COMPONENTS.
    4. SOLDER A 2-PIN MAINS CABLE TO THE PCB AS FOLLOWS: LIVE WIRE TO 'L' & NEUTRAL WIRE TO 'N'.
    5. ALSO SOLDER TWO MULTI STRAND WIRES (15" LENGTH EACH)(PREFERABLY RED & BLACK) TO THE '+' & '-' TERMINALS.

    Step 6: E: FINAL WIRING AND CONNECTIONS(LED PANEL+LED DRIVER)

    SOLDER THE FINAL CONNECTIONS AS SHOWN BELOW:

    GREEN WIRE LINKS THE PANELS

    YOU CAN ARRANGE THE PANELS IN WHATEVER MANNER YOU LIKE, JUST MAINTAIN THE CONNECTIONS AS ABOVE.

    THANKS FOR VIEWING THIS INSTRUCTABLE, HOPE IT WAS HELPFUL.

    NOTE: DUE TO HIGH OUTPUT CAPABILITY, SMD5730 TENDS TO DISSIPATE QUITE SOME HEAT.

    Comments

    author
    Mark Boulton (author)2016-09-09

    Thank you for a very detailed Ins.

    What is the DC output please?

    author
    JeremiahR4 (author)Mark Boulton2016-09-18

    ~150-160vdc
    I haven't really found any detailed info on this kind of supply and adjusting the voltage, but from my trials, it seems the output is related to the non-political cap.

    author
    JeremiahR4 (author)JeremiahR42016-09-18

    *polar

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