Converting a halogen spotlight into an LED one

I had an old 500 W halogen lamp lying in my garage. I used it to illuminate the lower part of the car from the inspection hole. A very convenient good lantern with a handle and a protective grille. But here's the problem: the halogen lamp burned out. Of course, such lamps are still on sale today, but I decided to update the lamp to make it more economical, brighter and more durable.
Converting a halogen spotlight into an LED one

Not very long ago, LED matrices with built-in drivers directly on the body of the matrix began to appear on the Chinese market. This driver is designed for 220 V AC voltage. In a nutshell, it’s simple Light-emitting diode, which is powered directly from mains voltage without additional boxes and accessories.

And the main advantage is the low price - look at Ali Express.

The purchase cost less than 150 rubles. I took a 50 W LED matrix and a voltage of 220 V, which is exactly what I needed. The brightness of this LED quite comparable to a 500 W halogen lamp.
Converting a halogen spotlight into an LED one

Converting a lamp to LED


I unscrewed the screw securing the glass and took out the glass with the rubber gasket. Another advantage of this lamp is that it is sealed.
And I started thinking about how to replace the lamp with Light-emitting diode. The idea came naturally.
Converting a halogen spotlight into an LED one

I unscrew the screw securing the reflector. I take it off, it is made of thin aluminum, it bends very easily.
Converting a halogen spotlight into an LED one

Then I unscrew the halogen lamp mounting block. I disconnect the mains voltage supply wires from the block.
Converting a halogen spotlight into an LED one

Converting a halogen spotlight into an LED one

I will strengthen Light-emitting diode on the back wall - it fits perfectly, and the body of the spotlight will act as a radiator (it is made of duralumin), since Light-emitting diode cannot be turned on without some kind of heat sink. Although it has built-in overheating protection, we will not test it.
Converting a halogen spotlight into an LED one

I will not make a cutout in the reflector, but will screw everything together with it. To do this, it is necessary that the reflector sits tightly on the housing of the back wall of the lamp. Therefore, we shape the aluminum reflector with pliers. We periodically check that everything fits tightly and well.
Converting a halogen lamp to LED

Converting a halogen spotlight into an LED one

Converting a halogen spotlight into an LED one

Converting a halogen spotlight into an LED one

If everything fits well, take a screwdriver with a thin metal drill and drill four holes to mount the LED right in place.
Converting a halogen spotlight into an LED one

Then take thermal conductive paste and apply it to four surfaces: the back wall of the lamp, the back and front of the reflector, and the LED matrix seat.
Converting a halogen spotlight into an LED one

Converting a halogen lamp to LED

Converting a halogen spotlight into an LED one

Let's put everything back together and secure it with self-tapping screws. You can also use screws with nuts, but I personally used small self-tapping screws. It's okay if they stick out a little at the back - I'll fix that a little later with a file.
Converting a halogen spotlight into an LED one

That's it, almost everything is ready. All that remains is to solder the network wires to the matrix, install the sealing rubber with glass and close the lamp.
Converting a halogen lamp to LED

Converting a halogen spotlight into an LED one

Converting a halogen spotlight into an LED one

Everything works perfectly.It seems to me that it has begun to shine even brighter than before, but it heats up several times less, that’s for sure.
The LED matrix is ​​decoupled in voltage from the landing pad, and the network phase will not transfer to the housing. But it’s better not to forget to tighten the grounding wire to the housing.

I used this converted spotlight for over a month. In principle, there are no disadvantages, only advantages. Especially the savings in rubles for electricity are obvious.
Converting a halogen spotlight into an LED one

Converting a halogen spotlight into an LED one

Watch a video of the process of converting a halogen spotlight into an LED one


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Comments (6)
  1. Vladimir Anisimov
    #1 Vladimir Anisimov Guests November 9, 2017 08:00
    3
    Not bad, but the question arises how good is the driver isolation and LEDs from the substrate? It is no secret that not everywhere there is a separate grounding wire.
    1. Denis
      #2 Denis Guests 9 November 2017 12:42
      1
      Chinese LEDs well isolated from the substrate. This can be seen even with the naked eye - the components are on the board.
      Even if you have doubts, no one is stopping you from taking a tester and measuring the resistance between the substrate and the network terminals at 220.
  2. Igor
    #3 Igor Guests 9 November 2017 14:12
    1
    Intense thermal conditions - 4 paste structures between the radiator and the lamp, and even a reflector. WHY? After application, the paste is spread as thinly as possible to fill uneven surfaces for a more complete fit (to increase heat transfer) - no more. The residue should come out after pulling the fasteners. The gasket must also be perfectly flat, which is unlikely. On old equipment I came across thin gaskets (less than about 1 mm) for transistors made of soft lead - when tightening the fasteners, the lead flowed and filled the unevenness. We can recommend only one layer of paste and apply it directly to the radiator. But the idea is good. By the way, “take a tester and measure the resistance between the substrate and the network terminals at 220” - it will be at a voltage of 9 volts, which is incorrect, but you need 250-300 volts - a megger is required here.
  3. zzz
    #4 zzz Guests 12 November 2017 14:13
    0
    Why do you need to manipulate the reflector and paste?
  4. Vyacheslav
    #5 Vyacheslav Guests 27 April 2018 20:54
    0
    yeah, and after 5 minutes the temperature of the reflector will become 90-110 degrees, power consumption will drop to 25-30 watts, and the service life of the LED matrix will decrease by 5-10 times. Or a matrix with a maximum of 30 watts, or an additional heat sink
  5. Guest Vladimir
    #6 Guest Vladimir Guests January 20, 2019 09:42
    1
    I agree. The case is not sufficient for cooling LED 50 watts.
    And in order not to fence the garden, it’s easier to buy an LED replacement for a halogen lamp there.