Electronic circuit issue.

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Ok,

Need some help peeps please!

I have a “problem” & I am struggling with a solution, as I am stuck, in a rut, on my own, trying to come up with an answer.

I have a variable voltage source, 16V +/-25% ac, ish, so about 12 – 20V ac.

Source impedance is quite low, so it has quite a volt drop, but it can deliver up to around 10A.

The frequency varies from about 250Hz (12V) to about 1kHz (20V).

It’s also, not, a good smooth sine wave output.

I need to run about 60W of tungsten lighting @ 12V, just shy of 5A.

Not going to split hairs.

The lights must be on whenever the ac source is present.

The ac source when loaded with say 3-5A does become a bit more stable, but, it has an inherent defect in that if a fuse blows elsewhere it becomes totally un regulated and can reach 110V ac, so, it can & has destroyed connected electronic loads.

My caution is prompted by the lack of availability of replacement electronics, and the difficulty of retrofit.

It’s a cheap rubbish design, fundamentally, but, it’s not mine, I’m just landed with protecting the electronics & keeping the lamps lit correctly.

Now I have thought about rectifying the ac source then smoothing then using a dc/dc buck boost, as needed to get a nice 12V dc supply.

I can then protect the electronics against overvoltage with a crowbar.

However, I am struggling with a bridge rectifier as one of the legs of the ac is grounded to the dc –ve.

Solution eventually has to be dust & water tight & vibration resistant and to be used out of doors so quite a wide operational temperature range.

When I prototype on the actual circuit, I don’t get the results I’m expecting so I am overlooking something, and I can’t see it because I’m looking at the problem myself alone from the same angle all the time.

I’ve tried a full bridge rectifier, with the ac & dc legs common, not good.

Obviously shunting one diode.

I’ve tried a single diode, not good.

I’ve chucked a couple of 470muF caps in across the dc, and the ac side, in various combinations.

Mind the caps are only 50V, but, really they, should, be enough.

I am really overlooking something, but, I can’t see it.

Any ideas please?

 
Could you use a “crowbar” circuit to clamp the over voltage? I know it’s as rough as hell but it will protect the down stream electronic gubbins.

Or use the crowbar to introduce a load on the source to bring the voltage within range.

 
Doing the crowbar thing for the electronics.

I have 3 supplies to protect, basically, as all 3 go into the electronics.

2 are straight dc, easy to do for a crowbar.

The 3rd is this damned ac supply which is used for rough & ready illumination.

This is the one I'm stuck on.

I can't get a rectifier to work, mind @ 1kHz the diodes I have on the shelf may be too slow, they are 1N5408G's, that all that were anywhere near on the shelf.

Going to get some quick Schottky's today with a recovery time of about 120ns @ 10A If.

 
Not quite Kurt, as most of the Tungsten lighting has to stay on, it's a pain.

Plus crowbaring the ac means it could trigger on spikes which would mean a LOT of downtime.

Struggling to rectify the ac too.

I could crowbar some of the ac but not all of it.

However, if I convert the lighting to dc, then it would be "better" and easier to crowbar.

Still looking into it, forgot to order the Schottky's today! ;(

 
what about clipping the ac, if the waveform is lettuced anyway, then it cannot hurt anymore. ..lol

 
The system is a bit "value engineered"!

It is quite closely balanced I:V on the load side.

The lights don't light up very bright if the voltage is low, so if I chop the peaks off, then the lights may not be very bright.

Plus if I Zener it off then I have to dissipate the heat somewhere...

I will look at my options for just truncating the peaks of the wave though, not going to be, very simple with what is effectively a CTE supply.

 
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