DIY Lights - V3

[dacianb]

After more than a year of testing and changing my DIY lighting systems I think time came to get rid of all errors and add all improvements in a brand new light system - I think is third generation...

As introduction, here is my tank (RS Reefer 350) with a second generation module on it... time for a massive upgrade

 

[dacianb]

For the beginning I redesigned the power boards adding extra-features to the ones available on market. Next to 4x Meanwell LDD-H or high current LDD-L (1200-1500 mA) drivers, I can add various DC/DC converters (fan power, controller, etc) and thermal switches to each individual channel (thermal protection of light).
Some pins / jumpers allow me to easily interconnect different such drivers, but also connect multiple drivers on same PWM channel.

Here is a picture with board equipped with all pins/ jumpers / sockets - no drivers added.

 

[dacianb]

Next step was to redesign the led boards in a way to offer a mixture of various types of LEDs, enough power, LEDs to be close enough to have good light mixture (no disco effects), but also to replace easily individual boards, without having to replace all the leds as on a single board.

I designed and ordered following board - 5/6/5 LEDs on 3 channels, where channels A and B are with Osram Oslon/Square or Cree XBD footprints and channel C is with CREE XP footprint.

I can place up to 4 such boards on each fixture and interconnect them (no soldering will be required to connect the boards). Each board is 150x20 mm.

 

[dacianb]

First step in any serious DIY project have to be a plate with lot of holes in it
This is the chassee of my fixture - 3mm thick aluminium plate with lots of holes in it, on which will fix leds, heatsinks, drivers boards, thermostats and side panels of enclosure too. Next to mechanical strength, will provide some thermal inertia, nice heat distribution to cooling system and side covers too.
Normally is a very nice "mirror" looking plate, in this picture still the protection foil is on it.

And the chassee (first of them) finally ready - main plate + heatsinks + power boards spacers...

 

[dacianb]

I just received the connectors for the lights - power and comm too. Are waterproof industrial grade connectors capable to handle the high currents of lights, but also salt and humidity.
Currently I am using some "domestic" style and after a year above saltwater are very corroded and have to clean them from time to time.

 

[dacianb]

This is the status of lights today

 

[stupidted]

Looking good. Good write up so far keep it coming.

 

[dacianb]

Looking good. Good write up so far keep it coming.

I still have to make some tough decisions regarding power.... Do I really need this 180W / module or not?? Or 130 W should be enough??? Will see how I will handle it in the end.
Each light module can handle this 180W, but to make it like this and use it at 30% is just a waste of money.... First image of my tank is with approx 50W LEDs. Looks enough for sps

 

[shohamsabo]

Waiting to see the finished project . If you can make a list of equipment and where you got him , I 'd appreciate it

 

[dacianb]

Waiting to see the finished project . If you can make a list of equipment and where you got him , I 'd appreciate it

shohamsabo, most of parts (led boards, power boards, plates, covers, etc) are custom made - I designed and ordered them. Those are not available. Common parts as screws and connectors are everywhere

 

[shohamsabo]

Ok

 

[michaelrc51]

Awesome write up.
Electrical engineering at its best!

 

[dacianb]

Awesome write up.
Electrical engineering at its best!

Thanks, but actually I have no electrical background at all. I am optical engineer
When I will arrive to spectrum/ powers and led types will be even more complicated

 

[michaelrc51]

Thanks, but actually I have no electrical background at all. I am optical engineer
When I will arrive to spectrum/ powers and led types will be even more complicated

Well then, you are doing one heck of a job!

I am pretty good at electrical and low voltage stuff and I wouldn't even know where to start to make boards and such.....

 

[dacianb]

Finally side covers are done.

Aluminium custom made and electrostatic field paint for heavy duty environment.
The 2 "wings" allow me to mount the lights in rail systems and to move them easily or to hang them as well.

Large number of holes are necessary for air flow, initially were smaller, but the air is rather noisy and almost whistle through them

 

[BeastMode335i]

Anybody use any of the 3w LED's from eBay to make something like this..??

 

[dacianb]

Anybody use any of the 3w LED's from eBay to make something like this..??

I am spending quite some money to build this as a top quality system. Using eBay leds on it would make all my efforts useless. 90% of LEDs in the system will be 6W Osrams powered at max 50% capacity.
Those are LEDs with a lifetime of >100 000 hours, together with all top quality parts and fans rated for 150 000 hours will make this light maintenance free for long years since now.

 

[michaelrc51]

Nice, don't skimp anywhere.....
Are you thinking of producing some more if the lights work well?

Osram is one of the highest quality LED manufacturers out.

 

[dacianb]

Nice, don't skimp anywhere.....
Are you thinking of producing some more if the lights work well?

Osram is one of the highest quality LED manufacturers out.

They work well already (version 2 is in test since 1 year already) - now I just improve some small flaws, not really functional, but rather aesthetics and to increase lifetime of some weaker components. For example as small clicks I heard when light warms up and then when it cools - too high rigidity between some components, now will be solved and silent , A4 grade stainless instead of A2, different painting / coating system

Commercially this light would be a suicide. I am using a bunch of very expensive leds and power them at only 50-70% and such. I think just the fan+DC/DC driver of it and all thermal switches I will add cost more than an eBay reef light. I am a led lighting designer for high end industries and I just apply on my private lights what 20 years of research and development experience teached me. In the end is a hobby light made at high end industrial standards. Everything started with a bet with a friend and went crazy, but I won the bet

 

[BeastMode335i]

I am spending quite some money to build this as a top quality system. Using eBay leds on it would make all my efforts useless. 90% of LEDs in the system will be 6W Osrams powered at max 50% capacity.
Those are LEDs with a lifetime of >100 000 hours, together with all top quality parts and fans rated for 150 000 hours will make this light maintenance free for long years since now.

Understood

I saw a DIY using eBay LED's and it actually came out fairly well so just figured I'd ask.. I'm a very novice DIY so I'd hate to spend such large amounts of money on something I've never done before so I contemplated on giving it a shot using less expensive items the first time around so figured I'd pick your brain a bit.. Thanks!