Bioload LED Fixture

[bioload]

Working on something new and thought I'd post some pics of the build to date:

http://i635.photobucket.com/albums/uu78/reefkeeping/led_star.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/led_heatsink.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/led_optics.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/led_timers.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_1832.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_1835.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_1840.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/DIYLED.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_1843.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_1844.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_1845.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_1846.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_1847.jpg

[StirCrazy]

Working on something new and thought I'd post some pics of the build to date:



http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_1844.jpg





you not using heat sinks on this one?

Steve

[bioload]

you not using heat sinks on this one?

Steve

Hi Steve,.....Heatsinks will be used. Took that one after completing the bottom of the unit.

Here are some more details of the build:

Whites - 40 x 3W Power LED 14000K (Maybe changed as required)
Blues - 40 x 3W LED 455nm (Maybe changed as required)
Heat sink - Individual Power LED Aluminum heat sink
Optics - 120 Degree
Timers - Weekly programmable timers Timer 1: Daylight Timer 2: Dusk/Dawn/Moon
Drivers - Mean Well LPC-35-700 constant current driver
Cooling - 4 x 11 Blade 12V 80mm
Relay - 110V AC Coil Power Relay DPDT on Timer 2 switching between dd/moon
Dimensions ~ 48" x 12" x 2"

[StirCrazy]

ahh ok, that makes more sense, where did you find thoes heat sinks? I like thoes ones.

Steve

[bioload]

ahh ok, that makes more sense, where did you find thoes heat sinks? I like thoes ones.

Steve

Got these ones from eBay.....really adds more flexibility when it comes to mounting the LED's.

[bioload]

Fired up for some tests and I'm pleased with the colour, and a big improvement from the 50:50 Cree's used previously. All I need to do is find the right settings that will allow me to take some pictures of the tank and fixture at the same time.

All of the pics are either overexposing the fixture or underexposing the tank, not to mention the white balance.

Here is the MDF version before I tear it all down again to start on the acrylic.

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_2227-1.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_2228.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_2234.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_2229.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/IMG_2226.jpg

I've managed to clear up a lot of room mounting everything into the fixture, and eliminated a few power cords as well. The fixture will have a standard C-13/C-14 connection, but I will need to order a locking cord to prevent an unintentional dip in the tank.

The cooling fans are shutting off after several minutes of running and I've identified the relay as the cause of the problem. The vendor is sending a replacement at the moment since this is a rare occasion where I only ordered a single unit. I'm hoping that it is just a faulty relay. Still waiting on what I'll be using for moonlights to arrive as well.

The 2x4 sand will not be in the final design...will be working on some mounting brackets, and maybe a hanging kit....still haven't decided.

[gregzz4]

Nice
Are you making the whole works with acrylic, or just some parts ?

[bioload]

Nice
Are you making the whole works with acrylic, or just some parts ?

Hi greg....top and bottom for sure, but still undecided regarding the sides.

Something like this

http://ansblog.com/wp-content/uploads/2011/01/apple-iphone-4-white.jpg

or this

http://www.computus.org/journal/wp-content/uploads/2008/08/iwood.jpg

[bioload]

ahh ok, that makes more sense, where did you find thoes heat sinks? I like thoes ones.

Steve

Found the link

http://www.ebay.ca/itm/100pcs-1W-Watt-LED-Aluminium-Heatsink-Round-/370530526354?pt=LH_DefaultDomain_0&hash=item5645572492

[gregzz4]

Hmm, aluminum or oak
Either would look very nice. I like the idea of it being recessed into the edging.
Get on it, we want to see :razz:
If you decide to make the top of the fixture really flush, these PC fan grilles catch lots of dust and then you just vacuum them off
I run them on my office tower and they don't create extra noise, even at 1600rpm
http://www.koolertek.com/computer-parts/pc/catalog/ff-1004-b-1.jpghttp://www.koolertek.com/computer-parts/pc/catalog/ff-1004-b-2.jpg

[gregzz4]

I shoulda mentioned ...
These grilles/filters go between the fan and acrylic so all you see is the dome
The holes are about 1.5mm. Avoid the ones with larger holes as you will get noise

[StirCrazy]

Found the link

http://www.ebay.ca/itm/100pcs-1W-Watt-LED-Aluminium-Heatsink-Round-/370530526354?pt=LH_DefaultDomain_0&hash=item5645572492

hmmm neat, did you do any temp readings to see how well they work?

Steve

[Blue World Aquariums]

Very nice work.

[reefermadness]

what kind of LEDs are those...bridgelux?

[bioload]

I shoulda mentioned ...
These grilles/filters go between the fan and acrylic so all you see is the dome
The holes are about 1.5mm. Avoid the ones with larger holes as you will get noise

Thanks.....I'll see If I can source 80mm to try.

[bioload]

hmmm neat, did you do any temp readings to see how well they work?

Steve

Thanks,...Readings from the exhaust fans are in the 105-110F range with all 80 LEDs fired.

[bioload]

Very nice work.

Thank You

[bioload]

what kind of LEDs are those...bridgelux?

No markings as such but I would assume they are based on others I've seen.

[bioload]

Finished a few sketches to help visualise the finish in solid maple or aluminum.

http://i635.photobucket.com/albums/uu78/reefkeeping/LED_009.png

http://i635.photobucket.com/albums/uu78/reefkeeping/LED_004.png

http://i635.photobucket.com/albums/uu78/reefkeeping/LED_008.png

http://i635.photobucket.com/albums/uu78/reefkeeping/LED_005.png

http://i635.photobucket.com/albums/uu78/reefkeeping/LED_007.png

http://i635.photobucket.com/albums/uu78/reefkeeping/LED_001.png

http://i635.photobucket.com/albums/uu78/reefkeeping/LED_006.png

http://i635.photobucket.com/albums/uu78/reefkeeping/LED_002.png

[Nano]

looks awesome, put a big mac symbol on top ;) and control it with windows 98 :lol: jk

[bioload]

looks awesome, put a big mac symbol on top ;) and control it with windows 98 :lol: jk

lol......The logo idea did cross my mind .....transluscent acrylic inlay backlit with the fixture :)

[reefermadness]

No markings as such but I would assume they are based on others I've seen.Im not sure what this means. Can you PM me what brand if you are not willing to say? Or somehow you dont know? WHere did you get them?

[gregzz4]

Thanks.....I'll see If I can source 80mm to try.
If you can't find them, I ordered mine from Performance PCs
Site is very slow to load
This is the filter page (http://www.performance-pcs.com/catalog/index.php?main_page=index&cPath=36_463_465) - 80mm is at the bottom

[bioload]

Im not sure what this means. Can you PM me what brand if you are not willing to say? Or somehow you dont know? WHere did you get them?

Hi reefer,.....Confirmed....they are Bridgelux. Sorry for the confusion really didn't know the brand. Purchased them on ebay.

[bioload]

If you can't find them, I ordered mine from Performance PCs
Site is very slow to load
This is the filter page (http://www.performance-pcs.com/catalog/index.php?main_page=index&cPath=36_463_465) - 80mm is at the bottom


Thanks,....you weren't kidding about the speed :)

[bioload]

Idea I have for the mounting bracket.

http://i635.photobucket.com/albums/uu78/reefkeeping/led_fixture_mount_bracket.jpg

Still thinking of the material, but leaning towards clear 1/2" polished acrylic. It would be nice if the light from the fixture would illuminate the edges of the bracket as well.

[bioload]

http://i635.photobucket.com/albums/uu78/reefkeeping/led_mounting_bracket.png

http://i635.photobucket.com/albums/uu78/reefkeeping/led_mounting_bracket_001.png

http://i635.photobucket.com/albums/uu78/reefkeeping/led_mounting_bracket_002.png

http://i635.photobucket.com/albums/uu78/reefkeeping/led_mounting_bracket_003.png

[beefORchicken]

wow, i know the fixture isn't done, but wow it looks great! can't wait to see the finished product

[StirCrazy]

you know, you could allways put a few stratigicly placed 5mm blue leds above your brackets to light them up. would make them glow and give you the look you were thinking of.

Steve

[bioload]

you know, you could allways put a few stratigicly placed 5mm blue leds above your brackets to light them up. would make them glow and give you the look you were thinking of.

Steve

I Like........a friend of mine told me he didn't like the brakets, BUT he did come up with an alternative that has me thinking.....more to come

The budget took a hit with the aluminum that I received for the frame. It’s WAY too heavy for the fixture for my liking. The weight of the aluminum alone is in the 20lb range and I’m worried that it may be too heavy for the tank. A friend of mine told me not to worry, that most canopies are heavier than that. However, once he picked up the aluminum bars his first words were, “Damn that’s heavy”…..so back to the drawing board

These are some sketches that I’ve completed with some modifications to the frame….I hope it will address the weight issues. The center will be a wooden frame with wooden or acrylic end caps, and using only a ¼” brushed aluminum trim on the front and back. I’m currently Google-ing “DIY Brushed Aluminum”, and finding some nice tips (as usual).

http://i635.photobucket.com/albums/uu78/reefkeeping/Untitled_10.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/Untitled_4.jpg

And just for kicks :)

http://i635.photobucket.com/albums/uu78/reefkeeping/Untitled_7.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/Untitled_8.jpg

http://i635.photobucket.com/albums/uu78/reefkeeping/Untitled_6.jpg

My wife really likes this one…..I might regret the fact that she knows I can change the colour

http://i635.photobucket.com/albums/uu78/reefkeeping/Untitled_9.jpg

[bioload]

After going through numerous threads and articles on LED color combinations I’ve come to the conclusion that the capability to change would be advantageous. With that being the case, having to remove and re-solder the LED’s into the fixture would almost certainly be tedious enough to prevent it from happening for any type of experimentation.

The idea I came up with is to solder PCB 0.1mm pins to the stars and use jumpers to connect the strings together. I’ve ordered a few of these from e-bay and await their arrival as I complete the remainder of the build.

http://www.elecfreaks.com/store/images/wire01-1pin-ff-jumper.jpg

http://www.adafruit.com/adablog/wp-content/uploads/2012/03/window-136.jpg

Initially the pins will need to be soldered but once that is completed I would have a star that can be connected/disconnected with relative ease, or at least I hope so.

http://i01.i.aliimg.com/photo/v0/383678851/PCB_CONNECTOR_PIN_HEADER_2_54MM_PITCH.jpg

http://i00.i.aliimg.com/photo/v0/383675748/PCB_CONNECTOR_PIN_HEADER_2_54MM_PITCH.jpg

[Snaz]

http://i635.photobucket.com/albums/uu78/reefkeeping/led_mounting_bracket.png



The problem with this design as I see it is if the fixture takes a bump from either side it will go for a swim. An extra down edge on the outside of the tank on each end would solve this.

I know you are going for a different design but I just wanted to point it out for others looking to build something similar.

[bioload]

The problem with this design as I see it is if the fixture takes a bump from either side it will go for a swim. An extra down edge on the outside of the tank on each end would solve this.

I know you are going for a different design but I just wanted to point it out for others looking to build something similar.

Hi Snaz, The mounts will be attached fixture using ¼-20 bolts that will go all the way though the mount and the fixture. I was thinking that the opposing edge would be on the other side of the tank preventing lateral movement, but I’ll give it a second , third, and fourth look. Would hate to have it fall….thanks

[smokinreefer]

impressive!
excellent workmanship!
looks great, such a clean build.
wish i had the ability to build that.

[bioload]

impressive!
excellent workmanship!
looks great, such a clean build.
wish i had the ability to build that.

Thank You....glad to have you aboard.

[bioload]

Does anyone have any experience with these drivers?.....I'm thinking of giving them a try.

http://a-starlighting.com/products_show.asp?c_id=104

http://a-starlighting.com/UploadPict/chanpin/201231000508.jpg

[sobe]

How's the wood holding up? Mdf is probably the worse type to use near any water as it absorbs moisture and expand. Great looking top btw