6 Foot LED Build

TheManicFishkeeper · #1 09-30-2011, 08:50 PM

Wiring and LED placement.

This is where things get finicky and time consuming. It took several days of scratching my head and tinkering to really figure out how best to string this many led's together. Jason came up with a fantastic mouting pattern and had a good chunk of it mapped out ahead of time, but I needed to translate it a bit more for how it was going to connect to the drivers and GHL Profilux EVG-AP-2F Ballast control boards.

The whole idea for this build, was to have a very distributed array of leds that can really shine with left to right style dimming. Vertex LED fixtures already do this, but in a DIY build it's fairly complicated to achive without a 3rd party controller. Thankfully Jason has a GHL Profilux III (which can do this dimming behavior really easily with one of the more current firmware releases.).

The Array is broken down so there is a Blue channel, and a White Channel every 12 inches. This will alow for a whopping total of 12 individualy dimmable sections of the fixture. The Profilux can use this with time shifting to simulate clouds going left to right, sunrise/sunset etc. Its surprisingly easy to program, but more on that later.

Here is the basic wiring pattern for each of the three 2 foot pendants (sorry this is hand drawn, I had to sketch it out while drawing with my 3 year old niece):

Then here is a rough idea of what I have to wire for the interface for the profilux.

Each pendant will require the use of two EVG-AP-2F Boards. Each board will be responsible for powering and dimming 3 Drivers (2 Blue bound to single channel and a Single White Driver). So basically there will be 1 EVG Boards every 12 inches.

Every 12 inches of light fixture is going to yield a wire harness with an 8 wire connector. This connector will will be waterproof (I usually use Marine boat trailor harnesses) and carry power for the 2 x Blue banks, 1 x White Bank, and 12V to power the cooling fans. This way I can build each pendant the same way, with the same wiring harness. They can be taken out, cleaned and maintained easily, and will be interchangeable with each other.

On a more simple LED build I used 4 wire connectors:

These are not photos of Jasons build, just examples of the connectors I plan on using.

I am still looking for a set that will be the most appropriate, but I think Lordco will have what I need. I'm hoping 6 of them dont set us back too much, but this is one of those touches that can make a DIY build much more durable (no corroding contact points).

StirCrazy · #2 09-30-2011, 08:56 PM

looking good so far.

heres a handy chart for next time you use self tapping screws
http://aaronsself-tappingscrews.com/...rill_sizes.htm

Steve

TheManicFishkeeper · #3 09-30-2011, 09:49 PM

Thanks for the link, that will make it easier for sure!

Let the tedium begin... Thermal Adhesive time. This stuff has a very quick curing time so you have to make really small batches and work very fast. Its a good idea to map out your LED positions well ahead of time to prevent wasted material.

TheManicFishkeeper · #4 09-30-2011, 10:28 PM

First one done all the adhesive. Time for a quick break. Probably gonna start the next pendant while the adhesive cures.

mseepman · #5 09-30-2011, 10:29 PM

Hey this is looking great! I have just started building a light fixture for my 290 (although the tank is not set up yet). I decided to do fewer LED's than you (180 total) and rather than the heavy heatsinks I have gone with large u-channel. Glad you are a few steps ahead of me so I can watch your mistakes (haha).

TheManicFishkeeper · #6 09-30-2011, 11:41 PM

This is my 6th LED build now, but by far the largest. The only things I have any legitimate concerns over are weight, and heat. Heat should be pretty manageable, but the weight is something I am now trying to wrap my brain around.

I think I've come up with a robust enough suspension/rail system to hold the weight of all three pendants now though. I'll take pics as I go.

TheManicFishkeeper · #7 10-01-2011, 01:21 AM

2 Down... One to go. Going to start tinning LED's now....

TheManicFishkeeper · #8 10-01-2011, 02:38 AM

It Begins....

mseepman · #9 10-01-2011, 02:47 AM

I was totally ready to go the solder route but after going to MACNA I saw how easy the BJB connectors were and have ordered them. I has cost me $200 more than I originally planned...but the one thing I don't have enough of is time...and this saves a lot of it.