LED DIY with photos
 

I am hoping to have this array done and ready for mounting by the end of the day:biggrin:
I just received the rest of the parts I been awaiting for.This array will be a separate additiong to what I already have it consists of 2 types of LED
parts I have and will be using.
Inventronics Model EUC-075S070DT (57w)
10K Ohm 1/2Watt potentiometer
22 AWG wire to use between the driver to the LED
22 AWG wire to use between all LEDs
0.025" diameter solder wire
shrink tubes to have clean wire ends
Arctic silver thermal adhesive for attaching the LEDs to aluminum
Hakko 936 soldering station
U Chanel aluminum tube
Acrylic sheet used as a splash guard
18 LED true violet 420nm 60 degree angle (max 700ma at 3.6V)
4 LED Turquoise 495nm 60 degree angle (max 700ma at 3.6V)
I will be placing prices
these are some quick photos as I need to get started and will have more to come (well more interesting photos)


http://i726.photobucket.com/albums/w...y/IMG_1827.jpg
http://i726.photobucket.com/albums/w...y/IMG_1826.jpg
http://i726.photobucket.com/albums/w...y/IMG_1825.jpg
http://i726.photobucket.com/albums/w...y/IMG_1824.jpg
http://i726.photobucket.com/albums/w...y/IMG_1823.jpg
http://i726.photobucket.com/albums/w...y/IMG_1822.jpg

It took me about 15 minutes to get some solder on 2 end of each LED (-+) and here are few more photos:biggrin:
here is sawing the U shaped aluminum using an ultra fine metal blade
http://i726.photobucket.com/albums/w...y/IMG_1828.jpg

Here is the solder station out of the box
http://i726.photobucket.com/albums/w...y/IMG_1829.jpg
http://i726.photobucket.com/albums/w...y/IMG_1830.jpg

Here are all the LED 24 pcs total
http://i726.photobucket.com/albums/w...y/IMG_1831.jpg

This is me (concentrating :biggrin:) placing the beads on the LEDs
http://i726.photobucket.com/albums/w...y/IMG_1834.jpg
http://i726.photobucket.com/albums/w...y/IMG_1837.jpg

I don't see any flux in the pics, did you use any?

I believe that is a flux induced solder wire that he is using.

Glad I didnt go this way........I HATE soldering. :twised:

Aww, c'mon man, you're a welder. Soldering is nothing more than low temp welding.

:biggrin::biggrin:
Soldering for me is like being in another world (world of piece :biggrin::biggrin:)
all soldering is done I have a visitor so put everything on hold for couple hours.but 1st here is a mix of photos with no labels yet..
http://i726.photobucket.com/albums/w...y/IMG_1839.jpg
http://i726.photobucket.com/albums/w...y/IMG_1841.jpg
http://i726.photobucket.com/albums/w...y/IMG_1843.jpg
http://i726.photobucket.com/albums/w...y/IMG_1850.jpg
http://i726.photobucket.com/albums/w...y/IMG_1852.jpg
http://i726.photobucket.com/albums/w...y/IMG_1854.jpg

I dunno, that wire seems awfully thin for the kind of current that array is going to draw....

Where'd you get the Hakko 936 ? Those have been discontinued for a while now (I have 2 of 'em)

Ya, 28AWG is small stuff. I think it's still within the ampacity limits for the current he's running, but might be worthwhile upsizing that several iterations to pad the safety factor. Thinner wire also presents more resistance & therefore voltage drop. This could be a factor depending on how many are hooked up in series with that tiny wire. Look up ampacity & you'll find plenty of charts. Here's one example:

http://www.powerstream.com/Wire_Size.htm

According to the chart, max current for 28AWG in a chassis wiring application is 1.4 amps or 1400 milliamps. That stuff could be tricky to solder as well. A little too much heat & the insulation will shrink back a ways or even start cooking.

I will post few more pictures and info later on tonight as the array was finished yesterday.
The wire I am using is of no hassle and is of correct amperage resistant to what its used for and its a little tricky not to strip it whyle soldering.
Unfortunately I need to upgrade to a bigger heat sink as the U Chanel aluminum gets too hot if run the array at full blast witch what I intend to do.So I have to wait a couple days to receive a 1.8" X 36" heatsink from Martin.

I run that type of U channel no problem with 3w leds run 2" apart. They are barely warm to the touch, no fans. I mount them so the fins are facing up though I think that would make a difference. I also paint them with a high high flat black paint. My research indicated that a painted heat sink has better heat dissipating properties (emissivity).

I definitely would have went with a larger awg wire.....for the small cost it's a nice piece of mind.