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.

I think the reason for over heating my array is because I placed 22 LED running at 700ma in a U shaped aluminum of 34" length.witch gives me a gap of aprox 1.4" between each LED.
I just placed another U shaped aluminum on the back side (with heat transfer grease) and turn the array on so far 15 minutes passed and its running warm that maybe the answer as more surface area for heat dissipationhttp://www.flippinghomes.com/images/...rs_crossed.jpg

I only run 12 LEDs over 5 feet of 1" fined heat sink. These are 3w Crees and that was the max recommended by RapidLed for that length. The 3w stars are about 4.5 inches apart.

That is crazy separation between LEDs I think I will need an AC fan or a couple to keep my array cool anyone knows where to find such a small diameter fan that run of AC power?

I went back and removed all 28AWG as I see that I used 22AWG on the array over my tank,thanks to DiverDude and mike31154 made me go and check:biggrin:

I think I got it from B&E by your recommendation about a year ago and I must say that I love it:biggrin:

While waiting for a couple fans and a heat sink here are couple photos of the 80% finished array:biggrin:

Here is what I am placing as lens on each LED as I had some laying around from a prior DIY with some phylips LED and must say these lens fit perfect.
http://i726.photobucket.com/albums/w...y/IMG_1856.jpg

All lens are on tight,last night I cut and bent an acrilic sheet for a cover I must say it turned out a perfect shield:biggrin::biggrin:
http://i726.photobucket.com/albums/w...y/IMG_1858.jpg
http://i726.photobucket.com/albums/w...y/IMG_1859.jpg
http://i726.photobucket.com/albums/w...y/IMG_1857.jpg

and now its wired and ready

http://i726.photobucket.com/albums/w...y/IMG_1863.jpg

Plug is going into the wall and voila

http://i726.photobucket.com/albums/w...y/SDC10366.jpg
http://i726.photobucket.com/albums/w...y/SDC10368.jpg
http://i726.photobucket.com/albums/w...y/SDC10369.jpg

Man its bright too bad the camera doesn't do it any justice.

Nice LED build. I imagine you were seeing spots after testing out the fixture.

Nice! One question, how do you get air evenly into here?

Because its a small array and not running at full blast,room temperature keep it cool with no added fans.
Although because I have 22 led and max at 700 ma it I was to run it at full shouldn' t br a problem in my case as it sits near 2 other arrays with high power fans to keep it cool.

In the next couple weeks I will have another build for my 220glns and another for the frag tank.Using similar design as above but their own fans

After looking at your array and Greg's DIY. I don't know which one should I go with.

These are 2 different arrays.mine is simply an addition to what I already have as for his is the main lighting for his tank.
If you are planning for an array over your tank as the main with good amount of LEDs I recomend having fans.the type of fans depends on how you pack the areay with the LEDs.