90g DIY LED Build Thread

[KrazieCanuck]

Hello All, I figured I'd post another one of those "DIY LED Threads" for you all to follow throughout my process if you wish.  There are numerous threads regarding this in other forums and communities that I have read through extensively but I figured I would do my own build thread for the OVAS community.  Feel free to ask any questions along the way and I'll try to explain them the best I can.  I plan on providing lots of pictures and details on how everything is setup, configured, wired, etc.  I anticipate this project to take place over the next month or so pending availability and time to work on this.

Purpose:
   Design a LED lighting array to replace my existing PC / Metal Halide solution, thus reducing power consumption and the need to replace bulbs on an annual basis.  LED lighting to be built into existing Aquarium cabinet hood.  LEDs to be controlled through the open source Reef Angel controller to simulate Sunrise / Sunset.  Possibly work on code to simulate random cloud generation and moonlight phases as a future project.

Parts List: (Already Purchased & Received)
Main Lighting:
48 - Cree XR-E 3w Cool White LEDs - Purchased from DealsExtreme.com
48 - Cree XR-E 3w Royal Blue LEDs - Purchased from RapidLED.com
96 - 40 Degree Optics for LEDs - Purchased from RapidLED.com
8  - Mean Well ELN-60-48P Dimmable Drivers - Purchased from RapidLED.com
2  - 8.460 Profile 20 Inch Heatsinks - Purchased from HeatsinkUSA.com
1  - 92mm Vantec Stealth Fan Kit - Purchased from RapidLED.com
FAN KIT INCLUDES: Two 92mm Fans, Variable Speed Control, Y-splitter to power both from one source
FAN FUTURE PLAN: Automatically control fans through controller based on temperature readings
4 - Arctic Silver Premium Thermal Adhesive - Purchased from RapidLED.com
2 - Cheap Extension Cords (to be cut and used for Driver Wiring to Outlets) - Purchased from Homedepot.com

Moon Lights:
6 - Cree XR-E 3w Royal Blue LEDs - Purchased from RapidLED.com
1 - 3023-D-E-350mA Wired BuckPuck (Dimmable) - Purchased from LEDSupply.com
1 - Aluminum U-Channel (Pocket Door Rail to be cut to 44") - Purchased from Homedepot.com
1 - 24VDC 40-Watt Power Supply for Buckpuck - Purchased from LEDSupply.com

Sump Lights:
3 - Cree XR-E 3w Cool White LEDs - Purchased from Dealsextreme.com
3 - Cree XR-E 3w Royal Blue LEDs - Purchased from RapidLED.com
6 - 40 Degree Optics for LEDs - Purchased from RapidLED.com
1 - 3023-D-E-700PmA BuckPuck w/ Potentiometer for Manual Dimming - Purchased from LEDSupply.com
4 - Aluminum U-Channel (Pieces from the original U-Channel put together to form a DIY Heatsink)
1 - 24VDC 40-Watt Power Supply for Buckpuck - Purchased from LEDSupply.com

Extras:
4 - Cree XR-E 3w Cool White LEDs - Purchased from Dealsextreme.com
4 - Cree XR-E 3w Royal Blue LEDs - Purchased from RapidLED.com
8 - 80 Degree Optics for LEDs - Purchased from RapidLED.com
NOTE: Possibly add a 13th LED to each Driver on the main lights that is spaced out with a 80 degree optic to add more overlap of light and coverage.


I plan on starting this on the evening of Oct 27th and then will pick away at things over then next few weeks to a month as I get the time.

[SeahorseGuyetGal]

Very cool!  Well, one of my other hobbies is high-end audiophile stuff.  I proposed building a pair of nice high-end speakers to the sig other.  She said - and I quote: " You're not going to mess up the study with a bunch of little wires and things for the next six months because it took you so long to get around to finishing it!"

That being said - how much did the equip cost u?

[JetJumper]

Nice!  I will follow this for sure! 

That being said - how much did the equip cost u?

My guess so far is around $1200-1400.00 based on equipment and possible pricing now a days.

[KrazieCanuck]

My guess so far is around $1200-1400.00 based on equipment and possible pricing now a days.

Well, your probably pretty close, but that would be including the controller as well.
Reef Angel Controller = $200
55 - Cool White XR-E = $4.11 each ($226)
61 - Royal Blue XR-E = $5.75 each minus 5% discount ($333)
8 - Meanwell Drivers = $30 each minus a 5% discount ($228)
2 - 20" Heatsinks = $95
Plus all other stuff...
Total = Enough (but the fun in building it and the sense of accomplishment...hopefully...at the end will be priceless. )

[JetJumper]

55 - Cool White XR-E = $4.11 each ($226)
61 - Royal Blue XR-E = $5.75 each minus 5% discount ($333)
8 - Meanwell Drivers = $30 each minus a 5% discount ($228)

Good prices for the LED's / Drivers

[johnrt]

Kool.

How large is the tank and what are the specs on the lighting that is being replaced?

Have you considered doing a PAR reeding before and after?

Anybody got one of those PAR meters?

OK, 'nuff questions.  John T

[Vincenzo.]

nice KC, g'luck. i cant wait to see.

[KrazieCanuck]

Hey Jonhrt, the tank is a standard 90 gallon (48" x 18" x 24").  The current lighting that i have is a light fixture i bought from Catalina Aquariums down in the US.  It's got 2 150w halides plus 4 65w Power Compact bulbs.  It;s been a pretty good light for me over the years and is still running strong.  It also has built in LED moonlights as well.  I will be selling it after the completion of this project to hopefully get a little bit of the money back that I've spent.

[KrazieCanuck]

Now for the first update...

I've accomplished quite a bit the last few nights.  I've modified the hood for the aqaurium cabinet to support two fans that will help cool the heatsinks.  I've also drilled all of my holes in the hood and heatsinks that will be used to secure the heatsinks to the hood top.  I've included pictures of the hood before and after for you to see.  I probably won't make much more progress until later next week though.

I've also managed to use the thermal adhesive to secure all the LEDs to the heatsinks.  I didn't go with the drill and tap method simply because I don't own a drill press and trying to do them all with a hand drill would be very teadious and probably inacurate.  The one downfall with this is that they are not easily removed if I need to replace one at some point.  The LEDs are spaced approximately 1.5 inches apart (center to center) in the four rows.  The rows are spaced approx 2" apart from each other so that I could utilize the space on the heatsinks, and spotlighting shouldn't be an issue from the research/calculations that i've done.  If it is then I will order 60 degree lenses to compensate.  I really don't think that will be an issue though.

Anyways, on with the first pictures...


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[Malyon18]

Looking pretty sweet, can't wait to see what it looks like when you are all done.

[KrazieCanuck]

Sorry for the lack of updates.  I have been slowly making progress over the past few weeks with a couple hours here and a couple hours there.  Things are comming together nicely though. 

Anyways, I've got the LEDs mounted on the heatsinks and now wired.  I also mounted the 6 moonlight LEDs and wired them as well.  So there is now a total of 51 LEDs per heatsink for a total of 102 overall that will be used. 

One mistake that I made was the LED layout between the two heatsinks.  You'll notice that when they are side by side, the LEDs on each end are the same and not staggered.  I blame this on the fact that I was watching hockey while doing the pasting and didn't pay attention to detail when starting the 2nd heatsink.  Good thing is that it doesn't appear to really have much affect when I tested it out on the tank.

I also did quite a bit of wiring and also created a few of my own cables for easy connect and disconnect.  I'll discuss these in further detail in the next post.

[Vincenzo.]

g money

[djtr]

That looks amazing!

[jon1985]

I am in the process of getting ready to do a very similar thing with the same bulbs.  I would only have 1 fixture though as its over a smaller tank.

Looks cool.

[cn]

NICE......How much did the whole project cost you ?

[JetJumper]

NICE......How much did the whole project cost you ?

Its like 5 posts up.. lol

http://ovas.ca/index.php?topic=47094.msg264317#msg264317

[cn]

Its like 5 posts up.. lol

http://ovas.ca/index.php?topic=47094.msg264317#msg264317

hehehe.... my bad, sorry bud

[KrazieCanuck]

Well, the project has been complete for about a month and a bit.  Still have to install a splash guard over the LEDs which I plan on using clear acrylic for.  Already purchased, just haven't had the time to do it and so far they aren't getting any sort of water on them anyways.

It's been running on the tank and I have to admit is BRIGHT!  I started at only 50% COOL White and 50% Royal Blues for the first 2-3 weeks and have since slowly raised it up to approximately 75% Cool White and 65% Royal Blue over the past few weeks.

Corals are loving it and I have seen some positive signs of growth so far.  I'll post some pictures shortly.  I don't really have a lot in the tank right now, but from what I do have things are growing faster then before.  Colours pop out nicely and all in all I have been very impressed with it.

I'm also not using any lenses right now and the brightness is incredible.  Though it is fairly low to the water unlike some other LED projects I've seen.

Anyways, hope to get some more results and pictures posted for you all soon.

[pt109]

Have you noticed any spotlighting with the 40 degree optics?

I  have been contemplating a similar build, and leaning toward 70 or 80 degree optics.

[KrazieCanuck]

Yeah, the 40 degree Lenses do appear to spotlight a bit.  It really depends how far away from the water surface you are.  Mine are pretty close (I'll try to get a measurement when I get a chance).  Right now I'm not using any lenses and it's still incredibly bright...even at 50%.

I've been thinking about reordering 80 degree lenses but haven't yet.