LED wall build 500W DIY

[karimwassef]

I wanted to try a very low cost LED strip based sheet to see how it would perform and the output it could deliver.

The theory is that the light PAR distribution should be very uniform and the build should be very low cost.

The plan is to use 7020 LEDs since they generate the highest light output for their size and are readily available @ $1.5 per strip.

https://www.amazon.com/gp/product/B00FMQOUB2/

I'm using 40 strips for $60.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/1_zpsewhikyl7.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/1_zpsewhikyl7.png" border="0" alt=" photo 1_zpsewhikyl7.png"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/2_zpsyrsirfkj.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/2_zpsyrsirfkj.png" border="0" alt=" photo 2_zpsyrsirfkj.png"/></a>

I'm testing it on my aux tank (ATS + refugium) and would look like this

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/5_zpscfn6bxes.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/5_zpscfn6bxes.png" border="0" alt=" photo 5_zpscfn6bxes.png"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/4_zpsm6dwpohr.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/4_zpsm6dwpohr.png" border="0" alt=" photo 4_zpsm6dwpohr.png"/></a>

The box on top is the power supply. Since the power level is 500W at 12V, that's 40A-50A (based on efficiency) and I decided to use a refurbished telecom equipment power supply rated for 900W at 115V. They're marked as 1200W supplies but that's only at 220V input. They're also available on ebay and other sources for ~$20 = DPS-1200FB DL580

http://www.ebay.com/itm/HP-PROLIANT...41830-001-1200Watt-Power-Supply-/322421767655

The distribution of 50A is heavy duty (8AWG) copper strip - https://www.amazon.com/gp/product/B01G7SRDJ4/

The copper I used from it was worth ~$5

Total = $85 so far.

and here is how it should look.

<a href="http://s1062.photobucket.com/user/karimwassef/media/Designs/3_zpsoiekjif3.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/Designs/3_zpsoiekjif3.png" border="0" alt=" photo 3_zpsoiekjif3.png"/></a>

I added a couple of 100W multi-chip LED pucks for placeholders (future use)

 

[karimwassef]

I used a U channel frame and aluminum strip (1/4") and corner brackets. I used metal epoxy to hold it in place while I drill and screw it together

<a href="http://s1062.photobucket.com/user/karimwassef/media/EE2CEC19-632F-4437-8375-F9D8FBC424E7_zpstoopvciv.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/EE2CEC19-632F-4437-8375-F9D8FBC424E7_zpstoopvciv.jpg" border="0" alt=" photo EE2CEC19-632F-4437-8375-F9D8FBC424E7_zpstoopvciv.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/4E96C575-2B65-4723-8A09-3EA6B9DE7135_zpsxeqtibec.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/4E96C575-2B65-4723-8A09-3EA6B9DE7135_zpsxeqtibec.jpg" border="0" alt=" photo 4E96C575-2B65-4723-8A09-3EA6B9DE7135_zpsxeqtibec.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/532F8590-F1A0-43CF-A391-92EDB9834957_zpsb7koccae.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/532F8590-F1A0-43CF-A391-92EDB9834957_zpsb7koccae.jpg" border="0" alt=" photo 532F8590-F1A0-43CF-A391-92EDB9834957_zpsb7koccae.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/7FE33071-C855-4B83-9FF9-35C784BF7A11_zpsj24loatt.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/7FE33071-C855-4B83-9FF9-35C784BF7A11_zpsj24loatt.jpg" border="0" alt=" photo 7FE33071-C855-4B83-9FF9-35C784BF7A11_zpsj24loatt.jpg"/></a>

 

[karimwassef]

I used Aluminum flashing sheet for the metal sheet

<a href="http://s1062.photobucket.com/user/karimwassef/media/8B9D7719-5F3F-4F5F-BE3E-B84C7D78BA37_zpsfojuflrn.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/8B9D7719-5F3F-4F5F-BE3E-B84C7D78BA37_zpsfojuflrn.jpg" border="0" alt=" photo 8B9D7719-5F3F-4F5F-BE3E-B84C7D78BA37_zpsfojuflrn.jpg"/></a>

The idea is to bend the ends and screw it to the frame

<a href="http://s1062.photobucket.com/user/karimwassef/media/A3A1462E-A8C4-4FAB-B6F6-534E2DDA9D58_zpstwz1tzsb.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/A3A1462E-A8C4-4FAB-B6F6-534E2DDA9D58_zpstwz1tzsb.jpg" border="0" alt=" photo A3A1462E-A8C4-4FAB-B6F6-534E2DDA9D58_zpstwz1tzsb.jpg"/></a>

I marked out the location for the LEDs.

<a href="http://s1062.photobucket.com/user/karimwassef/media/41DEF471-4902-4C46-BF68-9AA5E83DC917_zps5pu9gmn2.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/41DEF471-4902-4C46-BF68-9AA5E83DC917_zps5pu9gmn2.jpg" border="0" alt=" photo 41DEF471-4902-4C46-BF68-9AA5E83DC917_zps5pu9gmn2.jpg"/></a>

and made sure everything will fit

<a href="http://s1062.photobucket.com/user/karimwassef/media/23E117DF-E12A-4438-8310-1EC833929958_zpsmfjibomp.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/23E117DF-E12A-4438-8310-1EC833929958_zpsmfjibomp.jpg" border="0" alt=" photo 23E117DF-E12A-4438-8310-1EC833929958_zpsmfjibomp.jpg"/></a>

Then I drilled the holes for the individual LED strip wires to go through to connect to the copper bus bar.

<a href="http://s1062.photobucket.com/user/karimwassef/media/C7BA434A-38EB-4E5A-9606-E65E2A0A2456_zpsgj0kto6f.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/C7BA434A-38EB-4E5A-9606-E65E2A0A2456_zpsgj0kto6f.jpg" border="0" alt=" photo C7BA434A-38EB-4E5A-9606-E65E2A0A2456_zpsgj0kto6f.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/6A6C4FF5-4453-48C3-B7D9-20E57B1902D7_zpsm1skppq3.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/6A6C4FF5-4453-48C3-B7D9-20E57B1902D7_zpsm1skppq3.jpg" border="0" alt=" photo 6A6C4FF5-4453-48C3-B7D9-20E57B1902D7_zpsm1skppq3.jpg"/></a>

and bolted the sheet to the frame

<a href="http://s1062.photobucket.com/user/karimwassef/media/6CA6DC1F-3034-4524-8E40-590330EC2C11_zpsj5xabq5w.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/6CA6DC1F-3034-4524-8E40-590330EC2C11_zpsj5xabq5w.jpg" border="0" alt=" photo 6CA6DC1F-3034-4524-8E40-590330EC2C11_zpsj5xabq5w.jpg"/></a>

 

[karimwassef]

I could have gone with the strips with adhesive but they were expensive and I decided for the flexibility in using my own adhesive strip. These are made specifically for this application.

<a href="http://s1062.photobucket.com/user/karimwassef/media/2679B4CA-6D30-4CB5-BFF4-3F6CA1B1F9A8_zps9p9goxkt.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/2679B4CA-6D30-4CB5-BFF4-3F6CA1B1F9A8_zps9p9goxkt.jpg" border="0" alt=" photo 2679B4CA-6D30-4CB5-BFF4-3F6CA1B1F9A8_zps9p9goxkt.jpg"/></a>

https://www.amazon.com/Rextin-Meters-Double-Adhesive-Lights/dp/B00N7D62HC/

and started to line up the strips

<a href="http://s1062.photobucket.com/user/karimwassef/media/D560324B-EE89-47DF-AB70-672A92CB2CE6_zpslyiddxb2.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/D560324B-EE89-47DF-AB70-672A92CB2CE6_zpslyiddxb2.jpg" border="0" alt=" photo D560324B-EE89-47DF-AB70-672A92CB2CE6_zpslyiddxb2.jpg"/></a>

looks pretty from this side

<a href="http://s1062.photobucket.com/user/karimwassef/media/D5A85890-DBFA-4EF3-9C0A-8AD12EA8A219_zpsip0buhwn.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/D5A85890-DBFA-4EF3-9C0A-8AD12EA8A219_zpsip0buhwn.jpg" border="0" alt=" photo D5A85890-DBFA-4EF3-9C0A-8AD12EA8A219_zpsip0buhwn.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/2E24625F-6B94-431F-8C9A-113EEB784B2C_zps8uj3x0la.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/2E24625F-6B94-431F-8C9A-113EEB784B2C_zps8uj3x0la.jpg" border="0" alt=" photo 2E24625F-6B94-431F-8C9A-113EEB784B2C_zps8uj3x0la.jpg"/></a>

but uglier from the back

<a href="http://s1062.photobucket.com/user/karimwassef/media/5F07ECFB-1A6F-4BC3-86AF-AFA557A385E3_zps5ukgxvoq.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/5F07ECFB-1A6F-4BC3-86AF-AFA557A385E3_zps5ukgxvoq.jpg" border="0" alt=" photo 5F07ECFB-1A6F-4BC3-86AF-AFA557A385E3_zps5ukgxvoq.jpg"/></a>

took a little "wire management" to make this workable

<a href="http://s1062.photobucket.com/user/karimwassef/media/31738F4D-B7CE-46F3-B935-71F98B70A85E_zpsiohq3uzp.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/31738F4D-B7CE-46F3-B935-71F98B70A85E_zpsiohq3uzp.jpg" border="0" alt=" photo 31738F4D-B7CE-46F3-B935-71F98B70A85E_zpsiohq3uzp.jpg"/></a>

and I used an old wire shelf to mount the power supply and fans

<a href="http://s1062.photobucket.com/user/karimwassef/media/AE9D84EE-B05E-41A5-9006-E1E12E86D363_zpsicbcmonr.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/AE9D84EE-B05E-41A5-9006-E1E12E86D363_zpsicbcmonr.jpg" border="0" alt=" photo AE9D84EE-B05E-41A5-9006-E1E12E86D363_zpsicbcmonr.jpg"/></a>

I used some angled aluminum strip to bolt it down.

 

[karimwassef]

Now each of the positive and negative wires (red and black) were wrapped around the copper busbar (thick bare wire)

<a href="http://s1062.photobucket.com/user/karimwassef/media/E03E9D12-4795-4E24-B212-F041736FC7E0_zpsh87o7zsj.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/E03E9D12-4795-4E24-B212-F041736FC7E0_zpsh87o7zsj.jpg" border="0" alt=" photo E03E9D12-4795-4E24-B212-F041736FC7E0_zpsh87o7zsj.jpg"/></a>

and soldered

<a href="http://s1062.photobucket.com/user/karimwassef/media/02CFE298-5AC3-4536-95D5-559DF19C7AF2_zpsywr95gzb.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/02CFE298-5AC3-4536-95D5-559DF19C7AF2_zpsywr95gzb.jpg" border="0" alt=" photo 02CFE298-5AC3-4536-95D5-559DF19C7AF2_zpsywr95gzb.jpg"/></a>

Yes - I know it's bad soldering ... shame shame

But each wire is not carrying that much current and the voltage is very low.

and...

<a href="http://s1062.photobucket.com/user/karimwassef/media/5E26628A-1AAB-4563-BB47-4287A53ABB0E_zpsc8vprpmw.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/5E26628A-1AAB-4563-BB47-4287A53ABB0E_zpsc8vprpmw.jpg" border="0" alt=" photo 5E26628A-1AAB-4563-BB47-4287A53ABB0E_zpsc8vprpmw.jpg"/></a>

colored duct tape "sheathing"

<a href="http://s1062.photobucket.com/user/karimwassef/media/C47B51A7-C8C2-4C22-B739-8F7251A0FBA0_zpsxzt9wo2y.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/C47B51A7-C8C2-4C22-B739-8F7251A0FBA0_zpsxzt9wo2y.jpg" border="0" alt=" photo C47B51A7-C8C2-4C22-B739-8F7251A0FBA0_zpsxzt9wo2y.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/21439729-4768-4A96-B5AF-AFE25455B641_zpsk4r35etw.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/21439729-4768-4A96-B5AF-AFE25455B641_zpsk4r35etw.jpg" border="0" alt=" photo 21439729-4768-4A96-B5AF-AFE25455B641_zpsk4r35etw.jpg"/></a>

and direct soldered to the power supply... at 50A, connectors are not a good option

<a href="http://s1062.photobucket.com/user/karimwassef/media/C14BD7F5-7743-4180-9BEE-E383CD080132_zpsiu88ivrn.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/C14BD7F5-7743-4180-9BEE-E383CD080132_zpsiu88ivrn.jpg" border="0" alt=" photo C14BD7F5-7743-4180-9BEE-E383CD080132_zpsiu88ivrn.jpg"/></a>

I didn't cover how to make these power supplies work - I needed to add a resistor across two pads in the back (and covered with duct tape). Here's a good reference for that

http://www.instructables.com/id/How-to-Convert-a-File-Serve-Power-Supply/step2/Making-it-turn-on/

and you can see it here

<a href="http://s1062.photobucket.com/user/karimwassef/media/1D0EDFC9-7180-44D2-A72F-EA14CEC159B0_zps4gmlxdm8.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/1D0EDFC9-7180-44D2-A72F-EA14CEC159B0_zps4gmlxdm8.jpg" border="0" alt=" photo 1D0EDFC9-7180-44D2-A72F-EA14CEC159B0_zps4gmlxdm8.jpg"/></a>

 

[karimwassef]

I added two high speed fans (also 12V)

and now to hang and test

<a href="http://s1062.photobucket.com/user/karimwassef/media/000E7BC8-0799-4DB8-B987-EBE067B9EB57_zpsfqinwjbm.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/000E7BC8-0799-4DB8-B987-EBE067B9EB57_zpsfqinwjbm.jpg" border="0" alt=" photo 000E7BC8-0799-4DB8-B987-EBE067B9EB57_zpsfqinwjbm.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/2E340B93-C5FA-49E5-B70F-47D8731C1D59_zpsooczbinz.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/2E340B93-C5FA-49E5-B70F-47D8731C1D59_zpsooczbinz.jpg" border="0" alt=" photo 2E340B93-C5FA-49E5-B70F-47D8731C1D59_zpsooczbinz.jpg"/></a>

Here's the 100W multi-chips for future use. These were actually hard to wire around

<a href="http://s1062.photobucket.com/user/karimwassef/media/23AD30FB-0604-4E61-8236-A71DB61C4A10_zpsxxgiabsz.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/23AD30FB-0604-4E61-8236-A71DB61C4A10_zpsxxgiabsz.jpg" border="0" alt=" photo 23AD30FB-0604-4E61-8236-A71DB61C4A10_zpsxxgiabsz.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/4A877168-A9BD-4CC4-B78B-D3F434E6DDDC_zpsaf4i4qop.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/4A877168-A9BD-4CC4-B78B-D3F434E6DDDC_zpsaf4i4qop.jpg" border="0" alt=" photo 4A877168-A9BD-4CC4-B78B-D3F434E6DDDC_zpsaf4i4qop.jpg"/></a>

and I needed to fix some of the strips (I reused a few to save $$)

<a href="http://s1062.photobucket.com/user/karimwassef/media/194D5979-2226-4EC2-8968-91A560F54A7E_zpsrfyev1ne.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/194D5979-2226-4EC2-8968-91A560F54A7E_zpsrfyev1ne.jpg" border="0" alt=" photo 194D5979-2226-4EC2-8968-91A560F54A7E_zpsrfyev1ne.jpg"/></a>

I used a plastic sheet from a local plastic vendor for the cover.

<a href="http://s1062.photobucket.com/user/karimwassef/media/7571ACE1-6934-46B9-9CD5-05770C1B23B4_zps4cysnv04.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/7571ACE1-6934-46B9-9CD5-05770C1B23B4_zps4cysnv04.jpg" border="0" alt=" photo 7571ACE1-6934-46B9-9CD5-05770C1B23B4_zps4cysnv04.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/C7895A17-124A-4E7B-BE21-A4CADAC1463B_zpsioqeqq9v.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/C7895A17-124A-4E7B-BE21-A4CADAC1463B_zpsioqeqq9v.jpg" border="0" alt=" photo C7895A17-124A-4E7B-BE21-A4CADAC1463B_zpsioqeqq9v.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/891AEA19-0FF7-4800-9145-5DC1185CF894_zps06qtujf7.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/891AEA19-0FF7-4800-9145-5DC1185CF894_zps06qtujf7.jpg" border="0" alt=" photo 891AEA19-0FF7-4800-9145-5DC1185CF894_zps06qtujf7.jpg"/></a>

and made it into a box bottom by bending the ends

<a href="http://s1062.photobucket.com/user/karimwassef/media/7F88824D-4E10-4C08-9A6C-C0EB115EF2D2_zpslfr3jb6k.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/7F88824D-4E10-4C08-9A6C-C0EB115EF2D2_zpslfr3jb6k.jpg" border="0" alt=" photo 7F88824D-4E10-4C08-9A6C-C0EB115EF2D2_zpslfr3jb6k.jpg"/></a>

and held it all together with large clips (easy and strong)

<a href="http://s1062.photobucket.com/user/karimwassef/media/B5D6D516-0136-4B4D-80A6-EDD4F8804272_zps4uqwas31.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/B5D6D516-0136-4B4D-80A6-EDD4F8804272_zps4uqwas31.jpg" border="0" alt=" photo B5D6D516-0136-4B4D-80A6-EDD4F8804272_zps4uqwas31.jpg"/></a>

 

[karimwassef]

ta-da

<a href="http://s1062.photobucket.com/user/karimwassef/media/32D3889D-8813-4669-8FE7-6F12A05EECE2_zpsiebe4prt.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/32D3889D-8813-4669-8FE7-6F12A05EECE2_zpsiebe4prt.jpg" border="0" alt=" photo 32D3889D-8813-4669-8FE7-6F12A05EECE2_zpsiebe4prt.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/C4EA2407-3A6C-4470-964F-DF8EC364A08E_zps5bemyy78.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/C4EA2407-3A6C-4470-964F-DF8EC364A08E_zps5bemyy78.jpg" border="0" alt=" photo C4EA2407-3A6C-4470-964F-DF8EC364A08E_zps5bemyy78.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/843221D9-248D-4E98-9ED3-D10DA5CAAD7A_zpsn9dkvkwv.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/843221D9-248D-4E98-9ED3-D10DA5CAAD7A_zpsn9dkvkwv.jpg" border="0" alt=" photo 843221D9-248D-4E98-9ED3-D10DA5CAAD7A_zpsn9dkvkwv.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/12B4A178-3E6E-4419-9FF0-5FBCA7CC9A49_zpshgqonotn.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/12B4A178-3E6E-4419-9FF0-5FBCA7CC9A49_zpshgqonotn.jpg" border="0" alt=" photo 12B4A178-3E6E-4419-9FF0-5FBCA7CC9A49_zpshgqonotn.jpg"/></a>

Now to test the PAR.. eggcrate sheet for controlled testing

<a href="http://s1062.photobucket.com/user/karimwassef/media/595B1CEE-34C4-458F-9905-46A2233E0E77_zpsvcozl5yk.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/595B1CEE-34C4-458F-9905-46A2233E0E77_zpsvcozl5yk.jpg" border="0" alt=" photo 595B1CEE-34C4-458F-9905-46A2233E0E77_zpsvcozl5yk.jpg"/></a>

and a PAR probe connected to my Apex

<a href="http://s1062.photobucket.com/user/karimwassef/media/D9414CEF-1279-4697-8372-102D78F10666_zpspr7x6boi.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/D9414CEF-1279-4697-8372-102D78F10666_zpspr7x6boi.jpg" border="0" alt=" photo D9414CEF-1279-4697-8372-102D78F10666_zpspr7x6boi.jpg"/></a>

 

[karimwassef]

and clips work very well, by the way

<a href="http://s1062.photobucket.com/user/karimwassef/media/133E7718-82CE-406E-AD89-62BE0F85B683_zpsfhol6kmg.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/133E7718-82CE-406E-AD89-62BE0F85B683_zpsfhol6kmg.jpg" border="0" alt=" photo 133E7718-82CE-406E-AD89-62BE0F85B683_zpsfhol6kmg.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/43DFDC6A-027E-4520-B64A-036D0461B341_zpswwn4iru5.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/43DFDC6A-027E-4520-B64A-036D0461B341_zpswwn4iru5.jpg" border="0" alt=" photo 43DFDC6A-027E-4520-B64A-036D0461B341_zpswwn4iru5.jpg"/></a>

<a href="http://s1062.photobucket.com/user/karimwassef/media/23079D6E-7E87-4120-9974-0B3DE85C0474_zpsjozpg89s.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/23079D6E-7E87-4120-9974-0B3DE85C0474_zpsjozpg89s.jpg" border="0" alt=" photo 23079D6E-7E87-4120-9974-0B3DE85C0474_zpsjozpg89s.jpg"/></a>

The rest of the material are probably another $35 so ~ $120 (I'm excluding the 100W multichip placeholders).

I'll post the PAR results next

 

[mcgyvr]

You sir have way too much time on your hands..
Nice work though..

 

[karimwassef]

LOL!!! No I don't.

I just like making. And I like the idea of a very uniform light source at 500W for $120.

What's the cost of that kind of PAR if purchased??

 

[perkint]

Nice - be interested to see the PAR readings

Tim

 

[karimwassef]

here's the PAR map

<a href="http://s1062.photobucket.com/user/karimwassef/media/LED%20experiments/0_zpsg70aruxp.jpg.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/LED%20experiments/0_zpsg70aruxp.jpg" border="0" alt=" photo 0_zpsg70aruxp.jpg"/></a>

this is at 12"

In contrast, here's my MH PAR map. There's three 400W MHs at different heights (12in, 10in, 10in) and different reflectors (center is expensive reflector from Hamilton: Cayman Sun with double ended HQI).

<a href="http://s1062.photobucket.com/user/karimwassef/media/LED%20experiments/Capture_zpsqflx1soi.png.html" target="_blank"><img src="http://i1062.photobucket.com/albums/t496/karimwassef/LED%20experiments/Capture_zpsqflx1soi.png" border="0" alt=" photo Capture_zpsqflx1soi.png"/></a>

The top map is brand new. The bottom map is 8-9 months old (I think).

The window I wanted to get even light on is 36" x 18".

So, for the same window, here are the results for the new 500W LED and brand new 400W MH (mogul & cheap reflector) at 12":

500W LED PAR : PEAK = 804, AVERAGE = 648, STANDARD DEVIATION = 108
400W MH PAR : PEAK = 769, AVERAGE = 404, STANDARD DEVIATION = 227
If I create an equivalent 500W MH (just for comparison) by ratio:
~500W MH PAR : PEAK = 961, AVERAGE = 504, STANDARD DEVIATION = 283

The HQI and Cayman is superior in output, but it is also at 10":
400W MH PAR (Hamilton HQI @ 10") : PEAK = 1649, AVERAGE = 1104 , STANDARD DEVIATION = 225
and the equivalent 500W version
~500W MH PAR (Hamilton HQI @ 10") : PEAK = 2061, AVERAGE = 1380 , STANDARD DEVIATION = 282
but now I need to correct for the height (x 83% penalty... that's a separate thread)
~500W MH PAR (Hamilton HQI @ ~12") : PEAK = 1701, AVERAGE = 1139 , STANDARD DEVIATION = 232

 

[karimwassef]

So... the LED wall is always better in uniformity (1/2 - 1/3 the deviation) of the MHs.

The PEAK on MH is always higher. The LED wall is better than the cheap grow reflectors, but much worse compared to the high end HQI with Cayman reflector.

 

[karimwassef]

The DC electric current measurement did end up at 50A. So the LED is actually running at 600W.... so a lot more inefficient than I expected!

I think it's because the LED strips are very wasteful with resistors used to set the voltage.

At little conversion from PAR to Watts.. shows that only about 83W of the 600W is being converted to light! 14%... wow. awful.

Converting the full 1200W map of MH from PAR to Watts too... shows that 169W of the 1200W is being converted to light! 14% also... coincidental alignment? probably. There are too many variables at play, not the least of which is the combination of cheap and expensive MH fixtures.

I'll need to redo the MH PAR numbers above for 600W comparison instead of 500W.

 

[karimwassef]

Here's the redo on PAR:

600W LED PAR : PEAK = 804, AVERAGE = 648, STANDARD DEVIATION = 108
~600W MH PAR : PEAK = 1154, AVERAGE = 605, STANDARD DEVIATION = 340
~600W MH PAR (Hamilton HQI @ ~12") : PEAK = 2041, AVERAGE = 1367, STANDARD DEVIATION = 279

still better than a cheap MH, and still much worse than the Cayman in terms of peak and average. Great for distribution.

So.. it's $120 for the inefficient LED. The cheap MH was probably about the same ~$200. The Cayman was ~$500.

 

[karimwassef]

So here are the build details
840 LEDs
0.71W/LED
600W
12V
50A

I ran a peak PAR test with and without the plastic sheet

open = 829 PAR
plastic = 802 PAR

so a 4% hit due to the plastic cover reflecting some of the light back.

 

[karimwassef]

so... would I do this again?

It's better and cheaper than the cheap horticulture MHs
It's much cheaper than the expensive MHs
I haven't compared it to my 3W LED star build...

Yes. I would certainly use it on an ATS. I would probably use it on softies and maybe LPS. I wouldn't use it on SPS.

Is it a lot of work? eh.. only because I made it a lot of work.

There are probably easier ways to put this together, but I'd leave that to another DIY

 

[karimwassef]

Also.. 650 PAR average at 12" isn't bad for such a low cost solution. I would actually consider bringing the wall much closer to the water surface. That's probably a different measurement that I need to make later.

Given the power loss, I also got a measure of temperature on the back of the metal wall surface. It's very thin with very high conductivity, so I expect the temperature on both sides of the flashing to be almost the same:

Stabilized temperature without fans = 75 degC = 167 degF
Stabilized temperature with fans = 47 degC = 116 degF

I could use a second layer of flashing to create a duct for better airflow over the back of the hot flashing, but I think this is fine... maybe

 

[saf1]

Not a lot of tuning or changing of spectrum with that particular DIY though. Don't get me wrong, it looked fun. And, well, you can do it so why not Or, if there is spectrum and intensity in there I missed it.

 

[SantaMonica]

Temps and cooling ?