LEDBrick Project - DIY pendant w/ pucks
- Thread starter theatrus
- Start date
theatrus
100-mile-commuter
First shot of the 8-up with Luxeon C and SemiLEDs Violets (3535 size, the 1A N3535 is the target). I don't yet have the SemiLEDs in hand, so it'll be a week or so until I have something to show:
I designed it so a Luxeon C could be placed instead of a violet on each channel.
Also, the MicroDriver:
This is not the *nano* driver with the fan PSU on board, but a simpler, bigger version featuring two connectors.
48V capable, it is simultaneously adjustable with the pot (its tiny
) between 350mA-1000mA, and via the PWM DIM signal. I built it with the strips in mind (which also got a SemiLEDs dual treatment) in a revision not shown here, but can also power the round stars of course.
Two of them are a bit bigger than the "Basic4" driver, but its designed for flush mounting (all surface mount) and the DIM signals are connectorized, plus controller-less dimming and 48V!
Also, firmware is progressing on the controller. iOS app is taking shape (its not beautiful but functional). I got a final revision of the controller PCB and working on the mechanical drawing for the case cutouts.
I designed it so a Luxeon C could be placed instead of a violet on each channel.
Also, the MicroDriver:
This is not the *nano* driver with the fan PSU on board, but a simpler, bigger version featuring two connectors.
48V capable, it is simultaneously adjustable with the pot (its tiny
) between 350mA-1000mA, and via the PWM DIM signal. I built it with the strips in mind (which also got a SemiLEDs dual treatment) in a revision not shown here, but can also power the round stars of course.Two of them are a bit bigger than the "Basic4" driver, but its designed for flush mounting (all surface mount) and the DIM signals are connectorized, plus controller-less dimming and 48V!
Also, firmware is progressing on the controller. iOS app is taking shape (its not beautiful but functional). I got a final revision of the controller PCB and working on the mechanical drawing for the case cutouts.
theatrus
100-mile-commuter
Did some building of prototypes:
The drivers work pretty well, fully adjustable from 400-1000mA via the pot, and then dimmable on top of that. Need to exercise them some more.
The lighting controller board has only had basic testing done (power supply, programs, etc). I still need to modify the stock Polycase case with my drawing to confirm fit:
The drivers work pretty well, fully adjustable from 400-1000mA via the pot, and then dimmable on top of that. Need to exercise them some more.
The lighting controller board has only had basic testing done (power supply, programs, etc). I still need to modify the stock Polycase case with my drawing to confirm fit:
theatrus
100-mile-commuter
Yup! There are 6 vias under each IC to the bottom, which is one big ground plane. All SMT makes the board flush mountable to anything metal, which was a huge drawback from my prior Basic4 driver.
Again... that little driver board looks great! It just so happens that I finished up a new driver design using that same chip a little earlier this week! I've got the BOM coming in from Digikey & the Pcb's / solder stencil in production @ Elecrow. Can't wait to do some soldering!:bounce3:
theatrus
100-mile-commuter
Love to see it. The original power-SO8 ones have been running for over a year without any hiccups in my original LEDBrick pendants - they sit in airflow but the fan is variable duty cycle based on the puck temperature and is only on about 30% of the time. However, I will caution that they are NOT very robust against transients to their DIM pin - so be careful if you're plugging things hot.
Whats your target frequency? I've mostly settled at 500kHz - I lost some efficiency with the small inductors on this version, so be sure to size up if you have the space
Love to see it. The original power-SO8 ones have been running for over a year without any hiccups in my original LEDBrick pendants - they sit in airflow but the fan is variable duty cycle based on the puck temperature and is only on about 30% of the time. However, I will caution that they are NOT very robust against transients to their DIM pin - so be careful if you're plugging things hot.
Whats your target frequency? I've mostly settled at 500kHz - I lost some efficiency with the small inductors on this version, so be sure to size up if you have the space
Being that most of my parts inventory had been geared toward the A6211, I thought I'd try to save a few bucks by using components that I already had on hand. My target frequency is 500kHz too, but my inductor is 8mm in size and rated for 2A. The diode is rated for 100V/3A. I hope they'll perform well?
theatrus
100-mile-commuter
Shouldn't be an issue. The diode only factors in in lower duty cycle (much higher Vin vs Vout) majorly, and 3A is plenty there (though it will usually pulse higher), and efficiency can be improved with as low of a Vf as possible. My small size diode which performs really well is the PMEG6020ER.
That's good to hear. Thanks for the info. I'm sure my first attempt at building a driver with this chip will have a few bugs. I'll use your advice on the diode selection on the next design iteration. I'll probably shrink the size of the other components as well. Going from 1206 to 603 will help too. They'll be just a little tougher for me to see.....as I'm my own "Pick &place machine".
theatrus
100-mile-commuter
Just avoid may occasional mistake where I blindly order an 0603 (Metric) part! The 01005 parts are literally dust specks.
I hand place all the parts currently, though if I clean up some surface area in the workshop a Neoden PnP with vision looks awfully appealing
theatrus
100-mile-commuter
Sneak peak at violet mixed footprint strips
One channel has up to two violets, and one has one. Looking to do a 50/50 violet / blue mixed strip, along with normal full spectrum lineups. I'm experimenting with different 12-30" long heatsink segments to figure out what thermally works, if we need to fan boost, and driver mounting.
One channel has up to two violets, and one has one. Looking to do a 50/50 violet / blue mixed strip, along with normal full spectrum lineups. I'm experimenting with different 12-30" long heatsink segments to figure out what thermally works, if we need to fan boost, and driver mounting.
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jedimasterben
LED world domination!
Don't stress out over trying to get mint in there. As long as you have royal blue in the array, you won't be able to tell a difference between lime and mint.
theatrus
100-mile-commuter
Currently, won't fit Luxeon Cs. Once I knock out some other projects I'll try doing a staggered grid, but right now the 16 is with the Zs.
theatrus
100-mile-commuter
Yeah, visually I agree, the peaks will be at all the same spots, though a tad more violet (since its a higher frequency base LED in the Mint vs the RB). The upside to the C Mint/Lime is the full 1A rating (not the 700mA limit from the Z on the Lime), which is more of a driver convenience and not something you'ld likely want to run at 100%.
I'm thinking about using 5 of the AcroStar Mega4Z with the round heatsink with the small round fan how long would the heatsink need to be and what would you use for the controller the 2 of the 4 Chanel and mount in on a rectangular heatsink with fan or what would you do I'm going to eventually have 9 total over the tank just not all at once thanks for the help and great product
theatrus
100-mile-commuter
For the small fan and heatsink, the 48W is simply too much power. You'll need to use something with more energy movement - CPU coolers with heat pipes work pretty well, as do larger slabs of aluminum with 80mm fans.
The small round heatsink might work with a lot more forced airflow - but the little quiet 40mm is not going to cut it.
