RocketEngineer's 75g/125g Setup

Another thought occurred to me - are you looking to cycle the rock as well, rather than just let the phosphates leach out?

I remember that I soaked my dry rock in freshwater for a while (actually with a little vinegar, but not too much), and I never really had phosphate problems in the DT.

I would prefer to keep the surface of the rock unchanged as it has some very cool details. Thats why I'm not planning on using vinegar.

Cycling the tank is about creating the bacteria populations needed to support the life you add later. In my case, the rock has enough biological material on them to kick start this process. By doing it in saltwater I hope to get the same bacteria that I will need later. Keeping the rock in the dark prevents algae from growing and instead the nutrients drive bacteria growth. Right now the nutrient level in the water will cause bacteria blooms in the garbage can. Doing water changes pulls out the free floating bacteria, exporting the nutrients in the process. Eventually all I should have is rock with a bacteria population ready to go into the tank. If that is too early for putting the tank together I may add a shrimp or two to the bucket to keep the bacteria fed.
 
Lights are one step closer:
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Don't have the heatsinks yet so assembly will have to wait. That and a few other parts will be ordered before Christmas.

In furry friend news, the cat and dog were both sleeping on the couch the other night:
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Yup, Ariel regularly ends up with all four feet in the air. Silly dog.

RocketEngineer
 
Will they move if you are getting ready to reclaim the couch? :)

Exciting about the LED project. Have you posted any specs anywhere yet? How big are the heatsinks? One solid piece? Drilled and tapped?
 
I have my own chair. The dog doesn't fit in my seat anymore and the cat is easy to push around. Most of the time its just the dog on the couch and the cat sleeps elsewhere. Sunday night the cat was sleeping in the middle of the kitchen table and the dog was on the couch, dreaming. Every time the dog made a noise in her sleep, the cat's ears would twitch. Funny to watch.

Here is the layout I have settled on for the LEDs:

FinalLEDLayout.png


There are 90 LEDs total: (26) Neutral Whites, (8) Blues, (40) Royal Blues, (8) "UV", (4) Red and (4) Green. This gives me a total of eight strings (4 blue, 2 white, 2 "color") that I plan to run in parallel on four drivers. The LEDs will mount to two 7.28"X30" heatsinks. One of the guys at work has offered to drill and tap them for me. By going with RapidLED Solderless LEDs I can move LEDs around to balance the strings properly.
 
Wow, how the heck did you figure all that out? I like that you will be able to swap out easily, in case you don't like a color. Now, correct me if I'm wrong: don't some LEDs require different drivers than others, because they draw less power?

Are these dimmable drivers? Will you use acrylic shields? What optics did you choose for the lenses, considering the narrow heatsinks? Fans?

Sorry for all the questions! lol
 
I don't mind questions. It has taken over a year to get it all straight. I resorted to the colored spread sheet you see above to track the various ideas and to compare new ideas as they hit. I think there are 7 or 8 variations and I could use two of them on the 125g without too much change. For now I'm going with the big heatsinks but if I don't like the look I may try several smaller ones down the road. We will have to see how it plays out.

For parallel strings, its important to balance each string for proper operation. Using the solderless LEDs makes balancing a snap. The ability to change out colors later is just an added bonus.

The "UV" LEDs (V in the image above) are the only ones that are limited to 700mA. The drivers I got are dimmable and are rated to a max current of 1.3 amps. By dividing that into two balanced parallel strings, that maxes out at 650mA at full power. Now, these drivers have been shown to be capable of more than 1.3ma so I will use the dimming kit to keep the current around 600ma for those two strings.

Running the rest of the strings in parallel was a two fold solution. 1) It saved on drivers in the setup. At $34 each, I saved over a hundred bucks by going parallel strings. 2) Because of the way these drivers work, you should only have 6 or less on any circuit in your house. These drivers pull a high current at each peak of the 60hz AC cycle instead of constantly drawing a little throughout the entire cycle. This rush of current can overload the circuit briefly and heat the wires without tripping the breaker because the pull isn't long enough. Not good. Staying with only 4 drivers keeps it in the safe zone.

Once I paint the LED frames I will add a thin acrylic shield under the heatsink to keep splashes off the LEDs.

I'm going with 80 degree optics on the main LEDs but the color strings won't have optics. I want the colors to be more like highlights so the more spread the better.

Each heatsink will have one 200mm fan in the center. Given how much air one of them moves, overheating shouldn't be an issue. The fan and dimming kit will come on at the same time, before power is provided to any of the drivers. I will likely run the fans for a few minutes after lights out. Combined with the two 120mm fans in the hood, I should have enough air flow.
 
Based on the above LED layout I came up with the following wiring diagram.

FinalizedLEDWiringLayout.jpg


This is what I used to figure out the number of each length wire I needed. I have a combination of 3", 4.5", 6" and a couple 12" wires.

If you look closely you can see that the center of each LED is a different color. It helps for laying out the wire paths but the spreadsheet is still easier to see what color is where.
 
So, in the wiring diagram just above, you have four strings of LEDs with open ends...will one "fixture" (individual heatsink) connect to the other with a continuation of the strings?

Is it necessary to use a multimeter to adjust the output of any of the drivers? I know people use a potentiometer to control dimming, but is there any kind of indicator to buy to see the output as the potentiometer is adjusted?

Exciting stuff, IMO. Too bad I have so little knowledge, lol
 
The solderless LEDs are different than the typical LEDs that you solder to. If you look at this image you can faintly see wire traces under the black paint:
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The upper trace connects to either side of the LED but the lower one goes around the LED and just connects the bottom contacts in each socket to each other. So, if I have the red wire in the upper position on one LED, that same red wire goes into the upper position in the next LED. Doing so you get the + side of one LED going to the - side on the next just like you would on a standard setup. As long as you always keep the same color in that upper position, you connect them all in the correct sequence.

When you get to the end of the string, you add a plug that loops from the top side to the bottom. Now, instead of going through each LED, the current bypasses the LED until it gets back to the first one in the string. This first LED has a "drive jumper" that is basically a single ended jumper wire.

A diagram of this can be found here.

Here is the video tutorial on how the LEDs are wired:http://www.youtube.com/watch?feature=player_embedded&v=j7fwVP61kiM. The third wire is flipped so the black is on top but because it is the same at both connections, the current flows correctly. (I'm picky and would have kept the same color on the same side just to make sure I didn't screw it up).

SO, for my fixture, I get four strings on each fixture. They all have the end plugs on the outer edge and the driver wires in the middle. From there, the wires take a slight detour. Because I am using parallel strings, I need to measure each string to make sure the two are balanced. To do this, I put a 1 ohm resistor in line with each string. By measuring the voltage drop across that resistor, I can use the formula V=IR to get current because R=1ohm. With balancing, you want about the same current (+/1 50mA is what I have seen recommended) on each string. If they are too far off, you find the LED with the highest and lowest resistance and switch them. Continue testing and swapping until you get them balanced.

The other thing I add into the strings are fuses so that if one LED blows it won't take out the other string by dumping all the current into the string that's still working. My plan is to use mount the fuses and resistors between a pair of terminal strips and have the wires from the fixture come in one side and the connections from the drivers on the other.

The drivers I'm using are adjustable internally to set the max output voltage. This in turn limits the current at 100% on the dimming lines. Once that is set, the dimmer is used to back off from 100% to get the color combination I want. It also will let me acclimate the corals by starting at say 30% and working my way up. Eventually I will have an Apex and use the VDM to do dawn and dusk cycles rather than just on and off.

Where I work, there is a full scale electrical fabrication group. The technicians each have work areas with all the goodies needed build just about any hobby project you could dream up. By providing cookies on a regular basis I have enough favors to call in that borrowing a multimeter shouldn't be an issue. Also, the dimming kit needs to be soldered together and I hope to impose on one of them for a soldering iron to take home one weekend. I have a simple multimeter at home but their stuff is of much higher quality.

Once I get everything set up I will post pictures and instructions on how to commission an LED setup. The ones I have seen so far are good but could use with some updating.
 
Lol, the cookies are a good idea!

Thanks for that information. This is arming me with good knowledge for when I do my build. It will likely be to light a 120g (4') tank.

I like the idea of the fuses. Is that common practice in DIY builds? I'm looking forward to seeing this come together. I hope to see pics as you go, but will understand if that's too much trouble. :)
 
My mother and aunt (sisters) are both awesome cooks. I started setting out containers of baked goods soon after I started working. Having greased the wheels never hurts when you have to push folks.

A 120g is an great size. If you can get one that isn't drilled I recommend drilling it yourself rather than getting a reef ready one with those silly plastic overflows. If you go custom, have them make the overflow big enough for a BeanAnimal overflow. Everything I have read puts it leaps and bounds above a Durso only.

Fuses are recommended practice. Given the consequences, I would rather have to replace a $1 fuse than a string of 13 LEDs.

There will definitely be pics along the way. I'm starting to get impatient myself as this has been in the works since March. Part of it was working this spring and summer on lots of missions. Now all that is holding it up is ME. Maybe by the 1 year mark after buying the tank it will be all set up. One can hope.
 
Tonight I put together the dimming kit. Since I borrowed a soldering iron from one of the electrical technicians at work yesterday I figured I had better do it this weekend. It was fairly simple so even a mechanical type such as myself could do it. The only problem I had was a lack of wires but I got a bunch of cutoffs when I borrowed the soldering iron so problem solved. Tested it out and I get the full range of 0-10V.

PROGRESS.
 
The heatsinks have arrived. :bounce3: The pair of them arrived in good shape:
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Here is a shot of the profile:
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The heatsinks fit quite well into the frames:
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Next is getting the holes drilled. That may take a while as there are 94 holes per heatsink.
 
What's this, an early Christmas?
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Sorry, no. One of my items was on backorder so my Black Friday order didn't ship until yesterday. I found it on my back step when I got home from the movies.

Its a box of parts.....
AvastOrder008.jpg


AvastOrder015.jpg


I picked up a Swabbie:
AvastOrder018.jpg


A kalk reactor kit:
AvastOrder022.jpg


And a cone skimmer kit with pump:
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Now I have a bunch of things to work on. The only problem is they will all have to wait until after the holiday. Something to look forward to doing during the cold, dark winter nights though.

RocketEngineer
 
SO. Today was quite successful on the tank front. I went to a friend's house and we were able to get all the facing pieces cut for the hood. The next step for that build will be cutting the biscuit slots and pocket screw holes before assembling the four oak panels. I'm thinking about prefinishing the pieces before gluing everything. That way the glue won't interfere with the finish. We will see how it goes.

If that wasn't enough, this evening I assembled my Avast Marine kalk reactor. There were a few hiccups with what they sent me but otherwise it went fairly well. Pictures tomorrow.

RocketEngineer
 
Completed Skimmer:
Christmas2012041_zpsc206ae1e.jpg

It took me last night and this morning to do all the gluing. Overall I think the design is pretty good, especially for a kit. My only real issue was the quality of the cuts could have been better. It seemed like the cutter that was used was run too fast and didn't make the smoothest cuts. While it didn't affect the assembly, its something I noticed. Also, some of the holes weren't machined through to the far side and required cutting out the thin bit of plastic that was left. Easily fixed with a utility knife. I'm fairly happy with how it came out. The next step before I use it is to run it in the tub for a while to wash off the oils left on the plastic. Then I will see how it does on the 75g.

Completed Kalk Reactor:
Christmas2012049_zps07d3256d.jpg

I was able to finish this last night with the exception of the motor cover. That needed to be installed with silicone instead of glue in case there is an electrical issue. However, the one open tube of silicone I had was old and the bottom was solid. I had to cut the tube apart to get at the silicone that wasn't set. Not how I planned to do it but it worked.

I had two issues with the kalk reactor. First, the flange that came glued to the body tube wasn't positioned exactly right and that meant the tube wouldn't go in correctly. A little sanding opened the hole up enough for things the fit.

My second issue was the tube going between the inside elbow and the outside union was a good 1/2" too short. I understand that they were trying to make sure things fit but really? Did it have to be that far off? I would have preferred it to be 1/8" short but instead I had to glue it half way out of both fittings and not well placed on either one. A little extra pipe would have helped a lot.

Aside from the two issues, I realized that the reactor outlet sits about an inch below the rim of my sump. I would prefer to keep it outside the sump for now so I will have to build a platform of some kind to make it work. If I go with the new sump when I upgrade it will go into the sump.

On a side note my mother got me these for Christmas:
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Plastic Razorblades! No more rusting blades.

An individual blade:
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I will have to give these a try vs the coralline algae that has built up over the past week.

Happy new year.
RocketEngineer
 
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