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Making a DIY LED Fixture
Sam
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What we’ll cover
Pros and Cons of LEDs
Basics of LED fixtures and fixture design
Demonstrate a 27-LED fixture
Soldering demonstration
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Why use LEDs?
Physics:
◦ Low power consumption, high efficiency
◦ Can achieve very high light
◦ Long life
◦ Low heat input to tank
Cosmetics
◦ Point source generates shimmer effect
◦ Dimming options and color tuning.
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Why isn’t everyone using LEDs?
Costs can be high
◦ Individual high output LEDs ~$5. High end
DIY costs can easily exceed retail T5HO.
No great retail options
◦ High light products aim at reefers (blue light).
◦ Low output fixtures are too dim for us.
DIY approach still being refined
◦ No “tried and true” approach yet
◦ Not easy to see what you’ll end up with
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Basics of LEDs
Operate on DC power.
◦ Low power LEDs use 0.10-0.50 A
◦ Higher power LEDs use up to 1.5 A
Usually used in strings of multiple LEDs,
wired in series and powered by a driver.
Require a heatsink to dissipate heat.
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But what is all this stuff?!?
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Parts of a DIY LED array
Required: ◦ LEDs
◦ Heatsink
◦ Driver
◦ Something to hold the thing in place.
Optional: ◦ Dimming circuit
◦ Active cooling
◦ Optics for LEDs
◦ Something to make the thing look nice
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#1a: LEDs
Two basic approaches:
◦ Lots of cheap low-power LEDs
◦ Fewer expensive high-power LEDs
Well known producers: Cree, Luxeon, Bridgelux
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#1b: LED Packaging
LEDs can be small
and hard to work with
Solution: purchase
pre-mounted “stars”
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#1c: LED Optics
Bare LEDs generate wide arc of light. Optics
focus the light, allowing higher fixture
positioning and better light penetration in
deeper tanks.
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#2a: Heat dissipation
LEDs need to be kept cool.
◦ Cheap/Simple approach: Aluminum channel
or bar, preferably ¼” thick.
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#2b: Heat Dissipation
“Massive heatsink” approach:
◦ Use extruded aluminum heatsinks
◦ Many use HeatsinkUSA products
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#2c: Heat dissipation
Mounting options: glue or screw.
Adhesives are easy but more permanent.
◦ Two-part thermal epoxies
◦ Adhesive thermal tape
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#2d: Heat Dissipation
Screws are better (use thermal paste).
◦ Can buy pre-drilled and tapped heatsinks
◦ Learn to drill and tap.
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#3: “Driving” the LEDs
Driver provides constant DC current.
◦ Most people purchase this pre-made.
Number of LEDs per driver limited by driver
capacity and type of LEDs used.
◦ Meanwell driver can deliver 49v at 1.5mA, and Cree
XP-Gs each need 3.3v forward voltage 14 LEDs
per driver.
◦ Drivers also have minimum voltage requirements, so
you can’t have too few LEDs on a string either.
(Don’t test individual LEDs with your driver!)
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#4a: The theory of wiring LEDs
Simple: AC power goes into driver, DC
power goes out to LEDs wired in series
+
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+
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+
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+
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+
- +
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+
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Driver +
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AC in DC out
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#4b: Dimming Circuits
Dimmable drivers require another circuit
◦ Can voltage (e.g. 0-10v) or pulse-width
modulation (PWM) signal.
◦ Use retail “aquarium controllers” or control
voltage manually.
Driver +
-
AC in DC out
Dimmer control input
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#4c: The mechanics of wiring LEDs.
Soldering is a useful life skill.
Tips:
◦ Practice first!
◦ Use a large (40 watt or more) iron
Cheat:
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“Finishing” the completed fixture
Again, many options
◦ Suspend from ceiling or supports
◦ Integrate into hood
Height, optics and LED density interact:
◦ Large fixtures using widely spaced LEDs can
be mounted close to tank.
◦ Smaller fixtures with closely spaced LEDs can
be treated like MH fixtures – hang high and
project light into tank, focus with optics
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Remember!
You can mix and match LED types and
color—within limitations of your driver.
You can swap LEDs after you’re finished.
Easy to dim, hard to brighten.
Besides driver/LED compatibility, a lot of
room for creativity.
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Costs
My costs were pretty high
◦ 27 LEDs – $150
◦ 27 lenses- $30
◦ Heatsink - $100
◦ 2 Drivers - $75
◦ Hardware (screws, washers) - $20
◦ Tools (soldering iron, taps, etc.)
But you can do this much more cheaply.
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Observations
This is all somewhat experimental.
◦ Kits guarantee compatibility, support.
◦ Adding moonlighting to existing hood can be
easier project.
Kit manufacturers are good information
sources.
No individual part is hard, but a fair
number of steps.
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Resources
Planted tank forums
◦ RedfishSC
Reef forums
◦ Evilc66
DIY LED kit suppliers
◦ Nanotuners
◦ Rapid-LED
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List of things to bring
Fixture
Taps
Solder gun
Extra stars
Wire