Step by step full spectrum diy led build

greg0385

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INTRODUCTION:
This build is a step by step with lots of pictures, full spectrum 90- 3watt dimmable led build.

First, allow me to explain why i chose leds. I have a 150 gallon tall fish/reef tank (48 x 24 x 31)( l x w x h). I was using 2- 250watt Metal Halides Phoenix 14k, 4- 54watt ATI t5 bulbs overdriven by a icecapp 660 ballast. My rockscape is two islands that are 15" tall, which leaves 16" of water for the lights to penetrate. I have around 30 high end acros on my rockscape and the tank has been running for just over a year. Over the last year i have tried to solve my problem of acros not being as colorful as other people's tank. After borrowing my local reef club' s par meter, i realized that the par was only 200-225 ontop of my rockscape and 150-180 on the sandbed. Not being satisfied with the results my options were to replace the Metal Halides with- 4 more t5s or 2- 400watt Metal Halides or LEDS.

With leds becoming more popular and the savings on electricity and bulbs replacement made me choose leds over my other options. Now the choice was how diy or commercial? Being that I enjoy diy projects, i began doing research on a diy led kit. I knew I wanted the leds to be full spectrum. With some help from some local members(dwilliams, gmoney) I decided to buy Aquastyles 90-3watt bridgelux dimmable led kit. With this kit I had it customized to the following:
18- blue(460nm), 18- royal blue(452nm), 9- 10k, 9- 6500k, 6- UV(398nm), 8- violet(420nm), 6- green(525nm), 6- cyan(520nm), 6- pink(448/600nm), 4- red(660nm). The kit came with 5 dimmable drivers and 60° optics. I purchased a extra driver to allow me to have full control with each spectrum. Blue, royal blue had their own driver, 10k and 6500k are on another driver, UV and violet on a driver, cyan and green are on a driver, red and pink are on a driver.

LED BUILD:

With the kit ordered, I had a local member(dwilliams) help me draw out how I wanted the layout of the leds. I wanted the layout to replicate my MH reflector, so we decided on a 5 rows with 9 leds per row. This layout gave me 45 leds per side in a 9" x 17.5" design.
Here is the layout on paper:
1362358068219.jpg


Within a week my leds were at my house, so i made a trip to Home Depot to buy materials to build a heatsink and material needed to hang it. The material i bought was:
2- 3/4" x 96" aluminum C channel, 2- 3/4" x 36" aluminum 90° angled and misc drill bits, s-hooks, eye screws and chain
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I cut the C-channel into 17.5" peieces
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More to come on the next post in a few minutes


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greg0385

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After cutting the C-channel into 10- 17.5" peices, i cut the angle aluminum to 4-9" peices
Dry fit the peices together
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I wanted to hide all the wires inside the C-channel so i drill a 3/8" hole on both ends of the C-channel to allow me to run all the wires.
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More to come on next post


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greg0385

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After attaching all the peices together, it was time to measure out the layout for the leds
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Now that i had my design drawed out on the metal. I started to glue leds using the paper layout design
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I drilled a 5/64" hole in between where the leds would be at so i could route the wires onto the back side of the heatsink. That way all the wires wouldnt be seen.
1362360072422.jpg


More to come in the next post

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greg0385

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Now it was time for a local reef club ( dwillams) to help me by routing all the wires and start soldering.
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This bottom pic shows all the wires on the back routed
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greg0385

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With all the wires routed and leds now soldered i had 2- 6 wire leads coming out of each heatsink. Luckly there was a friend there who knew how to braid the wires so they would look nice. The braid she did is named FISHBONE!!
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More to come on next post

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greg0385

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With all the wires braided, it now time to test each channel
1362361472964.jpg

Green and cyan
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UV AND VIOLET
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10k and 6500k
1362361380060.jpg

Red and Pink
1362361424805.jpg

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greg0385

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Blue
1362361521227.jpg

Royal Blue
1362361557650.jpg


With all the channels tested, i drilled a hole in each corner so i can use a s-hook and chain
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Now to hang the leds in my canopy
1362361780241.jpg

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greg0385

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After testing the chains and height of the leds i put all the optics on
1362361877437.jpg


Now its time to fire up the leds over the tank. All i can say is WOW!!
Green and Cyan channel only
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Red and Pink channel only
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UV and Violet( my favorite) channel
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10k and 6500k channel
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Usctom

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Very clean looking. I really liked the braiding of the wires. How hot are the LEDs getting? Are you running a fan?
 
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greg0385

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Blue channel
1362362260728.jpg

Royal blue
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All channels on and adjusted
1362362363297.jpg

In the shadows there are tiny rainbows
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Unfortunately it doesnt show up well
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greg0385

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I made a bracket to hold all 6 dimming dials
1362362796934.jpg



Now for the results!!
With all 6 channels at 100% here is the par ontop of my rockscape through 16" of water!!
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Now on the sandbed, 31" deep!!
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Now with my t5 and leds on ontop of rockscape
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On the sandbed
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Im getting the same par using leds on my sandbed as i was using MH/t5s ontop of my rockscape!!
Currently i have the leds turned down to 275par ontop of scape and will gradually bring up the par as the corals adjust.

In closing i must say i am impress with what i was able to do. The craftsmanship in this build is top notch. A huge thanks goes to the local club memebers that help me build this. Especially dwilliams who did all the soldering and wiring. This build was so much fun to do and to know i now have all the par i want without loosing any spectrum. In the future i will post pics of the corals as they color up. I will also try to post any results i see as time passes. I hope this build is helpful to all and thank you for reading this.
I will post a link to my 150 build for anyone interested in it
https://www.reef2reef.com/forums/member-tanks/60051-gregs-150-build.html

Thank you all
Greg
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greg0385

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So far nothing is getting hot, the heatsink gets barely warm. The drivers are a little warmer than the heatsink but the t5s are way hotter. I do have 4-4" computer fans in the canopy but they only come on if water temp gets over 78.2F. I may change them to run at a different time then temp i notice too much heat from the lights.

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gmoney243

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Great builb bro. But im still afraid u may experience some bleaching or colors fading as 250 par of MH is way less light than 250 led par. Hope not tho :) cant wait to come see em.

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greg0385

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That can be fix with a twist of a dial

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CoralFragZ

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Very good job. As one with the similar build in the works It is not easy drilling all of those holes. In fact I broke so many bits I just used the circular saw and notched out a 1/8 in the backside to run the wires. You did a fantastic job and it is a great upgrade and will pay its dividends.
 

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