07/07/15 Finished Handmade CXA3590 - Lum5-90 light build - Beam shots are in Post #1

Reserved

GO-GO OL :smiley:
Edit 7-9-2015
Kabooooom light, I love the diamond patern reflector but you have to add the handle :smiley:

DAMN.

Humm Too Cool (or maybe too hot?) :wink: .

Random thoughts:

High Performance Potting Epoxy

Samsung INR18650-25R for the US post number #12

and maybe liquid cooling? Cells/driver/emitter hay who knows?

Cree.com / LED Components / Products / XLamp LEDs / CXA3590 XLamp CXA3590
High lumen output and efficacy from a single, easy-to-use LED array
The XLamp CXA3590 LED Array delivers high lumen output and high efficacy in a single, easy-to-use package that eliminates the need for reflow soldering. Optimized to simplify designs and lower system cost, the CXA3590 LED Array can deliver system-level performance of 10,000 to over 16,000 lumens, enabling very-high-lumen-output applications such as high-bay and metal-halide replacements.

Compare CXA LEDs
SpecificationsVariationsDocumentation Multimedia Data Sheet (pdf)
Size 34.85 x 34.85 x 1.7 mm
Product Options 36 V
77 V
High-CRI
Maximum Drive Current 1.8 A
Maximum Power 150 W
Light Output Range 10000 - 18000 lm
Light Emitting Surface (LES) 30 mm
Typical Forward Voltage 77 V @ 1.2 A (85°C)
Viewing Angle 115 °
Binning 85°C
ANSI (White)
2- and 4-Step EasyWhite®
RoHS Compliant Yes
REACH compliant Yes
UL recognized Yes - Level 4 Enclosure Consideration
Package Size 34.95 x 34.95 mm

WOW

Justin, you said you “hope” to get 10,000 lumens from this light at 3A drive current? The LED is rated for up to 3.6A at 36V and up to 18,000 lumens. I don’t know what the normal curve is, but I think you should easily get over 10,000 lumens. I’m looking forward to seeing the build!

A conservative 10000 OTF. It all depends on that unknown converter. If it's true that a higher voltage input will help it to get a 3+ amp output, then it should do it easily. Time will tell. I hope I can get 4 amps out of it, but won't know till I get the led in and start testing.

Why did you choose a boost driver instead of a buck? Is there such a thing as a buck with ~36V out?

I’m sure there probably are. These were available and had youtube reviews and I didn’t really want to go with more cells. They were what I found when searching the net. Lots of boost converters, probably meant more for 12V automotive than anything else.

That makes sense. Thanks!

Updated the OP - 06/05/15

You wont be the least surprised about this but l dont know what your doing. It seems to keep me enthralled though.

The battery pack with all the charging components looks like a real doozy.

This look like an interesting build, good luck :slight_smile:

I am sorry to hear you got unemployed :frowning:

Not your run of the mill mag mod.

Subbed

Great build as always, can't wait to see it finished.

Correct me if I'm wrong but this looks like protection circuit board (PCB), not a battery management system (BMS). This should work in charging mode but only with that charger that You bought that has a end cut-off voltage. BMS would work with any power supply with correct voltage. Hope You can provide status of every single cell in this battery pack after a few charging and discharging cycles. That would be very interesting.

PCM, but from what I read, besides balance charging, it also manages output, so that no one cell is getting very low. If one cell is lower, it “supposedly” balances the power to the other cells, but that may just be my lack of knowledge. I certainly don’t have a clue about these boards.

Very impressive.