15,000 Lumen Bridgelux C9000 Light Engine

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texaspyro
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15,000 Lumen Bridgelux C9000 Light Engine

Ok, what do you get when you take:

That’s a $67 Bridgelux C9000 array (cool white), $8 Intel copper CPU heatsink/fan, and a $6 150W Chinese DC-DC converter (modified for constant current output ). The DC-DC takes 10-30 volts in and outputs 5A at up to 35V out. I’m driving it right now at 15V, 12 amps. Even with a rather crappy power fet, it is around 88% efficient… who say’s boost converters can’t be efficient? A decent FET should get the efficiency up over 90%

You get:

It starts out at around 16,400 lumens and falls to around 15,300 lumens after 3 minutes (the heatsink does not quite fit in my sphere’s input orifice and I am losing around 1400 lumens in the transition). Note that the LED output is actually increasing over time.

The color temp numbers are bogus since the color sensor is saturated. The LED numbers are not valid since those sensors are not connected. The BATT numbers are the LED voltage/current/power.

It is driving the LED at 162 watts (30.7V, 5.3A). That little Chinese Dc-DC boost converter actually works rather well. The little heatsink fan is a screaming meanie… it keeps the LED at around 44 degrees C. Not too shabby sloughing off over 150 watts of heat.

Now to add a big honkin’ reflector and a dimmer/monitor/etc processor.

Edited by: texaspyro on 04/15/2013 - 18:24
texaspyro
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Reserved…

texaspyro
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More reserved…

Ledsmoke
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Uhhh! I can't wait for the next update. This will be epic. Mwuhahaha!

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ObiWan-Kenobi
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This gives true meaning to the phrase

“Let there be light”

Good luck with the reflector. When its done, make sure you use the same eye protection that the folks were using to witness the recent total eclipse in northern Australia before powering it up Smile

kahvitahra
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Looking forward for more tests. That is one badass LED!
Nice man!

scaru
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Texas, you should sell kits with the modded power supply and a heatsink. I would certainly get one. Big Smile

Pinetreebbs
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So much light it should have a sound effect each time it turns on.

http://instantrimshot.com/index.php?sound=csi&play=true

texaspyro
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ObiWan-Kenobi wrote:
Good luck with the reflector.

I bought some of those SST-90 reflectors from Illumination Machines (http://www.illuminationmachines.com/products.php?id=9&catId=1). Hopefully the back end can be opened up enough to fit the 32mm diam Bridgelux emitter circle.

I also have some of the Ledil reflectors built just for the Bridgelux, but they are 24 degree beam width.

scaru
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texaspyro wrote:
ObiWan-Kenobi wrote:
Good luck with the reflector.
I bought some of those SST-90 reflectors from Illumination Machines (http://www.illuminationmachines.com/products.php?id=9&catId=1). Hopefully the back end can be opened up enough to fit the 32mm diam Bridgelux slot. I also have some of the Ledil reflectors built just for the Bridgelux, but they are 24 degree beam width.

Hmm... If their specs are right at 46cd/lumen wouldn't this thing do something like 690kcd? Evil

texaspyro
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scaru wrote:

Texas, you should sell kits with the modded power supply and a heatsink. I would certainly get one. Big Smile

I’m not sure that I like that copper heatsink that I am using. It is nice and compact and works VERY well, but the fins are short and closely spaced. That requires high pressure air to get in there. The fan on it is a screamer and is recessed into the fins. I would like to build the engine up with a single fan that can provide air to both the LED and the driver.

I am planing on building a small board that fits on the back of the driver. It will have the ACS712 current sensor and an AVR (ATMEGA328?) that controls everything. It would have a FET for switching power to the driver, one for PWMing the fan, and one for PWMing the LED. Parasitic drain on the battery should be around 20 uA. Dimming via a button or pot. It would also monitor the battery, etc.

texaspyro
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And something tells me this thing will make an awesome puke light J)

When I was setting up the constant current mod, I had the current level set at around 2A. That is below the minimum level that the circuit wants to work at. The thing started flickering some. I went to crank up the drive level, but turned the pot the wrong way. Then it REALLY started flickering. The effect was rather awesome, even though it was only doing 5000 lumens at the time and the LED was shining into my sphere.

jamio
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Now this will be really a lot of light! Cool  I'm curious how it will perform with SST-90 reflector.

sacra
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How about a quick write-up on the conversions you made to the DC-DC converter?

My Bridgelux RS array arrived today. Only around 6600lm max so it’s just a baby compared to your C9000. Waiting for the power components to arrive…

texaspyro
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jamio wrote:

Now this will be really a lot of light! Cool 

It makes the sun squint… 8)

scheven_architect
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wow, would buy custom made with this inside Shocked

 

 
texaspyro
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sacra wrote:
How about a quick write-up on the conversions you made to the DC-DC converter?

Search Ebay for “600W DC-DC” There are some $20 DC-DC converter modules that are already constant current capable. They can output up to 80V (drive two C9000’s in series?) and they claim to by 95% efficient. I have a couple on order… http://www.ebay.com/itm/DC-DC-600W-10-60V-to-12-80V-Boost-Converter-Step...

pretzy
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Love

The light shines in the darkness, and the darkness has not overcome it.

texaspyro
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I kludged up an external PWM dimmer onto the constant current driver… it failed miserably. Any dimming caused the LED to go into puke-flicker mode. Turns out that the stock program in the dimmer is PWMing at 100 Hz… way too slow to maintain a stable output. The constant current driver has a 1000 uF output cap, which 5A of current significantly drains between 10 millisecond PWM pulses.

I need to reprogram that dimmer chip for something like 10 kHz PWM

Slewflash
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scaru wrote:

texaspyro wrote:
ObiWan-Kenobi wrote:
Good luck with the reflector.
I bought some of those SST-90 reflectors from Illumination Machines (http://www.illuminationmachines.com/products.php?id=9&catId=1). Hopefully the back end can be opened up enough to fit the 32mm diam Bridgelux slot. I also have some of the Ledil reflectors built just for the Bridgelux, but they are 24 degree beam width.

Hmm… If their specs are right at 46cd/lumen wouldn’t this thing do something like 690kcd? Evil

I think that spec is only for an SST-90. Perhaps if you could get 15k lumens from an SST-90 sized emitter you’d be able to get that kind of throw, but the array is freaking huge. I expect closer to 100kcd, given that the bare emitter already gives off 15kcd.

Slewflash 

texaspyro
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I tweaked the dimmer firmware to do 32 kHz PWM. The driver behaves a bit better, but still messes up below around 35%. I tried adding a bigger cap (another 1000 uF) across the driver output… it just made things worse. I need to see what happens if I shorten and clean up all the external wiring… and maybe reduce the output cap on the driver.

I did manage to blow the switching FET in the driver by pulling around 220 watts out of it (maybe 19,250 lumens). I replaced it with an IRF3036 (2 milliohm, 190 amp rating, the original FET was 10 milliohm, 75 amp). I was expecting to see some decent improvement in the driver efficiency, but it was minimal.

JohnnyMac
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Wowzers! That is sweet!

texaspyro
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The BHR’s (Big Honkin’ Reflectors) should be in tomorrow…

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texaspyro wrote:
I tweaked the dimmer firmware to do 32 kHz PWM. The driver behaves a bit better, but still messes up below around 35%. I tried adding a bigger cap (another 1000 uF) across the driver output… it just made things worse. I need to see what happens if I shorten and clean up all the external wiring… and maybe reduce the output cap on the driver.
I’m experiencing a similar problem with a AL8805 1A buck driver chip. PWM below 25-30% and it goes irregular blinky on me. I upped the PWM and still about the same deal. I might try a DAC output of my PIC, and see if that helps.

Maybe my problem is that it goes into a discontinuous mode? The inductor is only a 10uH one, so next up will be to try a higher value inductor. That, or my data sheet interpretation is messed up, it wouldn’t be the first time Smile .

EDIT:Heh, discontinuous mode not discontinuance

Kent

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Just warn me when you turn this thing on and start aiming it at things. I want to pull the shades down and put on sunglasses. Ought to be able to see it here in Tyler, when you fire it up, LOL.

I figure you will have about 5 minutes before the chopper arrives with their little spotlight, to search for you.Wink

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gords1001
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Chuck Norris’s edc! :bigsmile:

texaspyro
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Old-Lumens wrote:
I figure you will have about 5 minutes before the chopper arrives with their little spotlight, to search for you.

Meh, mine’s brighter than theirs… 8) The beam has enough photon force to push them away…

ObiWan-Kenobi
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:bigsmile: Just don’t turn it on within 20 miles of an airport. The helicopter that comes for you will have Bruce Willis as well as Chuck Norris in it.
texaspyro
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I got in the Big Honkin’ Reflectors (ok, 90mm is not that big) from Illumination Machines. Whacked 5mm of the bottom of one to get a 34mm hole. It cranks out 70,000 lux at 1 meter (around 10 degree beam width). The beam is as smooth as a baby’s behind. I’ll try and get some pics up soon.

Old-Lumens 1.3 mile SST-90 Aspheric Potato Masher Thrower does 39,000 lux at 1 meter. A Jacob A60 does around 35,000 lux at 1 meter. These lights have a considerably tighter beam.

simplec6
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Holy mother. This is very badass.

What kind of portable power source is used to power a light of this magnitude?

texaspyro
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simplec6 wrote:
What kind of portable power source is used to power a light of this magnitude?

It can run on 12V to 30V DC. At 12V it pulls around 15 amps. I was going to (and still might) power it with a 4S A123 20Ah LiFePO4 pack, but A123 is in a bit of a financial meltdown at the moment and their cells may no be viable in the long term. Or any 4S-6S LiPo pack. Or a car.

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