An ultra high power direct drive LED driver

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texaspyro
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An ultra high power direct drive LED driver

Here is a driver that I did for Old Lumens DIY Handbuilt contest. It is an ultra high power direct drive LED driver.

How high power, you ask? Well the LED MOSFET is rated at 60 volts, 195 amps! But that is a little misleading. The MOSFET is in a TO-220 package which one can’t really pull more than around 100 amps out of :_( Well, 60 volts at 100 amps is 6000 watts. I have actually used a very similar circuit to control a 4000+ watt composite curing oven.

The design and firmware is basically the same as my custom Sky Ray King driver: http://budgetlightforum.com/node/21794

The AMC7135 current regulator chips have been replaced by the MOSFET and gate drive circuit.

It uses an external LM35 temperature sensor instead of the sensor built into the processor chip. The temperature sensor is mounted on the LED “star”.

And it has a second PWM channel for driving a thermostatically controlled fan (the hotter it is, the harder she blows J) ). The parasitic drain on the batteries is around 20 microamps.

PilotPTK
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That's a friggin DC Motor Drive, not an LED Driver Smile

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texaspyro
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PilotPTK wrote:

That’s a friggin DC Motor Drive, not an LED Driver Smile

Funny you should ask… been there, done that. 2 Hp spindle motor.

eebowler
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I see deans plugs. is it going to be power by some LiPOs? Big Smile

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texaspyro
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eebowler wrote:
I see deans plugs. is it going to be power by some LiPOs? Big Smile

Yep, 2×4S 6000 mAh NanoTech’s… They can put out over 1000 amps…

But the main reason for the Dean’s plugs is the fact that they can handle a lot of current and can be soldered to a PC board. The batteries have EC5 connectors on them.

relic38
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Nice one pyro! so, how many of those 150W emitters are you putting in this light? Wink

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texaspyro
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relic38 wrote:
Nice one pyro! so, how many of those 150W emitters are you putting in this light? Wink

Probably just one, but might be driven at 300 watts or so.. J)

At 10 amps, the MOSFET is only dropping 1/4 watt of heat. It has a 0.002 ohm on resistance.

leaftye
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I have no idea what you're saying, but I'm pretty sure it's awesome.

The low mode should be lower.

Rufusbduck
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When I saw the deans plugs I could estimate the scale. Remote barbeque lighter?

Three Tanna leaves to give him life, nine to give him movement. But what if he eats the whole bag?

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Hikelite
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What's going to be driven with this monsterfet?

texaspyro
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Rufusbduck wrote:
When I saw the deans plugs I could estimate the scale.

The board is 2 × 2.5” and used through hole parts since I had them sitting around. If I do it over again, it will be surface mount and much smaller (and with lower capacity FETs). I’d probably also put the high-current gate driver on the second PWM channel/FET.

dave_
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Beautiful!
J) <= that emoticon pretty much sums up my feelings while reading the specs.
I’m looking forward to your build! Smile

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leaftye wrote:

I have no idea what you’re saying, but I’m pretty sure it’s awesome.


That’s exactly how I feel as well! :bigsmile:
Sirius9
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I you can spare couple of W you could use peltier cooler J)

 

texaspyro
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Sirius9 wrote:
I you can spare couple of W you could use peltier cooler J)

Peltier coolers are a joke. They take over 20 watts of power to produce 1 watt of cooling… and you have to get rid of the 19 watts of heat somehow…

Microa
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Awesome and powerful. Whether a 75×75mm CPU fan cooler can handle the heat of the LED and the driver. It should produce a lot………………of light.

Sirius9
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texaspyro wrote:
Sirius9 wrote:
I you can spare couple of W you could use peltier cooler J)

Peltier coolers are a joke. They take over 20 watts of power to produce 1 watt of cooling… and you have to get rid of the 19 watts of heat somehow…


hm, didn’t know that.

 

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That is some coolness right there, TP!!   >)

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texaspyro wrote:
Sirius9 wrote:
I you can spare couple of W you could use peltier cooler J)
Peltier coolers are a joke. They take over 20 watts of power to produce 1 watt of cooling... and you have to get rid of the 19 watts of heat somehow...

That's easy. Just use a second TEC to cool the first one. Party

relic38
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texaspyro wrote:
relic38 wrote:
Nice one pyro! so, how many of those 150W emitters are you putting in this light? Wink

Probably just one, but might be driven at 300 watts or so.. J)

At 10 amps, the MOSFET is only dropping 1/4 watt of heat. It has a 0.002 ohm on resistance.


MOSFET pr0n:
http://ixapps.ixys.com/DataSheet/DS100243%28IXTZ550N055T2%29.pdf
RDSon = 0.001 Ohm
This one is in a slightly different class though, the package is somewhat large for your board Wink

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texaspyro
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relic38 wrote:
MOSFET pr0n: http://ixapps.ixys.com/DataSheet/DS100243%28IXTZ550N055T2%29.pdf RDSon = 0.001 Ohm

27 bucks a pop… and you have to buy 9 of them. Also, they conveniently don’t spec some important specs…

relic38
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Not sure about missing specs being convenient for anyone… which missing specs should be there?

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leaftye wrote:

I have no idea what you’re saying, but I’m pretty sure it’s awesome.


Me as well. It sounds like your light may be used on a locomotive?

 

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nice! 300W=around 12000 lumens ? you win the lumen part of the contest.

texaspyro
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djozz wrote:

nice! 300W=around 12000 lumens ?

More like over 20,000 lumens… You get well over 15,000 lumens at 150 watts.

PilotPTK
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texaspyro wrote:
Sirius9 wrote:
I you can spare couple of W you could use peltier cooler J)
Peltier coolers are a joke. They take over 20 watts of power to produce 1 watt of cooling... and you have to get rid of the 19 watts of heat somehow...

Actually, you have to get rid of 21 Watts of heat in that circumstance.  The 20 watts generated by the pelt PLUS the 1 watt of heat that is "Moved" from the cold side to the hot side.

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simplec6
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texaspyro, any chance of you becoming some competition to TaskLED drivers? I love the H6Flex, but 40 bucks for a driver has gotta be a healthy profit margin, no?

Any chance of you making a cheaper version of the H6Flex?

PilotPTK
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simplec6 wrote:
texaspyro, any chance of you becoming some competition to TaskLED drivers? I love the H6Flex, but 40 bucks for a driver has gotta be a healthy profit margin, no? Any chance of you making a cheaper version of the H6Flex?

40 bucks for the H6 flex is a healthy profit, but depending on the volume of them that are sold, it's not totally crazy.  One cannot run a business for long on an unhealthy profit...

PPtk

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simplec6
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You would know better than I would PPtk, it just seems to me that the components itself would only be like 20 bucks?

If 40 is a good deal, then I won’t argue, I’m just a cheapo I guess.

PilotPTK
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You're probably not far off simplec6..  With the cost of parts that don't pass QC and require rework or rebuild, the cost of RMA parts that fail in the field and must be replaced for the customer and the cost of overhead in running a business, that is actually just about the right breakdown.  Most electronic manufacturers run at right around 50% material cost..

Anything less than that, and one is running a hobby, not a business.  When material cost is more than about 50% of your sell price, you'll be losing money just about every time.  There are limited exceptions (like products with VERY expensive materials or VERY cheap materials).

PPtk

I am currently extremely busy with work. Please do not expect a response from me quickly. I will be dropping in as time permits, but the amount of time I can dedicate to responding to topics and PMs is very limited.