Stealth LED Array light .

stardustsailor · Oct 6, 2014

Just a small example ...

The efficiency graph of The MeanWell-HLP-80H ....
For the 42 V model I use ,has a 100% full rated power of 81.9 Watts= ~82 Watt s

A single CXA operating at 35C and 350 mA ..
Power : 11,725=~12 Watts
CXA Efficiency : 52,51%
Drivers efficiency : ( 12 Watts is 14.6 % of full load ) = ~76 % ( 230 VAC )
Overall efficiency : ~64.2 %

Now....

A single CXA operating at 55C and 2000 mA ..
Power : 77.86=~78Watts
CXA Efficiency : 34,51%
Drivers efficiency : ( 78 Watts is ~95 % of full load ) = ~ 90 % (230 VAC )
Overall efficiency : ~62.2 %

As you see ,the overall efficiency remains "steady-stable" and at high level ..
Both at 350 mA and at 2000mA ...

Above 60% ..

And that is a rather great figure ...

Cheers.
:peace:

PSUAGRO. · Oct 6, 2014

Nice!.......very thoughtfully broken down SDS.......great #s indeed

Be safe friend

churchhaze · Oct 6, 2014

This is one reason why I find dimming to be sort of a novelty.

I've been designing lamps around drivers specifically with what SDS is saying, although cost is obviously a factor too.

For example, the UFO killer uses (4) vero 18 in series at 700mA with HLG-80H-C700A

4 * 28.5V * 0.7A = 79.8W

the driver is 90.3W max which means it's running at about 88.4% load.

According to the datasheet, the efficiency at 88.4% is the same as it is at 100%, in fact, it only starts to drop below 90% efficiency at 50% load (with 115VAC input)

http://www.meanwell.com/search/hlg-80h-C/HLG-80H-C-spec.pdf

Of course we seemed to have designed our vero 18 lamps to run at 700mA, which is is about half of what SomeGuy's vero 18 fence post bars are driven at.

guod · Oct 6, 2014

stardustsailor said:
Just a small example ...

A single CXA operating at 35C and 350 mA ..
Power : 11,725=~12 Watts
CXA Efficiency : 52,51%
Drivers efficiency : ( 12 Watts is 14.6 % of full load ) = ~76 % ( 230 VAC )
Overall efficiency : ~64.2 %

A single CXA operating at 55C and 2000 mA ..
Power : 77.86=~78Watts
CXA Efficiency : 34,51%
Drivers efficiency : ( 78 Watts is ~95 % of full load ) = ~ 90 % (230 VAC )
Overall efficiency : ~62.2 %

Above 60% ..

And that is a rather great figure ...

Cheers.

mean weighted is wrong here...

Overall efficiency = efficiency(a) x efficiency(b) x ...

52,51% x 76% = 39,91%
34,51% x 90% = 31,06%

relative loss or win is above 20%

back to work...

Mohican · Oct 6, 2014

I love the new feet on the piggys

bicit · Oct 6, 2014

stardustsailor said:
Just a small example ...

View attachment 3268640

The efficiency graph of The MeanWell-HLP-80H ....
For the 42 V model I use ,has a 100% full rated power of 81.9 Watts= ~82 Watt s

A single CXA operating at 35C and 350 mA ..
Power : 11,725=~12 Watts
CXA Efficiency : 52,51%
Drivers efficiency : ( 12 Watts is 14.6 % of full load ) = ~76 % ( 230 VAC )
Overall efficiency : ~64.2 %

View attachment 3268641
Now....

A single CXA operating at 55C and 2000 mA ..
Power : 77.86=~78Watts
CXA Efficiency : 34,51%
Drivers efficiency : ( 78 Watts is ~95 % of full load ) = ~ 90 % (230 VAC )
Overall efficiency : ~62.2 %

View attachment 3268643

As you see ,the overall efficiency remains "steady-stable" and at high level ..
Both at 350 mA and at 2000mA ...

Above 60% ..

And that is a rather great figure ...

Cheers.

I need to learn how to make graphs like that. That's amazing work.

stardustsailor · Oct 7, 2014

guod said:
mean weighted is wrong here...

Overall efficiency = efficiency(a) x efficiency(b) x ...

52,51% x 76% = 39,91%
34,51% x 90% = 31,06%

relative loss or win is above 20%

back to work...

Thank you Guod.
I'm fortunate enough ,in my most stoney-stupid moments to have someone correct my ..unearthy maths !

..
Yes you're right ...
(Imagine that I've done it-correctly- so many times in the spreadsheets !!! )

It's not 'averaging' but multiplying the correct method ...

Yes, more than 20% difference there ...
Still...
At worst case ... even at 2000mA ,efficiency remains ..same with a slightly used 400 W HPS ...
;-)

Cheers.

stardustsailor · Oct 7, 2014

Top cover/lid is almost ready ...
Needs some 'cleaning' and it's stainless hanging posts to be attached ...

Mechmike · Oct 7, 2014

It makes sense then to run drivers close to their max VF output for highest efficiency. If the CXA3070 run at 350ma is matched to a driver with ~90% efficiency it would run at ~47% overall efficiency.

stardustsailor · Oct 7, 2014

Mechmike said:
It makes sense then to run drivers close to their max VF output for highest efficiency. If the CXA3070 run at 350ma is matched to a driver with ~90% efficiency it would run at ~47% overall efficiency.

Yup !

stardustsailor · Oct 7, 2014

Well ..
I 've to put the construction of my light 'on ice' for a while,folks ..

I've a new order to build some custom lights ...
Unfortunately ,this time is the client ,that wants to remain totally 'stealth' .
So I won't be posting any pictures of this project ....

The client is going to supply me both the led arrays and the cooling system for them ...
I'm going to do the rest ...

But ...
I can't hold it ...
$#!T

Ok ..Some 'peeks' of it ..
And that's all !

No further questions will be answered ...

The Led Arrays of the new project :

4 x Dragon Series C117X-1726-500-01 3000K bin Q1/ E21

......

52.7 V * 4.450 A *2 = 509.08 Watt per array
x4 arrays (at max ) = 2036,32 Watts

Spectrum :

Lm/W :

vs CXA3070n AB (Tc=25C ) :

CNC Custom made " Heatsink(s) " :-)

..Sorry ..Water blocks :

And that 's about all ,that I can tell ....

Cheers ...

Positivity · Oct 7, 2014

Holy schmoley....

I knew something like that was around the corner...awesome

Mohican · Oct 7, 2014

Liquid Cooled!

Size is 65 mm square on the LEDs. Is the cooler close to the same size? Double the size?

Cheers,
Mo

stardustsailor · Oct 7, 2014

Mohican said:
Liquid Cooled!

Size is 65 mm square on the LEDs. Is the cooler close to the same size? Double the size?

Cheers,
Mo

Well ,the guy who made them (copied the design from somewhere on web ,I was told so ) ,
has made them 100 mm x 100 mm square from Oxygen -free copper block .
At the exact design shown .
The actual " cooling engine " is going to be installed by the customer and I was told that is taken directly from
a Whirlpool Freezer or something like that ...And probably "tuned" to fit ...
Cooling 2000 Watts is his job..He said so ..I do not have to worry about that ..
My job is to fix a light out of four arrays and four water-blocks ..
:cuss:

I 've to find the right drivers for these monsters ...

But please ,no more questions about it ...

I hope the guy never finds out about this thread.. :oops:

Cheers!

Mechmike · Oct 7, 2014

Oooh! That sure is a pretty copper cooler. This is going to be good!

Mohican · Oct 7, 2014

I was trying to be vague enough not to get secret details - thank you!

I wonder how the COBs would run using a super coolant?

Greengenes707 · Oct 7, 2014

http://www.powergatellc.com/pdfs/HLG-240H.pdf

stardustsailor · Oct 8, 2014

Greengenes707 said:
http://www.powergatellc.com/pdfs/HLG-240H.pdf

Thank you GG !
Great find !
So it will take 8x of these drivers (two per array ) ..

94% efficiency ,at full load !!!
And a bit less of 80% at 10% of full load ...

Not bad ,at all ...

Cheers.

indianajones · Oct 8, 2014

here's one for 600w. the hlg series has a 240, 320, and 600. the higher
the wattage the more efficient, the 600 is 96%.

stardustsailor · Oct 9, 2014

Working on more than one project is ...well ...time-consuming ,at least ..

I've managed to find a bit of 'free' time to prepare the heatsink of the 'stealth' fixture ...

Heatsink was sanded (mainly on where the CXAs will be attaching to ) .
An electric flat pulse-sander was used.
(EU sandpapers : 180 => 600 dry => 600 wet =>2500 dry=> 2500 wet )

Cheers.

Stealth LED Array light .

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