DIY Inspired 8x 450w Complete LED Grow Light Project (non-profit)

This page is linked from the youtube video with the same title, so I don’t think an explanation here is needed on what this is about.

Update 12/18/16: All parts are on hand, assembly in full swing and lights have already started shipping.

Update 12/02/16: The cases are almost ready! Here is a quick photo of the progress:

They are headed out to get powder coated, then will be silkscreened and should be all ready by the end of next week.

The Prototype is now complete! Obviously, there is no powder coating or silk screening but still nice to see it take shape in the physical world. See images below (click image for larger view gallery):

PROJECT NEWS & UPDATES - click to expand - Last updated on Dec 1st

Below is the latest information, I will update this section if there are any changes.

Which Version: Based on survey results most prefer the networked/controller dimmable version. So that’s the version I am building for you guys.

Controller: Since this is a non-profit project, I think it’s only fair to also make the controller non-profit as well. So if you order the controller together with a light, then the controller will only cost $99. Will start soldering all through hole components on the internal and controller PCBs this week.

Enclosure Progress: ~~The light enclosure parts have been ordered and I should have 1st article inspection/testing done by Oct 29th.~~ ~~Due to some of the PEM fittings not being in stock, there is a bit of a delay. They should be delivered in the next day or two and hopefully will have the first articles by the end of the week~~. Received and built, see gallery above. After that, the fabrication can start and should be completed by ~~Nov 24th~~ Dec 14th.

Drivers Issue: Unexpected hiccup with the drivers – all US distributors are out of stock with a 15 week factory lead time. Thankfully, the Meanwell factory in China had 190 units in stock. So I quickly ordered all of their stock, to be shipped via DHL Express, once payment clears.

The drivers have been delivered and I now have enough for all 50 lights.

~~Still need to find 10 more drivers so there are enough for all 50 grow lights. I should have all of them all on hand by the time the enclosure fabrication is completed.~~ Enough are now on order for all 50 units, found the remainder here and there locally.

Wire Harnesses: The wire harnesses are currently being assembled and should be ready by the time the cases are finished.

LED Modules: Have designed and ordered the LED PCB thermal paste screen and holder jig fabrication. Once received next week I will start assembling the modules.

Start Assembly: Next, will start assembling into complete units. This may take a while as I will probably end up doing this all myself. Will do my best to get them all ready for you guys as quickly as possible.

Ordering: ~~I will send an email update once all parts are in to announce that ordering is open. Barring any unforeseen delays, this should be around the middle of November.~~ Ordering is now open! To get this email you need to subscribe to our newsletter, which you can do at the very bottom of any page on this website.

The lights will be assembled and shipped on a first to order, first to ship basis.

DIY Grow Light Project Survey

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Your responses will help shape our decisions for this project.

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Thank you!

Some Clarification On Assembly

This light will be fully assembled and will ship ready to use – no user assembly will be needed.

The “DIY inspired” part comes from the fact that I’ve been getting many requests for this form factor and full controller capability. Due to the way the modules are built and designed to recess into an enclosure it was challenging to DIY a case/frame. This along with the interest in the internal controller lead me to create this project and provide the resulting product at cost for the DIY community.

Light SpecsFootprint TestController SpecsFile DownloadsCost BreakdownProject Survey

Light Specs

Power input: 100-240VAC 50/60hz, 450 watts
Dimensions: 40in x 16in x 3in
Material: Powder coated 5052-H32 Aluminum
Weight: 26 pounds

Lens Array Material: Optical PMMA
Optics Angle: 60°
Efficiency: 1.7 μmol/J
PPFD: 950 μmol/m2/s over 2 x 4 foot canopy @ 15 inch distance
Independent Lab Report: https://chilledgrowlights.com/independent-lab-reports

Dimming Channels: Red, White, Blue
Dimming Range: Off, 10% – 100%

Onboard Switches: Power | 50%/100% Intensity | White Viewing Mode | Veg/Gen Spectrum

Networking: RS485 protocol via on-board RJ45 net in/out jacks for cat5e or better cables.
Wired networks are immune to radio interference and attenuation by objects – higher reliability.
Signal pass through to next node even with no power.
Max light units per network – 1024 nodes.
Max total distance per network – 4000 feet.

Footprint Test

Click on image to see larger version.

Controller Specs

1 – Self powered via Power Over Ethernet provided from first node in network.
2 – Realtime Clock IC with supercap backup – retains time at least 14 days without power.
3 – Two independent 24 hour timer schedules, generative and vegetative.
4 – Full control over light ratios in each schedule in 1% increments.
5 – Sunset & Sunrise ramping, select none, one or both; 10 min linear ramp sequence.
6 – White Only viewing mode via quick access center button. Includes self canceling programmable delay, none through 480 min.
7 – Mini mono jack for connection on momentary switch, enabling control of the White Only viewing mode from a remote location and/or multiple controllers at once.
8 – Thermal safety monitoring and on-screen notification when one or more lights on network have overheated and shutdown.

File Downloads

~~If you know of a great sheet metal fab shop, you can use these files for quoting. Would be great if we can get the cost of the enclosure down.~~

Search is over, found a great local sheet metal fab shop who offered us a great price on the enclosure parts. Taking the files down as they are no longer needed here.

1 – 2D PDF Drawings (zipped)
2 – 3D Enclosure Step Files (zipped)
3 – 3D Enclosure Assembly File (zipped)
4 – Silkscreen Templates (zipped)
5 – PEM Fasteners Installation Instructions (zipped)

Cost Breakdown

With Net Controller/Color Channel Dimming

Full functionality with independent channel dimming, networking and external controller compatibility. Will be able to use this light along with our other lights on same network.

$292 – 8 LED Modules with lens & heatsink ($36.25 each)
$115 – Enclosure – aluminum, powder coated and silkscreened
$180 – 4 150w Meanwell dimmable drivers ($45 each)
$70 – Internal controller PCB
$42 – Internal wiring
$35   – Connectors, switches, screws, hangers, power & network cord
$25   – 3 fans (2 120mm & 1 92mm)
$25   – Custom size shipping box and EPS foam sheets
$40   – Assembly/packaging labor

TOTAL – $799