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--- projects:portable-led-bar [2021/03/20 18:13] – Formatting, some more data for the cells lepi
+++ projects:portable-led-bar [2021/03/21 20:57] (current) – lepi
@@ Line 5: / Line 5: @@
  | repo=[[github>lepi00/portable-led-bar]]
 }}
+\\ \\
+=== DISCLAIMER: ===
+=== This is not yet a finished project intended as instructions but only a means to share progress on the project. ===
+=== This might be dangerous to attempt !!! ===
+=== If you attempt to follow any of this, you do it at your own risk. ===
+\\ \\
+=== Adapting a mains AC led bar to work with a battery of 18650s ===
+by [[people:lepi:start|lepi]](lepi at-a hackerspace.pl)
+\\
+{{:projects:portable-led-bar_batteries.jpg?direct|}} {{:projects:portable-led-bar_voltage.jpg?direct|}}
+\\ \\
+{{:projects:portable-led-bar_ingredients_r0.1_1024.jpg?direct|}}
-====== Rebuilding a mains AC led bar to work with a battery of 18650s
+\\ \\
-======
+KiCAD files:
-by [[people:lepi:start|lepi]](lepi at hackerspace.pl)
+[[https://github.com/lepi00/portable-led-bar/tree/main/kiCAD-portable-led-bar]]
-===== Intro =====
+Revision 0.1\\
+{{:projects:portable-led-bar_kicad_0.1.png?direct|}}
+\\ \\
+=== Intro ===
 The purpose of this project is to adapt a 220AC UV LED-Bar to work with 18650 cells.
+\\ \\
 I have just started learning electronics, and my knowledge is very basic.
+\\ \\ \\
+== Specifications ==
-Specifications:
+The LED Bar - Light4Me LED UV 8
+^Characteristic                 ^Value                              ^Notes
-The LED Bar - Light4Me LED UV 8:
+|Voltage:                       |AC110-240V, 50/60Hz                | |
-^Characteristic                 ^Value                          ^Notes
+|Power:                         |30W                                | |
-|Voltage:                       |AC110-240V, 50/60Hz| |
+|Light source:                  |8x3W UV LED                        | |
-|Power:                         |30W| |
+|Light angle:                   |65°                                | |
-|Light source:                  |8x3W UV LED| |
+|Light wavelength:              |390-410 nm                         | |
-|Light angle:                   |65°| |
+|Dimensions:                    |450 x 50 x 40 mm + 55 mm pins      | |
-|Light wavelength:              |390-410 nm| |
+|Weight:                        |0,6 kg                             | |
-|Dimensions:                    |450 x 50 x 40 mm + 55 mm pins| |
+|                               |                                   | |
-|Weight:                        |0,6 kg| |
+|LED driver inside (IP65):      |                                   | |
+|Model:                         |ZW0820                             | |
-Cells:
+|Power:                         |27 W                               | |
+|Input:                         |AC85V-265V 50/60Hz                 | |
+|Output Voltage:                |27-36V DC                          | |
+|Output Current:                |600 mA ±5%                         | |
+|TA:                            |60 °C                              | |
+|TC:                            |80 °C                              | |
+\\
+Cells
 ^Characteristic                 ^Value                            ^Notes
-|Datasheet:                     |(https://www.tme.eu/Document/e06617d885c58dfb3fecaf4abbe330c4/ICR18650-26H.pdf)["datasheet"]| |
+|Datasheet:                     |(https://www.tme.eu/Document/e06617d885c58dfb3fecaf4abbe330c4/ICR18650-26H.pdf)["datasheet"]     | |
-|TME Symbol:                    |Samsung ACCU-ICR18650-26H| |
+|TME Symbol:                    |Samsung ACCU-ICR18650-26H          | |
-|Rated voltage:                 |3.63 V| |
+|Rated voltage:                 |3.63 V                             | |
-|Capacity:                      |2.6 Ah| |
+|Capacity:                      |2.6 Ah                             | |
-|Maximum current:               |5.2 A| |
+|Maximum current:               |5.2 A                              | |
-|Charging Method:               |constant voltage with limited current| |
+|Charging Method:               |constant voltage, limited current  | |
-|Charging Voltage:              |4.2 V ±0.05 V| |
+|Charging Voltage:              |4.2 V ±0.05 V                      | |
-|Charging Current (standard):   |1300 mA| |
+|Charging Current (standard):   |1300 mA                            | |
-|Charging Current (max):        |2600 mA| |
+|Charging Current (max):        |2600 mA                            | |
-|Diameter:                      |18.4 mm| |
+|Diameter:                      |18.4 mm                            | |
-|Length:                        |65 mm| |
+|Length:                        |65 mm                              | |
+\\
+Battery charger - Tangspower TP-L8S20 Li-ion charger
+^Characteristic                 ^Value                              ^Notes
+|Maximum Voltage:               |8 * 4.20 V = 33,6 V                | |
+|Charging Current:              |2 A                                |Passive, PFC filter|
+\\ \\ \\
+=== The Story ===
+\\
+=== Revision 0.1 ===
-Battery charger - JN-L8S20 Li-ion 8S
+A friend of mine performs POI with POI-tails that are neon-yellow. The thing is made to shine in UV light.
+Some AC mains LED bars I have, revealed a lot of space inside the casing profile - more than enough to house 8 18650 cells.  \\
-^Characteristic                 ^Value                            ^Notes
+The LEDs have a "PowerLed" package soldered in-series upon a pcb with no other elements, but most likely have some resistor inside the package, as multimeter LED tester does not show anything when testing a single LED.
-|Maximum Voltage:               |8 * 4.20 V = 33,6 V| |
+\\ \\
-|Charging Current:              |2 A|Passive, PFC filter|
+Remembering next-to-nothing about Electrical Circuits, I started designing a circuit, that would:
+ - Power the LEDs from cells
+ - Allow charging the cells without taking them out
+ - If possible leave the original charger with mains connection
+\\ \\
+First I considered two solutions:
+ - LEDs and cells in parallel
+   - Operating current would be         0.6 A * 8 =  4.8 A
+   - Charging  current would be         1.3 A * 8 = 10.4 A
+ - LEDs and cells in-series
+   - Operating voltage would have to be             26.9 V (3.36 V / LED)
+   - Charging  voltage would have to be 8 * 4.2 V = 33.6 V
+\\ \\
+== Parallel... ==
+ - I have a TP4056 03962A Lithium Battery Charger with protection module
+   - [[03962A description]](https://www.epal.pk/product/tp4056-lithium-battery-charger-with-protection-module/)
+   - [[TP4056Datasheet]](http://www.haoyuelectronics.com/Attachment/TP4056-modules/TP4056.pdf)
+ - Initially I thought that would be crazy to put 8 of these inside
+ - Also wiring LEDs in parallel would if I understand correctly require to put at least 40 cm * 8 = 3.2 m of thick wire - that might be difficult.
+\\ \\
+== In-series... ==
+ - A friend informed me to the fact, that I could use an external 33.6V charger which seemed to be easier.
+ - And also that I could use LM317 to regulate current out of the cells to LED's
+ - I decided to use a I/0/II switch and an IEC cord socket with the original LED driver if possible.
+\\ \\
+Emeryth suggested:
+ - to learn more about li-ion cells before I use un-protected or multiple cells
+ - to put some protection between cells and the cell charger
+ - to use a DC-DC converter instead of LM317 that produces too much heat
+ - to rethink if I need all LEDs in-series
+\\ \\
+=== Next Steps: ===
+ - Research Emeryth's suggestions\\
+ - Find a solution to connecting the cells
+   - decide whether to solder the cells (dangerous, potentially capacity hindering)
+   - contact weld the cells (I don't have access to a contact welder)
+   - design a 3d-printed casing for the cells with springs, that would slide into the LED bar casing
+   - remember to discharge cells before in case of soldering
+\\ \\
+Notes:\\
+ - https://pl.aliexpress.com/item/1000001962896.html\\
+ - https://lcamtuf.coredump.cx/electronics/