RapidLED Red Sea Max 250 Retrofit User manual
1
RapidLEDRedSeaMax250Retrofit
Contents
Foreword.......................................................................................................................................................2
Outline..........................................................................................................................................................2
HeatsinkPreparation..................................................................................................................................13
AttachingLEDstotheHeatsinks.............................................................................................................13
ThermalGrease...................................................................................................................................13
MountinganLEDtoaHeatsink...........................................................................................................13
AttachingtheBlueLEDStringstotheHeatsinks................................................................................14
AttachingtheWhiteLEDStringstotheHeatsinks..............................................................................15
HoodPreparation..........................................................................................................................................2
RemoveClearT5SplashGuard.............................................................................................................2
RemoveScrewsHoldingTwoHalvesofHoodTogether.......................................................................3
OpeningtheHood.........................................................................................................................................5
RemovingtheT5BulbSocketsandLargeBallasts........................................................................................8
RemovingT5SocketsandT5Wiring.....................................................................................................9
RemovalofBallastsandT5Sockets....................................................................................................11
DrillingtheReflectorforHeatsinkMountingHoles....................................................................................11
MountingHeatsinkstoReflector................................................................................................................17
PreparingtheLDDDriverBoard..................................................................................................................21
LDD‐H‐4BoardLayout.........................................................................................................................21
PulldownJumpers...............................................................................................................................21
InsertingLDD‐HDriversIntotheLDD‐H‐4Board........................................................................................22
InstallingStandoffs..............................................................................................................................24
InstallingtheHLGDriver.............................................................................................................................25
WiringtheLEDDrivers................................................................................................................................26
ConnectingHLGLEDOutputtoLDDInput..................................................................................................29
WiringLEDstoLDDDriversbyDrillingaHoleintheReflector...................................................................30
RoutingDimmingWires..............................................................................................................................31
2
ReassemblingtheHood..............................................................................................................................36
Foreword
Aswithanytypeoflightingretrofit,therearemanydangers,difficulties,andpitfallsthatmay
occur.TheRedSeaMax250retrofitshouldbeattemptedbypeoplefamiliarwithACpowerandwiring,
relays,electronics,LEDs,off‐LineandDC‐DCLEDDrivers,solderingLEDs,seriescircuits,andbe
comfortablewiththefactthatthisretrofitwillrequirecompletedisassemblyandremovalofsome
contentsoftheoriginalhood.Ifyouareuncomfortablewithpotentialhazards,dangers,orpitfallsthat
mayoccurinthecourseofperformingthisretrofit,youshouldnotattemptthisretrofit.Aswithall
projects,beforebeginningpleasedoublechecktoensureyouhaveallthepartsneededtocompletethe
buildandcontactusimmediatelyifanythingwasleftoutofyourorder.
Outline
Hereisageneraloutlineofassemblystepsintheorderthatworkedwellforus:
1. Removehood,removeT5bulbs,openhood,removethestockballasts,T5socketsand
bulbclips.
2. Drill4mountingholesinRSMreflectorforeachheatsink.ZiptieheatsinkstoRSM
reflector.
3. CompleteLEDwork:attachLEDstoheatsinkandthenwirethemtogether.YourLED
stringswilllikelyjumpacrosstwoheatsinks,sobeawareofthiswhenwiring.
4. InstallHLGandLDDdrivers.
5. Drillholefordimmingcontrollerwiringifnecessary.
6. CompleteWiring:WiredriverstoACpower,hookupdimmingwires,andLEDwires.
7. Testunderpower.
********ENSURETHEREISNOPOWERTOTHEDRIVERSUNTILALLWIRINGISCOMPLETE********
8. Closehoodup,re‐attachtoRSMandbaskintheshimmer.
HoodPreparation
Anyandallpowerwiresmustbeunpluggedanddisconnectedbeforebeginning.Firstwewill
separatethetwohalvesofthehoodandthenremovethelargeballastsandT5bulbsockets.
RemoveClearT5SplashGuard
First,removetheclearplasticlightcover.InstructionsforthisshouldbeinyourRSMmanual,butyou
likelywon’tneedyourmanual.Unscrewtheclearplasticcoverretainingscrewsandthenrotatethe
coveruntilitslidesoutofitsretainingclips.RemovetheT5bulbs.
3
RemoveScrewsHoldingTwoHalvesofHoodTogether
Next,therearehiddenscrewsthatmustberemoved.Eachscrewiscoveredwithaplasticplugthat
mustbepoppedout.YoumustremovetheclearT5splashguardasitcoverssomescrews.
Poppingtheplugsoutismosteasilydonewithaverythinlybladedflatscrewdriver;aregularflatblade
screwdrivermightbetoothick:
Afterremovingtheplugs,withaPhilipsscrewdriver,removeallscrewsthatwerepreviouslycoveredby
theplugs:
Theplugsareindicatedbythearrowsinthephotosbelow.Removeallplugsandscrewsrevealedby
theirremoval.Thereare20total:
4
5
OpeningtheHood
Thehoodiscomposedoftwomainpieces;atopandabottomwithtwoadditionalsideventpieces.To
begindisassembly,flipthehoodoversothereflectorisfacingtheground.Sinceallofthescrews
holdingthehoodtogetherhavebeenremoved,wecanseparatethetwohalves,whichhavea
somewhattightfit.Ifyouexperiencedifficulty,gobackandensureyoufoundallofthescrewplugsand
removedthescrews–wemissedoneinitiallyandalmostcrackedthehoodbytryingtoforceitopen.
Don’tforceit!Beginningwiththeouteredges,gentlypullitapartuntilyouseparatethetwopieces;
whentheouteredgesrelease,therestoftheseparationismucheasier.Donotberoughanddonot
forceitopen,itonlytakesabitofcoaxingtogetthetwomainpiecestoseparate.Workyourwayfrom
sidetoside,slidingapartthehalvesatevendistances,abitatatimeuntilthehalvesrelease.Once
separated,removetwoadditionalsideventilationpieces.
Beginseparationhere
6
Bygentlypushingupattheoutermostedges,wewereabletogetseparationandworkourwaytothe
center,eventuallyrotatingthetopcoverofthehoodawaytorevealtheinsideofthehood.
Beginseparationhere
7
Mainseparationpoint
Mainseparationpoint
TopHalfRotated90°
8
RemovingtheT5BulbSocketsandLargeBallasts
Eachsideofthehoodreflectorhas5T5blubsocketsthatareclippedinwithtwowhiteplasticclips.
Simplypushtheclipoutwardanddownwardswithascrewdrivertoreleaseeachsocket.Youmayhave
toclipsomeziptiestoreleasethefanwiresbundledtotheT5socketwires(whitewires)aswewill
removetheT5socketsandleavethefans.Repeattheprocessforbothsides/all10sockets.
PushClipsOutand
DowntoRelease
Clips(12totalperside)
ClipsforT5SocketsRemoved
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RemovingT5SocketsandT5Wiring
Next,wewillremovetheT5bulbsocketsandtheirassociatedwiringharnessesfromthehood.Todo
thiswemustdisconnectthemfromtheballasts.TodisconnecttheT5socketharnessesfromthe
ballasts,startbydisconnectingallwiresfromeachofthethreelargeballasts.Thewireterminalsonthe
ballastsarespringloaded.Simplypresstheterminaltounlockitandthenslidethewiresout.
Side2
Side1
10
Pushdownwith
screwdriveron
springLoaded
terminalsand
slidewiresout
Allwiresremoved
RepeatforALLwiresonALLballasts
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RemovalofBallastsandT5Sockets
Next,unscrewthescrewsatbothendsofeachofthethreelargeballastsandremovethescrewsand
ballastsfromthehood.AtthistimeyoushouldalsoremovetheT5socketsandwiringharnessesfrom
thehood.Youwilllikelyhavetosnipziptiestoremovethem.
AlllargeballastsandT5wiringsocketsandharnessesremovedfromhood(smallballastsatbottomright
ofphotoarenotremoved):
DrillingtheReflectorforHeatsinkMountingHoles
Unfortunately,wedonothaveanyphotosofthedrillingprocess,onlythecompleteddrilling.To
completethisstep,simplyplacetheheatsinkontopofthereflector,holditfirmlyinplace,andusingthe
holesintheheatsinkasatemplate,drillthroughthereflector.Weuseda9/64”drillbit.
HeatsinkHoles
UsedasGuidesfor
DrillingReflector
12
Aphotoofholesalreadydrilledontheleftsideisbelow.Theheatsinkwasplacedontopofwherethe
holesaredrilledandusedasatemplatefordrilling.Theprocesswasrepeatedfortherightside.Zipties
willbeusedtosecuretheheatsinktothereflector.
Drillingcompletedforrightside.Ballastworkshouldnotbecompletedyet.
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HeatsinkPreparation
Next,wewillpreparetheheatsinkbyattachingtheLEDstoitandthenwiringtheLEDstogether.
WehaveavideoavailableonYouTubethathasaquickoverviewofhowtohookupour
solderlessLEDs.http://www.youtube.com/watch?v=j7fwVP61kiM&feature=plcp
AwiringDiagramforsolderlessLEDsishere:
http://www.menarilighting.com/rapidled/documentation/RapidLED_Solderless_Wiring_Diagram.pdf
IfyouareusingsolderedLED’s,pleaseseethefollowingdocumentforanoverviewonhowto
wirethemtogether:
http://www.vinnymarini.com/pictures/rapid_docs/LED%20DIY%20Oveview.pdf
AttachingLEDstotheHeatsinks
ThermalGrease
WhenattachinganLEDtotheheatsink,firstapplythermalgreasetothebackoftheLED.This
ensuresgoodthermalconductionofheatawayfromtheLEDintotheheatsink.Asmalldabontheback
oftheLEDisallthatisnecessary.
MountinganLEDtoaHeatsink
Theheatsinkhasmanylittleholesinit.Twolittleholesareusedtosecure1LEDtotheheatsink
–oneateachendofeachLEDasshowninthephotobelow.Eachscrewshouldhaveaplasticwasheron
it,justabovetheLEDandbelowthescrewhead.EnsuretheLEDissnuganddoesnotmovearound.Do
notovertighten.
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Hereisatip:whenarrangingtheLEDsontheheatsink,layoutallofyourLEDsandthenrotate
themorarrangethemsothatifyouhaveastringthatgoesacrosstwoheatsinksthattheywillattach
properly.Weforgottodothisandendedupneedingtousesomeverylongwires.
AttachingtheLEDStringstotheHeatsinsks
Inthebelowsections,weinstalleachoftheLEDstringstotheheatsinks.Thesectionsaredividedupby
color.TheblueLEDstringsareexactlythesameonbothheatsinks.Thewhiteandcolorstringsneedto
‘jump’acrossheatsinks.OneheatsinkwillhavethepowerwiresfromtheLEDdriverconnectedtothe
white/colorstring,theendofthestringonthatheatsinkwill‘jump’acrosstothepartofthesamestring
onthe2
nd
heatsinkandthatstringwillhaveaplugattheendofthelastLED.
AttachingtheBlueLEDStrings
Below,youwillfindhowweattachedthebluestringsofLEDstobothheatsinks.
1.5”
6”
3.5”
4.5”
3.5”
Plug
3.5”
4.5”
3.5”
1.5”
ToLED
Driver
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AttachingtheWhiteLEDStringstotheHeatsinks
Next,weattachedsevenWhiteLEDstoeachheatsinkasshownbelow.
WhiteLEDLocations:
WhiteLEDstring1and2connectedtogetheracrossheatsinks:
3.5”
1.5”
6”
1.5”
6”
4.5”
Plugonone
stringonly
From1
st
string
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AttachingUVandColorLEDStringtoHeatsinks
LikethewhiteLEDstring,theUVandcolormixedstringissplitacrossthetwoheatinks.Inthephoto
below,theredandgreenLEDsarenexttoeachotherinthemiddle.YoucanseetheredLEDclearly
becausethecenterofitisred.TheotherLEDsinthestringareUV.
UV/ColorLEDStringWiredAcrossHeatsinks:
WhiteLEDString
powerfromLDD
Driver
Jumperconnectingwhitestringacrossheatsinks
Plugatend
ofwhiteLED
String
4.5”
4.5”
3.5”
1.5”
4.5”
ToColorandUV
LEDStringon
2
nd
Heatsink
FromLDDDriver
Plugatend
ofUV/Color
LEDString
JumperconnectingUV/Colorstringacrossheatsinks
FromLDDDriver
17
MountingHeatsinkstoReflector
Tomounteachheatsinktothereflector(yourheatsinkshouldhaveLEDsonitatthispoint),
placeeachintothereflectorasinthephotobelow.4holesintheheatsinkshouldlineupwiththe4
holesinthereflectoryoudrilled.Next,wearegoingtoinsertaziptieintoonecornerholeofthe
heatsink.ItshouldgothroughtheLEDfaceoftheheatsinkandthroughthemountingholeinthe
reflectorthatisco‐axialwithit.Pullitallthewaythrough.
Next,ontheundersideofthehood,slideasecondziptieoverthefirst,tighteningitsuchthatitwill
securethe1
st
ziptie,heatsink,andreflectortogether.
Ziptie1,from
heatsinkside
Slide2
nd
ziptie
over1
st
and
tighten
Ziptieshouldgothroughheatsink
andthroughreflectorholedrilled
earlier.
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Next,attach,onlyafewclicks,a3
rd
ziptietothe2
nd
.Insertthe3
rd
ziptiethroughthereflectorand
throughthemountingholeintheheatsink.
Lastly,slidea4
th
ziptieoverthe3
rd
,whichshouldbestickingthroughthesecondmountingholeas
shownabove.Tightenitdown.Trimexcessfromzipties.Repeatprocesstomountbothheatsinksto
reflector.
3
rd
ziptieshould
beattachedto2
nd
onlyafewclicks!
Afterattaching3
rd
ziptieto2
nd
,slide
3
rd
through
reflectorholeand
upthrough
heatsinkhole
2
nd
ziptie
3
rd
ziptie
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OneSideMountedandTrimmed.Repeat3moretimestoattachbothheatsinkstoreflector.
Slide4
th
ziptieover3
rd
and
tighten.Trimoffexcess.
Repeatthreemoretimesto
fastenbothheatsinksto
reflector.
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Yourcompletedziptiewiringwilllooksimilartothis
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