Saving $20,000 USD With A Single LED

January 12, 2014 by Adam Fabio 81 Comments

carrier

[N8Mcnasty] is a HVAC tech who works on some big machines. One of his charges is a Carrier 19EX Chiller, rated at 1350 tons of cooling. 1 ton of cooling = 12,000 BTU. This particular chiller contained an odd LCD screen. It used a fiber optic bundle and a halogen light for backlight illumination. The system worked fine for over a decade. Now though, the halogen bulb has begun melting the glue on the fiber bundle, causing a dim display. The display in question shows some very important operating parameters, such as oil temperature, current draw, and process temperatures. Since they couldn’t easily see the display, the machine’s operators weren’t running the machine, placing stress on the other chillers in the building’s physical plant. [N8Mcnasty] tried repairing the bundle, however the glue kept melting.

A replacement display was no longer available, meaning that the entire chiller control system would have to be upgraded to a newer system. The new control system uses different sensors than the old one. This is where things start getting expensive. Replacing the sensors would also require draining the 15-20 gallons of oil, 4500 lbs of R134a refrigerant, and bringing the whole system down for almost two weeks, a $20,000 job. Rather than go this route, [N8Mcnasty] found an alternative. LED’s have come a long way since 1996, when the chiller was built. He simply replaced the halogen bulb with an LED and appropriate resistor. [N8Mcnasty] was even able to reuse the halogen bulb bracket. A bit of heat shrink tube later, and the fix looks like it was a factory option. He’s documented his fix here on reddit.

I Am The Midnight Message Board What Messages At Midnight

January 11, 2014 by Kristina Panos 15 Comments

Photoluminescent stars on your bedroom wall or ceiling are pretty cool, though the stationary shapes can become boring. [Adi] felt this way, too. While doodling with a bright white light on some glow in the dark vinyl, it occurred to him that this could make for an interesting display. He set about making GLO, the midnight message board and RSS display.

[Adi]’s light writer uses 12 UV LEDs on a linear axis powered by a stepper motor to write RSS headlines, Twitter trends, or custom text on his wall. He finds the slow fade of the text very soothing to fall asleep by, and it’s easy to see why. The LED array imprints a section of a character consisting of a 6×5 bit pattern. The 12 LEDs are split into two groups, so it can write two lines at 45-50 characters each. [Adi] designed his own pixel font for this project, and advises that only upper case letter forms be used.

[Adi]’s write-up is quite admirable and comprehensive. In the circuit build section, he advises that the LEDs must be very close to the vinyl for optimum results, but that they should protrude farther than the shift registers so the chips don’t rub the vinyl. Of course you could opt for more intense light sources, like laser. See it in action after the break.

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A Transparent 7-Segment Display

January 9, 2014 by Marsh 40 Comments

Though [Connor] labels it as a work in progress, we’re pretty impressed with how polished his transparent 7-segment display looks. It’s also deceptively simple.

The build uses a stack of seven different acrylic panes, one in front of the other, each with a different segment engraved onto its face. The assembly of panes sits on a small mount which is placed over seven rows of LEDs, with 5 LEDs per row. [Connor] left an air gap between each of the seven individual acrylic panes to clearly distinguish which was lit and to match the separation of the LED rows. To display a number, he simply illuminates the appropriate LED rows, which scatter light across the engraved part without spilling over into another pane.

You can find a brief overview and some schematics on [Connor’s] website, and stick around for the video demonstration below. We’ve featured [Connor’s] work before; if you missed his LCD data transfer hack you should check it out!

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A Blindingly Bright Larson Scanner

January 8, 2014 by Marsh 31 Comments

craylarsonscanner

This hulking monument to illumination is [DJJules’s] 6-foot-long Ultimate Larson Scanner. If you’re scratching your head in confusion, the Larson Scanner is the ever-popular scrolling LEDs seen on KITT (the car) from Knight Rider and on Cylons in Battlestar Galactica (1978), named after the creator of the series.

[DJJules’s] iteration consists of sixteen 10W LEDs, each mounted on a heat sink which bolt on to a 6′ long piece of angle aluminum sourced from a local hardware store. He used a basic MOSFET constant current driver for each LED, attaching the MOSFETS to the heat sink with 4-40 screws. Each LED module then connects to a TLC5940 LED driver breakout board from Sparkfun, which plugs into an Arduino Pro Mini.

Check out the Instructables page for the source code and other important details, including safely powering the build (the LEDs can draw around 1A each), then grab your sunglasses and stick around for a quick video below.

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Controlling Cheap, Awesome Christmas Lights

January 7, 2014 by Brian Benchoff 13 Comments

LEDs

[James] was wandering around Walgreens after Christmas and found something very interesting – RGB LED Christmas lights that were individually addressable. At $6.50 for a strand of 15 lights, he just had to buy a few and figure out the control protocol. After all, who can turn down a big, cheap, controllable RGB LED strip?

The packaging for these lights – apparently manufactured by BriteStar – includes a ‘try me’ button that cycles through different light patterns. This button is what initially tipped [James] off to the fact the lights on this strand could be individually controllable. Opening up one of the lights, he found exactly what he wanted: an epoxy blob, two wires for power, and three wires for the signaling.

After checking out this light with a scope and logic analyzer, [James] realized there was a very, very simple protocol going on. Essentially, the entire string functioned as a gigantic shift register, taking the values for one light and pushing it down the string. In looking at the protocol, [James] also discovered] these lights support 16 levels of brightness. Yep, RGB LED Christmas Lights with PWM for under $7. Can’t beat that.

[James] wrote an Arduino library to control these strings and put it up on Github. While your local Walgreens has probably already hidden these lights away in the back of the store, it might be worth asking around to see if they have any left.

Green Light LEGO, Red Light Stop

January 6, 2014 by Kristina Panos 7 Comments

Master LEGO craftsman [Baron von Brunk] had the same childhood passions as a lot of us—LEGO (obviously), Transformers, and Nintendo. But he also harbored a passion for traffic lights and road signs. His latest offering, a fully functional LEGO traffic light, is some pretty fantastic plastic. You might recall that we featured [Baron von Brunk]’s LEGO mosaic lamps a few weeks ago. This project is that one on steroids.

The body is made of 1700+ LEGO and Technic pieces. [Baron von Brunk] was kind enough to provide his LDD file, though he says it should be considered a rough guide to construction. The red, yellow, and green 1×1 areas are each lit with a 48-SMD LED floodlight bulb. Colored lights are available, but he used the solid white variety for greater luminescence. The lights are driven by a traffic light controller typically used for model railroads.

[Baron von Brunk] ended up lining the inside with black 1x1s and metallic reflective duct tape to keep the light from leaking out of the masonry. He used some Technic bricks on the rear door to form hinges, and Technic pins to hold the LED lamps.

Current Limiting Diode Use And Tutorial

January 6, 2014 by Todd Harrison 20 Comments

Not that this happens often, but what do you do when faced with a repair where you don’t know the power source but you do know you have to drive LED backlighting? When faced with this dilemma [Eric Wasatonic’s] solution was to design for ambiguity. In this interesting hack repair [Eric] needed to restore backlighting for an old car stereo LCD display. First he guaranteed he was working with a DC power source by inserting a small full-wave bridge rectifier. Then knowing he needed 4 mA to power each LED for backlighting he used some 1978 vintage current limiting diodes designed to pass 2mA each regardless of voltage source, within limits of course.

Sure this is a simple hack repair but worthy of being included in anyone’s bag of tricks. Like most hacks there is always knowledge to be gained. [Eric] shares a second video where he uses a curve tracer and some datasheets to understand how these old parts actually tick. These old 1N5305 current limiting diode regulators are simply constructed from a JFET with an internal feedback resistor to its gate which maintains a fixed current output. To demonstrate the simplicity of such a component, [Eric] constructs a current limiting circuit using a JFET and feedback potentiometer then confirms the functionality on a curve tracer. His fabricated simulation circuit worked perfectly.

There was a little money to be made with this repair which is always an added bonus, and the recipient never reported back with any problems so the fix is assumed successful. You can watch the two videos linked after the break, plus it would be interesting to hear your thoughts on what could have been done differently given the same circumstances.

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