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DIY LED floodlight conversion module with PCB file. (full build)

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Published on Mar 6, 2016

It's clear that these very low profile LED floodlights with the "driver" chips on the same panel as the LEDs are not reliable. There seems to be an issue with the driver chips failing and blowing the multi-chip LEDs. So I thought it would be fun to build a complete new retrofit LED module to re-use the case as a much lower power LED floodlight that is best suited to low level ambient or functional illumination.
The design deliberately uses an ordinary through-hole PCB and very common components, and is completely serviceable with all components being changeable or upgraded if desired. The power output is low at about 1.5W, but still provides a modest level of illumination and has a negligible running cost.
You can download the PCB file from http://www.bigclive.com/freebies.htm if you want to make one of these yourself. I've put both files up, but the 5mm version is the recommended one.
Things worthy of note. There is a facility to connect the earth/ground wire from the flex to the case via the PCB. This does require a metal spacer like a metal nut slightly larger than the screw that the case is designed to accept. The screw holes in this case were M3 so an M4 or M5 nut might be a good spacer, noting that it shouldn't be too big in case it encroaches on adjacent tracks. The other positions could use either the same spacer or better still, a plastic spacer of the same height. The PCB needs to be well clear of the back of the case to avoid the solder connections touching it. I'd suggest around 4 or 5mm clearance to allow for the possibility of slight PCB flexing due to thermal expansion/contraction. You could also use a layer of insulating material on the back of the case as extra protection. As in the original light, there isn't really any proper flex grip other than the cable gland and the actual wires being attached to the PCB.
You can use any colour of LED you like in the case including infra red. But note that the 15-20mA drive current will not provide high level illumination. Still very useful for path lighting, security lighting and illumination of foliage with appropriately coloured LEDs though.

If you enjoy these videos you can support the channel with a dollar for coffee, cookies and LEDs at https://www.patreon.com/bigclive

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