LED battery operated

Norman99

Norman99

Well-known member
Just finished a request from a fellow videographer in New York wanting 3 battery operated LED lights.
Before I send them off, I decided to share a few pictures of the units as they were in the final stages of having the rear battery plated installed.
The 4 units are identical with the 14.4 volt pro battery plate.
the unit draws 80 watts and puts out 7000 lumens or equivalent to approximately a 500 watt filament.
There is a selector switch for 3 of the most commonly used color temperatures 3200-4000-5500K
The dimmer goes from 0 to 100% without flicker or color change, LED driver is non-PWM type so there is no banding at high shutter speed camera rates
Enclosure is one piece aluminum , dimensions are 6 X 4 X 3 inches, weighs in at 36 ounces without battery
Provision for powering DC in from 12 to 24 volts, 4 pin XLR and 2 pin DC barrel, as well as choice of battery plates 14.4 V such as the Sony BPU seriesor equiv.
Diffusion panel is Bayer Makrolon XT in the neutral rendition, beam angle with diffuser is 120 degrees in all directions
Without diffuser the beam is 35 degree or interchangeable TIR optic choices of 10-20-35-40-60 degrees
All wiring is mil spec silicone 18 72 strand silver
Dimmer pot is mil spec Allen Bradley 250,000 turn
Finish is powder coat black
Twin mounting 1/4-20 female as well as illuminated led blue indicator power switch
Fan is PAPST ultra silent 18db that activates when temp sensor requires it

3 of these units fit in a carry-on with room to spare for batteries, chargers, and 3 small 5' tripods

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I have been making custom units for over 5 years. Not mass produced or advertised. They are all made for different applications to suit the user. Yes, they are made from scratch but the aluminum frame is from extruded die that is ideal for the led's heat extraction especially when it has channeled fins along with a very silent DC fan in it. In my other posts I have shown smaller and larger units that are for specific uses. They are all battery capable and are made with quality components without regard to cost cutting. The less are hand picked from the same batches in their production as well as the same binning specs for consistency. I run the leds with dimmer up at 30% BELOW their rated maximum as they run cooler and have a much better efficiency range as compared to full powering at max values. Before a light is made, I make sure it not only fits the needed specs but also the physical size itself has to be in accordance to the use. As an example of one is a wedding videographer needed a very powerful light to be placed with the camera mounted on a 20 foot crane that had to move with the camera direction. It had to be not more than5 inches square with a beam angle to match his camera's wide end limit. It had to be 3000K ( to match with reception lighting) with remote dimming ( a must due to distance from operator), and called for 8000 lumens minimum with a beam of 80 degrees. The light had to weigh as small as possible, it weighed 30 oz.
Cost of materials is high as just the dimmer switch potentiometer costs $35, but it is very reliable.
Assembly time is about 10 hours and the lights are run for a full 24 hours straight at full brightness before delivery.
There is no fancy packaging, no labeling, no instruction booklet, just the light itself.
Material cost on this particular unit was just over $400 without labor.
 
I am working on a led unit for use on a large green screen. The single unit will be placed on top of the green screen at only 2 ft. distance in front of it. It will use special optics that have variable intensity so that more light is channeled at the farther distance ( asymmetric design) so that when seen from camera position the screen will be very evenly lit. This will eliminate large dual umbrellas placed near talent area, allowing more floor area to move around and producing much less heat. I will try to make it as small as possible to house just 6 Cree MTG-2 leds for 12,00 lumens or around a 750 watt bulb. It will most likely take 2 units to cover a 16 ft wide 10 ft high screen. I will post photos as it progresses. This one may take some time to completion.
 
Norman99 said:
I am working on a led unit for use on a large green screen. The single unit will be placed on top of the green screen at only 2 ft. distance in front of it. It will use special optics that have variable intensity so that more light is channeled at the farther distance ( asymmetric design) so that when seen from camera position the screen will be very evenly lit. This will eliminate large dual umbrellas placed near talent area, allowing more floor area to move around and producing much less heat. I will try to make it as small as possible to house just 6 Cree MTG-2 leds for 12,00 lumens or around a 750 watt bulb. It will most likely take 2 units to cover a 16 ft wide 10 ft high screen. I will post photos as it progresses. This one may take some time to completion.
Click to expand...

Very interested as I'm teaching green screen technique. Please keep me posted.
 
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