<html><head><meta http-equiv="content-type" content="text/html; charset=utf-8"></head><body dir="auto"><div><span></span></div><div><div>Rick, Hank, Cliff.</div><div id="AppleMailSignature">Rick, thanks, yes I made them. I need about 10 & was thinking of getting a </div><div id="AppleMailSignature">shop to make them up but now I have a good process I may do them myself.</div><div id="AppleMailSignature">Hank, yes I thought about the bubble taking up the oil expansion. I am leaning</div><div id="AppleMailSignature">heavily toward toward a borosilicate lens so probably won't fill with oil. As</div><div id="AppleMailSignature">Cliff says, the borosilicate lens will transfer any heat out the front a lot better than</div><div id="AppleMailSignature">the acrylic lens.</div><div id="AppleMailSignature">Cliff, thanks for those points. The housing is keeping cool so I am reluctant</div><div id="AppleMailSignature">to put in more fins. There is an extra fin on the latest photo I sent. I would need </div><div id="AppleMailSignature">to make up another tool for the grooves, & where the drill holes run through the </div><div id="AppleMailSignature">fins I can end up with burs that would be more difficult to remove with a smaller </div><div id="AppleMailSignature">gap. The problem is that the heat out the front may weaken the acrylic lens.</div><div id="AppleMailSignature">Even though oil filling is a solution, I am going to try a borosilicate lens.</div><div id="AppleMailSignature">Alan</div><div id="AppleMailSignature"><br>Sent from my iPad</div><div><br>On 17/04/2017, at 12:19 PM, hank pronk via Personal_Submersibles <<a href="mailto:personal_submersibles@psubs.org">personal_submersibles@psubs.org</a>> wrote:<br><br></div><blockquote type="cite"><div><div style="color:#000; background-color:#fff; font-family:Helvetica Neue, Helvetica, Arial, Lucida Grande, sans-serif;font-size:13px"><div id="yui_3_16_0_ym19_1_1492387740536_7447"><span>Alan,</span></div><div id="yui_3_16_0_ym19_1_1492387740536_7447"><span>An air bubble inside your light housing is a good thing. Your not oil filling for pressure, but for heat, now when the oil expands the bubble will shrink, perfect.</span></div><div id="yui_3_16_0_ym19_1_1492387740536_7447"><span>Hank</span></div> <div class="qtdSeparateBR"><br><br></div><div class="yahoo_quoted" style="display: block;"> <div style="font-family: Helvetica Neue, Helvetica, Arial, Lucida Grande, sans-serif; font-size: 13px;"> <div style="font-family: HelveticaNeue, Helvetica Neue, Helvetica, Arial, Lucida Grande, sans-serif; font-size: 16px;"> <div dir="ltr"><font size="2" face="Arial"> On Sunday, April 16, 2017 6:04 PM, Alan via Personal_Submersibles <<a href="mailto:personal_submersibles@psubs.org">personal_submersibles@psubs.org</a>> wrote:<br></font></div> <br><br> <div class="y_msg_container"><div id="yiv6084921555"><div><div>Rick,</div><div>I should mention that I have now gone with a 36V system &</div><div>have some pwm dimming controlled buck boost LED drivers being</div><div>made for me. These could drive Cliff & Alecs light. So waiting for these </div><div>& a reply on the borosilicate lens enquiry before I go any further.</div><div>Alan</div><div><br clear="none"><div>Sent from my iPad</div></div><div><br clear="none">On 17/04/2017, at 11:39 AM, Alan via Personal_Submersibles <<a rel="nofollow" shape="rect" ymailto="mailto:personal_submersibles@psubs.org" target="_blank" href="mailto:personal_submersibles@psubs.org">personal_submersibles@psubs.org</a>> wrote:<br clear="none"><br clear="none"></div><blockquote type="cite"><div></div></blockquote></div><div><div>High Rick,</div><div id="yiv6084921555AppleMailSignature">to insert the male subconn fitting it has to be turned 15 times as it</div><div id="yiv6084921555AppleMailSignature">winds down fully in to the thread; so the wire would be twisted 15 times if</div><div id="yiv6084921555AppleMailSignature">you went this way.</div><div id="yiv6084921555AppleMailSignature">Yes the bolts go right the way through. This avoids tapping threads & bolts</div><div id="yiv6084921555AppleMailSignature">seizing. It also has the advantage that I can have longer bolts out the back</div><div id="yiv6084921555AppleMailSignature">that an attachment bracket can be bolted to.</div><div id="yiv6084921555AppleMailSignature">The back section in the photo, has the led attached to it & an o-ring groove</div><div id="yiv6084921555AppleMailSignature">to seal against the bore of the middle section. The base of the middle section</div><div id="yiv6084921555AppleMailSignature">has an o-ring groove & the back section compresses this when the bolts</div><div id="yiv6084921555AppleMailSignature">are tightened up. So two o-rings on this section. The top ring that clamps</div><div id="yiv6084921555AppleMailSignature">the lens down on to an o-ring (also o-ring around the side of the lens) can</div><div id="yiv6084921555AppleMailSignature">be made a larger diameter with a second set of bolt holes so the light can</div><div id="yiv6084921555AppleMailSignature">be mounted in a recess.</div><div id="yiv6084921555AppleMailSignature">As the back section is the main heat sink & mount for the LED I don't have</div><div id="yiv6084921555AppleMailSignature">room for a bunch of twisted wires. The nozzle out back is designed so I </div><div id="yiv6084921555AppleMailSignature">can pour resin in to it, let it set, then coat the wiring about an inch up & </div><div id="yiv6084921555AppleMailSignature">the nozzle with silicone. Then I intend to mold a rubberised supporting</div><div id="yiv6084921555AppleMailSignature">section over the silicon. It should work!</div><div id="yiv6084921555AppleMailSignature">Pictures attached. </div><div id="yiv6084921555AppleMailSignature">Cheers Alan</div><div id="yiv6084921555AppleMailSignature"><image1.JPG><br clear="none"></div><div id="yiv6084921555AppleMailSignature"><br clear="none"><image2.JPG><div class="yiv6084921555yqt0874928186" id="yiv6084921555yqtfd85628"><br clear="none">Sent from my iPad</div></div><div class="yiv6084921555yqt0874928186" id="yiv6084921555yqtfd68208"><div><br clear="none">On 17/04/2017, at 10:08 AM, Rick Patton via Personal_Submersibles <<a rel="nofollow" shape="rect" ymailto="mailto:personal_submersibles@psubs.org" target="_blank" href="mailto:personal_submersibles@psubs.org">personal_submersibles@psubs.org</a>> wrote:<br clear="none"><br clear="none"></div><blockquote type="cite"><div><div dir="ltr">Hi Alan,<div><br clear="none"></div><div>Thanks for the picture. </div><div>The size housing you are using is kinda what I wanted to go with as well. Not sure what you mean about screwing something in 15 times. From the top view picture you sent, looks like the front head/lens is held on against a sealing surface with 6 Allan head bolts that go all the way threw the back plate so I assume that the back plate is threaded and screws on against an 0 ring or something?</div><div> If that's the case, can't you drill and tap the back and put a sub-Conn or strain relief fitting in and allow just enough length of wires to protrude inside just enough to connect the LED wires to it before attaching the lens? Do you have any pictures of everything inside the housing by them self's?</div><div><br clear="none"></div><div>Rick</div></div><div class="yiv6084921555gmail_extra"><br clear="none"><div class="yiv6084921555gmail_quote">On Sun, Apr 16, 2017 at 10:39 AM, Alan via Personal_Submersibles <span dir="ltr"><<a rel="nofollow" shape="rect" ymailto="mailto:personal_submersibles@psubs.org" target="_blank" href="mailto:personal_submersibles@psubs.org">personal_submersibles@psubs.org</a>></span> wrote:<br clear="none"><blockquote class="yiv6084921555gmail_quote" style="margin:0 0 0 .8ex;border-left:1px #ccc solid;padding-left:1ex;"><div><div>Hi Rick,</div><div>The light in the photos is mk 1 or 2. It didn't have oil in in those photos.</div><div>Funny but the oil bubble & the temperature sensor had no effect on</div><div>the light coming out. </div><div> The latest version has a conical lens machined in it & hides the attachment </div><div>bolts for the LED.</div><div>Still a work in progress as I have just made enquiries regarding pressure</div><div>rated borosilicate glass lenses. This light is 85mm D x 54mm long. (excluding</div><div>wiring nozzle) In the attached photo I have just temporarily siliconed around</div><div>the wires for the test. I do have 8 subconn male & female connectors & was</div><div>thinking of tapping a hole for the male connector to fit. The only problem is</div><div>how do I connect the wires? My two LED wires are either side of the LED & come</div><div>down two separate angled holes & meet in a central 8mm hole. I would need</div><div>to fit the LED then attach the LED wires to the subconn wires & twist them 15</div><div>times to thread in the subconn fitting. The subconn wires are very stiff & it</div><div>just wasn't going to work without a large amount of room for twisted wires.</div><div> I have some ideas for potting the wires that I will try & test.</div><div>The housing diameter was dictated by stock material sizes but works out well.</div><div>I have machined the cooling fin slots in to the bolt holes to give the fins a bit</div><div>more depth. </div><div>Alan</div><div><image1.JPG><br clear="none"></div><div><br clear="none"></div><div><br clear="none"></div><div> </div><div><br clear="none"><div>Sent from my iPad</div></div><div><div class="yiv6084921555h5"><div><br clear="none">On 17/04/2017, at 5:43 AM, Rick Patton via Personal_Submersibles <<a rel="nofollow" shape="rect" ymailto="mailto:personal_submersibles@psubs.org" target="_blank" href="mailto:personal_submersibles@psubs.org">personal_submersibles@psubs. org</a>> wrote:<br clear="none"><br clear="none"></div><blockquote type="cite"><div><div dir="ltr">Alan,<div><br clear="none"></div><div>Do these pictures have the silicone oil in them? Do you have any side and back shots of the housing and other data regarding the housing like wall thickness and what fitting did you use to get the power out of the back and such?</div><div><br clear="none"></div><div>Rick</div></div><div class="yiv6084921555gmail_extra"><br clear="none"><div class="yiv6084921555gmail_quote">On Sat, Apr 15, 2017 at 6:33 PM, Alan via Personal_Submersibles <span dir="ltr"><<a rel="nofollow" shape="rect" ymailto="mailto:personal_submersibles@psubs.org" target="_blank" href="mailto:personal_submersibles@psubs.org">personal_submersibles@psubs. org</a>></span> wrote:<br clear="none"><blockquote class="yiv6084921555gmail_quote" style="margin:0 0 0 .8ex;border-left:1px #ccc solid;padding-left:1ex;">I put a temperature probe inside the housing of my 80W LED light.<br clear="none">
The probe was up against the acrylic lens, as I was concerned about<br clear="none">
what temperature the lens was seeing on the inside. The lens is 10mm<br clear="none">
away from the LED.<br clear="none">
The LED manufacturer told me that on normal LEDs the temperature<br clear="none">
out the front of the LED can be 338F (170C) but my flip chips should<br clear="none">
run cooler.<br clear="none">
Briefly; when run at 30W in water they stabilised at 257F after 5 minutes.<br clear="none">
At 45W they stabilised at 280F after 5 minutes. I stopped upping the amps<br clear="none">
at this stage.<br clear="none">
Next experiment, I filled the housing with silicone oil.<br clear="none">
At 45W it hit 116F in 4 minutes & temperature stabilised.<br clear="none">
At 76W it hit 139F in 6 minutes & stabilised.<br clear="none">
So oil has massive advantages in lessening temperature on the lens,<br clear="none">
maybe because it is a buffer from the radiant heat & also transfers the heat<br clear="none">
out through the housing quicker.<br clear="none">
Greg your thoughts would be appreciated on this; I am thinking that without the<br clear="none">
oil the acrylic lens would see temperatures at which it is formed especially<br clear="none">
if I went up to 80W. Although the outside of the lens was cold there would be a<br clear="none">
temperature transition across the thickness of the lens & it would be considerably<br clear="none">
weakened. I am building to 500ft, so it would potentially see 250 psi in operation.<br clear="none">
At this stage I haven't made up my mind whether to go with a borosilicate lens<br clear="none">
or oil fill with an acrylic lens. I had a large bubble & it would be hard to eliminate<br clear="none">
all bubbles in the oil filling process.<br clear="none">
Will try & attach photos.<br clear="none">
<span class="yiv6084921555m_-4009840553512474043HOEnZb"><font color="#888888">Alan</font></span><br clear="none"><br clear="none">
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