Some images load today, I will upload and insert the rest of the images in a day or two.

2 LED types used
This part is a little out of my original order of things for the book, but relevent.
The basics of the LED choice is largely what you may have available. There are ways you can achieve white light. First is to simply use a white LED. The second is to use a combination of red, blue and green LEDs. Some of the multi unit LEDS are made exactly that way.
I will start with some basics here, if it sems a review, you can skip ahead.
Luminares in general are measured for light output in two ways, and the measurements are not able to be translated from one to the other with any accuracy. So if purchasing new LEDs, the greatest output in Candela or milli- candela should be chosen with the widest “viewing angle” available if you are going to use them general illumination. For point source lighting use, such as indicators, motor vehicle turn indicators or other use where direct viewing is the manner of use, the light output is not as critical, except when motor vehicle equipment standards are required. Surprisingly, there are a number of LEDs from a number of manufacturers that meet or exceed the required candela rating in a single 3 volt lampule.
The Candle, or Candela output is measured in a manner of light intensity on a surface at a set distance along the centerline of the light source output. Many LED lamps of the conventional bi pin style that many are familiar with are now available with greater than 20,000 millicandela output. Those usually have a fairly tight viewing angle. To give a reference point for the intensity, the turn signal lamp on most cars is a mere 20 candela, so 26,000 candela is a brighter light albeit in a tighter cone of radiation.
The white LEDS are additionally labeled with a “Temperature.” All that means is the light your eye perceives will have a certain “color cast” to it. The bad news is the “warm white” types also tend to have a bit of a greenish cast to them due to the coloring of the phosphors used.
The human eye is very adaptable, and most people who have experience with photographic film understand that color cast their color photographs will have when taken under flouresecent light: green or; orange: under incandescent light. Unless people look at the flourescent luminaire itself, they rarely notice the difference between a cool white and a warm white even. Color film that is daylight balanced show those colors in a very marked manner when printed without compensation for those special lighting conditions. Digital cameras are more forgiving, but not perfect, and even tend to have a blue or purple cast under a daylight 5000K LED.
All this means is colors have a temperature. Just as people consider white with a very slight blue tint to it as being a truer white than true white light, they also have a preference for interior light color or temperature. There is a difference in preference for light color regionaly as mentioned in the lighting Institute publications. European tastes are more often for the higher degree K luminaires and most people in the US have a preference for the “warm white” LEDs of about 3400K. I myself prefer a more accurate daylight coloring myself. The data I distilled some of this from was from literature available from Cree, LED City and various online resources dealing with LED lighting. Digikey for example, has numerous training modules available online to better inform and educate those engineers and designers involved with lighting with LEDs.
Yes, you read that correctly- “warm white” is a cooler temperature than “Cool white.” That cool or warm reference has more to do with color tones than temps- warm colors are yellow, orange, red, and the cool colors are blue green and purple. The general coloring of “white” are denoted for LEDS as a certain number denoting degrees kelvin, or K.
Daylight can be considered to be right around 5000 to 5400 K. Tungsten lighting is right around 3400K. White LEDs are made as initially a blue LED, with a phosphor coating on the cast lens body above the LED chip that reradiates the blue light energy that strikes it as a certain temperature “white” light depending on the formulation. As a result the “warm white” or those rated in the region of 3400K have a slightly lower light output than those same lamps that were made as a 5400K or 6000K unit due to a thicker layer of phosphor.
The Lumen measurement is taken as a spherical measurement a specific distance from the light source; spherically surrounding the entire light source where the Candela or “Foot Candel” is measured as a light intensity 1 foot from the light source. They are not easily translatable by any conversion equation either.
If you are going to try use a photographic light meter to measure relative outputs, you must reflect the light to be measured off of a “grey card,” usually “80 percent” which is the one provided for most light meters and they are calibrated to that grey card for accurate light response measurement. Simply pointing the meter at the light source is not going to be accurate at all unless the meter is specifically made for use in that manner.
LEDS are now available in a wide array of configurations and mounting styles. In the situation you may be in, rework may not be an option if you make a mistake. Even with a reasonably equipped workbench, some rework or salvage work just is not practical due to the physical damage the devices receive in removal from the circuit.
Currently from a salvage perspective you will encounter the discrete LED “bulbs” most often, followed by various Surface mount Devices, Multiple LED arrays, such as from a scrolling marque, and potentially some Mazda based (standard screw in base light bulb)”duds.”
Heat will kill LEDs almost as fast as over voltage, so any retrofit design at the component level you need to keep this in mind to assure adequate cooling of device.
Surface mount LEDS can be made in several ways, such as a single diode or as a “poly” multiple diode assembly under one lens, or several cast together. Some larger units are called “X-lamps” by Cree, who manufacturers quite a few that get relabelled by other companies that use them in their own assemblies have lumen outputs comparable to that of conventional incandescent lights in common use. The X-Lamps are usually mounted to a “star” or similar base for moutning in a fixture or assembly and some are further fitted with a lens. That star is a standardized size and is used to dissipate heat that is generated at the point junction of the LED when in operation.

Just one multi unit LED
When you are using the driver circuits, these are often designed around Pulse Width modulation circuits if the control circuit is to used as a dimming circuit as well in order to shorten the “duty cycle” (on time) of the LED. The driver circuits are intended to otherwise provide a constant current source. This works well if you are series connecting your devices providing they are all rated the same for voltage and current. Manufacturers typically suggest against wiring the LEDs in parallel as the light output can vary from device to device due to Ohms Law for parallel connected loads. Sometimes this may be the only practical way to use them however; especially if they are of a mixed type, be they arrays, or discrete devices.
When on straight DC, there is no off cycle, so there is constant heat generated that needs to be dissipated. So such things as heat sinks, increasing air flow, wider conductive pads, etc, should be factored into the design as well if you are working with discrete Power LEDs that are not mounted to carrier dies yet. Most manufacturers prefer the devices to be powered from a constant current source for maximum performance rather than a constant voltage source (direct connected to a battery). A rudimentary means of accomplishing this is to use a resistor in series with each parallel LED, or string of LEDs.
Another means of accomplishing this is little more involved and uses a MOSFET (any that have sufficient current capability for constant current will do.) All that is done is to wire the MOSFET as a “variable voltage resistor. While the circuit below does not look like it should work, it actually does work within limits if you can set the resistance where the MOSFET is operating near the pinch off zone so an increase in voltage increases the resistance. In the one schema, the one that really does not look like it will work since there is no visible path across the circuit without the load in the image, actually does work because the completed circuit references negative voltage (for N channel types) through the load itself.

A bipolar transistor could also be used, an NPN type would connect essentially the same, Emitter as input, with variable resistor to Base and the Collector as output.
In testing, it did seem the MOSFETS were a little easier to get to work correctly. Your results may differ.
Alternately, in the National Data Sheet for the LM117/317/317HV type 3 terminal regulators, they show the simple circuit for up to 1 amp of constant current. Some have used the LM317 as a current source for the cathode circuit of tube amps as well.
<a href="http://www.national.com/JS/searchDocument.do?textfield=LM117&x=0&y=0" LM317/117 Datasheet selector
National LED Lighting Ap Notes
If the resistors are variable for dimming purposes, these can yield non-linear results, even if the variable resistor is linear in it’s taper. Which is why the driver circuits are suggested by the manufacturer. If you are constructing these for your own use, and can live with results that are not mathematically predictable and consistent other than the point where the LED begins to conduct, the driver or current sink is not as critical.
Most of the Power LEDs are intended to be used with a lens assembly as well. If you are doing a custom assembly such as I have done with these fixtures in the images, those extra assemblies are not practical. However with the one fixture, the crackle glass is for all intents and purposes accomplishing much the same thing a certain diffusion lens assembly would do, and the other recieves a plastic difusion cover.

a view of one undercabinet conversion
If you want optimal performance from the LEDS with the capability of their being dimmed, a PWM circuit is the suggested way to go. The results can be predictable and linear in nature with correct parts values.
Most any PWM circuit can work as long as the output current and voltage is within the ratings for the devices to be lit. The simplest approach is to simply buy the driver that the manufacturer suggests, but this can become expensive, and if you are not able to order parts because you do not have reliable shipping or postal services, then you need to make do with what you have. in short the PWM circuits operate by pulsing the output.
If you ever made a type 555 oscillator, you could change the rate of the output frequency, and you could change the duration of the “on” or “Off” portion of the output. This is the basis of the PWM operation. Bridgelux has an application Note “AN-12″ that covers this in 58 pages more detail.
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Bridgelux link to ap note
Many of the “Light engines” or “Stars” that you will find when ordering “Power LEDs” from vendors (such as Mouser or Digikey), the light engines or stars use “X-lamps” as their luminaire if contracted from Cree, or other names if they were ordered from another company like Avago, or Seoul Semiconductor. The star itself is just a base mounting, and not much more than an aluminum planchet with an insulating layer and conductive tracks for the power LED.

A Power LED Star by Lite on.
Many are used with an additional lens for a specific shape of light output. Just as they are without a lens, they usually radiate in a 120 to 180 degree circular pattern from the backplane of the star depending on manufacturer.
Many of the mounted units have an integral means of reducing voltage to the LED itself as some manufacturers actually have assemblies suitable for wiring to mains power (not all of them though) or for limiting current applied to the on board LED. These stars also serve as an interface with a metal mounting base to radiate the heat that is generated from the lamp when in operation.
If you buy the commercially available mazda based units for retrofit to older light fixtures or lamps, some are composed of the discrete LED lamps and some are surface mount devices. Each has it’s own advantage. While those commercial units offer simple retrofit, the basic LED lamp or chip in itself can be wired to DC for low voltage use and fitted to just about anything.
The way most of the Mazda based retrofit bulbs are made, you have to break the glass or plastic envelope and remove the LED from the circuit board. Usually it is just easier to buy the LEDS from a vendor, although if you are using salvaged LEDs pulled from boards, those too will work, but there are no guarantees that the light intensities will be the same for many reasons, so you may want to set up the workbench to find suitable resistors to put in series with each LED to optimize it’s light output for higher voltage than merely 3 volts.
To make white lighted areas, or reasonably close to that rendering, if you happen to have a small pile of discrete blue LEDS, you can add red, and green LEDs, so when lit you will have some approximation of white light where they overlap in patterns. It will not be perfect, but it will be close enough to reduce eyestrain or to create certain effects.
When purchasing the LEDs, always download the application notes and specifications specific for that LED. Voltage is critical- you can use less than peak voltage, but you need to be mindful not to exceed the maximum applied voltage either. If you are able to supply optimal current at the Typical operating voltages you will get the expected rated light output of the device. Typical operating voltages and peak voltages are two different ratings, and they will vary between types/models, and with salvage LEDs, that range could be anywhere. 3 volts is usually safe for assembly and testing purposes.
If you are using unkown rated devices and have plenty to sacrifice a few for testing, that is the easiest way to find out at what point they burn out, and then use a lower voltage. If you measure current while testing, you may want to incorporate a current limiting resistor to limit current below the burnout point to allow for some flexibility.
While the current measurement may seem an odd inclusion here, if you have an adequate value of a resistor, which you can calculte, you can apply a greater voltage to the device than you initially expect. Back in the 1970′s I replaced the 12 volt lamps in a tape player with LEDs I had on hand to change the color of the display and replace all the lamps that a few had already burned out. It was just that value of resistor for each LED (many were different in that project) that allowed for 12 volts nominal to be “applied” to the diode- the current limiting was critical, the voltage drop was less critical and so led to a simpler installation. It is easier to maintain constant current on a 12 volt system than it is to maintain a constant 12 volts in an automotive situation for example.
Some of those earlier LED arrays for under counter lighting had high failure rates because of the effects of poor quality control in the LED and the effects of transients induced from many sources including the incoming power line from the power company. Transients can include RF energy as well.
One array I constructed, I used a cast off flourescent light trough. It measures about 2 feet square and was used with the drop ceilings commonly found in offices originally. I simply wired4-5 Watt power LED stars together after mounting them with a spot of heat sink compound to the backing side, plus I mounted a screw terminal to the top side of the housing so I could wire it easily to a battery, a mains supplied power supply, or whatever arrangement I might need for it later. Currently, it is wired to a mains supplied power supply salvaged from a printer. To achieve the correct voltage for the LEDS, I initially used an industrial wire wound potentiometer in series to limit current flow and to introduce a votage drop in the circuit. Once I determined the point where the LEDs were at maximum intensity; I measured my resistance of the rheostat out of circuit, and installed a suitably sized power resistor in it’s place. I also inadvertently found out the LED stars I had used, which were a 5 watt per unit rating, had a built in overload protection feature which strobed the LEDS at about 1 hertz when too much voltage had been applied. I was lucky they had done that because LEDS often just burn out once their maximum applied voltage is exceeded. Or worse- blow up (I managed to do that in high school with an adjustable power supply I was not familiar with and the little LED stood no chance when a full 35 volts at a few amperes was applied to it.)

5-watt-star JPEG
The quick projects I show below, one the finished product ready to be mounted, the other one yet to be assembled and the images will show the basic steps of assembly.


scored clad board
One advantage of using the LED lamps such as T-1, and T-13/4 and related outlines, is they have their own ability to dissipate the heat so no significan heat sink is required. However when clustered together, they can be a minor problem due to the nature of several focused lenses creating multiple shadows. Not a problem with reading a book, but it can be problem trying to read a component part number of a component still mounted to a circuit board.

Through hole style
An array of power LED stars mounted linearly present a similar problem but is less pronounced. The 5 grouped in the trough overlap enough that shadows cast are not as pronounced.
Multi LED Mazda based replacements can also lend themselves to some very creative lighting effects with some very basic square or pressed glass light globes. Each discrete lamp casting the shadow of the same portion of globe edge in a different location on a wall or ceiling, and if colors are mixed…. Very effective and dramatic in an Art Deco setting.
With the SMD devices that you can handle, you can construct an array simply by taking a copper clad board, removing any coatings or corrosion first. In my examples, I simply used a sharp knife to cut through the conductive layer approximately in the center of the small boards. It may seem wasteful, but the large copper foil area is an effective heat sink for the LED modules, and is needed as such.

Prep steps for a Surface mounted Device or SMD.
You could certainly do the same for mounting the individual leaded lamps, but they tend to be more easily managed when inserted through perf board, and do not need much for heat dissipation. The through hole units are also very amennable to wire wrap assembly. They may look a little odd from the side as it is difficult to get them to line up evenly and squarely unless an external holder is used, but that is not critical as you are not viewing the light source direct nor the luminaire you are looking at the light from those units within it as it illuminates in it’s path.
With a modest soldering iron with a small tip, the SMD devices are quite easy to manage. Tinning each side strip of copper is the next step, this makes handling the device, the solder and the iron a bit easier.

Action Shot.
If you notice the extra visible wires in a later image, that was due to one device being reversed from what it was supposed to be when soldered. I chose to make the alteration to the board rather than try extract the device because damage to the device is almost assured when you try to desolder for re-use a 6 padded (or more) surface mounted device as I had. If I had been salvaging equipment, I would have trimmed the board down to a size I could cement to the main carrier board and then make my soldered connections.
Once one side is soldered in place, the other side is very easy to solder. If you do not have a nice fillet on the first side, simply reheat and add a small amount to achieve a concave fillet after the other side is done. This may seem counter to what you see with wave soldered boards, however that sodlered connection is the junction where heat transfer takes place, so having a good solder fillet helps conduct heat out of the device.

Ready for wiring, Silicone anchoring is a later step.
When assembling in this manner, do not expect your solder joints to be perfect. You can strive for it, but the reality is the less time you spend on minor details that will be hidden from view, the more time you have for other things.
If you are working with salvage materials, obviously you use what you can get. In that situation the best two choices to use are red or amber if white is not available. Red does not wipe out your night vision, so are good for areas where you might be in and out of an a structure in the course of a night. Amber, while not the easiest colored light to work under, does allow for some lighting options in task areas and is better choice than red.
The small boards are just cemented in place with RTV silicone. Do not energize the circuit until the silicone has adequately set up because it will be conductive until cured to reasonable extent. The following images just show the steps of basic assembly. As long as your LEDS are oriented the same way, it simplifies the wiring and actually speeds things up overall.

Ready for dallops of silicone to anchor them in place.
One additional note, if you mix types, such as I did with the SMDs and the discretes, they have different peak voltage values, one at 4.2 volts and one at 3.9. while this does not sound like much, the LEDS when run close to their peak voltage, if they are going to fail early, they will fail earlier than you expect.
Some other considerations for LED lighting- Line noise. If you are on mains power and using a driver board as suggested by the manufacturer, you may consider adding a common mode filter to the input voltage of the driver.

filters
If you are suffering from chronic driver failures, or LED failures, you might consider adding individual ferrite beads to each power wire to the LEDs. This does however add a load to the driver and will usually mean failures for the marginal drivers, and I know energy efficient flourescent ballasts, which are more similar to PWM circuitry than you might think, are more prone to failure when ferrites are in place. Since I have used them with the flourescent lighting to supress RF radiation through the house wiring, those marginal ballasts tend to simply fail, yet the ferrites were placed only on the mains power input to the ballast, so that may not be the whole story yet, I am still researching, but so far this does seem to be the case.
In perusing Digikey for current high output LED’s, this one caught my eye:
This is just the LED on a carrier. You would need to review the data sheet, linked on that page, to see if your setup is able to utilize this. If you want cutting edge, here it is. And by the time you read this, something better has likely come along. I point this one out because it is equivalent to roughly 65 to 70 Watts of incandescent light in a single package. It is not cheap when compared to the leaded types, but you have the lumionous output now to easily replace all of the CFL’s you may have. Why am I down on CFL’s? The light quality, the mercury, and their inability to survive in some metal enclosures such as a range hood. LEDS are also cold friendly, and more efficient than CFLs. Digikey does also ship worldwide.
One thing I do find the CFL’s useful for- Their bases. If you are very careful you can remove the top from the base at the point where the grove is around the circumferance. Some are not glued, and they can be opened with a screwdriver blade, those that are glued need a utility knife or a saw blade to just cut through the plastic. There is an electronic ballast board in that base that may or may not have some useful parts intact (depends how the CFL failed). The bases allow you to assemble an array or an LED discussed below to be retro fitted to older lamps AS LONG AS THEY ARE ON LOW VOLTAGE, or a driver circuit suitable for your mains voltage.
If you pursue this for your own lighting, as always- YOU ARE RESPONSIBLE FOR THE RESULTS. In other words- If you failed to do due dilligence on research of the readily available documentation, Or even if you did- Not I, nor any company mentioned here, or manufacturer of the products can be blamed for your mistakes. Since I only have low voltage in my barn, I can use the bases to mount various LED arrays to them. Since I only have low voltage in the barn, I will not get conventional 120VAC light bulbs confused with the low voltage stuff so no surprises.

bases1

bases2

bases3
In short, if you have been waiting for a good LED module before you commit to them, these and others like it are now here, and at a justifiable price point. These make integration of an alternative energy system in your home rather simple if you have the knowledge to make use of these parts, or if you are just wanting to see what the components are of some of the “ready made” products that are available at significant prices still.

If you need the rough equivalent for 100 Watts, how about this one:
LED Link

These images linked to DigiKey are used with their permission.
Don’t get me wrong, I am not promoting these for any other reason than they are just good products that give you some flexibility. In a few months, these will potentially be obsolete just due to the nature of the technology advancing and innovation and refinements of production.
One thing to remember- with all of the obsolescences in this area of electronics, the “NOS” or New-Old Stock of those units that are no longer in demand in industry because something better came along leaves the door open for many of these to end up on the planet somewhere in bulk. If you happen to be one of those people in one of those areas, don’t be afraid to use them.
In addition, you can purchase LED flashlights right now, and they are pretty good. They can sometimes be adapted to an existing fixture, but the LEDS in use are not always cutting edge or even close to it. I have some LED flashlights with a very perceptable purple hue to them. They were made shortly after some of the first white LEDs of T1 and related sizes became readily available with decent output and reasonable cost. If you do this, it is best to wire them in parallel because there are some issues you will encounter if you wire them in series. first and foremost is that of equal intensities.
Another nice salvage light source that are reasonably energy efficient and give off good light for their size at 12 volts are the Cold Cathode Flourescent lights found in the light hoods for flat bed scanners. HP makes some that have a discrete hood with it’s own cord that plugs into a power socket on the scanner itself so you could scan 35mm films. These hoods make a nice “ready to go” light fixture where all you need to do is clip off the mini 4 pin Din style connector and strip the cable and wires out to a length you can work with and attach loops or gator clips. You can light up a work space or task space, and they are bright enough to read a book under with reasonable comfort, but don’t expect to light up a room with them.

HP Lighthood bottom view

Lighthood top
The CCFLs used in scanners, laptops, flat panel LCD monitors/TV sets can be extracted and used as well, and they are a bit more work, but the small ballasts are in themselves easy enough to work with. Determining a method of mounting the raw tubes can be a challenge if you want something better than dabs of RTV silicone on the ends to hold them in place. The tiny driver circuits are best salvaged with the tubes rather than being fabricated. They will not work reliably in series, so should be wired in parallel if you are using multiple hoods.
I will cover more on using conventional bi-pin flourescent lighting on 12 volt systems without having to add an inverter to them in the future. I have a bank of cast off 2 foot square drop ceiling troughs converted to 2 foot conventional flourescent tubes with low voltage ballasts on them as well as a number of 2 foot fixtures on the rafters of my barn to light the general walkway through the barn currently. Their drawback and that of any CCFLwhen compared to other types of lighting is the RF generated by the flourescent ballast circuits and low conversion efficiency of about 4 amps at 12 volts for about 70 Lumens. There is no getting away from that due to the prinicples of flourescent lighting, and the principles of the circuits. Cold weather is also an issue, and where the LEDS far surpass them for performance.