In the first of two posts, I described how I was setting about trying to install blue LEDs in my Light Unit to use as Moonlights. Today I got out of bed early for a Sunday and decided to get on with the rest of the project. I am going to say this up front, this was not a easy task and was not enjoyable at all. I started at about 8am and after some very very harsh words, blisters and pain, I finally got the light unit back up and temporally wired in by about 4pm. It is just about 8pm and I noticed one of the LEDs had come loose so I had to open the unit up again and try get it sorted out. Unfortunately this time the MH ballast decided to punish me and gave me one hell of a shock. My head is still spinning and fingers still tingling.
Ok so enough bitching and onto the details of the project. The first step was to get the light unit down. This involved removing all the electric conduit and cabling that has been installed to get at the light unit cables. This was not to much of a worry because my next big project will be to move all the electrics and put them in a cabinet just as I said I would not do when I started this tank. Just for interest sake, the light unit weighs in at 25 Kg and has to be taken down by unscrewing it from the suspending cables. A little contortionist like maneuvering is required here.
Once the unit was out and I had recovered from all the spasms in my back, it was time to disassemble it (Not my back, the light unit). This involved removing the the glass and then the reflectors. I had to remove some of the actual MH light bulb holders to get some of the reflectors out, but in retrospect I did not have to do this.

Stripped Down Light Unit
To remove the MH reflectors, I had to remove the MH bulbs. I know from Halides, you do not want to touch them as the oil from your fingers will somehow cause them to blow. I used a combination of rubber gloves and tissue paper to pull the bulbs out. These are the double ended kind and here we hit problem one in many the day. I managed to break the one ceramic end.

Buggered MH Bulb
I was in a panic where or even if I could get a new one on a Sunday – you also don’t want me to tell you what these things cost. Anyway, deep breathes and count to 10.

MH Ballast
These are the 2 x 250 watt Metal Halide (MH) ballasts. Part of the project that also wanted to carry out today was to split these onto their own power cord. That way I can control each one individually.

MH Starter and Bulb Holder
The bulb holders in the image above have been removed. Bad idea. The way they are held in place is with a bolt that has to try and capture a nut in one of those groves that is not fixed in place. Does not make sense, did not to me either and was a major ball ache. The cabling on this side is for the MHs so this is where I would add a new power cable and split the ballasts.
In the near future, I will also be adding two more T5 lights to the unit. (T5 are smaller florescent tubes to what you would be used to in a building etc and give off a better light). This image below shows the current electronic 54 watt T5 ballast.

T5 Ballast
I then marked the reflectors where the LEDs would be positions and then used my Hudy reamer to make the holes. I did the holes from the outside to create a small ridge on the inside to act as a small LED holder. This did not really work as the reflectors are soft ali and cut very easily.

Making Holes in the Reflectors

Holes for the Moonlights
Now this is where the blisters come in. I am a big fan of hot glue, but when I am sticking something with it, and it get on my finger, I am to stupid to let go just in case what I am sticking moves. Doh so thumb has a nice size blister to show for it.

LED Hot Glue Mount
I cut a bit of air line and then fitted the LED into that. Once that was done the LED was pushed into the tub and pressed through the reflector so that as much of it was in the mounting hole as possible but would not fowl the glass when it was refitted. You can also see my Hot Glue “Welding”. I was not shy here.

LED Mount
The holes for the new cables came next and after I marked them, I drilled a 5mm pilot hole and then finished off with a 8mm hole to accommodate the new cable. I will have to keep my eyes oped for some protective sheaths like the ones the original unit is using.

5mm Pilot Hole

8mm Hole for new Cable

Moonlight Connection
This is the new cable that will be used to power the Moonlights. Notice the small white cable tie that is used to keep the cable from being pulled out. Moonlight are not fitted here but the chocolate bloc that they will be connected to is on the left.

New MH Cable
The new MH cable and connection. I am not sure what it is, but these MH scare the hell out of me. I disconnected the original cable form the white chocolate block and then ran the new cable to the black chocolate block and that connects to the MH ballast by the blue and brown wires.
Time to put the unit back together. After checking my connections, I replaced the reflectors that I had washed thoroughly in warm soapy water and I also tested the MH bulb I broke right at the beginning. I was happy that it worked first time. Um friendly word of advice, don’t watch the MH as it comes on…… that white light when you close your eyes will stay with you forever. The reflectors were in place and I slid the glass int place. All gong well and I was so excited to put the unit back up.
Turned it over and something sounded very loos so had a look. The one MH bulb had fallen out. This meant I had to remove the side panels and glass to see what was happening. It seems even though I had tested them, the MH had been working just by contact, the were not properly seated in their mounts. This is where the bad language and temper flared. No matter what I tried I could not get the bulb into the holders – remembering here that I could not touch the bulb with my bare hands and I did not want to get finger prints on the reflector. I broke both ceramic ends on the bulb and was freaking out. Poor Cally tried to help me but thought it would be safer to be in a cage with a hungry Tiger. I swear it took me 2 hours to get the bulb back in. Now I cold not get the reflectors and glass to fit properly. Eventually that was sorted and I noticed the joint in the center of the glass was over the center Moonlights so I had to strip the sides off again and then put the glass in from opposite ends. 20 min later I was lucky I still had glass to use.

Moonlight

Moonlight

Moonlight

Moonlights
Lights just went out so I tried to get a shot of the Moonlights. (The room lights are still on so the tank does still have light)

The Final Product
This is what it was all about (I think I might have to long an exposure as the real thing is a little darker.

Moonlight Full Tank Shot

Close up on the SPS side of the tank