In this post we see how to build an enhanced and efficient car headlight lamp using Pirhana LEDs.
Using 4-pin Pirhana LEDs
You might be pretty familiar with the ordinary two-pin, 5mm white LEDs, which are by no means “ordinary” and produce lights at reasonably high intensities.
However when it comes to 4-pin LEDs, the 2-pin types stand no where near it. Include just 50 of them in a group, and you are well producing lights that may be more dazzling than conventional car headlight intensities.
Here we discuss how to implement 4-pin LEDs in automobiles for making their headlights more power efficient and more powerful.
In fact the application may not be restricted to just car headlights, you might want to use them for other applications also, like as a LED tube light in your home, that can result in a lot of saving in your electrical utility bills.
Before we proceed with the proposed circuit of efficient high power LED head light design details, let’s first analyze the important specs of this interesting light emitting device.
A 4-pin super bright piranha LED might look complex at the first appearance, but a careful look will assure you that it’s as easy to understand as a two pin type.
Though the device includes 4 pin outs, two on each side are actually shorted internally, and therefore technically it has just two outputs, one anode and the other cathode quite like our ordinary two pin LEDs.
However a four pin arrangement is made to suit it’s size and for assisting firm PCB mounting, the square extra large shape of a 4-pin LED is designed to introduce some special features in it, attributing the qualities of generating extravagant light emissions to them.
Main Specifications of 4-pin super flux LED
The following text provides some of the important specs related to 4-pin LEDs:
Safe operating temperature – 25 to 80degree Celsius
Typical operating voltage – 3.5 volts,
Maximum operating voltage – not to exceed 4 volts.
Normal continuous operating current – 20 mA,
Peak instantaneous current – up to 100 mA Viewing angle – 50 degrees.
Efficient Car Headlights Using 4-Pin Super Flux Piranha LEDs
The DIAGRAM illustrates a simple application circuit using 48 high intensity 4-pin LEDs for automobile headlights.
Since the operating forward voltage of the LED type is around 3.5, three of them accommodates in each channel, in series.
The series are further connected in parallel for making the total number up to 48. Voltage is derived from the car battery via the dashboard switch.
Preferably the LEDs may be arranged in circles for uniform distribution of light across the whole headlight enclosure.
Circuit Diagram
The PCB used must be a glass epoxy type, double sided; the hind side copper of the laminate is not etched and is used as a heatsink for absorbing heat from the LEDs and dissipating it in the air.
Using a Single 10 watt LED
If you thing the above discussed method is too laborious, then you can opt for a single 10 watt LED for enhancing your car headlights with low consumption LED lights.
The following image shows how a 10 watt LED actually looks like:
The two fins across the sides are the two terminals which will connect with the 12V supply from the car.
Not to mention each of these LEDs on the headlights must incorporate a current control circuit in order to ensure a safe and an optimal illumination.
I have already posted a couple of LED current limiter circuits which you can study through the following links, and implement those in between the LED lamp and the 2V supply from the battery:
Current Limiter using Transistors
Any of the above concepts can be applied for protecting the 10 watt car headlight LED lamps from over current or a thermal runaway situation.
However make sure the LEDs are mounted over well calculated heatsink, which could be a round finned type as shown below, this may be mounted behind the headlight box:
Using other Forms of LEDs
If you wish to use any other form of LED having different specification than the above, you can definitely do that by calculating the resistor values appropriately by using the formula:
Resistor = Supply voltage - Total Forward V spec of the LED series / LED current
For example suppose you would want to make a headlight lamp using 1 watt, 3.3V 350mA LEDs, and your supply voltage is 12V from your car battery, in that case the above formula could be calculated in the following manner:
Consider each string has 3 LEDs in series:
R = 12 - (3.3 x 3) / 0.35 = 6 Ohm
o it is 6 ohms resistor that you would need to put in series with each of the LED strings having 3 LEDs in series.
And what about the resistor wattage?
For evaluating wattage simply multiply the difference between the supply and LED total voltage drop with the LEd current, therefore for the above case we get:
Wattage = 12 - (3.3 x 3) x 0.35 = 3.46 wattage, the nearest safer value is 4 watts.
In this way you can use any desired LED for your car headlight by suitably calculating the series current limiting resistor.
Caution: When high wattage LEDs are used always make sure to add a specialized current limiter stage in between the supply input and the LED module, as already explained in the previous paragraphs of this articles.
Suhail Paul says
Hi Swagatam,
I want to build a led top light for aquarium using 4 pin leds the circuit mentioned above can it be used off a 12v DC adapter?
Swag says
Hi Suhail, yes you can build it for the mentioned purpose. You can add or deduct the LED strings as per your preference for increasing or decreasing the illumination
Suhail Paul p says
Thanks
Please provide a circuit diagram If I use straw hat 5mm Leds .in a string of day 200.
Driving it thru a 12v DC adapter.
Thank you.
Swag says
The circuit design will be the same, just the resistors values will change to 450 ohms…1/4 watt, but whether 200 numbers can be accommodated or not will depend on the current consumption of your adapter
Gaurav Ranu says
Hello Swagatam,
I can't see the attached pics and circuit diagram. Following error is shown: HTTP Error 404 – File or Directory not found
I wish to make DRL and tail light using superflux led's in place of regular 3 or 5mm led's.
Can you pls help me out in making a drl & tail light for my bike using your circuit diagrams and layout. I am a novice in electronics with but love doing DIY stuff.
Thanks
Swagatam says
Hi Gaurav, I am not having any difficulty in seeing the diagram from here…you can open this link to see it separately
3.bp.blogspot.com/-ACwhhtZz-L4/Tu2YkUeuO2I/AAAAAAAAAXA/jq3lf3vNzY8/s640/4-pin+LED.png
for a DRL you can follow the following concept and apply it suitably for your specific application
https://homemade-circuits.com/2013/07/making-led-halogen-lamp-for-motorbike.html
if you have any doubts please feel free to ask
basit momin says
Hello sir I don't know about piranha leds as I have seen it have 4 pins so how to solder it in series can u explain pls
Swagatam says
Hello basit, see the diagram in the above article, you can see two leads on each side of the LEDs are shorted and connected to each other in series, you can do it in this manner.
nofear says
Hi all,
I build a replica Iron Man ARC reactor last year for Halloween.
https://drive.google.com/file/d/0B32qJakASDM4OENsSzJBMTZXeG8/view?usp=sharing
I used 17 LEDs used here in this project, directly connected to a 3.7v LiPo cell. Unfortunately the cell runs at ~4.1v at full charge. This caused several of the LEDs to fail over the course of the evening.
I want to replace the LEDs and build in a regulator or a resistor to stop this from happening again.
I'm fine with the mechanics, but not entirely 100% on what I'd need, or how to place it regarding the electronics. Can anyone assist?
Swagatam says
If you have used 5mm LEDs, you could connect 50 ohm 1/4 watt resistors separately with each individual LEDs. in the array.
. says
Hello Swagatam,
Really nice and useful projects.
Can you upload a bigger circuit diagram. The one present doesn't show other compopnents very well.
Swagatam says
Thanks,
please click on the diagram, it will enlarge in a new window with the all the details magnified.
Swagatam says
….sorry it's not responding to a click, I'll make it bigger in a moment.
Anonymous says
i do not see the diagram from the OP. Can you please repost, thanks
Swagatam says
i didn't understand your question??
ra66ju99 says
Hi Swagatam,
Thanks for the prompt reply. So now I am ready with the circuit and will construct it.
Also I do have 12v and 2A adapter with me. what LED circuit can i use in conjunction with it.
And lastly, I have brought LED strip light which has its own resistors connected. can you suggest me a circuit using these LEDs.
Regards
Nagaraj
Swagatam says
Hi Nagaraj,
You can use the adapter with the LED strip, they are perfectly matched for each other.
Regards.
ra66ju99 says
HI Swagatam,
Thank you for your prompt reply. So i am in the final stage of building the circuit with hopefully one last help requesting a good PWM circuit as mentioned by you and the integration. Also i need this circuit to work from mains and hence any modification needed. Usually whenever i see any circuit, i straightaway go to the comment section to see what are the queries asked, any modification required and then make note of all the details and lastly will request your help in getting the required refinement before going ahead and building one.
Regards
Nagaraj.
Swagatam says
Hi Nagaraj,
You may refer the following article, it's a PWM controlled circuit:
https://homemade-circuits.com/2012/10/automatic-40-watt-led-solar-street_2.html
Regards.
ra66ju99 says
Hi Swagatam,
One hopefully last set of questions to get clarified before spearheading to build the circuit.
1. Can i use 1 watt LEDs as suggested in the above circuit?.
2. Will there be any modifications for me to do?
3. Should I use heat sink for the 1 watt LEDs and if so what type of heat sink should i use.
4. Will there be any power saved by using 30 nos 1 watt LED to that of 28 watt normal tube light.
I think these above questions are all i need for me to start the project.
Regards
Nagaraj
Swagatam says
Hi Nagaraj,
feel free to ask as many question as you want…
1) you may use 1 watt leds in the above circuit.
2) The resistors will become 10 Ohms 2 watt for each string
3) Yes heatsink type PCB is strictly recommended.
4) Power saving would be there if a PWM circuit is used otherwise no difference.
Regards
ra66ju99 says
Hi Swagatam,
As these LEDs are much brighter than the ordinary LEDs, I need your advice on the following points.
1. How much LEDs do i need to have in the above circuit if i need to get a brightness as that of tube light (28 watts).
2. Can i use 1 watt LED in the above circuit instead of Piranha LEDs)
3. What will be the total power consumed.
Since I am planning to have LED lights in place of ordinary Tube light as they consume more current, Kindly enlighten me on this above query so that i can decide if it is feasible for me to switch over or not.
Swagatam says
Hi Nagaraj,
I think 50 nos piranha LEDs would be more than enough.
If you are using 1 watt LEds then 30 nos would be enough.
Put them in a straight line with 2.5 cms or an inch gap between each LED, that will help to produce light equivalent to a normal FTL.
Definitely it should be feasible for you or anybody to do it.
Regards.
ra66ju99 says
Dear Swagatam,
Further to my question asked here, some more queries that i wanted to get clarified. Is this LED will be more brighter than the 1 watt LED? Can i think of using this for tube light application using the above said 133 LEDs and how bright will it be and what is the current consumed.
Regards
Nagaraj
Swagatam says
Dear Nagaraj,
1 watt leds will produce diffused high intensity light, while piranha LEDs will produce sharp clear focus type light, both are blinding to see, difficult to say which one is brighter.
133 leds will definitely produce a lot of light but again not sure how much, i think you must spread the angle in 180 degree direction, that will help to distribute the light uniformly and efficiently.
current is given in the above comment.
ra66ju99 says
Dear Swagatam,
Again Nagaraj here. Using 4-Pin Super Flux Piranha LEDs, can I have up to 133 LEDs in the above circuit? and what would be the approximate cost of the LEDs.
Regards
Nagaraj
Swagatam says
Dear Nagaraj,
Yes you may use any number of leds, but the series/parallel connections should be as shown in the diagram.
Each series will consume about 60mA, means 133/3 = 44 strings x 60 = 2.6 amps, means the battery should be at least 20AH rated
Anonymous says
Hello Sir,
i want to use 3w or 5w led for my bike headlight can u plz tel me which resistance i can use
Swagatam says
At 12V supply, use 12 Ohms for 3 watt LED, and 7 Ohms for 5 watt LED
Rajat says
Thank you Bro.
i also want to add power led in the mid of 5mm led's.can i use the same resistance what u had suggested to above person 15 ohm 2w for this?
brother i hv 1 confusen abt voltage.i think scooty will give me different v on different speed bcoz of this light will dim/bright every time when the speed will change.can i use any capacitor or anything else for constant voltage?
Swagatam says
You are welcome Bro,
If you are three in series, then you may use 15 Ohm resistor, however a 56 Ohm would be safer.
You may add a 2200uF/25V cap across the bridge rectifiers positive and negative points…
Rajat says
Brother by mistake i had write wrong in my post i m using 130 nums of 5mm
led and 3 nums of power led 1w.
Rajat
Swagatam says
Hi Rajat,
Make the LED connections just shown in the diagram.
In the diagram 16 strings have been used, you can add 28 more such strings to make 133 LEDs.
For rectifying AC, you can make a simple bridge rectifier using 1N5402 diodes, as shown in the following article and wire it with the LED assembly and your scooty's AC input.:
https://homemade-circuits.com/2012/01/how-to-understand-diodes-and-build.html
Regards.
Swagatam says
Te LED resistors can be reduced to 56 Ohms for brighter illumination.
Rajat says
Hello Swagatam
I m 15 year old student i have so much interest in electronics.
i want to use this headlight on my scooty with little change in led i m using 30 5mm and 3 1w Power led.my scooty lights running on ac supply.
(i think i have to use diode rectifier for ac to dc convert and a 100ufd / 50v capacitor)Battery power is 12v 2.5 ampere. plz guide me i m going rite???? Help me in this project.
rahul says
sir can i use 1w six led for making bike headlight?if yes then wt num resistance i can use….
Swagatam says
six nos will be insufficient, you may have to use at least 24 of them, however 1 watt leds don't produce focus type light, so i'm not sure about these for this application.
rahul says
Thanks for reply me Swagtam sir.Sir i m using 60 degree lenses on 1w led for focus.sir i m using 2.2 ohm 1w one resistance on 3 led and bike Battery is 12v is resistance value is fine?
and 1 thing more how many 1w led i can use with 12v battery?can i use led in parallel plz help me if u can.
Thanks
Swagatam says
Hi Rahul,
2.2 Ohms is far to low, use 15 Ohms/2 watt resistors for each string of three LEDs….yes you may connect more such strings, to an extent though otherwise your will become flat pretty quickly.
Anonymous says
Thanks.
And a little note that "Comment as :" combo box is missing "Anonymous" option from your other blogs. Plz. do add it, it is more easier then using available options.
Regards
Sam
Anonymous says
Hi Swagatam
Thanks you have a great number of projects for automobiles. I would like to have your valuable comments on one of my Chinese Honda CD-70 like bike.
Within 5 years I have two alternator regulator burn outs which fries all lightning bulbs etc. My questions are:
1). In absence of a regulator how much voltage & ampere a bike alternator produces.
2). if a regulator burns then it is supposed to be an open circuit and bulbs shouldn't be burned but it does.
3). You had a 12V solid state flasher circuit at BrightHub, if introduced here (even if regulator burns out) will it continue working?
4). If indicators and back light is replaced with LED's and your invented circuit of regulating voltage to LED's is used, will it protect the burn outs?
5). Does homemade regulator justifies itself as a replacement for commercial regulator?
If you have some spare time, then do answer these questions.
Thanks and regards
Sam