Mag 62138 Regulated Build. Originally started as Mag623 DD.

[bigchelis]

Re: Mag623 with 4D Stock switch/4 imr 26650 and 85K lux

UPDATE:

I asked Jimmy if he could re-set it with a softer soft start and he SET the Voltage at 13.5V to the 62138.

With the big 2.5in Throwmaster by Fivemega I get 217~220K lux. No drop in lux since its regulated. The 4D Mag with 4*18650 warning kicked in about 15min into the run but I had 2500mAh cells. Looks like I need some 26650's with 5000mAh to give it some more runtime.


bigC

 

[bigchelis]

Re: Mag623 with 4D Stock switch/4 imr 26650 and 85K lux w/KAI SMO Mag reflector

In summary of this project.

With 62138 in 4D Mag regulated at 13.5V to the bulb.

• Tailcap current starts at 9.5~9.8A

With the 2.5in Throwmaster bezel LUX is 217~220K


With Kai SMO reflector for Mags LUX is 110~112K ( the 117.5K lux I was flashing these bulbs, hence why JimmyH redid the voltage setting for me).






I actually like the Kai SMO reflector format best. As the beam hotspot is still respectable and with over 100K lux of warm incan light leaves nothing to be desired.



Next Project is a 6D Mag623 regulated with the 2.5in Throwmaster (The Mag623 beam looks bad with Kai SMO, but very good with the 2.5in Throwmaster)

 

[The_Driver]

Re: Mag623 with 4D Stock switch/4 imr 26650 and 85K lux w/KAI SMO Mag reflector

Very nice!
How about some beamshots?

 

[Justin Case]

Re: Mag623 with 4D Stock switch/4 imr 26650 and 85K lux

I must have misread the voltage setting options. You are correct I have to measure the voltage under load. I assumed as long as I had a TRUE RMS meter I would just put those leads to the resistor and I would get a reading. That's clearly not the case.

I have sent the switch and driver and bulbs to Jimmy. He offered to synchronize them correctly for me.


Will update as soon as I have updates.


bigC

bigC, if you have the right type of RMS meter, you just measure the bulb voltage setting directly. You don't need to know Vbatt. You use Vbatt only if you have an averaging meter.

The likely problem in your case is that you don't have the right kind of RMS meter. You need an AC+DC true RMS meter. An AC-only true RMS meter, which is probably what you have, discards the DC component.

If you have only an averaging meter, then it's probably best to use a good bench power supply to run the JimmyM Mag switch to set Vbulb. That way, Vin has no sag and it is easy to adjust the driver for the desired drive voltage.

 

[Justin Case]

Re: Mag623 with 4D Stock switch/4 imr 26650 and 85K lux

He also did not actually test the bulbs lifetimes for different voltages (that many combinations would take years ).

Lux's various bulb tables clearly label the filament lifetime column as "Predicted Life (Hrs)*". The word "Predicted" is a clue. The asterisk indicates that the prediction came from Welch Allyn and AWR's Hotrater program. Welch Allyn estimates overdriven filament life using a power law, with the exponent equal to 12, and it looks like that's the same exponent used in Lux's 62138 table.

Obviously, power law re-rating equations are only a rough guide. As you deviate farther from the bulb's rated spec, the re-rating reliability gets worse. IMO, a Vbulb of 14.0V puts you in that unreliable regime. I would suggest picking a Vbulb by staying above 10 hr estimated life.

 

[bigchelis]

Re: Mag623 with 4D Stock switch/4 imr 26650 and 85K lux

Lux's various bulb tables clearly label the filament lifetime column as "Predicted Life (Hrs)*". The word "Predicted" is a clue. The asterisk indicates that the prediction came from Welch Allyn and AWR's Hotrater program. Welch Allyn estimates overdriven filament life using a power law, with the exponent equal to 12, and it looks like that's the same exponent used in Lux's 62138 table.

Obviously, power law re-rating equations are only a rough guide. As you deviate farther from the bulb's rated spec, the re-rating reliability gets worse. IMO, a Vbulb of 14.0V puts you in that unreliable regime. I would suggest picking a Vbulb by staying above 10 hr estimated life.

JustinCase,
You are right on both fronts. I got the wrong True RMS meter. Figured it cheaper to just send the regulator back to Jimmy: which he re-tuned for FREE.

He set at 13.5V out


I do have another Driver he sent me. He regulated the other driver for Mag623 build I have planned.

Mag623 in a 6D Mag Host with 6 IMR 26650's.
16V out
18.6V Vlow
Slow start

 

[The_Driver]

Re: Mag623 with 4D Stock switch/4 imr 26650 and 85K lux

Any updates?

 

[bigchelis]

Re: Mag623 with 4D Stock switch/4 imr 26650 and 85K lux

Long overdue update.

I have the 6D Maglite with an already soldered regulated driver from JimmyH, just waiting on Osram 64623 bulbs in the mail I seem to have lost my spares.

Mag623 in a 6D Mag Host with 6 IMR 26650's.
Jimmy tuned the driver for me:
16V out
18.6V Vlow
Slow start






I had previously built this Mag623 on a 4D host, but I was very disappointed with the runtime using 4 Keeppower 4500mAh IMR 26650's in direct drive. If I recall I would get about 5 minutes of bright light than very reduced output for another 20 min or so. BTW: this bulbs beam looks great on 2.5in throwmaster bezel from fivemega.

My hope is that I can get 20~30 minutes of regulated bright incan light. With 25.2V input and 5200mAh (granted it has a driver) and not sure how the runtime is recalculated now but I will test those cells to get a live test going.

 

[The_Driver]

Re: Mag623 with 4D Stock switch/4 imr 26650 and 85K lux

Nice light! Please try to post pictures, measurements etc. when it's finished .

Runtime calculation:
Bulb power consumption: 16V * 10.5A = 168W
Energy in Batteries: 6 * 3.4V * 5Ah = 102Wh (see here, look at curve for 7A current draw)
Battery life: 102Wh / 168W = 0.6h = 36min

 

[bigchelis]

Re: Mag623 with 4D Stock switch/4 imr 26650 and 85K lux

So, I have a 36mm reflector and used that instead with a UCL high temp lens to keep the Maglite size stock length. BTW: The lens provides a near perfect floody beam.

I had to move the switch up a bit via drilling a new hole and I will use a Kaidomain 52mm OP reflector that I ordered today since I sold my last one a month ago.

Here she is with its 8.5A at the tailcap.