MikeAusC
Enlightened
As my first LED upgrade, I modded a Magcharger for a friend to take an SSC-P7.
The clearances inside the head are tiny, and having seen how much heat gets produced from shorted NiCds, I wanted some bombproof shortcircuit protection.
The user is totally non-technical, so I realised a standard fuse could be a problem, as well as being hard to fit.
I then realised the Polyfuse was the ideal solution - small, little voltage drop in normal operation and self-resetting once the fault is cleared.
There was no point putting it in the head, because there was a chance of a short before the fuse. Then I realised that with a bit of careful work, I could fit it in the tail, where it would protect against a shortcircuit anywhere.
I used a piece of very thin Double-Sided Printed Circuit Board to interrupt the connection between the battery and the spring. I ground away the copper near the edges to make sure contact with the case wouldn't short out the Polyfuse.
To keep the side against the battery flat, I ground away through the copper and fibreglass so I could solder the Polyfuse to the inside surface of the copper that's in contact with the battery.
Since the torch would work perfectly without it, I put a clear explanation in place for the owner.
If there is a short circuit, the Polyfuse will stay hot until the short is removed, so you have to make sure there are no heat-affected parts near it - you don't want it melting through wire insulation.
The clearances inside the head are tiny, and having seen how much heat gets produced from shorted NiCds, I wanted some bombproof shortcircuit protection.
The user is totally non-technical, so I realised a standard fuse could be a problem, as well as being hard to fit.
I then realised the Polyfuse was the ideal solution - small, little voltage drop in normal operation and self-resetting once the fault is cleared.
There was no point putting it in the head, because there was a chance of a short before the fuse. Then I realised that with a bit of careful work, I could fit it in the tail, where it would protect against a shortcircuit anywhere.
I used a piece of very thin Double-Sided Printed Circuit Board to interrupt the connection between the battery and the spring. I ground away the copper near the edges to make sure contact with the case wouldn't short out the Polyfuse.
To keep the side against the battery flat, I ground away through the copper and fibreglass so I could solder the Polyfuse to the inside surface of the copper that's in contact with the battery.
Since the torch would work perfectly without it, I put a clear explanation in place for the owner.
If there is a short circuit, the Polyfuse will stay hot until the short is removed, so you have to make sure there are no heat-affected parts near it - you don't want it melting through wire insulation.