homemade 75mm aspheric sst90 build log

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gt40

Enlightened
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Oct 13, 2009
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bainbridge island
After testing 4 aspheric 3" lens, I settled with the dx 75mm lens. It really puts out a nice beam without spill and the price is right. For the host, I am making a bigger version of my sst90 with magnetic ring switch detailed here:

http://www.candlepowerforums.com/vb/showthread.php?t=279245&page=3

Changes:

1. (3) 26650 batteryspace batteries
2. Emerson 20 amp driver
3. Larger head
4. Mount thermister directly under the led
5. 75mm DX aspheric lens

I built version 1.0 with an aluminum/copper core heatsink and the raptor driver and it works great at 8-9 amps but there is room for improvement-

At 10 amps, the driver protection turns on till the thermister heats up because I mounted it too far from the led and no possibility of pushing the led any higher than that.

As a result, I am trying out this driver:
http://www.powerconversion.com/assets/lf_sil20c2_1199509977_techref.pdf

It can handle up to 20 amps, has low voltage lockout and over current protection. Basically ldo10c's big brother. I figure I can use it to drive an sst90 to within an inch of its life:devil:

Now some pics of the initial build so far. I will clean things up once the design is finalized:

Side shot of the heatsink:
heatsink-side.jpg


Heatsink tail with delrin insert machined:

heatsink-tail.jpg


Heatsink head with groove for thermister to be mounted under the led:

heatsink-head.jpg


Emerson driver in heatsink:

driver-in-heatsink.jpg


Emerson driver:
driver.jpg


Light head with 75mm lens:

head1.jpg


Light head with old heatsink:

head2.jpg


Light body:

75mml-ight.jpg


Beamshot at 10 amps with old driver heatsink:
beamshot1.jpg


Farther away:
beamshot2.jpg


That is it so far. The light is switched on with a reed switch and a magnet imbedded in a knurled ring like my smaller light. Once the basic design is finalized, I will focus on making the body shape better and finishing it. I am hoping for 12+ amp stable range out of an sst90 with the massive head and copper heatsink driven by the emerson driver. 12000mah worth of battery should give it a semi reasonable run time...

Thanks for looking.
 
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Nice work, using the thermistor to adjust the output voltage of the driver? Similar to how people do it with the LDO10C?
 
That's some beautiful machining to fit the Driver inside the pill.

So is copper so much harder to machine than Aluminium or Brass ?

This is usually given as the excuse for using a material with such poor thermal conductivity like brass for pills ?
 
Nice work, using the thermistor to adjust the output voltage of the driver? Similar to how people do it with the LDO10C?

Exactly. I started with the ldo10c and went to the raptor because it is more durable/higher build quality imo and now am with this 20amp rated emerson. I like the low voltage shut off. you put a risister between the remote switch and ground. 305 ohm resister with the (3) 26650 batteries shuts the light down at 9volt. So basically the emerson is a 20 amp version of ldo10c + low voltage lockout
 
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So basically the emerson is a 20 amp version of ldo10c + low voltage lockout

According to the datasheet, the LDO10C has the same adjustable low-voltage shutdown.

If RS Components ever send me my LDO10C (so far 3 phone calls of fictional delivery dates ) I'll verify this.

I've just ordered a TI equivalent of the LDO10C which Farnell have in stock in Australia - PTH08T240W. It has more pins that allow for easier voltage clamping - it may make it easier to implement Constant Current drive and a dimming dial. It also has the same adjustable low-voltage shutdown.
 
Great job, making nice use out of your new Lache?

Woops, I meant Lathe
 
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Got a bit more done.

Head and magnetic ring switch:
head3.jpg

I still have to trim the end of the insert that holds the aspheric lens...

fitment of heatsink in the head:

head4.jpg


Made progress soldering the connections for the driver:
heatsink-wiring1.jpg


You can see the white box glued to the heatsink of the emerson driver. That is the trimmer resister that allows me to change the voltage to dial in the output.

Thermister mounted on heatsink:
thermister.jpg
I
I wrapped the leads of the thermister in teflon tape to insulate them.

Making a bigger lights makes lots of shards:

32 gallon trash can:
shards.jpg


Thats it for now. I hope to have it up and running this weekend.

Thanks for looking.

Mark
 
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