Luxeon Emitter in Arc AAA

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LED_ASAP

Enlightened
Joined
Dec 13, 2002
Messages
567
City & State/Province
British Columbia, Canada
This mod was first described two months back in here.

Initially it was made from an empty casing from Peter. But by the introduction of hundreds of parts from the Arc AAA seconds auction, it makes more sense to take a dead Arc AAA and try to modify it to host a LS emitter.

Arc AAA heads are completely sealed in epoxy and it's not easy to disassemble. One way worked for me was to first pry open the crimp-seal, then dip the head in liquid nitrogen until it stops bubbling. A quick and decisive knock on the LED will free the epoxy plug inside:

ArcAAA_001.jpg


Attempts to disassemble the epoxy-sealed circuitry resulted in total distruction:

ArcAAA_002.jpg


ArcAAA_003.jpg



Luckily some of the factory seconds are not sealed, so we can see what's inside the Arc AAA head:

ArcAAA_004.jpg


I will not discuss the details of the boost converter in the Arc head (as that is Peter's secret and the result from the hard work of the Arc team), but I can tell you it is not ZLT-based as in the infinity series. There is no sense resistor and there is no convenient way to hack the circuit to deliver more power to the LS.

So, back from scratch and built my ZLT booster:

ArcAAA_005.jpg


ArcAAA_006.jpg


The beam pattern is mostly flood. The Arc head will catch some of the side spills and give a notable hot spot, but the hot spot is no where as bright as the Solitaire mod or MicroIlluminator or the N-cell light. I would say this Arc LS mod is mostly for close-up works.

ArcAAA_007.jpg


The battery draw is about 300mA so there will be around 100mA to the LS---the heat-sinking condition in the Arc head will not allow for much higher current.

I have a few empty casings around

ArcAAA_008.jpg


If someone is interested, I can mod them and put up for sale. The price will be $70 (including plain letter mail by CanadaPost and the 3% surcharge by PayPal). If you prefer registered mail, then it's $78. Please PayPal [email protected]
 
Can it be potted to make it waterproof? If it can, ill take one. That circuit is unbelievably small.
 
Excellent work as usual.
You definitely deserve your name. /ubbthreads/images/graemlins/thumbsup.gif

P.S. those shinny silver heads... are they bare AL?
I am thinking of stripping the HA off one of my AAA's and polishing it.
 
kakster

Yes, the "head" will be epoxy-plotted. But I will not claim it is as waterproof as the original Arc AAA so please don't take it for a dive.

BentHeadTX

The LS will be Q2-level by default. As in the Solitaire mod, you can send me whatever better LS you can find and I will put it in with no extra charge. If you send your own LS, you can take $10 off the price.

jtice

Yes, two of the Arc heads are bare aluminum.

robk

The Toroid was a tricky part of this mod. It was hand-wound, but the core was not commercially available. It was a section cut off a longer piece with a diamond cutting disk. I then rounded the edges and wound the coil.

I've tried quite a few commercial inductors but none of them gave the same performance as the hand-made ones. That's why I ended up taking my time to cut the ferrite core and wind my own inductors.
 
The inductor does seem to be the most difficult part to obtain (or make), I've tried several commercial units with bad results.
Rob
 
A small lens can be added in front of the LS to generate a more focused beam and give it some throw.

ArcAAA_009.jpg


You will have the typical square beam, image of the die chip itself.

ArcAAA_010.jpg


The lens is small enough to hide completely in the bezel cavity and does not introduce any extra length or width to the light

ArcAAA_012.jpg

ArcAAA_013.jpg
 
Very nice!!!
Is it possible to buy one with the installed Lens?
I would be interested!

best regards,

Peter
 
I have only one small acrylic ball left, which hopefully will yield two lenses. I will give them to the first two ordered this mod, which happened to be SnoopyM (GJW) and kakster /ubbthreads/images/graemlins/grin.gif I will look into obtaining more acryllic balls. But until then, there may not be more lenses available.

I have tried once to extract the centre lens from a NX-05. It worked OK (the beam is not as tight as that from the 1/2 acrylic ball), but it takes a lot more work to cut out the lens and polish the surface, and adds the cost of a NX-05.

The top section of a 5mm Nichia is too small and it seriously eats the total light output.

An epoxy droplet should work OK opticly, but it's too soft and easily gets scratched. (I knew this first-handed from my early Solitaire mod experience)

If people out there have other brilliant ideas, or have a supply of small acrylic balls, please share them with our fellow CPF'ers /ubbthreads/images/graemlins/blush.gif
 
Got mine yesterday and it's very impressive.
Much whiter than the standard Arc and the throw makes it a completely different light.
The hotspot is more diamond shaped than square but I'm guessing that's a trick of the ball lens.
/ubbthreads/images/graemlins/thumbsup.gif
 
I'd like one of your latest creations --
but I'd like one of the lenses too.
What size 1/2 acrylic ball is needed?
 
[ QUOTE ]
amtrak said:
I'd like one of your latest creations --
but I'd like one of the lenses too.
What size 1/2 acrylic ball is needed?

[/ QUOTE ]

The balls are 6mm diameter. Unfortunately I have run out all my stock of the lens /ubbthreads/images/graemlins/frown.gif I will look into alternatives and hope some one out there can provide some source of them /ubbthreads/images/graemlins/broke.gif
 
Mine arrived this morning, very very nice indeed! /ubbthreads/images/graemlins/thumbsup.gif
Now i just gotta wait for it to get dark....
 
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