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Thread: ArcLS NexGen400 SX0H LuxI mod

  1. #1
    Flashaholic* chimo's Avatar
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    Default ArcLS NexGen400 SX0H LuxI mod

    I wanted to do an ArcLS mod that has a good balance between run-time and output. I decided upon a BadBoy NexGen 400 and a SX0H LuxI. I used a custom heatsink with a hole for the inductor to shorten the stack height to about 4.8mm (0.19"). The hole for the inductor left part of the emitter slug sitting in free air, so I thermal epoxied thin copper sheeting to the top of the heatsink.

    I used an IMS17 reeflector and a 2mm thick mineral glass window. I measured the output to be around 700Lux @ 1m. The current draw from the battery is quite reasonable (~700mA from NiMH and ~600mA from a slightly used primary CR123). That should equate to around 3+ hours runtime for good NiMHs and 2 hours for a CR123.

    I would have preferred to use a Wiz2, but I didn't have any on hand. Here are the pics:

    Heatsink. Hole made for the inductor. Copper plate is epoxied on the top.


    NexGen400 driver. Insulator is to keep components grounding out. The actual mod has epoxy under the insulator to distribute force from the battery across the board.


    Light Engine installed in LS Head. I used a SX0H LuxI emitter.


    With two battery tubes. Draws about 700mA from 2xAA NiMH and 600mA from a CR123 primary.


    Beamshot (L) with compared to R123 FLuPIC TX0H ArcLS (R). Note that the FLuPIC version is running at about 3x the current (1200mA) while this mod is running at 400mA. Both are using and IMS17. Window/lens is a 2mm mineral glass.


    O-Ring still hidden while off.


    Front End.


    On in hand.


    Run-times.


    Thanks for looking,

    Paul
    Last edited by chimo; 09-12-2006 at 08:37 PM.

  2. #2
    Flashaholic* mosport's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Another clean chimo mod, if you need thinner 1mm mineral glass just PM me Paul


  3. #3

    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Nice. That S flux led and IMS reflector must really bring the old LS back to life. The LS twisty is still one of the solidest and most cleanly designed lights out there. With these modern components it's still a great EDC.

  4. #4
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Thanks guys, I think I'm going to like the run-time on this.

    Thanks Derek, I think I have still may have some thinner ones (I went for the extra strength 2mm).

    For comparison purposes, my McLuxIII PD (with a UW0J) running at 530mA to the emitter was drawing 1000mA on the same CR123 battery as the one used above.

    Paul

  5. #5

    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Nice mod Chimo.

    Question:
    Why use a 2mm window in such a crowded space ?
    Whrere did the "can" come from ?
    What is the transparant disc on the Emitter-boards ?
    Can you provide me with the total height of your sandwich
    (excl. emitter)

    Keep the mods coming !!

  6. #6
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Quote Originally Posted by bombelman
    Nice mod Chimo.
    Thanks!

    Quote Originally Posted by bombelman
    Question:
    Why use a 2mm window in such a crowded space ?
    Because I can. I cracked a 1mm one before - the 2mm ones are nice and strong.

    Quote Originally Posted by bombelman
    Question:
    Whrere did the "can" come from ?
    I had a friend produce a couple of rough cans. I did the "finishing" machining with a dremel, a drill press, and a bench sander.

    Quote Originally Posted by bombelman
    Question:
    What is the transparant disc on the Emitter-boards ?
    It's just a piece of insulating plastic sheet I ripped out of some other electronic product (probably and old video camera). I used epoxy under the plastic and a bit around the inductor to absorb the force from the battery pushing on the board to transfer it more evenly to the can.

    Quote Originally Posted by bombelman
    Question:
    Can you provide me with the total height of your sandwich
    (excl. emitter)
    It is about 4.9mm (0.193")

    Here are a couple more pics:

    LE alongside a MiniPro


    LE side view


    LE thickness

  7. #7
    *Retired* NewBie's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Thats pretty nice!

    Big improvement over stock?

  8. #8
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Thanks Newbie,

    I hope it's better than stock but I don't know - the two LS bodies I have came empty.

    The emitter tint should at least be better (X0 slightly overdriven) and the regulation should be improved with the NexGen.

    I will have to put this on a run-time test once a set of batteries finish charging.

    Paul

  9. #9
    *Retired* NewBie's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Quote Originally Posted by chimo
    Thanks Newbie,

    I hope it's better than stock but I don't know - the two LS bodies I have came empty.

    The emitter tint should at least be better (X0 slightly overdriven) and the regulation should be improved with the NexGen.

    I will have to put this on a run-time test once a set of batteries finish charging.

    Paul

    With the higher efficiencies of the NextGen, I'd not be surprised if you ended up with the same runtimes as stock, with additional output due to the higher current and better emitter.


  10. #10
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    Kiessling's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    I have one such Arc LS modded with R2H and IMS 17mm reflector ... and it revived the old lady. What you have done takes it to the next step ... GREAT!!

    I still love the ArcLS ... it has a magic form factor IMHO.

    bernie
    There is a type of perfection that transcends the quest for lumens. Buying a $250 1-cell light for "lum factor" is like buying a $250 single malt Scotch for the alcohol content.
    - paulr


    It's always darkest just before it goes pitch black.
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  11. #11
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Thanks for the kind words.

    Alkalines: It fell out of regulation at 124.6 minutes but did not reach 50% until 131 minutes. The alkalines exited the tests at about 1.2V so I think the tail (moon mode) would have been fairly long.

    NiMH: I have a 2100mAh NiMH test running now.

    Here is a run-time with Energizer Alkalines (no cooling):

    Last edited by chimo; 09-10-2006 at 04:08 PM.

  12. #12
    *Flashaholic* IsaacHayes's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Cool, long runtime due to effieceint converter and low vf. And high output S flux. Sounds like a real winner! Very usefull and bright! A comparison with an unmodified would be really cool, but I'm guessing it's way brighter with sidespill to boot!
    Mags: 2C: R/O, True Cyan, UV. 3C:Penta-XR-E Q5, Single SSC P4. Nitecore D10, Fenix LOD-CE, ArcAAA

  13. #13
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Here is another plot which includes NiMH.

    A couple of comments:

    1. The plot has been normalized to percentage of starting output

    2. The NiMH does not have as much of a dip from initial output than the alkalines. I attribute that to the fact that the tests were run consecutively and the light was already warmed up form the alkaline test.

    3. The NiMH cells are a little old. I had to leave the test unattended so I used some older ones in case they got over discharged. I would expect new 2500+ mAh cells to run at least 3 hrs.

    4. The light is using an IMS17. The output at 1m is between 750-850 Lux.



    Paul
    Last edited by chimo; 09-10-2006 at 08:24 PM.

  14. #14
    *Flashaholic* greenLED's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    chimo!!
    Luv your mods.

  15. #15
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Thanks Miguel!

    This is one I had been waffling on. I couldn't decide which driver/emitter combo. I may also make a 1W CreeUV light engine as well. I have a single 1W Cree UV emitter left.

    I have a runtime started on a set of 2500mAh NiMH Duracells.

    Paul

  16. #16

    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Cree XLamp ? Will it work on this reflector ?

  17. #17
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Quote Originally Posted by bombelman
    Cree XLamp ? Will it work on this reflector ?
    Not well. For UV, precise focus/throw is not overly important for me. A McFlood would be good. (I also have some optics for Cree emitters. However, they are a little on the large side.)

    Paul

  18. #18

    Default Re: ArcLS NexGen400 SX0H LuxI mod

    You're saying the Nexgen dropped out at 2.4 volts input? Oh well, that's disappointing.

  19. #19
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Quote Originally Posted by paulr
    You're saying the Nexgen dropped out at 2.4 volts input? Oh well, that's disappointing.
    That was the unloaded voltage - I was not monitoring the loaded cell voltages. Under load, they would have been less.

    Recall that the NexGen is fully regulated - as the battery voltage drops, the current goes up to maintain the power level. This really hits the battery hard at the end of the regulated phase. When the batteries cannot maintain the power output to meet the regulator's demand, the regulator will fall out of regulation and the power demand changes - often there can still be a long "moon mode" tail.

    Paul

  20. #20
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Here is an update run-time chart with the Duracell 2500 NiMH cells.

    Alkaline:
    Out of regulation: 124 min (2hr4min)
    To 50% of Starting Output: 131 min (2hr11min)

    2100 NiMH:
    Out of regulation: 158min (2hr38min)
    To 50% of Starting Output: 159min (2hr39min)

    2500 NiMH:
    Out of regulation: 182min (3hr2min)
    To 50% of Starting Output: 184min (3hr4min)


  21. #21
    *Flashaholic* IsaacHayes's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    What about a 123 primary runtime? 2 hours you think?

    326 lux is what a LSH-P throws, so you've doubled the lux, and the runtime is the same, unless you measure and find it's better than 2hrs. (info from flashlightreviews.com). In addition you've got more sidespill than the NX05 puts out I'm sure.
    Mags: 2C: R/O, True Cyan, UV. 3C:Penta-XR-E Q5, Single SSC P4. Nitecore D10, Fenix LOD-CE, ArcAAA

  22. #22
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Quote Originally Posted by IsaacHayes
    What about a 123 primary runtime? 2 hours you think?

    326 lux is what a LSH-P throws, so you've doubled the lux, and the runtime is the same, unless you measure and find it's better than 2hrs. (info from flashlightreviews.com). In addition you've got more sidespill than the NX05 puts out I'm sure.

    Isaac, I'll try a 123 on it tomorrow evening. Around 2 hrs is a good guess.

    The Lux reading is around 830 @1m. The hotspot also seems large compared to my other ArcLS modded with a FLuPIC and an IMS17. That would tend to reduce the lux figure.

    Paul

  23. #23
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    OK, here is the last of the run-time tests.

    I tried a Titanium CR123 (old version). SilverFox's testing showed that these only had about 2/3 capacity of the better quality cells.

    I would expect run-time to be about 50% longer with one of the better CR123 cells.

    Alkaline:
    Out of regulation: 124 min (2hr4min)
    To 50% of Starting Output: 131 min (2hr11min)

    2100 NiMH:
    Out of regulation: 158min (2hr38min)
    To 50% of Starting Output: 159min (2hr39min)

    2500 NiMH:
    Out of regulation: 182min (3hr2min)
    To 50% of Starting Output: 184min (3hr4min)

    CR123:
    Out of regulation: 105min (1hr45min)
    To 50% of Starting Output: 110min (1hr50min)



  24. #24

    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Nice graphs ! Really good regulation...

    Would a 1xAA configuration also work ?
    Or would you need a madmax ?

    Curious how such a curve would look in this same image...

  25. #25
    *Flashaholic* IsaacHayes's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    cool, sounds like it would do at least 2.5 hours with a good cell then! Pretty amazing to be almost at 1000 lux from 1 123a and have over 2 hr runtime in something that can fit in your pocket easily!
    Mags: 2C: R/O, True Cyan, UV. 3C:Penta-XR-E Q5, Single SSC P4. Nitecore D10, Fenix LOD-CE, ArcAAA

  26. #26
    Flashaholic* Morelite's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Quote Originally Posted by bombelman
    Nice graphs ! Really good regulation...

    Would a 1xAA configuration also work ?
    Or would you need a madmax ?

    Curious how such a curve would look in this same image...
    A Nexgen will not regulate with a Vin of less than 2.0v

  27. #27
    *Flashaholic* IsaacHayes's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Would it fire up though? It may not be in regulation or full brightness, but may run still with brightness of a Fenix AA light maybe?
    Mags: 2C: R/O, True Cyan, UV. 3C:Penta-XR-E Q5, Single SSC P4. Nitecore D10, Fenix LOD-CE, ArcAAA

  28. #28
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Quote Originally Posted by IsaacHayes
    Would it fire up though?
    Nope. Just checked.

  29. #29
    Flashaholic* chimo's Avatar
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    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Quote Originally Posted by bombelman
    Nice graphs ! Really good regulation...

    Would a 1xAA configuration also work ?
    Or would you need a madmax ?

    Curious how such a curve would look in this same image...
    A MadMax should look like the stock ArcLSs (non first-run). IIRC they use the same chip. The early LSs used parallel ArcAAA circuits.

    Paul

  30. #30

    Default Re: ArcLS NexGen400 SX0H LuxI mod

    Quote Originally Posted by chimo
    A MadMax should look like the stock ArcLSs (non first-run). IIRC they use the same chip. Paul
    But the non First Run heads don't work on a single AA config, right ?

    I do know there is a flashlight (bwldesign I think) that runs a MadMax400 on a single AA.....


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