ordered some xp-g2s that I thought were on 16mm stars but they were on 10mm. I figured I would try to put one in my Small Sun ZY-A629. I took the dome off, took out the xr-e and put the xp-g2 in. It fired up and I was just surprised that it did! When I left it on high it was kicking back into low the first couple times. It stopped doing that, and I took measurements of the new output.
Old output:
Low - 12
Medium - 31
High - 82
Turbo - 311
Lux - 11780
New output:
Low - 18
Medium - 47
High - 118
Turbo - 400
Lux - 22300
I was happy and took some pics to post here, that’s when things went wrong.
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In the pic the little plastic seperator disk was showing because it was off center. I loosened the reflector a little and tapped it some to center it up, then put it back together. When I pushed the button no light, but I heard humming from the tailcap. I turned it off and inside the reflector was smoked up. Took everything apart and tried again nothing. One more time I got a flash but that’s it. I’ll try to get a pic but I’m bummed right now. I probably won’t have much time to mess with it until next week either. Frustrating!
When the reflector gets screwed down, is it making contact with both the pos. and neg. solder points on the LED star (as pictured)? This could be your short, and something to always watch out for.
Lol maybe the wires from the driver being burned up has something to do with it. I guess I’ll just try replacing the wires and hope the driver isn’t burned up.
If you have a dmm, check resistance between the solder points and the case and each other. If you can, sit the reflector on the pill with the pill removed to see if the reflector touching solder is the problem. There might even be a mark where the short occurred. Make sure the wire insulation comes last the surface of the board and the solder on the pads doesn’t touch either the pill or the reflector. It ok to use an exacto knife to trim away excess solder.
Could you post up a pic of just the reflector out of the light showing where the reflector would be laying on the led pill not the inside of the reflector.
Mizjif beat me to it.
I was modding my t08 and had to watch the solder on the star hitting the reflector. The reflector was hitting the solder points on mine but no short because it is a plastic reflector S) Try to solder with a higher temp iron QUICKLY and keep the solder flat. If you take too long with the wrong wire, your jacket will melt and likely cause a short. If you cant achieve a flat joint, grind or trim the solder as previously stated.
Maybe the wire on the + side of the led is shorting out on the aluminum pcb. Looks like the insulation is gone from soldering.
Silicone wire or Teflon wire would be a better choice. It doesn’t melt the insulation when soldered to.
I agree with TrakTuned. In your picture it looks like the ground is shorted to the heatsink and the positive probably is too. The insulation on the wire pulls back when heated and shorts, my last mod did the same thing. I ruined the tailswitch and took the temper out of the pos spring. I managed to repair everything but it’s ugly. High temp insulation would help.
Driver usually but can get the led. The led is wired in parallel with the short so must of the current wants to run through the short cooking the driver.
I’m hoping the + wire burned in two before the driver fried. Actually the driver might be in the tailcap, I don’t know how these tail side switch lights work.
I've been getting really spoiled with teflon wires - it is really hard to damage with heat, and gives you a better cushion on the top of the star. Also, I find it easier to strip for some reason, but I use a simple cutter to do stripping. The 22 gauge silver coated teflon wire I use (O-L reocmmended on ebay) though is stiff and can pull pads right off a driver if bent and moved around.
On that particular star, the solder pads are really close to the thru-holes - I'd try to solder the wires as far away as possible from the thru-holes - you definitely want more wire insultation on the top.
Yeah, when I looked at the picture I took I realized how bad it was. I was just happy to get the thing soldered on. I need.three hands just to hold the wire in place, hold the solder, and put the iron on it!
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