Below are some notes and comments on installation of a BadBoy converter in a
Pelican M6 module:
The LED is placed on a small drop of thermal epoxy for mounting. The module is installed
in the empty battery tube with the tail switch also removed. The reflector is dropped down
over the LED and the LED can be moved for centering with a round headed tooth pick or
other non scratching device.
In the picture above, lead attachment points as well as LED orientation on module can
may be seen. The anode contact of the LED is cut but the cathode is left as is. It is
important to be sure that the soldering of the LED leads, especially the anode lead doesn't
contact either the module or rise above the plane of the top of the module can.
A double sided adhesive foam tape is used to both cover the live battery anode contact
of the PCB as well as serve as a mount for holding the PCB against the backside of the
LED Bulkhead. Note that the cathode lead wire passes over the lead of the LED where it is
soldered and then is terminated under the ground screw.
NOTE: In the case of a red or amber LED the sink slug must be electrically isolated from
the module can with either two coats of epoxy or by some other method. In the case of
using a buck or wizard driver where the LED's cathode is not common to ground, an
additional lead would be provided for the LED's cathode and the ground lead would
only be connected to the ground screw.
The PCB cavity is filled with a thermally conductive RTV or other appropriate
sealer/ adhesive and this retains the anode contact and isolator.
Below is a front shot of a module using a "wizard" driver which requires separate leads
for the ground and LED cathode:
The DownBoy converters require different lead considerations as well as that the LED's
sink slug is electricaly isolated from the module. Prepping the slug with one thin coat of Arctic
Alumina and then an additional coat for bonding the LED to the module is one solution.
The LED's anode and cathode lead may never come in contact with the ground (module) or the
converter will be destroyed. Below are some images of a DownBoy with leads pre-formed for feeding
into the module. The - Vin or ground lead is solid bare wire. The negative LED Lead is bent over the
PCB and alligned with the ground lead. The LED + lead is bent over the PCB to a position where it is
180 degrees opposed to the ground lead. The converter is pushed into the module until the resistance is
felt of the bent LED leads against the module. The ground lead is routed and fastened to hold the
module in place. The LED leads are then trimed, stripped and pre tinned. After the leads are soldered
to the LED, they are bent and a side view of the module confirms that the solder connections as well as
the leads are below the surface of the module's lip.
