Electrical – OK to hook up LED without resistor

currentled

I got around to fixing an ATOM headlamp, and upon opening it up realized it was only an LED that had apparently burned up (brown coloring around LED and wires from battery). I suspect that the absence of a resistor led to more current than the LED could handle. While the lamp still turned on, it was not as bright as before. The lamp is powered by 3 AAA batteries in series.

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Now, I replaced the LED (from what I could tell online it's an SMD LED) with an LED of the solar light variety, but was not sure if a resistor was necessary. Do you think adding a resistor would be worthwhile since it wasn't included in the circuit in the first place?
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Best Answer

That's a Cree XP LED. The best replacement would be a 2 Amp (max) Cree XP-G3. This is the highest efficacy (167 lm/W) LED that can generate sufficiently more light (≈70%) than heat. There is no brighter LED available than the XP-G3. Over 150 lumens at 350 mA.

The Cree XP-G3 will be A LOT brighter than the clear LED you used.

The problem is what value resistor to use. An AAA lifespan voltage ranges from 1.2v to 0.8v.

To rely on the discharge rate of a battery is not good when the batteries are replaced with a different brand or chemistry.

With 3 AAA the efficiency with a resistor ranges from 76% at 3.6V and improves to near 95% as the battery discharges.

So yes, a resistor is highly recommended. I would try a 3Ω or 4Ω resistor and see how hot it gets. The Cree XP LEDs can only take about 250 ma without a heatsink so a 3Ω (300 mA) may be insufficient and get too hot. A 4Ω (200 mA) may work better. Depends on heat transfer characteristics, i.e. how the star board is attached to the head lamp housing.

In an experiment I found the temperatures without a heatsink to be:

mA => temp °C
200 => 55-60
250 => 65-70
300 => 100

Based on experience with the Cree XP LEDs, I would expect the forward voltage to be about 2.75V.


To solder put some 360°F 63/37 solder on the pads place the LED on the pads. Preheat the oven to 500°F and put it in making sure the LED stays in place. Turn off oven if temp is over 450° after you close the oven. Bake for about 90 seconds, no more than 2 minutes.


With a 5° spot lens you can get a very bright small spot out of a Cree XP LED.
Example: LEDiL FCA12077_IRIS