Difficulty

Moderate

Steps

6

Time Required

                          30 minutes

Sections

1

  • Orascoptic Spark Loupe Light Battery Disassembly
  • 6 steps

Flags

2

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What you need

Step 1

              Opening the battery pack
  • The battery pack for the Orascoptic Spark is fairly straight forward to open. The spring loaded retainer clips that clip into the lamp have to be removed first. Use a small flat headed screwdriver to lift up the tabs and the clips will come off. It’s recommended to aim them into something that will catch the springs.

The battery pack for the Orascoptic Spark is fairly straight forward to open. The spring loaded retainer clips that clip into the lamp have to be removed first. Use a small flat headed screwdriver to lift up the tabs and the clips will come off. It’s recommended to aim them into something that will catch the springs.

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Step 2

              Removing the screws
  • The screws are Torx T5, but can be unscrewed with a 1mm flat head bit. You don’t have to back them out all they way, they will stay captive in the casing. Otherwise they are difficult to put back in the holes without fine tweezers.
  • Open the battery pack, inside you will find a printed circuit board (PCB) with two sets of wires connected to it.

The screws are Torx T5, but can be unscrewed with a 1mm flat head bit. You don’t have to back them out all they way, they will stay captive in the casing. Otherwise they are difficult to put back in the holes without fine tweezers.

Open the battery pack, inside you will find a printed circuit board (PCB) with two sets of wires connected to it.

Step 3

              The insides of the spark
  • The battery in the Spark is a 3.7v 405mAh pouch battery with 3 leads, red, white, and black. It is adhered to the top part of the enclosure with a double sided adhesive. The battery can be purchased online for less than $20. The connector is difficult to find online.
  • The touch bar is connected with a black wire. It is not necessary to remove or mess with this while replacing the battery.

The battery in the Spark is a 3.7v 405mAh pouch battery with 3 leads, red, white, and black. It is adhered to the top part of the enclosure with a double sided adhesive. The battery can be purchased online for less than $20. The connector is difficult to find online.

The touch bar is connected with a black wire. It is not necessary to remove or mess with this while replacing the battery.

Step 4

              Replacing the battery
  • Due to the difficulty of finding an OEM replacement battery with an identical connector it’s easier to clip the battery wires and tie them into the replacement. The wires are 30 gauge, which is very small and are difficult to work with.
  • Clip the wires as close to the battery pouch as possible to give yourself as much length as possible. Strip about a quarter inch of the wire sheathing back on the replacement battery leads and the wires coming from the connector. Tie black to black, red to red, and white to white using heat shrink wrap to ensure protect the connection.
  • Due to the small gauge of the wire I found it helpful to slide .75-1" length of heat shrink wrap onto the wire then bend a hook into each wire. Hook the wires together and slide the heat shrink wrap onto the joint. Use a heat gun or lighter to shrink the wrap and seal the connection.
  • Try to shove everything into the battery enclosure and screw it back together.

Due to the difficulty of finding an OEM replacement battery with an identical connector it’s easier to clip the battery wires and tie them into the replacement. The wires are 30 gauge, which is very small and are difficult to work with.

Clip the wires as close to the battery pouch as possible to give yourself as much length as possible. Strip about a quarter inch of the wire sheathing back on the replacement battery leads and the wires coming from the connector. Tie black to black, red to red, and white to white using heat shrink wrap to ensure protect the connection.

Due to the small gauge of the wire I found it helpful to slide .75-1" length of heat shrink wrap onto the wire then bend a hook into each wire. Hook the wires together and slide the heat shrink wrap onto the joint. Use a heat gun or lighter to shrink the wrap and seal the connection.

Try to shove everything into the battery enclosure and screw it back together.

Step 5

  • Optional steps:
  • Due to the limited length of the leads coming from the PCB and the difficulty fitting all the wires in the casing, I decided to attach a connector to them to attach to an external battery. Any 3 lead connector will work. You will have to put a small hole in the casing of the battery pack.
  • Use the same steps to splice the wires to the battery to splice in a 3 lead connector instead. I recommend splicing in the female end of the connector and keeping the length of wire from the PCB and connector fairly short.
  • Splice together the wires for the replacement battery to the male connector. Make sure to leave enough wire length to connect to the battery pack.
  • I used a 1500mAh pouch battery to give myself a much longer working duration between charges.
  • Note: the colors of the wires from the PCB and battery may be different from what the wires from the connectors are. If you have to connect black from the PCB to white of the connector, make sure to connect black from the battery to white of the connector.

Optional steps:

Due to the limited length of the leads coming from the PCB and the difficulty fitting all the wires in the casing, I decided to attach a connector to them to attach to an external battery. Any 3 lead connector will work. You will have to put a small hole in the casing of the battery pack.

Use the same steps to splice the wires to the battery to splice in a 3 lead connector instead. I recommend splicing in the female end of the connector and keeping the length of wire from the PCB and connector fairly short.

Splice together the wires for the replacement battery to the male connector. Make sure to leave enough wire length to connect to the battery pack.

I used a 1500mAh pouch battery to give myself a much longer working duration between charges.

Note: the colors of the wires from the PCB and battery may be different from what the wires from the connectors are. If you have to connect black from the PCB to white of the connector, make sure to connect black from the battery to white of the connector.

Step 6

              Finished!
  • This is my loupe setup with an external battery. I attached the larger battery to one of the splash shields with double sided adhesive. It can be charged just the same via the USB port on the battery pack.

This is my loupe setup with an external battery. I attached the larger battery to one of the splash shields with double sided adhesive. It can be charged just the same via the USB port on the battery pack.

The Spark battery is tightly packaged and difficult to replace, but with some modification it can be improved upon.

Cancel: I did not complete this guide.

Author

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                    Jonathan Ting

Member since: 10/11/2022

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