I am working on a design that involves an array of sources.  To speed-up simulations, emitter/source details are reduced to saved ray-set files.

FILE-A:   (Emitter Ray-Set)

I generate a source file (ray-set) by combining an LED source with a custom TIR lens and a detector.  The detector is placed following the output face of the TIR lens.  The captured rays are then saved to a  (*.SDF) file. 

FILE-B:.. (System)

I create a larger system model, that involves an array of “n” emitters.  I setup “n” sources, using the saved  (*.SDF) file above.  I place a detector between the sources and downstream optics.   Those rays then propagate forward. 

The issue I am having is that when I check the angle of the rays from [File-A] incident upon the detector following the TIR lens , it is significantly different than the angle of the rays I get from using the “generated sources” [File-B]

I measure around 18 degrees (half-angle) in [File-A] with the TIR lens, that I am using to generate the source file (ray-sets).  But I only measure about 13 degrees when using that generated source file (ray-sets) in [File-B]  Any ideas why that might be the case? 

The TIR lens, of [File-A] that generates the source file (ray-sets) is a boolean object. 

Could that be messing something up?   Any help would be appreciated.  Thank you.