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Thread: Stanley HID 3000 pot mod 17-83W

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    Default Stanley HID 3000 pot mod 17-83W

    I finally got myself a Stanley hid spotlight a few days ago, I have always been curious about the startup/boost circuit, this is what I found.

    The rear tail stand cover contains a PCB, this controls charging and luckily also the power output from the ballast unit.

    The picture below shows the internals of the spotlight, I have placed a red/blue dot on the PCB connector, this is the control signal to the ballast that regulates output power, in normal operation with the standard battery it ranges from .75 to 2 volts, though its own upper limit is 2.7v, and the lower practical limit is whatever voltage corresponds to the ballast operating at 20W, below 20w it will cut out.



    All the power reading are taken from the ballast supply lines, I assume the bulb Watts would be close to 85% of the given figures.

    Upon startup the Ballast operates at 77 Watts, drifting down to 40 Watts continuous.

    Once the bulb is hot, the ballast operates in a constant power mode, in standard form the ballast runs rock solid at 40 Watts input, from 9.6 volts to 15 volts, unfortunately my usual power supply was broken and I could not find the high voltage cut out.

    As the supply voltage increases the control voltage decreases to keep the output power constant, you can see this by following the 40 Watts line in the below spreadsheet, from 1.01V to 0.64V.

    The rest of the spreadsheet shows the control voltage needed to achieve a power level at a given input voltage.

    The ballast operated at as much as 125W on a hot bulb for 5-10 seconds, however at each supply voltage level there was a maximum Wattage that the ballast would settle to, the higher the supply voltage the higher this wattage was, the graph below shows this curve at points from 10 to 15 volts.



    The standard SLA battery in my case is only good for 2Ah, it has a 60mOhm IR and on a fresh charge sags to 12.4v under load, when I switch my pot mod on it sags to 12.1v therefore giving around 67 Watts, falling to 50 Watts at 10 Volts.

    Due to this I have simply set my pot mod to deliver 1.5 volts to the control circuit when activated, setting the ballast to maximum output with no constant power regulation.

    The device I made is as follows, it contains only a few cheap components.

    1x, 10K Ohm trim pot.
    1x, 600 Ohm resistor.
    1x, switch.
    4x, Diodes.

    Last edited by 2filthy3; 09-29-2011 at 01:29 AM.

  2. #2
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    Default Re: Stanley HID 3000 pot mod 17-83W

    Finally! Someone has dissected the Stanley ballast control circuit! Thank you!

    Would you be interested in making and selling two units for me?
    WWII 60" Anti Aircraft Carbon Arc (Sold), Short Arcs: 1.6KW NightSun, 1KW VSS-3A, .8KW TrakkaBeam, 600 Watt M-134 Gun Light, 500 Watt X-500-14s, 500 Watt Starburst, 300 Watt Locators, Megaray, 150 Watt Set Beam & Communicator, Maxabeam Gen3, LarryK14@52V

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    Default Re: Stanley HID 3000 pot mod 17-83W

    I would be interested in one myself.
    Last edited by Colonel Sanders; 04-02-2012 at 08:18 AM.
    SPY 007 XM-L2, BVH 150w Vec192 HID, Gen III Maxabeam, Barn Burner, FireFox III, Mac's Customs 3840L & Damascus/Cu/Al Tri-EDCs, ma_sha1 FrankenMag, Drake, MF Scorpion 4x XM-L2, Tri-219 EYE10, XP-G2 X10

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    Default Re: Stanley HID 3000 pot mod 17-83W

    This Stanley was a single mode only light, I could not guarantee that the older dual mode would behave the same, it probably would though.

    I could make more if needed, and ship them, however it truly is a simple circuit that anyone can make, what I could do is take a picture of the device before I have applied any heat shrink to it, it would be very easy to copy from that.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    Yes, more pics please! (Mine is a very recent single mode light.)

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    Default Re: Stanley HID 3000 pot mod 17-83W

    i agree! more pix! and TYTYTY!

    i am also curious about the long term side effects of this operation on the stock ballast, please keep us updated as far as run tests go. i'd hate to tear apart & mod mine again w/this mod just to find out that within 20mins of operation the ballast smokes. i can't really afford to replace it @ this point in time. but again, TY for probing this out for us!
    Last edited by FRITZHID; 09-30-2011 at 12:25 PM. Reason: ballast concerns
    if your not wearing a #12 welding screen than it ain't bright enough! "Hand-Sun H.I.D." 55w & 75w(for sale), Rocky 3w LED, Stanley 109 35w mod'd, Maxa-Beam Gen II, 55w hid/100w incan Vector Twin, 400w MH long arc, 100w MH mid arc. Amondotech n30.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    pics and a component part number list plus where you got the parts?
    WWII 60" Anti Aircraft Carbon Arc (Sold), Short Arcs: 1.6KW NightSun, 1KW VSS-3A, .8KW TrakkaBeam, 600 Watt M-134 Gun Light, 500 Watt X-500-14s, 500 Watt Starburst, 300 Watt Locators, Megaray, 150 Watt Set Beam & Communicator, Maxabeam Gen3, LarryK14@52V

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    Default Re: Stanley HID 3000 pot mod 17-83W

    so, has anyone time tested this mod yet?? i'd Love to know if the ballast can handle the prolonged high power!
    if your not wearing a #12 welding screen than it ain't bright enough! "Hand-Sun H.I.D." 55w & 75w(for sale), Rocky 3w LED, Stanley 109 35w mod'd, Maxa-Beam Gen II, 55w hid/100w incan Vector Twin, 400w MH long arc, 100w MH mid arc. Amondotech n30.

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    Default Re: Stanley HID 3000 pot mod 17-83W


    I'm very interested in one also, either for purchase or build myself.

  10. #10

    Default Re: Stanley HID 3000 pot mod 17-83W

    Quote Originally Posted by Greenbean View Post

    I'm very interested in one also, either for purchase or build myself.

    guess this project went up in smoke

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    Default Re: Stanley HID 3000 pot mod 17-83W

    Ok, I should be home in a few weeks, and I can make a few of these mod's if anyone want's to try one.

    Though I must say that at this point that I have not done any stress testing at prolonged higher power running.

    If anyone is interested, will you want the option of adjusting the maximum power yourself, or just a device to wire in and have the lamp run at maximum power, the line shown on my graph above, which is at the bulb approximately 57 Watts on a full charge down to 40 watts at the low battery cut off.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    I'd be cool with a simple pedal to the metal version.


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    Default Re: Stanley HID 3000 pot mod 17-83W

    Quote Originally Posted by 2filthy3 View Post
    Ok, I should be home in a few weeks, and I can make a few of these mod's if anyone want's to try one.

    Though I must say that at this point that I have not done any stress testing at prolonged higher power running.

    If anyone is interested, will you want the option of adjusting the maximum power yourself, or just a device to wire in and have the lamp run at maximum power, the line shown on my graph above, which is at the bulb approximately 57 Watts on a full charge down to 40 watts at the low battery cut off.
    Definitely would like one! Adjustable is first choice but fixed is still great! I have two lights and would enjoy building one. By having one that you made, would I be able to ID the parts and buy them from Digikey, Mouser, etc?

    On second thought, full throttle is great, don't need it adjustable. But maybe a little instruction on what to buy and where to install the adjustable POT(?) so I can do it on the one I'd like to build.
    Last edited by BVH; 03-16-2012 at 10:20 AM.
    WWII 60" Anti Aircraft Carbon Arc (Sold), Short Arcs: 1.6KW NightSun, 1KW VSS-3A, .8KW TrakkaBeam, 600 Watt M-134 Gun Light, 500 Watt X-500-14s, 500 Watt Starburst, 300 Watt Locators, Megaray, 150 Watt Set Beam & Communicator, Maxabeam Gen3, LarryK14@52V

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    Default Re: Stanley HID 3000 pot mod 17-83W

    after the known consequences of over-driving, i'd love a "plug/solder & play" version as long as it doesn't fry the only stanley i own
    if your not wearing a #12 welding screen than it ain't bright enough! "Hand-Sun H.I.D." 55w & 75w(for sale), Rocky 3w LED, Stanley 109 35w mod'd, Maxa-Beam Gen II, 55w hid/100w incan Vector Twin, 400w MH long arc, 100w MH mid arc. Amondotech n30.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    The power adjustment feature on this mod is not very good, all it can do is raise or lower the line of power input shown on my graph, it cannot just dial in 50W at all times, so it's really not that useful, though instruction on how to use one and install it would no problem, or any part of the mod for that matter.

    When I have a chance I will do a full discharge test at full mod power, it should be fine.

    The main concern would be if this mod as used while the torch was plugged into the car charger, as the maximum of 13.8-14.4 volts that could be seen would have the ballast operate at 68 to 77 output Watts, this could be a problem if used for extended times, though I have run my ballast at 85 output watts for 1 minute with no problem.

  16. #16

    Default Re: Stanley HID 3000 pot mod 17-83W

    Too bad about your power supply -- I'd like to see some testing beyond 15V. I may have to dig mine out and try this.

    Looking at your numbers, it seems just doubling the stock voltage would give a consistent 70-80W, or more generally, a fixed multiplier gives a fixed power -- I'd use an op-amp to make a non-inverting amplifier, and use a pot to adjust from 1x to maybe 3x, at least for testing.


    I'm thinking, if nothing blows up with a couple more volts, you can retrofit it with a 4-cell Li-ion polymer battery -- could probably fit 4Ah or so (instead of stock 3Ah), and allow high power throughout the operating range from 12V-16.8V. Of course, a fixed 1.5V probably won't work (too much power at 16.8V), but with an appropriate control circuit (or judicious pot adjustment), you could get near-constant 75W or so.

    Wonder how long a bulb holds up at 75W... only one way to find out, right?
    Last edited by Benson; 04-29-2012 at 04:33 PM.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    i'm still waiting to hear if anyone has run this mod at full power for a while (2-3 batt cycles) to test the durability of the ballast under these conditions... bulbs can be replaced fairly easily, ballasts on the other hand, not so much.
    i'm waiting on these results before i mod mine..... unless i can find a 75w short arc ballast, then i'll be modding it to a MB bulb that BVH was kind enough to send me, and swapping out the reflector.... a short arc stanley!
    it may not have the Lm's a stock stanley has, but it will be a throw beast that fits in hand very nicely!
    if your not wearing a #12 welding screen than it ain't bright enough! "Hand-Sun H.I.D." 55w & 75w(for sale), Rocky 3w LED, Stanley 109 35w mod'd, Maxa-Beam Gen II, 55w hid/100w incan Vector Twin, 400w MH long arc, 100w MH mid arc. Amondotech n30.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    Sorry guy's been busy and waiting for some parts, I will make these up in the next few days.

    Who want's one? should be <$15 dollars including postage, if I send it as a letter.


    Quote Originally Posted by Benson View Post
    Looking at your numbers, it seems just doubling the stock voltage would give a consistent 70-80W, or more generally, a fixed multiplier gives a fixed power -- I'd use an op-amp to make a non-inverting amplifier, and use a pot to adjust from 1x to maybe 3x, at least for testing.
    I had also looked at the numbers and found a fixed multiplier on the control circuit would give a fixed output, within the bounds of the above graph anyway, I just could not be bothered setting up an op amp do it, and as you say a multiplier mod would be a lot more useful if combined with a battery upgrade, or the 12V boost board http://www.ebay.com.au/itm/DC-DC-10-...ht_3974wt_1396 though I guess if the boost board has a constant output the original mod would be good enough.

    Though with the stock battery full power all the time is good enough for me.
    Last edited by 2filthy3; 05-14-2012 at 06:24 PM.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    total cost to Wausau, WI, USA 54403?
    if your not wearing a #12 welding screen than it ain't bright enough! "Hand-Sun H.I.D." 55w & 75w(for sale), Rocky 3w LED, Stanley 109 35w mod'd, Maxa-Beam Gen II, 55w hid/100w incan Vector Twin, 400w MH long arc, 100w MH mid arc. Amondotech n30.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    I'd like two!
    Last edited by BVH; 05-15-2012 at 06:19 PM.
    WWII 60" Anti Aircraft Carbon Arc (Sold), Short Arcs: 1.6KW NightSun, 1KW VSS-3A, .8KW TrakkaBeam, 600 Watt M-134 Gun Light, 500 Watt X-500-14s, 500 Watt Starburst, 300 Watt Locators, Megaray, 150 Watt Set Beam & Communicator, Maxabeam Gen3, LarryK14@52V

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    Default Re: Stanley HID 3000 pot mod 17-83W

    I would like 1 maybe 2.
    Collins Dynamics CD-12, CD-12 Magnum, Microfire Warrior, Iluminator HID, Costco HID, ,Maxabeam, Polarian Helios, RayzorLite ,BarnBurner,and a bunch of small lights.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    I just ran the torch with the mod on continuously, the battery lasted for 16 minutes, the ballast was fairly warm to the touch, but no signs of trouble.

    $12 USD shipped worldwide, $17 USD for two.

    I Hope to make them in the next few day's.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    deleted
    Last edited by BVH; 05-15-2012 at 06:19 PM.
    WWII 60" Anti Aircraft Carbon Arc (Sold), Short Arcs: 1.6KW NightSun, 1KW VSS-3A, .8KW TrakkaBeam, 600 Watt M-134 Gun Light, 500 Watt X-500-14s, 500 Watt Starburst, 300 Watt Locators, Megaray, 150 Watt Set Beam & Communicator, Maxabeam Gen3, LarryK14@52V

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    Default Re: Stanley HID 3000 pot mod 17-83W

    2filty3

    What would be the effect running the light with mod from a 4s 14.8v nominal (16.8v topped off) Lipo pack. Too much power or ok? I run my light now occasionally by plugging the cig plug into my Lipo battery setup and it works fine...

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    Default Re: Stanley HID 3000 pot mod 17-83W

    Why hasn't someone just transplanted one of those adjustable ballast or a common 50W ballast?

    Also, be careful about overdriving pressurized glass chambers. You might consider getting some DL-50s or the fatboy versions of those if you can find 'em, but you'll have to construct a spacer or adapter, they are p32/d.

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    Rolleye11 Re: Stanley HID 3000 pot mod 17-83W

    Quote Originally Posted by bshanahan14rulz View Post
    Why hasn't someone just transplanted one of those adjustable ballast or a common 50W ballast?

    Also, be careful about overdriving pressurized glass chambers. You might consider getting some DL-50s or the fatboy versions of those if you can find 'em, but you'll have to construct a spacer or adapter, they are p32/d.
    have you opened a stanley? if so, then you'd know why, lol.... theres not alot of breathing space in that casing, and along with the ignitor, would be a tight fit, not to mention theres NO ventilation at all. i'm not say'n it can't be done, but would be a tight and risky mod. if i were to do it, i'd make sure to keep as much of the original hardware intact as i could so i could always return it to stock when the new ballast goes
    and at 30 mins runtime on the stock 35w system, i can't see getting more than 15mins outa the SLA, so..... upgrade there as well
    Last edited by FRITZHID; 05-15-2012 at 01:54 PM.
    if your not wearing a #12 welding screen than it ain't bright enough! "Hand-Sun H.I.D." 55w & 75w(for sale), Rocky 3w LED, Stanley 109 35w mod'd, Maxa-Beam Gen II, 55w hid/100w incan Vector Twin, 400w MH long arc, 100w MH mid arc. Amondotech n30.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    *Just about to put some of these together, realized I can very easily incorporate a 30W LOW mode, any interest in this?

    Though it will only work with standard internal SLA battery.


    Quote Originally Posted by Lips View Post
    2filty3

    What would be the effect running the light with mod from a 4s 14.8v nominal (16.8v topped off) Lipo pack. Too much power or ok? I run my light now occasionally by plugging the cig plug into my Lipo battery setup and it works fine...
    I could not recommend this, at 16.8 volts I would predict around 118W into the ballast, I have not tested this output for extended periods and could not say what the ballast life would be.

    The above mentioned mod from Benson would be needed in this case, with it your output would follow my above graph, and then at a point of your choosing, say 75W it would go flat for constant power regulation, note that I am not doing this mod atm.
    Last edited by 2filthy3; 05-15-2012 at 07:26 PM.

  28. #28
    Flashaholic* Lips's Avatar
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    Default Re: Stanley HID 3000 pot mod 17-83W

    My opinion a 30 w low would be great because the run-time on these lights is so low, especially at even higher outputs. I have 4 or 5 of these laying around and the batteries are all dead.


    Mine all have the Hi-Low switch. Can't remember, this mod work on these or only single mod version.

    How is this mod effected (if any) when you plug the cigarette plug in.

    thanks!

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    Default Re: Stanley HID 3000 pot mod 17-83W

    Quote Originally Posted by Lips View Post
    My opinion a 30 w low would be great because the run-time on these lights is so low, especially at even higher outputs. I have 4 or 5 of these laying around and the batteries are all dead.


    Mine all have the Hi-Low switch. Can't remember, this mod work on these or only single mod version.

    How is this mod effected (if any) when you plug the cigarette plug in.

    thanks!
    i may be interested in acquiring most if not all of those!
    i have a FIST FULL of good SLA's in the 3ah to the 9ah range. and (with your sales) a fist full of lipos as well! (theres a big demand for hand held HIDs here in the "north woods". alot of people admire my stanley yet NONE are available at any store.
    if your not wearing a #12 welding screen than it ain't bright enough! "Hand-Sun H.I.D." 55w & 75w(for sale), Rocky 3w LED, Stanley 109 35w mod'd, Maxa-Beam Gen II, 55w hid/100w incan Vector Twin, 400w MH long arc, 100w MH mid arc. Amondotech n30.

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    Default Re: Stanley HID 3000 pot mod 17-83W

    Quote Originally Posted by Lips View Post
    My opinion a 30 w low would be great because the run-time on these lights is so low, especially at even higher outputs. I have 4 or 5 of these laying around and the batteries are all dead.


    Mine all have the Hi-Low switch. Can't remember, this mod work on these or only single mod version.

    How is this mod effected (if any) when you plug the cigarette plug in.

    thanks!
    When plugged into a car I would expect to see a maximum of 14.4V (minus the protection diode), or around 90W at the ballast, this will not cause immediate failure but it is pushing it fairly hard, The low mode will most likely not work in this case either.

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