Sold/Expired Orders - Programmable Hotwire Regulated Driver drop-in for D-M@g

[Alan B]

Semi-Kit Assembly Notes have been added in post #4. These are presently in Draft form.

 

[Alan B]

Progress Report:

The first board of the new batch was tested last night. Seems to work fine.

Soldered up six more boards this evening.

The first batch of ISP Programmers have been shipped (order was delayed) and should be here in a few days.

Regulators should start shipping out later this week.

Batches up through #3 can pay when ready.

Thanks!

 

[Iliger]

Alan, I didn't manage to buy a quad-bored 2D. So a little update for my second regulator:
"Regulator Number: 2
Regulator Model: (standard)
Bulb Data:
Bulb Type (manufacturer, model): Philips 5761
Maximum Bulb Voltage (RMS full output): 7.2 V
Minimum Bulb Voltage (RMS fully dimmed): 2.0V
Battery Management:
- Battery Chemistry: Li-on
- Number of Cells: 3
- Minimum Battery Voltage: 8.7 V
Socket: Kiu"
Paypal is ready. I'm waiting for your sign.
Thanks.

 

[Alan B]

OK on the update. I'll have to get that logged. I received 3 sockets from someone, have to log that also. Probably BSBG.

I had a couple of long days at work and progress on regulators has been... slow. :mecry:

It should pick up this weekend..

I have been working on the software. Cleaning up, and working on a future upgrade that will make programming A LOT EASIER. The current method takes way too many installs, windows, and buttons. If this works out it will be totally simple to change the software. :twothumbs

I do have a local beta tester that has built a semi-kit and calibrated it this week. He used a scope and DVM to calibrate and it worked out well. I will add that procedure to the instructions later. Are many folks going to want to use the scope and meter technique?. The scope is used to measure duty cycle and the meter to measure battery voltage. Together that gives RMS from a simple calculation.

I have also cleaned up the standard meter instructions and simplified them a lot, but have not tested that method yet.

Many little things to do.

I think LuxLuthor will have time soon to try his hand at calibration, as soon as he has some time (and a working netbook computer). My netbook is also coming along and ready to program a chip though I haven't tried it yet. I do have detailed instructions from that installation to put on the web.

Here's how I program the regulator: (no )

(With no power on the regulator) Plug in the programming plug to the regulator and computer. Hook up the DVM (no bulb). Apply power to the regulator with a power supply (or put the batteries in if the regulator is mounted in a light). Set the software for "uncalibrated" and load it into the regulator. Double click the flashlight. Read the meter (full on voltage). Put this reading into the software. Reload the regulator. Double click and verify the output. Done.

Additionally I test the low voltage dropout by adjusting the power supply, and any other interesting features of the user interface, but this is just a verification.

The next six regulators will be assembled and tested in the next couple of days.

 

[BSBG]

Yes, probably my sockets

Here is my order detail: Onelevel Mode for all 3

Order:
- Quantity of Regulators: 3

-- Standard Model Regulator:3

- Quantity of User Supplied Sockets:3

- Quantity of Programming Adapters: 1

- Shipping: 9

- Sales Tax: 0

Payment (do not pay until directed):

- Total Amount: 3x97 + 12 + 9 = $312

- Paid via PayPal on 11 July 2009

- make sure to include your CPF Id and posting number in this thread in your PayPal



Regulator Number (for each regulator in multi-regulator orders): 1


Regulator Model: (standard)


Bulb Data:
- Bulb Type (manufacturer, model): Osram 64642

-- Note that if the bulb information is given, and the voltages are not specified, we will use the default values for this bulb.

- Bulb Height

Max Overall Length (MOL)

1.969 in (50.0 mm)

Bulb Diameter

0.433 in (11.0 mm)

Light Center Length (LCL)

1.260 in (32.0 mm)

Order Codes

64642 HLX
- Maximum Bulb Voltage (RMS full output) (optional): 26.0

- Minimum Bulb Voltage (RMS fully dimmed) (optional): 10

- Locked Out Basic flashlight Bulb Voltage (RMS) (optional): 15



Battery Management: (will compute from Chemistry, Ncells if not specified)

- Battery Chemistry: LiMn

- Number of Cells: 8

Note that if the voltages are not given we will use the default values for the battery chemistry and number of cells specified.

- Maximum Battery Voltage: (optional)

- Nominal Battery Voltage: (optional)

- Minimum Battery Voltage: 3.6 each


Socket:
Basic, Osram Socket Upgrade, User Provided (specify): Kiu provided


Other Features: (indicate if NOT wanted or specify value)


- Click to Memory Level (if not then Max)

- Double click to Max Voltage

- Press from off to Min voltage
- Press from on to Ramp - alternates up/down (ramping feature)

- Triple click to Mid Voltage (halfway between minimum and maximum voltage)

- Quad click to alternate between ramp and 7 level step
- Five clicks to Lockout

- Lockout Basic Flashlight mode (click on/off low power only)
- Fast Soft Start: 100mS – No – slower 3-500 ms

- Temperature Brightness Reduction at: 50C (shutdown takes place approx 10C hotter)

- No Activity Shutdown Timer in Minutes: NOT

Regulator Number (for each regulator in multi-regulator orders): 2


Regulator Model: (standard)


Bulb Data:
- Bulb Type (manufacturer, model): WA 1185

-- Note that if the bulb information is given, and the voltages are not specified, we will use the default values for this bulb.

- Bulb Height (default is 14.3mm for WA1185 in standard reflector): 
- Maximum Bulb Voltage (RMS full output) (optional): 11.0

- Minimum Bulb Voltage (RMS fully dimmed) (optional): 4

- Locked Out Basic flashlight Bulb Voltage (RMS) (optional): 8



Battery Management: (will compute from Chemistry, Ncells if not specified)
- Battery Chemistry: Nimh
- Number of Cells: 12

Note that if the voltages are not given we will use the default values for the battery chemistry and number of cells specified.
- Maximum Battery Voltage: (optional)

- Nominal Battery Voltage: (optional)
- Minimum Battery Voltage: 

Socket:
Basic, Osram Socket Upgrade, User Provided (specify): Kiu provided



Other Features: (indicate if NOT wanted or specify value)


- Click to Memory Level (if not then Max)
- Double click to Max Voltage
- Press from off to Min voltage

- Press from on to Ramp - alternates up/down (ramping feature)

- Triple click to Mid Voltage (halfway between minimum and maximum voltage)

- Quad click to alternate between ramp and 7 level step
- Five clicks to Lockout

- Lockout Basic Flashlight mode (click on/off low power only)
- Fast Soft Start: 100mS – No – slower 3-500 ms

- Temperature Brightness Reduction at: 50C (shutdown takes place approx 10C hotter)

- No Activity Shutdown Timer in Minutes: NOT

Regulator Number (for each regulator in multi-regulator orders): 3



Regulator Model: (standard)


Bulb Data:
- Bulb Type (manufacturer, model): WA 1331
-- Note that if the bulb information is given, and the voltages are not specified, we will use the default values for this bulb.
- Bulb Height (default is 14.3mm for WA1185 in standard reflector):
Maximum Bulb Voltage (RMS full output) (optional): 11.0

- Minimum Bulb Voltage (RMS fully dimmed) (optional): 4

- Locked Out Basic flashlight Bulb Voltage (RMS) (optional): 8



Battery Management: (will compute from Chemistry, Ncells if not specified)
- Battery Chemistry: Nimh
- Number of Cells: 12

Note that if the voltages are not given we will use the default values for the battery chemistry and number of cells specified.
- Maximum Battery Voltage: (optional)

- Nominal Battery Voltage: (optional)

- Minimum Battery Voltage: 

Socket:
Basic, Osram Socket Upgrade, User Provided (specify): Kiu provided



Other Features: (indicate if NOT wanted or specify value)


- Click to Memory Level (if not then Max)
- Double click to Max Voltage

- Press from off to Min voltage
- Press from on to Ramp - alternates up/down (ramping feature)

- Triple click to Mid Voltage (halfway between minimum and maximum voltage)

- Quad click to alternate between ramp and 7 level step
- Five clicks to Lockout

- Lockout Basic Flashlight mode (click on/off low power only)

- Fast Soft Start: 100mS – No – slower 3-500 ms
- Temperature Brightness Reduction at: 50C (shutdown takes place approx 10C hotter)

- No Activity Shutdown Timer in Minutes: NOT

 

[sylathnie]

I'm confused on status. You state that the next 6 regulators will be assembled in the next few days but that will only take care of the first two or three orders. If I pay now does it guarantee me an earlier place in the production line or should I just wait until production approaches my turn. :thinking:

 

[Alan B]

BSBG thanks for the parameters. One question. Click to memory uses the memory value set by ramping. You specified a voltage value for this. If you want me to do that then memory won't work. I can probably do that if you wish. Please confirm that you don't want memory.

Sylathnie: Excellent question. I have been considering the details and I think I will handle it this way:

I don't want a lot of payments waay ahead of time.

But within a wave I will ship by payment order.

How does that sound?

Wave #3 is open for payment. Wave #1 will ship approximately monday. Wave #2 will follow shortly after. Wave #3 within about a week. It partly depends on my workload at work, and I expect that to be high the next 2 weeks. Then I will be on vacation one week, RV camping. I will work on the code then. Hopefully finish up the new configuration software.

I plan to open the waves for payment about 1-2 weeks before they will ship.

Now I need to get off the computer and back to the shop.

Till my next break!

 

[BSBG]

BSBG thanks for the parameters. One question. Click to memory uses the memory value set by ramping. You specified a voltage value for this. If you want me to do that then memory won't work. I can probably do that if you wish. Please confirm that you don't want memory.

Doh, right - no set value, I will set it in the standard manner.

Paypal on the way!

 

[donn_]

Great Watson-Watt's Ghost!

This project fell completely off my radar screen!

Apologies, Alan. I'll get your money to you this weekend, and will mail (Priority) the KIU sockets on Monday. Then all I have to do is figure out the parameters on my units.

Sorry again!:shakehead

 

[Alan B]

Doh, right - no set value, I will set it in the standard manner.

Paypal on the way!

PayPal received! Thanks!!

No problem, donn_, I figured you would return soon. Thanks again for the bulb, it got me started. I bought a few more of them and blew through several between a tight new socket, mechanical interference and selecting too high a voltage and too short a soft start. Now I've turned off fast soft start on that one and I think the big bulbs are fine without the fast feature. The bulb is probably safe now. Good thing as it is my last. Have to order a couple more.

I have assembled 6 regulators now and will test/calibrate them shortly. These are mechanically a bit tricky to assemble. Getting the grounding screw, washer, and spacer in is the hard part.

 

[Alan B]

Six regulators calibrated.

Roland's is waiting for the programmer, due monday.

The rest of these are probably destined for LuxLuthor.

I'll have to make some more up.

 

[donn_]

Are Lux's parameters posted anywhere, or are they proprietary information?

 

[Alan B]

Lux has a programmer and didn't decide yet so I programmed his all for the philips 5761, 2 li-ion and full features. He can change them to whatever else he needs. I needed to test them so had to pick something.

 

[donn_]

I have the programmer as well, and I'm thinking about just ordering the dongle with my switches, and going the same route. But, if I can come to a couple of conclusions first, I'd rather order them pre-programmed and avoid the learning curve until gardening season is over.

 

[Alan B]

Ok donn_. You have a few days while the sockets crawl through the mail to select parameters.

I built up four more pc boards last night, plus some programmers and switches. Here's how the process is working out:

Process of Building a Regulator

1) Mill multi-board into regulator, switch and programmer boards
2) Build up the regulator board (two phases - SMT and through-hole)
3) Build up switch and programmer boards
4) Attach socket and mount board in sled
5) Test and Calibrate

 

[donn_]

for 2x sleds and a dongle. I'll hold off on the third sled until we can figure out the config for the battle lantern.

Parameters to follow, but one will be a '623 set up at your current default for A123 cells....~16V and no fast soft-start.

3x KIU sockets leave for the left coast tomorrow.

 

[Alan B]

for 2x sleds and a dongle. I'll hold off on the third sled until we can figure out the config for the battle lantern.

Parameters to follow, but one will be a '623 set up at your current default for A123 cells....~16V and no fast soft-start.

3x KIU sockets leave for the left coast tomorrow.

Got it, thanks.

 

[sylathnie]

So... got the details of that high power version worked out yet? :naughty: I've got 12 IMR 18650s that need a home.

 

[Alan B]

Regulators have left the building!

Worked a lot this weekend on regulators. Probably too much. A number were finished, and most of those were shipped. Many more are in various stages of partial assembly. More parts have been ordered for those parts in short supply - cone screws, spacers, etc. Waiting for the programmers that should come in today for one order.

I made a prototype jig for cutting the circuit boards apart in the mill that made the process a lot quicker. Ordered some material to make a production jig.

On the high voltage unit, we are discussing it on the discussion thread.

 

[Alan B]

Added a feature to the software. The number of levels in the multilevel mode can be selected anywhere from 3 up to 7. If neither VariLevel or MultiLevel are selected the light operates single-mode.