PWM Regulator for Lantern bodies, JM-PhD-X1

WOW, just read that Jimmy! Very sorry you have this hassle.
Computer has been fixed. It turns out I have a bad USB device. My microscope. When ever/where ever it's plugged in, the PC won't boot. I haven't had a chance to get another yet. I've been busy with work, home projects, family vacations, etc. Summer is tough. I've put in some time fine tuning the smaller unit. The PCB design is just about complete. Now all I have to do is secure financing from my CFO (wife). I also want to breadboard the entire thing from HV section to the bulb and 2 BIG FETs. Another design I finished for another CPFer a few weeks ago uses the same FET driver I'll be using and it worked fantastically. 50Vin, 36-40Vout, 1 FET, 12 amps and it barely even warmed up without a heatsink. I think Dual FETs at 20-30A here will be a walk in the park.
 
Last edited:
Jimmy,
I need 2 of these regulators. I would be happy to send you $200 now, and you can deduct that from my order later.
 
Jimmy,
I need 2 of these regulators. I would be happy to send you $200 now, and you can deduct that from my order later.
I appreciate the offer, but $200 is a drop in the bucket. And I can't guarantee when you get them.
I'm pushing these back to the top of the priority list.
 
Discussing financing now. I'll be in the basement this week to confirm hardware design. Then I'll buy parts. I was able to get 2 sample HV primary regulators for testing. That will help prove the entire design.
 
Hardware design is confirmed.

Added one more component to make the primary regulator stable at such a low current draw.
Added an LC (inductor/capacitor) filter to the battery ADC input to make the battery voltage reading less noise sensitive.
Added a jumper to disable the regulation output during programming.
Added 2 additional pads. One for my use during diagnostics (but can be used to drive an LED if necessary), and another for future use (ON-OFF control, ADC for external temperature, etc).

For testing I set voltages of 8.0-12.0 (5 steps)
Accuracy was excellent (7.999V, 8.997V, 9.995V, 11.000V, 12.001V).
Even when I increased/decreased input voltage from 14V to 27V, Vout was always within 0.02V of target.

I've got software pretty much completed.
As it is coded right now, you get 5 levels, a Memory start feature (turns on to the last level in use before shutdown), Low voltage warning/shutdown, high temp (in the AVR only) warning/shutdown. These are standard configuration options.

Auxiliary PWM outputs (2) that can be used for warning LEDs or Fans, etc. There are 2 DIP switches onboard for future options, also there are 2 12V (actually 11.4V) connections available to power things like fans, LEDs, external digital displays. Current drawn from these 2 points CANNOT exceed 450mA.

The use of these auxiliary PWM outputs, ports, and switches is up to the user. But requires additional coding to implement. I won't be offering to write custom code for each regulator. There are sooooo many possibilities built into this board that each user's custom code would take hours to nail down requirements and implement/test. Perhaps in the future I may offer custom code, but it can't be free.
 
Jimmy,
Glad to see that things are progressing, especially since football season is about to start. (You might get distracted.) I still need two.
 
Jimmy,
Glad to see that things are progressing, especially since football season is about to start. (You might get distracted.) I still need two.
Lucky for all of you I'm not a rabid football fan. Unless the Patriots make the playoffs.

Starlight, When these are done and tested, I'm not even going to post all 25 for sale. I'll post 23, and just send 2 directly to you. 🙂
 
Computer has been fixed. It turns out I have a bad USB device. My microscope. When ever/where ever it's plugged in, the PC won't boot. I haven't had a chance to get another yet. I've been busy with work, home projects, family vacations, etc. Summer is tough. I've put in some time fine tuning the smaller unit. The PCB design is just about complete. Now all I have to do is secure financing from my CFO (wife). I also want to breadboard the entire thing from HV section to the bulb and 2 BIG FETs. Another design I finished for another CPFer a few weeks ago uses the same FET driver I'll be using and it worked fantastically. 50Vin, 36-40Vout, 1 FET, 12 amps and it barely even warmed up without a heatsink. I think Dual FETs at 20-30A here will be a walk in the park.


Details sound great. Please reserve me 1 or 2 if you can.

Imagine that...."our" cute little USB microscope made with the highest quality Chinese junk causing a problem!!! I still use that software you sent me from the baby cd. Someday when I clean up my "work area," I'll find my original cd.
 
Details sound great. Please reserve me 1 or 2 if you can.

Imagine that...."our" cute little USB microscope made with the highest quality Chinese junk causing a problem!!! I still use that software you sent me from the baby cd. Someday when I clean up my "work area," I'll find my original cd.
There are other USB microscopes available (Chinese junk I'm sure) that are better, but still the same form factor. I'd rather not post an eBay link here since I'm not keen on promoting any particular seller. But item#370389432200 is representative of the model I'd like to get to replace my old one. 8x LEDs and 400x magnification.
 
It's been a while. Been pretty busy with other stuff. But I thought it was a good time for an update.
The design is about as solid as I can make it. Hardware has been fully prototyped and functions as expected. Finding is near and will start buying parts ASAP.
Thanks for your patience, guys.
 
Jimmy,
Is this regulator capable of running a 64663 bulb (40v, 12A)? I can't remember the specs for it. I was only planning to run a 4559 (30v, 24A) bulb, but I might want to try the 64663. I may now need 3 regulators.
 
Jimmy,
Is this regulator capable of running a 64663 bulb (40v, 12A)? I can't remember the specs for it. I was only planning to run a 4559 (30v, 24A) bulb, but I might want to try the 64663. I may now need 3 regulators.
No problem. 17-70V. up to 40A. The upper current limit is based on thermal considerations. A small FET with no heat sink can do 13A on the PhD-D1. This one has 2 BIG (lower resistance) FETs and heatsinks. So we'll see. I'm not even sure how I'll test the full capabilities. I might have to get 5 car batteries and a few giant bulbs.
 
I have a bit if a problem here. I don't have the equipment to test this thing under maximum expected operating conditions. I'm hoping to get high current test results with 48-60V input and about 40A output. Does anyone here have equipment capable of doing that type of power?

Current is what makes heat. If no one can test the regulator at those voltage and current levels, I'll have to do testing at lower voltage but still high current.
 
Jimmy,

That is a LOT of power :devil:

I am not even close as my largest power supply is a HP that can do 60 volts at 10 amps. But if that helps, then let me know.

Will
Mine will do 30A and 50V. I'm trying to team up with Lux Luthor and his 20A/30V supply to see if we can get 40A and 30V available. I think 4 or 5 24V 250W bulbs ought to suffice for a load.
The math says it will do 40A RMS while dissipating only 2W each. At that power dissipation, the heat sinks should warmup.
 
Ordered parts today from Digikey. One of the items, the big FETs are on backorder for a couple weeks. But that's OK. They're nice 3.9 mOhm units.

(*$%*@!! I just found out that the switching regulators can only be bought in a minimum quantity of 42 and since the pricing I got previously was for 100+ units, they're more expensive now. The unit price of these regulators has to go up accordingly. I'm sorry guys. These are the ONLY regulators that will allow the regulator board to perform at such a wide voltage range. The unit's are now $110 each.

Again, sorry I used a unit price previously that I can't meet now.

EDIT: Now the parts are not available until January of 2011. Delays, delays, delays. But the end is in sight. Thanks for keeping the faith.
 
Last edited:
What about a pre-order offering at $100 each?
If you folks are amenable to this idea I could start a pre-order thread in the Market Place.
 
Mine will do 30A and 50V. I'm trying to team up with Lux Luthor and his 20A/30V supply to see if we can get 40A and 30V available.

Sorry we can't do this as discussed in emails.

What about a pre-order offering at $100 each?
If you folks are amenable to this idea I could start a pre-order thread in the Market Place.

Can you give a summarized list of features you have decided on, since there has been some changes made along the way?
 
Can you give a summarized list of features you have decided on, since there has been some changes made along the way?

I'll figure out some other way to test it.

I'll put together a full description and features (implemented and some possibilities available through custom programming).
 
Back
Top