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Thread: SKU 26106 5xCree 15W driver schematics + 12V mod

  1. #1
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    Default SKU 26106 5xCree 15W driver schematics + 12V mod

    I'm not sure it this belongs here, but I will give it a try.

    I have manage to reverse engineer the SKU 26106 5xCree 15W driver board from DX and made a schematic. I have also identified the switching regulator on the board, that's AS2001 from Anisem
    Having done this, I verified that the regulator also will work fine for 12V battery voltage. The only modification needed is to change the value of the series resistor R4(marked with a circle) from 150ohm to 1Kohm. This is the large 1206 resistor marked "151". this is a zener shunt regulator, and will draw about 50mA with a 150ohm resistor and generate too much heat. It could work still, but I would not recomend it.
    The switching reguator is spesified up to 15V, and the other components is not a problem. The only thing is that the input voltage needs på be lower that the output voltage for the LED's.
    The switching transistor can handle 30V, and the peak voltages are actually lower with 12V supply voltage. The power dissipation should also be lower because the current is reduced.

    If a driver without the 5 modes is needed, just move the LED- wire to the sense resistors (R1/R12). Then the mode switch is disabled.

    Hope anyone else finds this useful. I was wondering if I could use this board on a 12V battery, and now I know

    Edit
    Here is link to the schematics, that I converted to jpg:
    http://img511.imageshack.us/img511/3...erboard15w.jpg


    A short discription on how it works:
    - U2 is the controller/ASIC that is used to make the modes.
    - R6/C4/C2 is timing for mode switiching
    - R4/D3 is a 5V shunt voltage regulator
    - U1 is the boost switching controller (AS2001)
    - T1/T2 is drivers to speed up the gate switching and reduce switching losses
    - L1/D1/Q1/C1 is the boost circuit
    - D5 will limit max. output voltage when the LED is disconnected or Q2 switched of, to avoid overvoltage on Q1
    - Q2 is the current switch to controll the PWM/blinking for the modes
    - R1/R12 is current sens resistors, with a constant 0.5V drop
    - C5/R11 controls the switching frequency
    - R9 controls the output drive current on pin5
    - C6 is reference voltage filter cap
    - C7/R10 is soft start timing

    Hope this will help someone. This is a nice and flexible circuit that easily can be modded
    Last edited by HansV; 04-29-2010 at 11:44 AM. Reason: Update with picture and discription

  2. #2
    Flashaholic aurum's Avatar
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Pm send ...

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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Sounds like some good work. Thanks for sharing. What format are your schematics in?
    No, a torch does not always mean flames.
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  4. #4

    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    hi,

    i also done some mod´s on this driver. i often got problems with the charge-cap from the setp-up output section, so i always replaced it with a better cap from an old mainboard or so...



    markus

    p.s. why can´t you post the shematics here?

  5. #5
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    The voltage rating on the output cap seems to be OK(20V), but I think the switching current is too high. That is probably the reason that it breaks. Good quality 25V capacitors or cheramic multilayer caps should do the trick.
    I have now uploaded the schematichs on ImageShack, it was too late to figure out how yesterday when I found out that I could not post the pdf file directly here on the board.
    Last edited by HansV; 04-22-2010 at 01:15 AM.

  6. #6
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Post more mods or report other problems with this driver board here, and I will update the schematichs and the top post!
    It's a good driver design, but the componets are a bit cheap(OK for 4$. Therefor it is usefull to know what tends to break so it can be upgraded in advance to avoid problems.

    Possible mods is for example to make a constant voltage output regulator in stead of constant current. That is easy with this board, just replace D5 with a resistor and connect output GND to board GND

    Other possibilities is to replace the mode controller(U2) with another controller circuit to get other modes. Just connect 5V, GND and the control signal to R3/Q2 gate. It works with 3-15V control voltage on the gate and does not pull any current other than through the pull-down (R2).

    For higher output current it is possible to upgrade L1, Q1, D1, C1 and C3. If the switching frequency is increased, the value of L1 can be lower to reduce inductor loss.

    The switching circuit can be turend completly off by disconnecting R9, with for example a switch or a transistor.

    I quess there are other possibilities as well, to fit specific needs. The input voltage is always limited to 15V because of the switching regulator, but the output can be higher if Q1 is changed to a higher voltage MOSFET. Then it scould be possible to drive 6, 7 or 8 LED's. Driving 3-4 LED's should work fine without any modifications.

  7. #7

    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    I have a feeling that switching regulater is Feeling Technology FP5138B or FP6201

    http://www.micro-bridge.com/data/Fee...ch/FP5138B.pdf
    http://www.feeling-tech.com.tw/km-ma...6201v01-lf.pdf

    Could you confirm this could be or not HansV

  8. #8
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    I can't be sure, because the driver board manufacturer has removed the text on the IC, but it's not FP6201. The pins doesn't match.
    FP5138B has correct pinning and functionality, but doesn't come in SSOP8 package.
    I still think AS2001 from Anisem is the regulator used here, but there could apperently be others that is compatible/interchangeble. Then it realy does not matter witch one they have use, as long as we can understand how it works and modify it.

    http://www.yasemi.com.cn/pdf/AS2001_...ary_080303.pdf

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    Default Simple mods for better performance

    As mash.m stated, the charge capacitor (C1) on this board is underrated and prone to break. I have now tested alternative capacitors for performance.
    I found that when I replaced C1 with a 10uF ceramic capacitor(1210 25V X5R), the input current dropped 50mA (at 8V input). The reduced power was mostly burned up in the tantalium. Use two capacitors in parallel to get the same value as before if you want, it will reduce ripple but is't nessesary.
    I also changed R4 to a 1kohm 1206 resistor, enabeling the board to work fine with 5-15V input voltage.
    One more modification I have done was to replace the rectifier diode(D1) with two BYS10-45 diodes to reduce the diode loss. They have lower forward voltage.
    Increasing the frequency by changing R11 to 6.8k(150kHz) or 5kohm(200kHz) also reduces the loss in the switcher. I simply soldered another 10Kohm resistor on top of R11.

    Newark parts list suggestion:
    10uF 1210: 10R6036
    BYS10-45: 96K7236
    1Kohm 1206: 53K1779
    10kohm 0603: 52K8062

    I managed to drop the input power with about 1W with these modifications, so it is easy to increase the efficiancy of this board.

    I recomend eneryone using this board and have the skills to change the capacitor for lower loss and better reliability.
    If the board will see more that 8V, I also recomend to change R4.
    The other mods is not nessesary, but will increase efficiancy. Higher frequency will also give better regulation.

  10. #10
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    HansV,

    Thank you for taking the time to post all of this. What value do you recommend for R4 if driving this from 8xAA NiMH? (~10V-6.4V over the discharge)

    Also, do you have a recipie for increasing output current (to ~1400mA) to drive 4 XP-G emitters in series? Or is that asking way too much of this board?

  11. #11
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    1Kohm for R4 works down to 5V, so you can use that. 470ohm would also work fine.
    For 1.4A you will need 0.5V/1.4A=0.36ohm. Maybe 3x1ohm resistors in parallel works? R12 (the 4.7ohm on top) can also be changed to 0.68ohm.
    I will test this when I can and see if the board can handle this. You should definitly change the capacitor C1 when increasing the current.

    Edit:
    3x1ohm in parallel for sense resistor gives about 1.42A drive current.
    I have tested this with load similar to four LED's. It seems that the rectifier diode(s) gets to hot with this current. Measured almost 90 degrees C on the diodes with 6V input voltage. Put this inside a hot flashlight, and it may not last long. The transistor seems to operate fine around 60-70 deg and the inductor is only 35-40 deg.
    You can try connecting two driver boards togeather and strap the control signal from one board to the other, that should work fine. Do you want the modes, if not it is just to connect them in parallel.
    Another solution is to replace the rectifier diode with a schottky power diode that can take the current. A TO-220 package can be heatsinked to the flashlight.

    Or you can just modify the board and see how long it lasts. It could work just fine. If you mount the board so it's not enclosed in the heat sink/LED mounting base it will ceep cooler. You can put it the other way around or mount it sideways.
    Just get a spare driver board or two, so you can repace it if it burns up. The components that is stressed when you increese the current is Q1, C1 and D1. All these can be replaced to deliver a lot more current. Just monitor the temperatures when you test it. It will get warmest with the lowest input voltage.
    Last edited by HansV; 04-29-2010 at 12:22 AM.

  12. #12
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    When increesing the current on this board, the regulation becomes unstable and gets a audible low frequency noise.
    This is caused by radiation from the big inductor picked up by the board and interfreing with the current regulator. It can be fixed by moving the inductor away from the board like this:

    This is a good modification it there is room for it. Now you also have the possibility to add a heat sink on top of the transistor and diode to cool it down. Small heat sinks for motherboards that is glued on should be fine. The inductor can also be placed vertically and the wires can be swapped or extended if needed.
    This board now has a 10uF cheramic 1210 capacitor for smoothing and 3x1ohm parallel for current sense. Works fine, but gets hot at lower voltages.
    Unstabillity in the regulator is not a big problem if you don't mind the noise, so this driver should work fine even without this mod.

  13. #13
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Hans, awesome. Thanks so much.

  14. #14
    Flashaholic* Essexman's Avatar
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    I used this board with a DX 3×cree dropin in a maglite. I thought it best to try and heat sink the board. I remembered seeing photos from one of you guys using copper tube in a maglite which worked well. So I made something similar. The driver is soldered to the copper plate via the outer solder ring (neg). I cut a hole in the centre of the plate to clear the Pos connection.



    The board is std with no modifications.

    I measured the current draw on each setting to calculate the Run times. The times are based on using 2000mAh Sanyo eneloop batteries.

    High: 1.35A current draw = 1hr 29mins
    Medium: 0.84A Current draw = 2hrs 22mins
    Low: 0.43A Current draw = 4hrs 39mins

    I run it on high one evening with fully charged batteries and got 1 hour 30 mins before it went into a constant flashing mode, which I believe is low battery signal. Amazingly the theory works!
    The head and body of the maglite was hot to touch, but not too hot. I put a freash set of batteries in and it worked fine. A great little driver!

    Question: What would be the lowest input voltage used on this driver? Could it run 3 LEDs from 3.6V (3AA or 3C) or 4.2V(4AA) ?

  15. #15

    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Hi Essexman,

    You can use it for 3*Cree setup with 3*Ni-Mh. If you made resistance fix on Mag.

    Here is my setup's runtime using 3*D size Sanyo 4400mAh Ni-Cad in 3*D Mag. Cree MC-E wired 2S2P and driver set for 1450mA.



    Offcourse 4*Ni-Mh will work better.

  16. #16
    Flashaholic* Essexman's Avatar
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Hi Eprom, thanks for the details. I really like this driver, it has so many uses!

    Wow that's some current draw on your D cells!!

  17. #17
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Quote Originally Posted by HansV View Post

    This board now has a 10uF cheramic 1210 capacitor for smoothing and 3x1ohm parallel for current sense.
    Hi,

    since all the components on this picture are visible, would anyone mind to mark the R4 that should be increased to 1kohm for extended voltage range, the 3x1ohm current sens resistors and the location where I should solder the led- wire to disable the modes?

    This would be my first driver mod, so I'd like to be sure I'm doing it right.

    Also, I'd be interested in a better quality schematic since the text is hardly readable in the JPG in the OP.

    edit: seems the 'single-mode-mod' was already mentioned here so that is solved.
    I also used a multimeter to measure some resistances. Is the 150Ohm the one that I should upgrade to 1kOhm?
    Last edited by jspeybro; 08-14-2010 at 07:49 AM.

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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    does the inductor needs to be close to the board, or can I extend the leads a bit and put it on the other side of a heatsink (as if there would be a 10mm heatsink between the board and the inductor)?

    The inductor is slightly too large for the space I have.
    or maybe I could get an inductor that is a little smaller?

  19. #19
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Make the wires as long as you like - you're just adding a little bit of inductance to a lot of inductance !

    But -
    - use at least the same diameter wire, so you don't get resistive losses.
    - don't run the wires close to the electronics on the board - this can cause instability
    - if the run will be long, twist the two wires around each other.

  20. #20
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    I need a Boost Converter to charge a LiIon battery with 16.8 volts from 12 volts - this module will be ideal - with the Mode switch bypassed.

  21. #21
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Quote Originally Posted by MikeAusC View Post
    I need a Boost Converter to charge a LiIon battery with 16.8 volts from 12 volts - this module will be ideal - with the Mode switch bypassed.
    This module increases output voltage to whatever level necessary to provide 800mA of forward current. I don't think it would be safe to use it for charging batteries as it would surely overcharge them and keep on going until

  22. #22
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    Default Re: SKU 26106 for battery charging

    Yes, I forget to mention I will be changing the Zener Diode D5 to provide voltage limiting at 16.8 volts.

    It would also be useful for charging 2x18650's to 8.4 volts from a USB port 5 volt output, if D5 is changed to 7.9 volts - say 2 3.9 volt zeners.

  23. #23
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    I wonder if the driver being heat sinked can be used to drive 7-up XPG ?

    Blue shark was also rated for 5 Cree (XRE) & I used it to drive 7 XPG w/o problem due to XPG has lower Vf. Here is a link to that light:
    http://www.candlepowerforums.com/vb/...d.php?t=251539

    What is the max boosted volt on this thing?
    Did I read it right that Q1 says 30V? That should be enough for 7 XPG.
    I think the blue shark max volt was around 25V.

    It was pulling at jut over 3 amp on 3 li-ion/12v with the blue shark.

    I'd like to driver 7 XPG on two Li-ion 8V, if works, it would pull at least
    4 amp, may be 4.5 Amp from two C Li-ion.

    Can the board handle 4-4.5 Amp input with good heat sinking?


    thanks
    My Mods.. http://www.candlepowerforums.com/vb/...5&postcount=78
    Hobby only, I don't do custom mods as a service, thanks for understanding.

  24. #24

    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Hi ma_sha1,

    You can use this driver to drive 6 XP-G's. I have pushed the limits for this driver. Max open voltage is ~21V but ~1000ma regulated maximum voltage is ~19V.

    When pushing 6*XP-G with 1A, it will pull ~3.5A @7V from two Li-Ion batteries. With good heat-sinking it will handle this.




    Quote Originally Posted by ma_sha1 View Post
    I wonder if the driver being heat sinked can be used to drive 7-up XPG ?

    Blue shark was also rated for 5 Cree (XRE) & I used it to drive 7 XPG w/o problem due to XPG has lower Vf. Here is a link to that light:
    http://www.candlepowerforums.com/vb/...d.php?t=251539

    What is the max boosted volt on this thing?
    Did I read it right that Q1 says 30V? That should be enough for 7 XPG.
    I think the blue shark max volt was around 25V.

    It was pulling at jut over 3 amp on 3 li-ion/12v with the blue shark.

    I'd like to driver 7 XPG on two Li-ion 8V, if works, it would pull at least
    4 amp, may be 4.5 Amp from two C Li-ion.

    Can the board handle 4-4.5 Amp input with good heat sinking?


    thanks

  25. #25
    Flashaholic* Essexman's Avatar
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Quote Originally Posted by ma_sha1 View Post
    I wonder if the driver being heat sinked can be used to drive 7-up XPG ?

    Blue shark was also rated for 5 Cree (XRE) & I used it to drive 7 XPG w/o problem due to XPG has lower Vf. Here is a link to that light:
    http://www.candlepowerforums.com/vb/...d.php?t=251539

    What is the max boosted volt on this thing?
    Did I read it right that Q1 says 30V? That should be enough for 7 XPG.
    I think the blue shark max volt was around 25V.

    It was pulling at jut over 3 amp on 3 li-ion/12v with the blue shark.

    I'd like to driver 7 XPG on two Li-ion 8V, if works, it would pull at least
    4 amp, may be 4.5 Amp from two C Li-ion.

    Can the board handle 4-4.5 Amp input with good heat sinking?


    thanks
    This is what I love about CPF, there's me looking for how low an input voltage this driver can take, and then there's you looking for how high we can take it!!

    I've no idea about the answer to your question, maybe one of the other guys will chip in, but if it does work I might have to make another maglite

  26. #26
    Flashaholic* ma_sha1's Avatar
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Quote Originally Posted by eprom View Post
    Hi ma_sha1,

    You can use this driver to drive 6 XP-G's. I have pushed the limits for this driver. Max open voltage is ~21V but ~1000ma regulated maximum voltage is ~19V.

    When pushing 6*XP-G with 1A, it will pull ~3.5A @7V from two Li-Ion batteries. With good heat-sinking it will handle this.

    To have one of the led not lit in a 7-up would bother me, that's not an option.

    How about this idea:
    I could drive 6 led with one driver, then wire the 7th led with an independent driver that goes to the battery directly.

    So when On, all 7 led would be on, when change modes, 6 led will change modes while the 7th led would remain constant on. So the low modes won't be that low, I can live with that, at least no led goes to waste, do you guys think it'll work?


    If it would work, I'll make another 7-up on Mag 2C, probably using XPE R3 this time to get a bit more throw.
    Last edited by ma_sha1; 08-16-2010 at 02:54 PM.
    My Mods.. http://www.candlepowerforums.com/vb/...5&postcount=78
    Hobby only, I don't do custom mods as a service, thanks for understanding.

  27. #27

    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    Quote Originally Posted by Essexman View Post

    Question: What would be the lowest input voltage used on this driver? Could it run 3 LEDs from 3.6V (3AA or 3C) or 4.2V(4AA) ?
    I think i read somewhere that the driver is the same that sit in this http://www.dealextreme.com/details.dx/sku.35242

    If this info help..
    I did a test on the 5* R2 Module from DX on full with with freshly charged 3, 4 and 5AccuEvolution D Cell 10000 NiMH

    Measured at tailcap
    3 in series 4,35 Volt, draw 2,2A = 9,5W
    4 in series 5,70 Volt, draw 4,0A = 22W (was up to 4,2A and decreased)
    5 in series 7,22 Volt, draw 2,5A = 18W

    Tested before with 1 Li-ion cell but i didn't measure Amp, works fine and approx light output visible is about 80% of full output.
    Last edited by ttwhin; 08-17-2010 at 11:44 PM. Reason: more info

  28. #28

    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    My Feeling was right. Switching Regulator is Feeling-tech FP5138


  29. #29

    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    nice job dude? Can anybody give some of these schematics
    1. Single mode boost driver for driving xp-g from 1.2v ni-cad/ni-mh

    2. Single mode driver which can give 2.8 amps for sscp7 c bin from 3.7v-4.2v 2000ma imr.

    3.single mode driver for xr-e from 2.4v (2*ni-cad).

    Good if it use mosfets and other components and not using any ic's.

    Thankz in advance

  30. #30
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    Default Re: SKU 26106 5xCree 15W driver schematics + 12V mod

    So you got one where the component text was not removed? Great!

    I was only quessing on what I found that would fit physically and functionally. But other circuits can also be used, it is not nessesary the same on all boards.


    Quote Originally Posted by eprom View Post
    My Feeling was right. Switching Regulator is Feeling-tech FP5138


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