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Fatman  
Manufacturer: Taskled
Fatman

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The Fatman is a Boost regulator (step up), so input voltage must be less than the output voltage to ensure Fatman remains in regulation. If the input voltage exceeds the output voltage (at the dialed in drive current), Fatman will no longer regulate and the input voltage will go through the series inductor and schottky diode directly to the load. This will cause the output current to a LED to rise rapidly since LEDs have a very steep Current vs Voltage curve (Vf). Fatman must never be powered up without a load connected or it will be damaged.

 

  • Constant current regulator.
  • Boost topology (step up converter), must always have a load connected.
  • Dimming capability via external potentiometer.
  • Onboard trimpot to set maximum output current.
  • 0.80" diameter board, single sided components. 0.26" maximum thickness.
  • High efficiency (typically 90% or better).
  • 2.7V - 12V input voltage.
  • 3V - 16V output voltage.
  • Output current 1000mA (max), depends on input/output voltage differential.
  • Capable of driving 1 or 2 series connected 5W LEDs or 2 to 4 series connected 1W Leds or 3W LEDs.


 

POT(GND) and VIN-(GND) are electrically identical and connected together on the PCB.

LED+ and LED- provide the connection point to the LED(s). LED- is NOT the same as the GND connection.

POT and POT(GND) provide an connection point for an optional external potentionmeter. To mimic the human eye logarithmic response to light intensity a 50kohm logarithimic taper potentionmeter is a good choice. A linear taper will not appear to the human eye to have a linear response in intensity and is not recommended.

Trimpot usage:

The trimpot (just to the left of POT pad) provides a way to adjust the current output of the driver. The minimum current output is a nominal 30mA (fixed resistor in series with the trimpot). The maximum current is dependent on the input voltage and the output voltage (total Vf of the LED load).

The trimpot is in parallel with the external potentiometer, so it can be adjusted to compensate for deviation in the potentiometer resistance. Most potentiometers have a +/- 20% or worse specification for their open circuit resistance.

Note, the trimpot has a nominal life specification of 20 sweeps - so it should only be used to configure the current limit, not to perform the dimming function. The newer V2 PCB has an uprated Schottky diode (D1) and a different looking Trimpot than what the picture below shows.

 

Current setting table:

To adjust R1 (the trimpot), measure the resistance with an ohm meter with probes across VIN- and POT and then refer to the following table. Turning the trimpot clockwise increases the resistance and increases the output current.

LED Current

Resistance
1000 mA

13.50K

800 mA
10.84K
750 mA
10.10K
700 mA
9.37K
650 mA
8.70K
400 mA
5.22K
300 mA
3.82K

If you require a current output that is not in the above table, the following equation derived by a Linear fit works well:

Resistance_in_ohms = ( 13.87 * Current_in_mA ) - 322.7

Using the Fatman driver with an external Potentiometer to provide dimming control.

The following picture shows the hookup to an external Pot. One wire connects to the Wiper contact of the Pot, the other wire connects to one end of the Pot. The Pot should have a Logarithmic Taper (similar to Audio pots), this will allow the intensity to appear to change linearly to the human eye. The onboard trimpot is adjusted as per the table and equation above. Prior to adjusting the trimpot ensure the external Pot is adjusted to its maximum resistance. Then the procedure is the same as above, measure the resistance across the VIN- and POT and adjust the trimpot as above.

Note: Fatman dims by lowering the output current. As the output current is lowered the Vf of the Luxeon(s) will also lower, so, it is possible that the output voltage (total of the Luxeon Vf's) becomes lower than the battery input voltage. When this occurs no further dimming can occur because there is a DC path through the inductor and schottky diode (typical of boost converters) between the battery and the load and thus Fatman will essentially go direct drive.

Some possible configurations for Fatman:

Given the boost nature of Fatman and the Vin range of 2.7V to 12V and Vout range of Vin to 16V many possible battery/LED configurations are possible. Below are some of the common ones that customers have implemented.

3.6V Li-ion cell driving 2 series connected 3 watt leds or a single 4-5 Watt Led

4.8V 4 cell NiMH driving 2 or 3 series connected 3 watt leds or a single 4-5 Watt Led

6V SLA or 7.2V 6 cell NiMH driving 3 series connected 3 watt leds or 2 series connected 4-5 Watt Led's

Potting Warning:

Areas of the circuitry on Fatman utilize high impedance paths and if potting (not required) is to be utilized, the user must ensure than the compound is non-conductive and non-capacitive otherwise correct operation may be compromised.

Some preliminary efficiency and runtime measurements:

LED current
Led voltage
Input Voltage
Input current
Efficiency
30mA
11.0V
9.64V
43mA
80%
158mA
11.73V
4.12V
0.50A
90%
158mA
11.73V
9.61V
0.20A
96%
302mA
12.13V
4.06V
1.00A
90%
429mA
12.40V
4.00V
1.50A
88%
873mA
13.25V
8.94V
1.37A
94%
964mA
13.41V
9.46V
1.44A
95%

A runtime test was performed with 4 AA Powerex NiMH cells (2000mAHr capacity) driving 750mA into 3 series connected Luxeons. Continuous runtime was 57 minutes on the prototype Fatman converter board.

Examples on how to calculate battery/LED combinations:

Step 1: Determine output power

Power_output = Number_of_LEDS * Vf * Output_current

Step 2: Determine input power

Power_input = Power_output/efficiency

For calculation purposes we can assume efficiency will be around 90%

Step 3: Determine input current

Input_current = Power_input / Battery_voltage

Do this calculation for the lowest Battery_voltage you plan to run

Now, Input_current should be around 2A or less for optimal performance of Fatman. Fatman can run up to around 2.2A max. When running at high input power it is recommended to thermally epoxy the back of the Fatman PCB to a heatsink or the body of the flashlight.

Fatman 
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Price: 43.95 (48.35 Inc. Tax)
40.06 USD 31.44 EUR 26.14 GBP

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12th April 2010 — Cree, Inc. (Nasdaq: CREE), a market leader in LED lighting, announces a breakthrough new lighting-class LED platform, the XLamp® XM LED. This new single chip LED delivers record-breaking efficacy of 160 lumens per watt at 350 mA. The LED also delivers 750 lumens at 2 A, which is equivalent to the light output of a 60 W incandescent light bulb at less than 7 watts.

“This new platform continues Cree’s well-established record of turning R&D innovations into products,” said Chuck Swoboda, Cree chairman and CEO. “We continue to set the pace for LED performance, establishing new benchmarks that make you wonder why anyone would consider last-century’s energy-wasting technology.”

A cool white XM LED driven at 350 mA can produce 160 lumens at 160 lumens per watt. The new platform has a larger footprint than Cree’s XP family and also offers the unique combination of very high efficacy at very high drive currents. At 2 A, an XM LED produces 750 lumens at 110 lumens per watt. The thermal resistance of the XM platform is 2 degrees C per watt— an industry-leading technology breakthrough and a 350 percent improvement over Cree’s flagship XLamp XP-E LED.

Samples of the XLamp XM LEDs are available for order with standard lead times and commercial availability is targeted for Fall 2010.

 

30th Sept 2009 - Cree Raises the Bar for Lighting-Class LEDs with Commercial Availability of the XLamp XP-G LED

Single LED Delivers Up to 367 Lumens at 111 Lumens per Watt

DURHAM, N.C., SEPTEMBER 30, 2009 — Cree, Inc. (Nasdaq: CREE), a market leader in LED lighting, announces the commercial availability of the XLamp® XP-G LED, the industry’s brightest and most efficient lighting-class LED. The XP-G LED can produce up to 367 lumens when driven at 1A, at a typical efficacy of 111 lumens per watt; making it 46 percent brighter and 64 percent more efficient than the highest-performance XR-E LED, with an 80 percent smaller footprint.

Cree XLamp XP-G LED“Cree’s XLamp XP-G cool white LEDs set a new standard for LED performance,” said David Chow, president, 4Sevens, LLC. “For our flashlights, the XLamp XP-G LED was a clear choice because of its high lumen output, unmatched efficacy and compact package size.”

This level of performance can potentially reduce the required number of LEDs, as well as the size and cost of LED fixtures. High efficacy at lower current (up to 132 lm/W typical at 350 mA) can lower the total power requirement for a portable or solar lighting application, which can reduce the amount of solar cells or batteries needed.

“This establishes a new level of performance for LEDs,” said Paul Thieken, Cree director of marketing, LED components. “We now deliver lighting-class efficacy at 1A drive current. In addition, we have begun offering limited samples of an S2 flux bin, providing up to 400 lumens at 1A. We target availability of XP-G neutral and warm white LED samples by end of calendar 2009.”

XP-G LEDs extend the leadership of Cree’s lighting-class LED family, giving lighting designers a wide range of price and performance options that all share a common package footprint. The cool white XP-G LED is available now with order codes up to 139 lumens minimum at 350 mA and ANSI-compliant cool white bins (5000K – 8300K CCT) through the Cree distribution network

8th May 2009 - Cree Announces Industry’s Brightest and Highest-Efficiency Lighting-Class LED

Cree to Demonstrate XLamp® XP-G LED, Features 132 Lumens per Watt Efficacy, at LIGHTFAIR International

Cree, Inc. (Nasdaq: CREE), a market leader in LED lighting, announces it is demonstrating the newest addition to its lighting-class XLamp® LED family—the XLamp XP-G LED—at LIGHTFAIR International in New York, May 5-7, 2009.

The cool white XLamp XP-G provides 139 lumens and 132 lumens per Watt at 350 mA. Driven at 1 A, the XP-G produces 345 lumens, which is 37 percent brighter and 53 percent more efficient than the brightest XR-E LED. The XP-G LED has the highest lumen density of any available lighting-class LED, and it is based on the XLamp XP family package.

“The XLamp XP-G again raises the level of performance available from our XLamp LED family,” said Paul Thieken, Cree, marketing director, LED components. “This product is designed for customers requiring the highest levels of brightness and efficacy.”

4th May 2009 - Cree Announces Industry’s First Red-Green-Blue-White Multichip LED and XLamp® Color LED Performance Breakthrough

Cree, Inc. (Nasdaq: CREE), a market leader in LED lighting, is expanding its high-power color LED product offerings. Cree is unveiling the industry’s first multichip MC-E LED with red, green, blue and white chips—all in a single package. It is also pairing new LED chip innovations with its industry-leading XLamp® XP-E package to deliver the highest performance family of discrete, high-power color LEDs available.

Cree XLamp MC-E Color LEDThe XLamp MC-E color is a unique package design, combining white, red, green and blue LED chips in a single component. The first of its kind in the industry, this compact component provides design flexibility for color-changing LED applications that require high flux from a small lighting source, such as entertainment and architectural lighting.

Cree XLamp XP-E Color LEDWith the industry’s highest performance, the XLamp XP-E color LEDs provide up to 22 percent more flux than the existing XLamp XR color portfolio, with an 80 percent smaller footprint. The XP color portfolio is available in flux bins, at 350 mA, up to:

* Royal Blue: 500 mW
* Blue: 39.8 lumens
* Green: 107 lumens
* Amber: 56.8 lumens
* Red: 56.8 lumens

Compared to the current XLamp XR color LEDs, space between the LED die can be reduced by 75 percent with the new XLamp XP-E color LEDs and 94 percent with the new XLamp MC-E color LED. This reduction in spacing can allow better color mixing and shadow reduction for color-based applications, including decorative, architectural and entertainment lighting. Cree is sampling the MC-E and XP-E color LEDs, with production quantities targeted for Q3 calendar 2009.

“We have leveraged the LED chip and packaging innovations developed for our lighting-class white LEDs to deliver real performance gains in high-power color LED applications,” said Paul Thieken, Cree marketing director, LED components. “The combination of technology innovation and package flexibility gives designers working with Cree’s color LEDs increased brightness, flexibility and control.”

Learn more about these products at www.cree.com/products/xlamp_new_colors.asp.

27th May 2008 -

Cree Demonstrates New XLamp MC-E LED Extends Lighting-Class XLamp LED Performance with Multi-Chip Package

DURHAM, N.C., MAY 27, 2008 — Cree, Inc. (Nasdaq: CREE), a market leader in LED lighting, announces that it is demonstrating the newest addition to its industry-leading XLamp® LED family—the XLamp MC-E LED—at LIGHTFAIR International in Las Vegas, N.V., May 28-30, 2008.

The multi-chip XLamp MC-E being demonstrated retains the same 7mm x 9mm footprint as Cree’s existing XLamp XR family LEDs while providing four times the light output of the existing XR-E, the highest lumen output for a package of this size. This powerful combination is designed to enable new applications and reductions in overall system cost compared to other LED packages. At 9.8W, the XLamp MC-E LED being demonstrated provides up to 790 lumens at 6000K and up to 605 lumens at 3000K.

The XLamp MC-E LED is being demonstrated in both cool and warm white at Cree’s LIGHTFAIR International Booth #2635. Visitors to LIGHTFAIR can also see the XLamp MC-E LED applied in indoor and outdoor luminaire demonstrations at the following booths:

8th May 2008 - Cree Expands XLamp® XR-C LED Family to Include Full Range of High-Performance Colors

DURHAM, N.C., MAY 8, 2008 — Cree, Inc, a market leader in LED lighting, has expanded its family of XLamp® XR-C high-power LEDs to include Royal Blue, Blue, Green, Amber, Red-Orange and Red. These LEDs are available in production quantities.

Standard flux order codes at 350 mA are available up to:

* 350 mW in Royal Blue,
* 23.5 lm in Blue,
* 67.2 lm in Green,
* 51.7 lm in Amber, Red-Orange and Red.

The XR-C color LEDs feature the same isolated thermal path, low thermal resistance and high reliability as the white LEDs in the XR-C family. They also offer a smooth upgrade path for customers looking to use the same footprint as the XR products.

“We are extending our industry-leading XLamp LED portfolio with new, higher-performance, lower-price options in the XR family form factor,” said Paul Thieken, Cree director of marketing for lighting LEDs. “Cree enables design flexibility for color LED applications with consistent drive currents and footprints throughout the XLamp XR-C and XR-E LED families.”

1st March 2008 -

With increased emphasis on energy efficiency, developers are being asked to go a step further in planning future subdivisions. In planning the Morning View subdivision in the NSW town of Quirindi the developer; Independent Group Australia investigated an environmentally friendly option of solar street lighting for their estate. With the blessing of Liverpool Plains Shire Council IGA contacted Weidemuller NSW to design and manufacture custom LED luminaires which would operate as stand alone units powered by solar panels on specially designed Vicpole poles. The result is the first P5 rated LED stand alone street lights using the Cree XR-E Power LEDs, to be used in a residential subdivision in Australia – quite an achievement. Apart from zero carbon emissions, it’s said the LED’s have a life expectancy of 50,000 hours and the solar panels are self cleaning. From all reports, the poles and lights which were installed in July 2007, are “working perfectly”.

10th September 2007 - Cree, Inc. (Nasdaq: CREE), a leader in LED lighting components, today announced it has demonstrated light output of more than 1,000 lumens – an amount equivalent to the output level of a standard household light bulb – from a single R&D LED. Cree’s achievement demonstrates continued leadership in the development of LEDs that can make traditional light bulbs obsolete.

A single-die LED, driven at four amps, produced 1,050 lumens in cool white and 760 lumens in a warm-white version. Efficacy of the cool-white LED was 72 lumens per watt and 52 lumens per watt from the warm-white device. Both LED versions operated at substantially higher efficacy levels than those of today’s conventional light bulbs. Historically, Cree’s R&D demonstrations generally have been commercialized within 12 to 24 months.

1st September 2007 - Cutter Electronics are delighted to have been appointed the Australian and New Zealand distributor for Marquardt. Marquardt are a global manufacturer of Automotive, Appliance, Power tool Switches and keymodules. They are a leading manufacturer of Appliance Control Sensor systems as well as custom keyless entry systems in Automotive applications.

23rd June 2007 - Cree Announces Breakthrough 100-Lumen XLamp LEDs Available in Volume Quantities

DURHAM, NC, JUNE 27, 2007 — Cree, Inc. (Nasdaq: CREE), a market leader in LED solid-state lighting components, today announced commercial availability of XLamp® LEDs with minimum luminous flux of 100 lumens at 350 mA. XLamp LEDs are the first LEDs to be available in volume with this level of performance. This advance sets a new standard in lighting-class LED brightness and efficiency.

XLamp LEDs have now achieved a 100% improvement in performance over the past 17 months. They can deliver either 25% greater brightness with improved efficacy, or they can deliver up to 55% greater brightness at the same efficacy when compared to the previous generation of XLamp LEDs. Moreover, the new XLamp LEDs retain the same footprint as previous XLamp LEDs, thereby protecting customers’ design investments.

"Cree is to be congratulated on surpassing the 100-lumen level in its commercial white LED products," said Robert Steele, director of the optoelectronics practice at market research firm Strategies Unlimited. "The availability of such high-performance devices should certainly accelerate the conversion of the lighting market to solid-state sources."

“This is an announcement of volume availability, not an R&D result or availability of a few parts,” stated Norbert Hiller, Cree vice president and general manager for lighting LEDs. “These LEDs can enable lighting manufactures to create fixtures using fewer LEDs than before, thereby lowering initial product cost and reducing energy consumption.”

 

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