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Maxflex5A  
Manufacturer: Taskled
Maxflex5A

  • Description
  • Reviews

MaxFlex5A

  • Additional dedicated ground solder pad from momentary action switch (maxflex5 improvement).
  • Enhanced reverse polarity protection.
  • Microcontroller based Constant current boost regulator.
  • User configuration options stored in non-volatile EEPROM.
  • Ships configured for 350mA current limit.
  • User reconfigurable current limit: 350/500/700/1000 or 1200mA (or 1300mA MaxFlex5A, total of 6 current tables) at any time.
  • UI-uni firmware.
  • 3 user configurable voltage trip points to set independent Medium, Low warning levels and Cutoff.
  • If an optional 3mm or 5mm status LED is connected, the user can configure the status LED to warn when the voltage reaches Medium (status LED lights constant) or Low (status LED flashes). Now with on-board 100 ohm series resistor.
  • Onboard pullup resistor on switch input to provide reliable performance of external momentary action switch when used with longer wires.
  • Temperature monitoring of driver board. If closely coupled with the light's body, it can be user configured to force the current output to reduce. Optional trip points of 50, 60, 70, 80, 90C or off.
  • UIB2: Bike optimized, Choice of 2 level (duomode) or 5 level (multimode) operating modes.
  • UIF: 8 level dimming, fixed lighting use optimized..
  • UIP: 5 level dimming, flashlight use optimized.
  • Non-volatile storage of brightness level.
  • Draws < 50uA when in 'sleep mode' (25uA typical).
  • User selectable voltage trip point to warn of low input voltage, useful to protect rechargeable batteries from overdischarge (Refer to technical section).
  • >85% efficiency.
  • Can drive up to 24V (29V for MaxFlex5A) of series connected LEDs. Open circuit protected.
  • Operates from 2.5V to 20V (input voltage). Being a boost converter, input voltage must be less than output voltage.
  • Board is circular (0.90" diameter, 0.25" thick).

Note 1: MaxFlex5A uses the same PCB as maxFlex5 so the silkscreen will still say V5.0. The maxflex5A version increases the voltage to 29V by 3 component changes on the PCB rather than a change to the actual PCB design.

Note 2: The 1300mA table is nominally 1330mA - obviously there are component tolerances that can affect the actual maximum output current of a particular driver board up to +/-5%.

Latest News (Oct 2009): New maxFlex5 hardware design with incremental improvements over maxFlex4.

MaxFlex5:

  •     Additional dedicated ground solder pad from momentary action switch (maxflex5 improvement).
  •     Enhanced reverse polarity protection.
  •     Microcontroller based Constant current boost regulator.
  •     User configuration options stored in non-volatile EEPROM.
  •     Ships configured for 350mA current limit.
  •     User reconfigurable current limit: 350/500/700/1000 or 1200mA at any time.
  •     UI-uni firmware.
  •     3 user configurable voltage trip points to set independent Medium, Low warning levels and Cutoff.
  •     If an optional 3mm or 5mm status LED is connected, the user can configure the status LED to warn when the voltage reaches Medium (status LED lights constant) or Low          (status LED flashes). Now with on-board 100 ohm series resistor.
  •     Onboard pullup resistor on switch input to provide reliable performance of external momentary action switch when used with longer wires.
  •     Temperature monitoring of driver board. If closely coupled with the light's body, it can be user configured to force the current output to reduce. Optional trip points of 50, 60, 70, 80, 90C or off.
  •     UIB2: Bike optimized, Choice of 2 level (duomode) or 5 level (multimode) operating modes.
  •     UIF: 8 level dimming, fixed lighting use optimized..
  •     UIP: 5 level dimming, flashlight use optimized.
  •     Non-volatile storage of brightness level.
  •     Draws < 50uA when in 'sleep mode' (25uA typical).
  •     User selectable voltage trip point to warn of low input voltage, useful to protect rechargeable batteries from overdischarge (Refer technical section).
  •      >85% efficiency.
  •     Can drive up to 24V of series connected Luxeons.
  •     Operates from 2.5V to 20V (input voltage). Being a boost converter, input voltage must be less than output voltage.
  •     Open circuit protected (boosts to 24V maximum).
  •     Board is circular (0.90" diameter, 0.25" thick).

 

MaxFlexuni.pdf (V3.30 of the manual for MaxFlex3, MaxFlex4 and MaxFlex5- firmware update for product shipped after 29 Dec 2008)Latest News (Mar 2009): New maxFlex4 hardware design with incremental improvements over maxFlex3.

MaxFlex4:

  • Reverse Polarity Protected (New V4 feature).
  • Improved thermal path (New V4 feature. Thicker copper and more thermal vias with thicker plating).
  • New uController regulator (New V4 feature).
  • Microcontroller based Constant current boost regulator.
  • User configuration options stored in non-volatile EEPROM.
  • Ships configured for 350mA current limit.
  • User reconfigurable current limit: 350/500/700/1000 or 1200mA at any time.
  • UI-uni firmware.
  • 3 user configurable voltage trip points to set independent Medium, Low warning levels and Cutoff.
  • If an optional 3mm or 5mm status LED is connected, the user can configure the status LED to warn when the voltage reaches Medium (status LED lights constant) or Low (status LED flashes). Now with on-board 100 ohm series resistor.
  • Onboard pullup resistor on switch input to provide reliable performance of external momentary action switch when used with longer wires.
  • Temperature monitoring of driver board. If closely coupled with the light's body, it can be user configured to force the current output to reduce. Optional trip points of 50, 60, 70, 80, 90C or off.
  • UIB2: Bike optimized, Choice of 2 level (duomode) or 5 level (multimode) operating modes.
  • UIF: 8 level dimming, fixed lighting use optimized..
  • UIP: 5 level dimming, flashlight use optimized.
  • Non-volatile storage of brightness level.
  • Draws < 50uA when in 'sleep mode' (25uA typical).
  • User selectable voltage trip point to warn of low input voltage, useful to protect rechargeable batteries from overdischarge (Refer technical section).
  • >85% efficiency.
  • Can drive up to 24V of series connected Luxeons.
  • Operates from 2.5V to 20V (input voltage). Being a boost converter, input voltage must be less than output voltage.
  • Open circuit protected (boosts to 24V maximum).
  • Board is circular (0.90" diameter, 0.25" thick)

MaxFlexuni.pdf (V3.30 of the manual for MaxFlex3 and MaxFlex4 - firmware update for product shipped after 29 Dec 2008)

MaxFlex3

New maxFlex3 hardware design with incremental improvements over maxFlex2.

  • Microcontroller based Constant current boost regulator.
  • User configuration options stored in non-volatile EEPROM.
  • Ships configured for 350mA current limit.
  • User reconfigurable current limit: 350/500/700/1000 or 1200mA at any time.
  • UI-uni firmware.
  • 3 user configurable voltage trip points to set independent Medium, Low warning levels and Cutoff.
  • If an optional 3mm or 5mm status LED is connected, the user can configure the status LED to warn when the voltage reaches Medium (status LED lights constant) or Low (status LED flashes). Now with on-board 100 ohm series resistor.
  • Onboard pullup resistor on switch input to provide reliable performance of external momentary action switch when used with longer wires.
  • Temperature monitoring of driver board. If closely coupled with the light's body, it can be user configured to force the current output to reduce. Optional trip points of 50, 60, 70, 80, 90C or off.
  • UIB2: Bike optimized, Choice of 2 level (duomode) or 5 level (multimode) operating modes.
  • UIF: 8 level dimming, fixed lighting use optimized..
  • UIP: 5 level dimming, flashlight use optimized.
  • Non-volatile storage of brightness level.
  • Draws < 50uA when in 'sleep mode' (25uA typical).
  • User selectable voltage trip point to warn of low input voltage, useful to protect rechargeable batteries from overdischarge (Refer technical section).
  • >85% efficiency.
  • Can drive up to 24V of series connected Luxeons.
  • Operates from 2.5V to 20V (input voltage). Being a boost converter, input voltage must be less than output voltage.
  • Open circuit protected (boosts to 24V maximum).
  • Board is circular (0.90" diameter, 0.25" thick)

 

MaxFlex3 (V3.0 of driver)

    • MaxFlexuni.pdf (V3.10 of the manual for MaxFlex3 - firmware update for product shipped after 29 Dec 2008)
    • MaxFlexuni.pdf (V3.00 of the manual for MaxFlex3)

The picture below shows the top view of MaxFlex3. The exposed rectangular gold area just above the (C) TaskLED is a direct thermal interface to the bottom of the switcher IC (on the other side of the PCB). If the power dissipation of the MaxFlex3 board exceeds about 1W it is recommended to affix a heatsink or copper tab to a heatsink to the exposed area. The exposed area is at Ground potential - i.e. electrically connected to the battery GND and LED- pads. This means it is safe to mount the tab to a heatsink that connects to the body of a flashlight, IF the body of the flashlight is the same as the Battery negative or ground.

The VIN+ hole (top left corner) is the input power to MaxFlex3.

The two holes below VIN+ (anticlockwise) are both ground pads (input ground and LED- output). MaxFlex3 has LED- common to battery ground input.

The LED+ hole connects to the LED positive pin and is the 'output' of MaxFlex3.

The SW hole below LED+ (anticlockwise) is one side of an external momentary action switch. The other side of the switch must be wired to Ground.

Note: it is recommended to keep the maximum wire length between the switch and maxFlex3 less than around 4" (10cm). Having wire leads that are too long can cause the wires to act as an antenna and cause maxFlex3 to respond irregularly or turn on/off by itself.

Note: There are 2 GND connections provided on the PCB, but most installations will require 4 connections to ground (Battery negative/ground, LED-, SW ground and ground for the STAT LED- if used). It is recommended to wire LED- and Battery negative to the same PCB ground hole and wire STAT LED- and SW ground to the other PCB ground point. Both PCB ground points are equivalent.

Bottom view of MaxFlex3.

Note the pin labeled STAT in the bottom/center of the board. Refer to the operating manual above for how STAT can be used to drive a Red or Amber LED to warn of low voltage.

Note, MaxFlex3 is a Boost regulator (step up), so input voltage must be less than the output voltage to ensure MaxFlex3 remains in regulation. If the input voltage exceeds the output voltage (at the dialed in drive current), MaxFlex3 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).

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 88%

Step 3: Determine input current

Input_current = Power_input / Battery_voltage Do this calculation for the lowest Battery_voltage you plan to run

Note, Input_current should be around 3A or less for optimal performance of MaxFlex3. When running at high output power it is recommended to solder or use thermal epoxy to mount a tab to the pad on the back of the MaxFlex3 board (the pad is at ground potential) and to thermal epoxy/solder/bolt it to a heatsink or the body of the flashlight.

Some Efficiency Measurements:

Below are some example measurements with 4 and 6 LEDs.

Input Volts Input Amps
# of LEDs
Output Volts Output Amps Efficiency
5.5
2.25
4
14.4
720mA
84%
6.58
1.82
4
14.4
720mA
87%
7.65
1.54
4
14.4
720mA
88%
9.78
1.18
4
14.4
720mA
90%
11.74
1.66
4
15.3
1190mA
93%
5.89
2.86
4
14.4
975mA
83%
7.07
2.29
4
14.5
982mA
88%
9.52
1.65
4
14.5
990mA
91%
9.41
2.91
6
23.3
1024mA
87%
12.0
2.21
6
23.3
1030mA
90%
14.3
1.84
6
23.2
1038mA
91%

Note: it is not recommended to run maxFlex3 at >3A input current, the above tests were to demonstrate the reduced efficiency at the higher input currents.

Adequate heatsinking is essential when running at high output power.

To determine the heat being dissipated on the maxFlex3 driver, calculate the output power as in the above equation (Step 1). Use the chart above to approximate the efficiency that the driver will be running at.

Lets assume 4 LEDs running at a nominal 1A from a 9.6V NiMH battery pack. From above we have the following:

Output_power = 14.6V x 1A = 14.5Watts.

Efficiency is 91%, so losses in maxFlex3 are 9%.

Power dissipated as heat in maxFlex3 is 14.5 x 0.09 = 1.3Watts

This will require heatsinking via the thermal interface pad on maxFlex.

As power being dissipated increases beyond 1.5W the thermal path to the heatsink becomes critical to reliable operation. Most of the heat being dissipated in the driver is from the switcher IC, U1. The thermal interface (the gold area) is tied

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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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