making a small batch of Texas Avenger "TA" Drivers fully tested running Bistro or Narsil, Clicky or E-switch, SIR800

Ok, your posted instructions and the link you provided a few posts up though are for Bistro-HD not TA 1.3, but a very old version of bistro HD. So I think you were just showing that in response to questions about getting recent stuff.

FWIW I just updated HD with a one click build script so that importing into Atmel Studio is no longer needed. You need Atmel Studio installed (or WinAVR), just to have the compiler tools available, but compiling just requires double-clicking the included buildal-AS.bat file. You can edit configuration files in any editor you like, including Atmel Studio (or even Notepad or maybe Notepad++ which seems very recommended), but again, without the need to import the project or configure options in AS. This has the added benefit that you are guaranteed to get the same compiler options I used.

Also FWIW, the OTSM build in HD use the TA 1.3 modegroups. The only noticable differences for the basic OTSM build is just that click timing is far more stable (but only with OTSM components). The thermal control is also changed a bit in the latest version, and there are three extra modes included. Otherwise it works like trippledown with TA modes.

Yeah Bistro with OTSM is no option as it requires a quite expensive capacitor and this batch progress is too far advanced to change to OTSM

you can choose soldering paste
lead free 96.5 % tin, 3% silver, and 0.5% copper
or
with lead 62% tin, 36% lead, and 2% silver

Oshpark has all boards from first order shipped, so it wont be long till first drivers go into production
Check the Excel screenshot if the information to your order is right, I keep it up to date dayly

Yeah, it's a little expensive, maybe adds about $1.70 to compared to OTC build if you're buying small batches.

I'm actually thinking folks may try it with cheaper hardware and see how it goes. I bought that cap to make sure it would work well, but with like 3 or 4 seconds of sleep time even at low voltage, it works more than well enough. I like this cap: CL21A476MQMNRNG Actually my original ceramic build wasn't too terrible, but that was 3 by 16V 10uF caps stacked, not one 6.3V 47uF cap. Still even a good ceramic cap of that size is somewhere around $0.60 to $1.00 so maybe $1 saved.

I am though thinking of increasing the timing resolution. Unless I do it pretty cleverly that will eat some capacitor time. Using a 500 ohm bleeder can get a little energy back too as possibly. I have wondered if just using a Ta cap for OTC would stabilize things quite a bit. It's still just annoying form a modding and design perspective, because you have to get the calibration right on every new build, but it may actually work fairly well.

Just fyi... Hoping to get to updating NarsilTriple this week to support the new UI configuration I have in Narsil 2-channel, where the thermal regulation trigger point can be configured.

Not sure yet in the "how to", but would like to combine both Narsil versions into one code base - will be easier maintaining going forward.

If I can get this working, this would also bring 2S battery support into Narsil 3-channel support.

Tom, that’s a great announcement! Thanks for all the coding work you do for us here at BLF! Narsil is amazing!

Thanks! As many as you know, Narsil is built on top of, and using tools by other major contributors.

Roughly, and probably leaving a lot out - Dr Jones, JohnnyC, ToyKeeper, Werner

Also a hugh contribution from BLFers for input on adding features, and others involved in testing and providing feedback.

I should have kept better track of it all...

The leaded solder is FAR better then the tin, both in paste and rod forms.

Also, you can order solder paste stencils from https://www.oshstencils.com/ using the files from oshpark. These make it WAY easier to apply solder paste and is HIGHLY recommended if you are making these in bulk. I assumed you would already be doing this is the only reason I didn’t mention it before.

I would also recommend the stainless steel versions for the top sides at the very least. You can shrink the outside overhang to the minimum they allow for these small drivers as well without an issue.

as i am a little short on SIR800 FETs to assemble more drivers

I stripped some FETs from an dead gaming Laptop mainboard
7 nice Infineon that are as good as the SIR800

IRFH7932PbF - Infineon: 3.3mOhms@VGS = 10V
SIR800: 2.3mOhms@VGS = 10 V

How is it possible to put more board sizes to one stencil foil?

I personally use the NXP FET’s just fine in most of my lights, only the extreme hotrods do I even worry about using the sir800.

You can’t put multiple stencils on a single sheet as far as I know, this would be a question for oshstencil. You could make up a custom stencil by extracting the different pcb paste files and combining them. Although I have no idea how to actually do this easily.

Yeah I've used some cheaper FETs too and not cared. Most of the time I'd rather spend the $1 on having the controls not be frustrating, but then I don't mind spending it on both. Infeons in general are not low quality fets though, and hard to even call them inferior. Actually there are some that are possibly better, although not that one. That particular one is going to struggle a little when the battery is very low, because it has a high turn on voltage, but the voltage falls so quickly when the batteries are that low anyway, that it's probably the equivalent of running out of battery 1 minute faster, no big deal.

yeah that Infineon has 12mOhms at 3V

Anyway our TA drivers with Bistro and Narsil have LVP which reduces output anyways ramping down output when the cell gets low, so the FET wont be used at that level

On Narsil you can see it, when Battery is low you can get to DD the brightness raises a lot, then you see 3 blinks and it steps down, 3 blinks next stepdown aso. as the LVP kicks in

That would be awesome. I’ve been loving v1 narsil in one of my headlight builds. I’m looking forward to checking out how its matured. I still haven’t got around to learning how to flash drivers, so I’m glad Lexel is whipping these up so I can upgrade to the latest Narsil.

Good, point, not much use for the FET at low output.

I got a stupid setback

Tried to do paste on the boards the first were OK, then it gets harder to squeeze out the paste and I get way too thin stuff containing almost flux
then the remaining stuff gets rock solid in the syringe

Crappy stuff they sold me, my lead free 10 year old stuff is better

I recycled some from the syringe and applied it with a toothpick

could do 10 boards with remaining fluxed solder paste

I had the same thing happen with some of my solder paste. I ordered another tube and so far it has been working fine. I think it is more a matter of age, the older it is, the more it separates.

Yeah, I bought a tube of solder paste from eBay a while back, and it was a bit dried out. They also sent me a tube of just flux as a bonus. I took the ‘needle’ off the tube of solder paste and squeezed it into a cup. Then, I added some of the flux from the other tube and stirred until there were no more lumps. I got as much solder paste as I could back into the tube, and it seems to work fine now. Maybe you can do something similar with yours?

I bought some Kester EP256 on ebay. Vestureofblood recommended it in one of his “how to” youtube videos. I’ve only used it a few times but it’s been working great. I’m pretty sure solder paste has a limited shelf life. The one I bought on ebay was fresh when I bought it last year with a date of manufacture written on the tube.
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I’ve tried the lead free regular solder, but had a much more difficult time getting nice solder joints with it. So I just stick with the leaded stuff now.

Sorry for the setback. I understand if things get delayed while you wait for additional supplies.

Thanks for the support of our service budgetlight community in using our stencils at https://www.oshstencils.com

Just a heads up that we also sell solder paste in syringes, similar to the one shown here. We carry only high quality paste for reasonable prices, and are proud to see many of these designs come through our site.

Let us know if you have any questions!

Thanks Oshpark. Do you have a link to your solder paste etc?

I hope tomorrow new solder paste arrives
today I got 3 21mm and 6 more 30mm LDO boards