Lume1-FW3X: Constant Current Buck-Boost & FET Driver with Anduril1/2 + RGB Aux

definitely interested in a few of these :+1:

Hello all,

Just a quick progress update. I'm happy to say that we have first light with the lume1 driver.

For the flashlight, I used a FW3C bead-blasted host previously purchased from Nealsgadgets. The stock 1+7+FET driver was removed from the flashlight. This is quite easy, but does require desoldering wires from the LED MCPCB first. After that, it's a simple procedure with no glue involved.

The lume1 driver was then dropped into place and installed. As a quick note, the FW3 flashlight has a small screw hole drilled through the MCPCB shelf, which acts as a locating pin for the LED MCPCB to prevent it from rotating when the top cover is screwed on. This screw hole had a few sharp edges on the driver side, which I deburred away.

I think this PCB colourway works quite well with the FW3C. The lume1 driver fits! No issues with the inductor hitting the driver cavity, as designed. Programming was done using a HQ pogopin which I put together myself, and an AVRISP2. You can obviously use whatever programmer you want.

The original emitters were SST-20 4000K 90CRI. They seem to be quite popular, but I never really liked the tint of the SST20s, since they are very green especially at the lower power levels, and never really getting better unless driven at Turbo.

I thought this would be a good opportunity to use some of the fairly rare but extremely nice Nichia 219B 9080 4500K 'rose tint' LEDs I had in the past. These were reflowed onto the original MCPCB. The thermal paste was cleaned up and replaced with Arctic Silver 5. Finally, a TurboGlow glow gasket was added between the optic and the LEDs, just for fun.

Fun Question - if you had to build your own flashlight with this driver, which LED would you choose and why?

But does it work?

I'm happy to say that it does!

Anduril Firmware

With the support from ToyKeeper, I was able to get Anduril working on this flashlight. Fortunately ToyKeeper had already done a massive amount of work with Anduril and it had all sorts of capabilities built in to allow easy support of this driver. Since I work on a Windows machine, I used Atmel Studio for the firmware builds and flashing - I had a few requests about this surprisingly, so I thought it would be better to get something going with Atmel Studio, since most people don't have a unix environment.

There's still a little bit of work left to do for me to evaluate all functionalities of Anduril, but all the basics are working, including:

  • Ramping functionality (in this case, 1024 levels of brightness with 10-bit PWM, similar to Noctigon K1), all regulated with Buck Boost up to 3A
  • Turbo with FET
  • RGB aux LEDs verified working (on my dev board; the FW3x does not have a LED aux board for it, yet!)
  • Standard strobe modes all working (candlelight, bicycle, party, tactical, and thunderstorm)
  • Utility functions working (e.g. voltage reading, lockout modes, aux LED control etc)
  • [Update: External temperature sensor is now working and much more accurate, likely no user calibration required]

There are still some functions on the lume1 board not taken advantage of yet including:

  • 4 solder jumper pads are connected to MCU but no firmware written to take advantage of them yet

Once most of the bugs are sorted out, the firmware will be posted up on TK's repository.

Finally, I took a quick video to illustrate some of the basic functionalities so far:

Please keep in mind that this is a video of preliminary hardware and firmware, and work on it is still in progress.

Regardless, this one is shaping up to be my new go-to flashlight already. It's not as bright as my GXB drivers but I think it's a lot more useful! I'm even thinking of swapping the battery out for a Samsung 35E for longer runtimes since the point of this driver is to be more efficienct. I'm also glad to say that there isn't any issue with noise from the switching regulator at all power levels. And finally, it's not obvious in the video but the Nichia 219B tint is absolutely beautiful, redder than blackbody!

Hopefully this will be a driver which people will find useful. Feedback, comments and suggestions much welcomed.

Thanks for reading.

Excellent! Will the external temp sensing be compatible with the MCPCB’s FROM led4power.com?

Can’t wait for this already!! Most exciting thing since the FW3A in the first place. This is really the only thing the light was badly missing from the beginning (an efficient driver esp for low Vf emitters). I have so many plans for this already!!

It might be a silly thing but the single sided feature with programming pins REALLY satisfies my OCD.

I'm not familiar with how the temperature sensor on the led4power boards are like (looks like just an NTC), so the likely answer is no. There is an external more accurate temperature sensor on the lume1 driver board, which also has a better physical thermal path on the PCB - its should provide a more accurate temperature reading than the internal MCU one. Just need to tweak the firmware to support this since it's simply an ADC read + some math. However, as is, it'll work just as well as existing drivers, which honestly seems good enough. :)

Thanks! I placed all the components on one side to simplify things and it also makes PCB assembly costs cheaper too.

And by the way… The series sense resistor I personally find a bit of a feature to this drivers ideal application, which is allowing full FET power with super low Vf LEDs. I want to run an E21A/E17A quad under a TIR, so this helps me there.

Your an amazing person loneoceans. Nice work. :beer:

great job!

Beautifully done, loneoceans. Very nice. I almost wish the host was transparent so the driver could be seen from the outside.

Well done, maybe I will have aux leds in mine one day after all!

I haven’t bought an FW3A yet, but this driver further increases the temptation to do so. I actually have several 4000K LH351D’s on hand specifically to dedome and put in an FW3A, although I’m not 100% committed to that plan.

I also could go either with 219B’s or perhaps if I were ambitious, disable the FET in the firmware and use E21A’s.

I have a pair of Convoy S2+ lights I’d also like to upgrade from Qlite drivers to a buck driver with Bistro. If Anduril can run on your design, Bistro should be adaptable, as well.

This looks super simple to assemble compared to the GXB172. I ended up making a 18650 powered vacuum pen using a cheap motor/pump,silicone vacumn hose and a footswitch from Bangood to deal with the 402’s and temp sensor on it. Have a small syringe and hose dedicated to slurping up excess solder paste as well. Now I use it on everything, fet + drivers are so simple now.

Any chance you will be modifying Narsil to work with this driver? The internal temp sensor is good enough for me. I can see a lot of uses for this driver and modifying Anduril is way beyond me.

This is really exciting. The only drawback with the FW3A and similar flashlights with linear driver is the poor efficiency. With this buck boost constant curent regulated driver that problem will be solved and the FW3A will become a real EDC tool and not just a toy. I wish Lumintop would sell a special batch with your driver.

Please note that so far none of the loneoceans driver was available for sale. Though there’s hope it will change myself I wouldn’t purchase a light before that happens.

Another great peace of work from you loneoceans :+1: . I have one simple question to that driver. Is that will be fully open source or only partial of it? I mean if you will share whole PCB project with source files with full schematic or only gerber files like in anothers of your projects.
Also the best improve over firmware for Anduril is the support of 1024 PWM levels compared to 255 which don’t allow us to use fine steps especially at low modes for LED current regulation in one channel driver.

Excellent work loneoceans. Coming from the GXB172 its hard to believe everything fits on one side of the board with so much space left over.

This driver has so many possibilities beyond the FW3A. Do you think future versions could have pads for Bat+, Bat- and an E-switch on the component side of the board?

Will there be a version of Anduril available that does not use the direct drive fet?

Could you release your preliminary firmware? A few simple modes work best in some applications.

A few people have been asking about using clicky switch firmware with this driver although it would require significant modifications to Bistro and Ramping IOS. Would the input capacitor be able to be used as an off time capacitor?

I have a question: If the IC (I assume it’s a TPS63020) boosts voltage to let’s say 5V, and your battery is 3V, how do you avoid all the current flowing through the p-fet body diode back to the battery?

Presume he used p mosfet as load switch: http://www.farnell.com/datasheets/2049687.pdf
So if it is will be trully open source hardware that will be great. We can improve it or port to another flashlight very easy.

Understand, and thanks for checking. I guess there is no service equivalent to Oshpark for PCB assembly in small quantities?

I’ll be following this thread to see if a perhaps a group buy is ever possible.

I know he’s using a p-fet. I worked on something similar and used a p-fet as well. I ran into the problem that the current of the boosted voltage goes through the body diode back to the cell, rather than through the led. I found a solution to that, but I can’t see how he is doing it on his board.