The Scorpion TGX
This is posted exclusively to aditnow for the lamp buffs as the lamp is still undergoing testing and evaluation as at this time is not in production. So far its showing great promise.
A great deal of thought has gone into this not to mention the time sourcing components, this is why its been on the burner for so long.
I have for some time been aware of the requirements of cavers, especially those who go to extremes and often purchase the expensive Scurion Dive model so as to feel confident that they have a lamp which will stand arduous conditions.
I have tested my regular lamps at a depth of 8 feet which of course exceeds the IP 67 rating and found that about 1 cc of water will enter by passing up inside the cable after an immersion time of about 2 hours. I have concluded that increased waterproof integrity is a prerequisite for any lamp designed for extreme use. This was the thinking behind this project and has been achieved by the elimination of the connecting plug between battery and lamp.
I have looked at other lamps and don’t feel happy with the designs of battery cases that open up for recharging. The off the shelf component I use for my battery case would run the risk of gasket displacement, I have therefore designed it with a removable plug to give access to a jackplug socket, the plug is rated to 10 BAR and only requires finger tightening.
Obviously with a lamp of this design there are two potential issues. One is the risk of accidental switch on as described above, the other is the standby current drain depleting the batteries.
These have been addressed as described later.
I have taken a lot of input from my use of the Imolent DX80 rechargeable torch. The lockdown feature from the single operating button has proved unreliable with the torch coming on inside its case and burning a hole through it. Not good enough. I have therefore opted for a two button design
Designed as a waterproof to IP68 5 metres and impact resistant lamp, possibly suitable for diving with higher rated buttons (expensive!), but as yet untested. The lamp has been tested to a depth of 8 feet for days, this is the best I can do with facilities available. All lamps of this type will be tested in this way before final assembly. It has been deliberately designed for the extreme caving market and is engineered to take hard use and abuse.
In line with the lamps tough assignment its fitted with 4mm laminated glass.
Key features:
Lockdown by separately controlled CMOS safety lock, draws approx 16 uA (16 millionths) amp on standby.
Permanent cell connection, no plug to allow water to pass up inside the cable.
4mm Laminated Glass
IP 68 5 metre immersion extended control buttons, 8 Newtons pressure, resistant against mud and accidental activation
Cell charging plug 10 BAR pressure rated.
GoPro mounted with full GoPro compatibility
Available in three types. TGX (standard) Tight spot beam and flood, power divided equally, TGX-B twin beams and low level roomlights, TGX-F bare flood emitters to suit some cavers.
Max output 1800 lumens.
Simple push button operation
Three easy programs.
Quick touch #1 On - walk mode, middle, and max.
Longer touch #2, On - the flashes for those who like them.
10 sec press #3, On - 10 different brightness modes starting with a low mode up to maximum.
Battery level indicator acts as pilot light. Green, amber, red, and flashing red.
Additional blue strip ‘nightrider’ battery indicator on power up
Weight 180 grams.
Description
The lamp utilises an all in one cable without a plug that would allow water to get inside the lamp by getting up inside the cable, and a sealed battery box. The 2 X 18650 serial Li Ion cells charge by removal of a 10 BAR rated plug to expose a standard 2.1 mm jack plug socket. Spare plug supplied with each lamp. The charger for this lamp has a jack plug rather then the usual XT 60.
The lamp utilises a soft switching design governed by a CMOS controlled safety lock. As such it has 2 buttons, the left is the lock and unlock control, the right the main on/off and power control. On locked standby the current consumption is about 16 uA or 16 millionths of an amp. Pressing this button and holding down for a short while will unlock the lamp and cause the blue ‘nightrider’ battery indicator to light up indicating the battery state. Releasing this, the battery indicator will go off and a green ‘all well’ LED to illuminate. The lamp can then be powered up by the right hand button.
The “B” model will have its low level room lights additionally switched by the safety lock as they will only be drawing 60 mA and would take a considerable time to flatten the battery should it become activated accidentally.
The buttons are of the extended type in order to minimise the intrusion of mud etc off the operator’s finger and have a fairly strong return spring requiring a force of about 8 Newton’s (1.8 LBS) to make contact. The lock switch is also not instantaneous but engages after about 1 second.
A rear heatsink stands proud of the buttons and passes between them making accidental activation of both buttons simultaneously very difficult.
Pressing the right hand button will turn on the lamp to standard mode, two more presses cycle through middle to high which is about 1800 lumens. While on, a long press will go into the ten sub modes, an extra low up to the high. Long press while off will initiate the flashes for those who want them. This driver is a modified ‘off the shelf’.
The CMOS lockdown PCB is my own design and build and cannot be purchased off the shelf. I searched the Internet for a schematic for a circuit of the type but was unsuccessful. It’s possible that the Maxim controller is a recent development. It certainly makes design of this type of circuit an easy matter
and I am able to easily assemble this using plain stripboard. Having custom PCBs made up would jack up the price of the finished product.
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I make a point of using electrolytic capacitors; note the remarks re the ESR in the schematic, ceramic capacitors are conductive to ESR issues. The Maxim controllers are good but an expensive little chip, I am pondering on the possibility of using them to make an analogue multi mode driver, I need a life.
It should be noted that the output of these is in the form of what I would call “voltage logic” which is a flip flop + and 0 voltage but with the inability to generate any current. The inductive load driver is necessary due to this, its logic activated, and also to the magnetic tendencies of the relay coil, the “inductive load”. They are good for up to 50mA which nicely covers relay coils.
Note that the schematic shown is designed for a 2 series Li Ion input, single or parallel cells would only require the left hand section (5V), this would work fine with the lower voltage range.
Lamps will be delivered in an ‘off’ state and will initiate on first charge same as a lot of electronic goods for safety in transit, so purchasers will need to charge before use. Returns will require the lid removal from the battery case and a physical disconnection (mini Deans) as per supplied instructions. Again, this is for safety in transit.
Prices will be £195 for the standard and F model, £225 for the B. Provisionally.
Gallery
1/ Model variantions
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2/ Rear view, buttons etc
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3/ The lamp
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4/The power up 'Lightshow'
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My avatar is a poor likeness.