Hi all,
I spent some good time w/family and had a nice break, but it's also good to be back. Here are a few updates on the project.
Power relay MOSFET issues:
I have seen a spike in power relay MOSFET failures recently. It has affected heaters of all coil sizes.
These MOSFET failures present in one of two ways:
A. The heater won't heat. The red LED may still illuminate when the switch is pressed, but the heater doesn't energize.
B. The heater heats as soon as the power switch is turned on.
If this happens it is due to an internal failure in the power relay MOSFET.
Root Causes:
I am still investigating, but I have some ideas as to the cause. These problems began to appear recently, and I suspect that I may have gotten a batch of power relays with "B" and/or "C" quality MOSFETs. The MOSFETs used in the power relays may not be manufactured to the same tolerances as the ones used in power relays I installed on previous builds. Since replacing a failed power relay MOSFET with a new MOSFET fixes the problem*, I have to believe that component quality is at least one of the factors behind these recent failures.
*Actually, this failure requires replacing all four of the circuit's MOSFETs at the same time to prevent the failure from coming back immediately. Also, sometimes the replacement MOSFETs themselves fail, which is another thing that can happen.
The argument for more post-build testing continues to make itself stronger.
Fixes and remediations:
Since I suspect the quality of the MOSFETs is a big factor in these failures, I am now changing out 100% of the stock power relay MOSFETs and replacing them with new MOSFETs sourced from a quality vendor (e.g., digikey.com, mouser.com, etc.). I had thought I might get by with just performing more pre-installation bench testing (i.e., if I can prove a part is good before I install it, I don't need to change out its chips), but I found that some relays worked OK on the bench but still failed after installation.
Upon thinking it over I feel I'm better off proactively replacing the stock power relay MOSFETs with new/identical MOSFETs sourced from a quality vendor, like digikey.com, mouser.com, etc. This should address the "quality of the components" issue.
I am also extending my post-build quality testing, and will perform more heating cycles (at different power levels) before declaring a heater good-to-go. This will hopefully shake out the power relays failures earlier, while the heaters are still on my bench.
However, even with better quality components and more testing, there will still be some heaters that work fine on the bench and yet fail shortly after they are delivered to you, the customer. I'd like to tell you that won't happen, but I know it will - that's just the nature of personal electronic devices, unfortunately, this one included. If that happens to you, you have my sincere apology, and a promise that after you send it in for repair I will fix it and get it back to you ASAP. (I can promise you that it worked on my bench before I boxed it up, but that's not a lot of comfort when your shiny new heater just stares at your vapcap instead of heating it.
)
Best practices and safety recommendations:
1. Test the heater from time to time to make sure the power relays has not failed "hot":
A. Put your dynavap in coil with the heater off.
B. Turn on the Deluxe, but don't depress the dynavap.
C. Wait ~10 seconds. Maybe less.
If the dynavap clicks from being heated, even though you did not explicitly activate the heating element by depressing the tactile switch, you have a MOSFET failure, and will need to send your heater to me for repair.
2. PLEASE turn the heater power switch OFF (i.e., the green LED is not illuminated) when charging the heater via the mains charger. The battery pack will still charge with the switch OFF.
The thermal fuse is currently tied to the battery's B+ lead, meaning that battery power is protected thermally, but power from the wall charger is not currently part of the thermal protection circuit. Recharging with the power OFF removes the power relay from the charging circuit, and is therefore the safest way to charge your heater.
3. Going forward, I plan on adding a second thermal fuse to kill power to the entire heater circuit in the event the heater overheats. This will make the heater even safer, and offer protection for overheating events that take place while on mains power as well as battery power. On paper this looks like it will be a straightforward change that I can also retrofit to existing Deluxes. I will know if that's true sometime Thursday night, after the parts arrive. I'll hope to post more about the feasibility of this future safety modification by the end of the week.
Other Flux Deluxe news:
I am continuing to chip away at the waiting list, and I appreciate your patience.
February has been a challenging month. The power relay issue has taken a lot of time to figure out - to the extent that I have - and I may still have more of it ahead of me. Between that issue, being offline last week, and my cold earlier this month, I had a much lower rate of production in February than I anticipated. I'm sorry, though we all know that it goes that way sometimes. Hopefully, March will be better.
Thanks, as always, for your patience and support! It's nice to be back.
Cheers,