REGULATORS - Technical Information

SPECIFICATIONS

Background: The DURALITE regulator design is now on its fourth generation. The original was a straight linear design. As the demand for more performance went so did the amount of heat being dissipated and a revision was needed. We wanted to go away from having a large heat sink and keep the size and weight down while improving the overall efficiency of the product.

Unique Hybrid Pulsing Design:We came out with a way of pulsing the FET's which is similar to the switching regulators function. A switching regulator turns on and off thousands of times per second. Although not a switching regulator and not truly a linear regulator our DURALITE Regulator is somewhat of a hybrid – essentially a unique pulsing style regulator. This has been a very successful regulator design with in excess of 30,000 of them sold and in use all over the world every day.

All products have their limitations. The standard version or 7.4 volt version is intended for 2s1p/2s2p cell 7.4volt lithium battery and is not intended for 11.1 volt packs. We make a version that is suited to 11.1 volts by special order.

Also this regulator will hold its voltage up to 7.5 amps but at this amperage there is a lot of heat generated and it is not intended to function at that level on a continuous basis. Keep in mind the limitations of the connectors and the wires. The connectors (JR or Futaba style) are limited to about 3 amps continuous and the 22 gauge wire is rated for about 7.5 amps.

Graph: Actual data of a combination of 4 flights made on a 102 Yak 54 with 2 8611 aileron servos, 2 8611 elevator servo's, 2 8711 rudder servo's and one 4721 throttle servo. All 4 flights were 3D style flying with the usual rolling harriers and snaps etc. The battery being used was a DURALITE 4300 lithium ion and a single DURALITE fail safe switch regulator 5.6 volts with standard 22 gauge wiring. You can see the regulator function at the 5.6 volt level.

High Current Regulator The High Current version of the DURALITE regulator uses 16 gauge wire and the Ultra Deans connectors to reduce resistance in the wiring and the connectors which improves the regulators overall efficiency. We have found that the minimum voltage is significantly higher when the HC-wiring is used. We hope to have another graph of this same situation that will show as soon as the weather co-operates this spring.

MOUNTING INSTRUCTIONS

SHOCK MOUNT the regulator. Shock mount the switch in the switched models as well. Do not cover up the ends - leave open for air to pass through. Soft mount by using Velcro to strap it down and never use wire ties to mount. Do not put the regulator between the battery pack and the switch. The regulator draws current and will kill the battery if incorrectly connected thereby voiding your battery warranty.

UNSWITCHED REGULATOR INSTALLATION

1. Battery to stock radio or after market switch
2. Switch to regulator
3. Regulator to receiver

IMPORTANT - Do not put the regulator between the battery pack and the switch. The regulator draws current and will kill the battery if incorrectly connected thereby voiding your battery warranty. Simply connect the regulator between your switch and receiver.

SWITCHED REGULATOR INSTALLATION

1. Battery to switched regulator
2. Switched regulator to receiver

Simply connect the regulator between your battery and receiver. The switch has a wire coming off of it with a black male lead. Connect this lead to your DURALITE Digital Load Tester to monitor battery voltage.

ANSWERS TO MOST POPULAR QUESTIONS

Q. I took a voltage reading off my regulator output and it was reading too high ie 6.9 volts verses 6.0 volts?
A. That is normal. Voltage needs to be tested with the regulator plugged into the receiver and the measurement made with a one amp load. The reading will be taken by plugging the Duralite load meter into the receiver (any open port) and pressing the one amp load button.

Q. I plugged my battery into the unswitched regulator and then into the switch is that correct?
A. No. The battery must have a switch plugged into it in order to shut off any current drain. The unswitched regulator must be plugged into a switch between it and the battery.

Q. My plane crashed and I think it was caused by the regulator failing. I tested it and there is no output.
A. It is unlikely that the regulator failed. Send it back to us and we will run a diagnostic check on the circuit board. They are easily damaged if the plane crashes.

Q. My regulator is hot is that normal?
A. The regulators especially the 5.1 volt will run warm. The air must be allowed to flow through the opening and over the heat sink to cool it.

Q.Do I need to soft mount the regulator?
A.Yes it has a printed circuit on it and must be protected from excessive vibration. Use Velcro to strap it down. Never use wire ties.

Q.I have a switched regulator and I get no voltage out of the lead. I am using the single lead off the switch to the receiver.
A. You have it hooked up wrong. The single lead coming off the switch is for voltage testing only, refer to your instructions for clarification.

Q.I have hooked up the switched regulator but I cannot shut off the plane.
A. If this has happened to a regulator that was just installed it is hooked up wrong. The single lead off the switch is for voltage checking only. Please look at your instructions. If this has happened on a regulator that has been functioning fine up until now then the switch has failed and needs to be serviced.

DURALITE'S in your Turbine

How to eliminate ECU RF interference using a Duralite Regulator and Receiver Battery.

1. Wrap the DURALITE Regulator in shrink wrap tube that has been split open

2. LIGHTLY fasten with tie wraps

3. Install on top of DURALITE PLUS Receiver Battery

Voltage Step Down for Helicopter Tail Servo

SPECIFICATIONS

The Duralite Flight Systems 5.3 Volt Step Down for Helicopter Tail Servos is an economical and light weight option for pilots who want to use a 6 volt regulated power supply in a helicopter while not effecting the operation of the gyro. A 6 volt regulated power source is required.

This step down has been tested and is recommended for use with Futaba 9241, 9251, 9253, 9254, 9255, 9256 servos.

The difference between a regulator and this step down is that the step down is designed to operate on a 6 volt power supply and to step down the voltage to 5.3 volts. It will always be .7 volts lower than your 6 volt power source. Duralite Lithium ions or polymers operating at 7.4 volts while using a 6 volt regulator will always ensure that the step down is operating at 5.3 volts.

This step down is not recommended for NiCad or NiMH use as the terminal voltage may not always be at 6 volts. Example: If a 5 cell NiCad or NiMH drops to 5.8 volts then the step down would operate at 5.1 volts as it always operates at .7 of a volt less than the power supply. A regulator in turn would continue to operate at 5.3 volts until the pack dropped below that voltage.

Specifications: 6.75 inches long (170 mm) .2 of an ounce (5 grams)

INSTALLATION

There are two ways this step down can be installed;
a) Connect the step down directly to your tail servo lead. This method will supply 5.3 volts to your tail servo while the rest of your helicopter operates at 6 volts including the gyro.
b) Plug the step down into your receiver and then into your gyro. This method will supply 5.3 volts to your gyro and tail servo while the rest of your helicopter operates at 6 volts.

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CHARGERS - Technical Information

SPECIFICATIONS

Our chargers operate at the correct charge rate and voltage for DURALITE PLUSTM batteries. The charging rate is a continuous 400 mah/hr. The charger comes with output ports that are set at specific voltages. The REC or 7.4 volt port is designed to charge 7.4 volt Li-ion batteries. The TX or 11.1 volt port is designed to charge 11.1 volt Li ion batteries. The charger's power supply receptacle is center negative and the charger's receiver and transmitter battery charging receptacles are center positive.

Two power supply options are available. A power cord with alligator clips comes with each unit to allow charging from a 12-volt batteries source. The other option is a 120-volt A/C Adaptor for charging at home, (#21915) 2200mah 13.5volt.

DURALITE® Charger is very simple to use. Connect the power source to the charger. Plug the battery charging lead into the appropriate port on the charger. Plug the battery connector into the chargers charging cord, a green light comes on to verify charging is in progress. When the charge light goes out you are fully charged and ready to go. Always check battery condition with an appropriate load tester before and after each flight.

Custom chargers are available for purchase. Chargers can be built to order with a choice of any combination of either 7.4, 11.1 or 14.8 volt outputs in the specific ports. Call for details.

The recommended safe charging procedure for all Li-ion batteries is to charge them out of the aircraft in a fire proof area or container. Always be present during the charging cycle. Unplug the batteries from charger when charging cycle is complete.

Q.My charger is not charging up my batteries fully.
A. If you are using a 12 volt source you will need to have a charger that is at least 12 volts to get a full charge on the pack. If you are using an A/C wall adaptor you will need to insure that the leads are all making good contact with both the charger port and the battery charge lead.

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DURALITE POWERBOXTM - Technical Information

System Requirements
Each Power Box requires
2 - Duralite Plus Power Box Batteries
(between 1450-4300 mah)

Your Motor Ignition System will require:
1 - Duralite Plus RX battery
(between 1900-4300 mah)
and
1 - 5.1 or 6.0 volt regulator

SPECIFICATIONS
· Uses no regulators
· Power internally regulated to 5.9 volts
· Requires (2) Lithium Ion Duralite Power Box Batteries.
· Power to the servos amplified to ensure that a constant 5.9 volts are supplied at all times.
· Eliminates the need for servo match boxes (SC12).
· Externally mounted LED battery warning lights for "quick look status".
· Series of LED's on the face of the PowerBox to indicate individual
battery voltage visible through canopy.
· Clean, compact installation.

		POWERBOX IN DETAIL Written Instructions For POWERBOX 40/24, 40/16 and SC-12 Written Instructions For POWERBOX ROYAL Video Instructions SC-12 Installation & Servo Matching Videos Installation photos How the pros install the Powerboxes

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DIGITAL LOAD TESTERS - Technical Information

SPECIFICATIONS

The DURALITE Digital Load Tester is designed to read input voltages from 4 to 18 volts. This tester can be used on most types of batteries. It is Reverse Polarity Protected and works best at a temperature of 32 to 140 degrees F (0 to 60 degrees C).
·Do not allow tester to become wet, as it is not waterproof.
·Testing a battery under load for more than 10 seconds can cause overheating of the tester and possible damage.

INSTRUCTIONS FOR USE

Connections:
·Plug in the male end of the supplied cord into the female port on the top of the load tester.
Plug the black male battery connector into the black female end of the lead off of the load tester.

No load voltage:
·Simply by plugging in the connections (as above) you will be reading the battery at no load voltage.
One AMP load voltage:
·Depress the one amp load button for only 2 to 5 seconds. You will then be reading the battery voltage under a one amp load.
·Make your fly/no fly decisions from this reading using the DURALITE PLUS Battery Parameters.
·Always check the battery voltage with a one-amp load prior to each flight. It is the pilot’s responsibility to verify safe operating voltage before each flight.

ANSWERS TO POPULAR QUESTIONS

Q.My meter seems to be reading low (or high) compared to a friends. A.Send it back and we can re calibrate it for you.

Q.Why do I need to place a one amp load on the batteries.
A.The load represents the draw of the servo's. High voltage batteries such as the 8.4 volt lithium's need a load to bring down the surface voltage. The loaded voltage is indicative of the health of the battery where the unloaded voltage is representative of the state of charge of the battery.

Q.Can I use a longer test lead?
A.The longer the lead or extension to the battery the lower the voltage reading will be.

LOW VOLTAGE CUTOFF

INSTRUCTIONS

Join the female connector of the low voltage cut-off to the black male connector of your 7.4 volt RX battery. The male connector of the low voltage cut-off is then plugged into the female connector of your switch or regulator with switch. In the event your switch is left in the "on" position, the low voltage cut-off will shut off the system at 5.5 volts saving you battery.

GLOW DRIVER & GLOW TESTER

INSTUCTIONS

Before trying to start the engine, hook up the clip to a plug and push theswitch on the DURALITE Power Driver to check the LED’s for current draw. If no light comes on you either have a bad connection on the plug or the plug is blown. Each light that comes on indicates a .5 draw. Two lights equal 1 amp, three lights equals 1.5 amp, etc. After you get a reading you can use this as a reference as to what your DURALITE Power Driver should normally show when you are staring your engine EQUIPPED WITH THE SAME PLUG. If the meter shows a higher current reading, the engine is flooded and the DURALITE Power Driver™is boosting the power to the plug to “burn out” the extra fuel. Each time the switch is pushed the DURALITE Power Driver will stay on for one minute.

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STAY BALANCE MODULETM Technical Information

FUNCTION
The DURALITE STAY BALANCE MODULE is a unique balancing unit specifically designed for the FlightPower EVOTM, DURALITE e-PLUS GOLD & e-PLUS SILVER lithium polymer packs. By balancing the cells the STAY BALANCE MODULE optimizes pack capacity and performance, increases cycle life of your battery and is an asset in your safety regime.

The STAY BALANCE MODULE’s is a true passive cell balancer independent of the charging cycle. It performs this function by examining each cell in the ‘1p e-SILVER and Flight Power EVO™ packs’ and each parallel group of cells in the ‘2p or 3p e- GOLD and Flight Power EVO™ packs’ by equalizing the voltage throughout the pack until it is in balance.

#90-2S: 2 cell 7.4 packs #90-3S: 3 cell 11.1 packs Click to enlarge

90-2s & 90-3s Instructions For best results connect the STAY BALANCE MODULE up to the pack prior to charging so that you charge a fully balanced pack. · Simply plug in the module to the pack via the special connector. As long is the module is plugged into the battery it will balance the battery. It is strongly recommended that you connect the module to your battery pack before charging. · Once plugged in you will notice that the lights will flash at random and go out once the pack is balanced. If you plug in the module and the lights don’t come on, don’t be alarmed it just means that the pack is already in balance. · Wait for the lights on the module to go out and then commence charging. · NOTE: DO NOT leave the balancer attached to the pack once the lights go out as the micro processor will continue to draw 25 mah from the pack. · NOTE: If there is a dead cell in the battery pack the lights on the MODULE will not go out. To confirm this, take a voltage reading to determine if a cell has in fact gone dead or been damaged. DO NOT CHARGE pack if this has occurred. Dispose of the pack in a safe and ecologically responsible manner. Never burn or incinerate any battery.

#90-2/6: for 2-6 cell packs Click to enlarge

90-2s & 90-2/6s Instructions BALANCING PARALLEL GROUP OF CELLS in DURALITE e-GOLD™ And Flight Power EVO™ packs · For best results connect the STAY BALANCE MODULE™ up to the pack prior to charging so that you charge a fully balanced pack. · Connect the MODULE to the battery pack using either the 10 Pin or the 14 Pin connector. These connectors are polarized: 10 Pin for the 3s - 5s Packs, 14 pin for 6S packs, (sold separately adaptor for e-PLUS SILVER and Flight Power EVO™ packs) · All lights will momentarily go out, and then come on one at a time while the MODULE senses how many batteries are in the pack. All the lights will then go out momentarily. · If any cells are out of balance, a light corresponding to that cell will come on and stay on until the battery is balanced. · The single light, off to the side, will flash every couple of seconds during the entire process. It will continue to monitor the pack and make sure it remains balanced. The lights corresponding to the cells may go on and off as the microprocessor fine-tunes the pack. · Wait for the lights on the module to go out and then commence charging. · NOTE: DO NOT leave the balancer attached to the pack once the lights go out as the micro processor will continue to draw 25 mah from the pack. · NOTE: If there is a dead cell in the battery pack the lights on the MODULE will not go out. To confirm this, take a voltage reading to determine if a cell has in fact gone dead or been damaged. DO NOT CHARGE pack if this has occurred. Dispose of the pack in a safe and ecologically responsible manner. Never burn or incinerate any battery.

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