Planning a new mod. I'm calling it micrOKR

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DrMA

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Finally I was able to source all the parts required. I'm not yet sure it's gonna fit. What do you think?

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It's a 2s 600mAh setup with a DPDT switch to go from series (vape) to parallel (charge); Evolv USB charger, LiPo monitor (kinda big), OKR-T/6, small tact fire button, and a micro DTDP switch to switch the screen from battery voltage to vaping voltage indication. All in a 9V box :unsure:
 
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LucentShadow

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That's a lot of stuff to put into a 9v box. I'd look for something bigger. I have not seen a datasheet for that charger, either.

I don't know what the charger would do with up to 8.4v on it's output. I'd be surprised if any here did, as it's highly unusual to try that, and many may not want to even try to answer this because of that. For some reason, that compels me.

A charger should have a higher potential than the batteries, else I'd guess that the batteries could discharge to the charger. Personally, I wouldn't try it. I would advise getting 14500s or better and charge the batteries externally.

Someone else recently wanted to do this, and their design ideas had all sorts of problems with the batteries being in series and parallel at the same time, which is very bad. It looks as if you've figured out how to reconfigure the batteries using a DPDT switch. Looks like that can be done using 5 of the terminals, but that still leaves the charger problem.

That seems dangerous to me, as does the possibility of a slide switch making both circuits momentarily while transitioning between positions, causing the batteries to short-circuit. I would not trust the switch that much.

If I were to try such a thing (which I would not do,) I'd look for a 3P3T slide switch. The 3rd pole to disconnect and connect the the positive charger output to the circuit, and the 3rd throw as an 'off' position in between the 'charge' and 'vape' positions, hopefully minimizing the risk of making both contacts at once while switching. That center 'off' position would also be the 'kill switch' that is usually advisable to have, as well.

That's a bit complex, and any mistakes in that wiring could easily short-circuit the batteries and/or the charger. I'd probably also put fast-blow fuses on the possible short-circuit paths as well. It's an interesting problem, but it gives me the willies.
 

DrMA

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Good points, LS. The switch is an ON-OFF-ON DPDT rated for 6A @125V. I made sure it's the type of switch that breaks one connection before it makes the other. I agree a 3PDT switch would be ideal, but I cannot find one with a sufficient current rating in a small form factor...

Other USB chargers I've seen have a "shutdown mode" that is triggered, among other things, by an Under Voltage Lockout (UVLO) circuit which is always active. The ULVO monitors Vdd and Vbat and only turns on the device if Vdd>Vbat, otherwise the charger remains off.
 
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DrMA

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Charging
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Battery voltage. Plus a look at the POT and the selector switch for displaying Bat V or vaping V
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Along side it's older cousins: a DNA 20D "Stealth Mod" (Mamu's design), and a huge battery OKR mod "Big Boy":
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Here are a few build pics.
First, the external components soldered directly to the OKR chip to save space:
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All the wires tucked in neatly in between the components together with some liberal use of liquid electrical tape. The fat, red heat shrink visible on the red wires towards the bottom houses a SMT PTC fuse for battery #2. The other battery also has a PTC fuse on the positive wire, but it is tucked in on the bottom. Now, this is what I call efficient use of space:
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DrMA

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In the foreground two SMT resettable fuses soldered back to back to give 6A hold current and half the resistance.
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Every last centimeter of extra wire was removed to fit all this in the tiny box.
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The DPDT 3-position switch on the bottom selects between vaping mode (batteries in series), charge mode (parallel) or OFF.
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The display side of the mod contains the POT for adjusting the voltage and a tiny SMT DPDT switch (small blue dot right next to the POT) that selects between displaying vaping volts and battery volts.
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DrMA

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Congrats! I was worried about the wires making it not fit, but great job.

That was a major concern for me too. Wiring this thing was a real challenge. Some creative modding was involved, including some shaving and sanding interior walls.

Wow very impressed now build me one LOL :vapor:

Thanks. Building this mod took three weeks of researching and sourcing components and about a week of labor including planning; placing, moving, and replacing components; modifying the box and the components to fit; and finally, sizing and routing wires. I think it's going to remain a one-of-a-kind for me... there are easier ways to build small mods.
 
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