atch. Those FETs had an on resistance of under a tenth of an ohm in our operating conditions. The circuit worked very reliably, but the 1000uF electrolytic cap was huge and we struggled with the mechanics of such a large part hanging off the board...
It turns out that 3.7 volts is way more than enough to fire a typical low-current e-match or equivalents like the Quest Q2G2 igniters. In fact, bench testing with a good digital oscilloscope showed that a typical e-match with resistance of 1.3-1.8 ohms will fire in approximately 13 microseconds when hit with the nominal 3.7 volts from a LiPo.
So, starting with our v0.2 boards, we switched to using the LiPo battery voltage directly to fire the pyro charges, eliminating the clunky electrolytic capacitor entirely. We also switched to the Fairchild FDS9926A dual N-channel MOSFET whose specs are better in all regards for our application. The on resistance is down around 40 milli-ohms in our circuit, such that the current ratings are much higher (FET current limits are primarily driven by how much heat is generated due to current flowing through the channel's on resistance).
Because using the LiPo voltage directly means we're effectively temporarily putting a very low resistance across the battery during the pyro events, the input voltage to the voltage regulator gets pulled down. To ensure the processor could "ride through" these events, we added a 100uF surface mount bulk capacitor on the 3.3 volt regulated voltage rail, which bench testing demonstrated was more than sufficient to maintain processor operation through pyro events. And that is essentially the same pyro circuit on all the boards, both TeleMetrum and TeleMini, that we have shipped to date.
The LiPo batteries we source and sell with our electronics come with a protection board and cable terminated in a 2-pin, 2mm "JST" connector. The specs on the protection board have always been "2C continuous", but we observed the ability to source much higher currents for short periods such as the 13 micro-seconds or so required to fire an e-match. Thus these protection circuits seemed just fine .. we could fire e-matches with a burst of current but were protected against short circuits in the wiring or our boards by the 2C continuous limit.
Unfortunately, the most recent batch of batteries we sourced seem to have a much "twitchier" protection circuit. We can draw more than 2C for short bursts, but not as much as with prior boards, and not for as long an interval. With a 1 ohm power resistor on the pyro terminals of one of our boards, we get about 9 milliseconds of power before the protection circuit cuts in and shuts the battery down. The power stays down until all load is removed, which at least means the board is turned off and back on again, and in some cases could even mean the battery is unplugged and re-plugged since we draw trace current to keep the GPS memory alive even when the power is turned off, and at least some of the new batteries see that as enough to keep the power turned off after an over-current event.
For many e-matches, this isn't an issue, since 9 milliseconds is way longer than the 13 microseconds needed to fire the charge. Unfortunately, we've discovered that many of the e-matches bought and used in the rocketry hobby are actually made for use in the fireworks industry, where it is desireable to retain continuity after firing so that series connections of e-matches all can fire even if some fire faster than others! This means that while the resistance goes up some after firing, sometimes the drain on the battery remains sufficient to cause the protection circuit to kick in even after the pyro charge has fired.
What We're Doing About It
If we remove the protection circuit from the LiPo (or jumper around it), all existing Altus Metrum products will operate successfully with pyro charges thave have an effective resistance of as low as 1 ohm. That's lower than any e-match or Q2G2 we've ever seen, so in effect what this means is that if you have an existing Altus Metrum flight computer, and you remove the LiPo 