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DIY SMPS Cooling

The power supplies I have recently built from surplus Cisco switch boards have started displaying a rather irritating problem – continual load of over 9A causes the supplies to shut down on overheat.

This was partially expected, as the original switches that these supplies came from are cooled by a monster of a centrifugal blower that could give a Dyson a run for it’s money. The problem with these fans is that they’re very loud, draw a lot of power (3-4A) and aren’t small enough to fit into the case I’ve used for the project.

The solution of course, is a bigger fan – I’ve got some Delta AFB0612EHE server fans, these are very powerful axial units, shifting 60CFM at 11,000RPM, with a power draw of 1.12A.
They’re 60mm diameter, so only just fit into the back of the case – although they stick out of the back by 40mm.

Monster Fan
Monster Fan

Here’s the fan, not the beefiest I have, but the beefiest that will fit into the available space.
These will easily take fingers off if they get too close at full speed, so guards will definitely be required.

To reduce the noise (they sound like jet engines at full pelt), I have ordered some PWM controllers that have a temperature sensor onboard, so I can have the fan run at a speed proportional to the PSU temperature. I will probably attach the sensor to the output rectifier heatsink, since that’s got the highest thermal load for it’s size.

More to come when parts arrive!

73s for now 🙂

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LED Lighting Part 1

Here I will document progress in replacing standard halogen MR10 lights with LEDs.

3x1W LED
3x1W LED

These units are from TruOpto, available through Rapid Electronics in the UK. They are 3W total, from 3x 1W emitters on an aluminium back plate.

LED Test Rig
LED Test Rig

Here is the LED attached to a heatsink for testing purposes – these units dissipate nearly 2W in heat at full output.

As the lights are to be run from a 12v battery bank, for simplicity a master regulator is required to provide a stable 11.4v rail for LED supply.

Regulator Module
Regulator Module

I have used a Texas Instruments part – PTN78020WAH. This is a 6A capable adjustable regulator module.

The LED lights are to be fully dimmable – the low voltage PWM dimmers are in progress of being built.

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PSi 150 Power Inverter

Front
Front

This is a small 120W power inverter, intended for small loads such as lights, fans, small TVs & laptop computers.

End Cover
End Cover

End cover of the unit, 12v DC input cord at the top, power switch & indicator LEDs at the bottom.

Mains Output
Mains Output

Opposite end of the unit, with the standard 240v AC 50Hz Mains output socket.

Cover Removed
Cover Removed

Cover removed from the top of the unit. Main power transformer is visible in the centre here, MOSFET bank is under the steel clamp on the left, the aluminium case forms the heatsink.

PWM Controllers
PWM Controllers

On the right is a KA3525 switchmode PWM controller & on the left is a LM324N quad Op-Amp IC. The buzzer on the far left is for the low battery warning.

PCB Removed
PCB Removed

PCB removed from the casing, with the MOSFET bank on the right hand side. Two potentiometers in the centre of the board tweak the frequency of the switcher & the output voltage.