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post #41 of 116
What is your PWM frequency? Did you try decreasing it to reduce power losses in the MOSFET?
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post #42 of 116
Thread Starter 
Quote:
Originally Posted by ARandomOWL View Post

What is your PWM frequency? Did you try decreasing it to reduce power losses in the MOSFET?

It's around 45KHz +/- 10%, seems to be the sweet spot with 100uH and these loads. It does vary a bit with duty cycle because of the 555 timer configuration.

Good suggestion, but it's not really a problem, by the time the MOSFET starts warming up the load is already starting to exceed the spec of other components (diode and inductor). If I lower the frequency, I would probably need a higher value inductor and that would mean lower power rating on it and higher resistance, so a bit of a balancing act.
post #43 of 116
Nice, I would want to build a quad channel version of this once you are done getting the design done.
post #44 of 116
Thread Starter 
Just a final load test with real fan load, I borrowed some more fans from a friend and added a couple of old CPU fans:


304


12 fans in total on 1 channel. According to labels on the fans the load should be 52.2W, but the highest I measured was around 45W and that was only during acceleration, at steady speed the load was around 34-36W. Some of the small ones are actually the most power hungry.

So I'd say this will work well for builds with loads of fans, large radiators push/pull etc.
post #45 of 116
Thread Starter 
Quote:
Originally Posted by zdude View Post

Nice, I would want to build a quad channel version of this once you are done getting the design done.

Great, I just need to get everything together, then I'll post a component list and the final PCB layouts including negatives if you do photo resist.

I'll post a 70W+ version (2 channels) and a 140W+ version (4 channels). I'll probably do a dual supply on the 4 channel version, I seem to remember there is a 75W limit on a single 4 pin connector. If anyone knows for sure, correct me if I'm wrong.

Cheers
post #46 of 116
Quote:
Originally Posted by jvjessen View Post

Just a final load test with real fan load, I borrowed some more fans from a friend and added a couple of old CPU fans:
304
12 fans in total on 1 channel. According to labels on the fans the load should be 52.2W, but the highest I measured was around 45W and that was only during acceleration, at steady speed the load was around 34-36W. Some of the small ones are actually the most power hungry.
So I'd say this will work well for builds with loads of fans, large radiators push/pull etc.

1 channel with 12 fans...? this is insane drool.gif
post #47 of 116
Thread Starter 
Quote:
Originally Posted by mr one View Post

1 channel with 12 fans...? this is insane drool.gif


Yeah, it's got POWER biggrin.gif
post #48 of 116
Quote:
Originally Posted by jvjessen View Post

Yeah, it's got POWER biggrin.gif

too much power even for chuck norris biggrin.gif
post #49 of 116
Thread Starter 
Quote:
Originally Posted by mr one View Post

too much power even for chuck norris biggrin.gif

Nah, not that much power smile.gif
post #50 of 116
Thread Starter 
First version ready to be built:

2 x 35W Manual Control


Buck converter based, 2 channels, up to 35W per channel with small heatsink on MOSFET. Superior to basic PWM drive, and much more powerful than regular linear drive.

Goes all the way from off to full speed.

Design based on commonly available components.


Diagram:


484


PCB Layout:


420


PCB Back side - Negative (300 DPI)


519


PCB Back side - Positive (300 DPI)


519


Materials needed

4 x 1N4148 (D2, D3, D5, D6)
2 x 1N5822 (D1, D4)
2 x 3nF (C3, C6)
2 x 20K Potentiometer Lin (R3, R4)
2 x 100R (R1, R2)
2 x 100uH/3A (L1, L2)
3 x 470uF/50V or 220uF/25V (C1, C2, C4)
8 x 3 pin fan socket
2 x MTP50P03HDL (or similar TO220 low voltage high amp MOSFET p-channel) (Q1, Q2)
2 x NE555 (IC1, IC2)
1 x Molex power socket (optional)

Plus some circuit board and the optional heatsinks for mosfets (TO220 small size)

All needed components are available at e.g. www.digikey.com I can add links if interested.

Built and tested (1 channel for testing)


450


Load testing 1 channel: (with 12 fans)


304


Have fun and feel welcome to ask for any questions, and let me know if you find any mistakes post a picture if you build one.


Note: It is possible to take the RPM (tachometer) output from 1 fan on each channel and plug it into the motherboard for monitoring, if anyone is interested I can post a wiring diagram.

Edit: added DPI on the Layout)
Edited by jvjessen - 6/28/12 at 9:49pm
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