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Fix / Build a Fan Controller

post #1 of 25
Thread Starter 
I've got a Mutant Mods Furious Fan Controller right now. Thing is, the resistors popped in it.

What I know about the fan controller:
  • 3 Channels, with High / Medium / Low / Off settings
  • Supposedly only built for one fan per channel (didn't know this till now)

What I want out of it:
What I WAS getting out of it (after the popped resistors):
Intake only section was tested.
  • 11.92v / 3.90v / 2.71v

Here's a picture of the PCB (you can see the blown resistors areas):


Now, if you focus on that burnt area (just the left side, that's channel 1), you can follow what I'm about to explain.
  1. Voltage comes in at the bottom left connector.
  2. The entire outside is ground.
  3. Voltage goes up into the three switches (just focusing on the first).
  4. Voltage comes OUT of that switch in 3 locations.
  5. Voltages goes UP and DOWN on the PCB.
  6. Up goes to resistors, then the front panel LED's. This area is fine.
  7. Down goes into a Diode.
  8. From the diode it goes into resistors (Medium / Low), or straight out to the connector.

If you follow the far left burnt resistor area, the solder points go to the following:
  1. Bottom solder point (shared trace with all 3 selections) is bottom of resistor.
  2. Next up solder point in line is top of resistor / bottom of diode.
  3. Next up solder point in line is top of diode / connection to input / bottom of LED resistor.
  4. Next up solder point (top in line) is the top of the LED resistor.

Now, what can I do to make this thing work correctly with the given load? I'm looking for 12v / 7v / 5v output to my fans (all fans). I'm THINKING all I need is stronger resistors, with the proper resistance rating. But I'm not entirely sure. I don't even know for sure exactly what ratings I'd be looking for. I'm also not sure if I'd need to replace the diodes as well. Seeing as they're on the same circuit as the resistors that popped. I'm not sure which direction things would pop in. I know the current direction (input goes to output goes to fans). But like I said, not sure which direction shorts would happen. So if the diodes need replaced too, let me know on that one.

Can anyone with some electrical knowledge lend me a hand here?

EDIT:
The Resistors that are there currently:
51ohm, 1/4w, 5% (Low Speed)
22.2ohm, 1/4w, 5% (Medium Speed)
Edited by pioneerisloud - 2/11/11 at 7:01pm
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post #2 of 25
Thread Starter 
Bump.
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post #3 of 25
Well, I guess you can't see the resistor codes to work out the proper resistance? Oh yeah and with controllers that use resistors, the voltage will be different for a 5W fan than a 50W fan. A lot actually.
I'd build anew one if I were you. Check out the LM317, its good up to 18 watts.
You need 48W if i calculated correctly, and I don't know if you want to control this with only one knob, or one for every fan, or every fan type :/
Well anyway, check out http://www.rigacci.org/docs/biblio/o...rial-full.html
and
http://www.muzique.com/schem/lm317.htm
The LM338 is good up to 5A and with 12V that's 60W, and it's exactly the same as the 317, except it can take more load.
Check those out, they're really easy and cheap to make.
And sorry, can't help you with fixing it really
    
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post #4 of 25
Thread Starter 
Quote:
Originally Posted by Skiivari View Post
Well, I guess you can't see the resistor codes to work out the proper resistance? Oh yeah and with controllers that use resistors, the voltage will be different for a 5W fan than a 50W fan. A lot actually.
I'd build anew one if I were you. Check out the LM317, its good up to 18 watts.
You need 48W if i calculated correctly, and I don't know if you want to control this with only one knob, or one for every fan, or every fan type :/
Well anyway, check out http://www.rigacci.org/docs/biblio/o...rial-full.html
and
http://www.muzique.com/schem/lm317.htm
The LM338 is good up to 5A and with 12V that's 60W, and it's exactly the same as the 317, except it can take more load.
Check those out, they're really easy and cheap to make.
And sorry, can't help you with fixing it really
I understand the load will change depending on the fans. This is why I listed the exact loads that I plan to use on it. And what the goal is with them. If I can get the Sunon's to work at 12v / 7v / 5v, and put that same cicuit with the other controllers (as long as its SAFE), then that's fine. I know the Delta's would likely get slightly more. And the Rosewill's would get slightly less.
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post #5 of 25
Well, if you happen to need 5v/7v/12v then i guess a three-position switch would be good..
You wouldn't even have the extra heat dissipated in your case, which is cool
Tryin to help
    
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post #6 of 25
Thread Starter 
Quote:
Originally Posted by Skiivari View Post
Well, if you happen to need 5v/7v/12v then i guess a three-position switch would be good..
You wouldn't even have the extra heat dissipated in your case, which is cool
Tryin to help
If you notice in the picture, I've already got 4 position switches, on the fan controller. Off / Low / Medium / High.
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post #7 of 25
Well, then I sort of don't get the idea of why the resistors would have to be there..
If I were you, I would scavenge those nice 4 pos. switches and just set it up to work with off/5v/7v/12v
:/
Well, sort of too tired to think about the resistor stuff, I'll think about it perhaps later.
    
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post #8 of 25
Wow, really my skills arent enough for calculating the resistors, but you can't see the codes on the resistors i presume?
    
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post #9 of 25
Thread Starter 
Quote:
Originally Posted by Skiivari View Post
Wow, really my skills arent enough for calculating the resistors, but you can't see the codes on the resistors i presume?
I already know what the two resistors are currently. 51ohm 1/4w / 5% for "Medium", and 22.2ohm 1/4w / 5% for "Low". Problem being that even "Medium" shut off my Sunon fans completely. And the fact they they all popped being 1/4w.
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post #10 of 25
Thread Starter 
Sigh. I'm about to pull out these fans and just go back to stock. This is driving me nuts .
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