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09-29-2018 05:43 PM  10 months ago
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wjvail

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Meridian, Mississippi

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Power Supply Fans
I have two hobby specific power supplies (i.e. not re-purposed computer power supplies). One is an eFuel 50A and the other a Chargery S1200. On both the fans will sit there an moan constantly. It's become very annoying. It's 72F in my shop this morning, nothing is being charge, and my eFuel charger is just sitting there making this ridiculous fan sound. You'd think it is running at max capacity on a 95 deg Mississippi day. It sounds as if the fan is being modulated to some very exact temperature. But it's 22C and the unit is at idle. I wouldn't expect the fans to be on at all.

Both power supplies do it. Is it just mine? Do everyone's power supplies do this? Can I fix it? Don't get me wrong - the sound of a fan on a unit that is struggling to cool itself is fine. As it is, I can't help but look at these units and hear them groaning and wonder "what are you doing"?

I just want some peace and quite while I tinker.

https://www.progressiverc.com/charg...wer-supply.html

https://www.motionrc.com/products/s...mp-power-supply
"Well, nothing bad can happen now."
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09-29-2018 06:43 PM  10 months ago
JuanRodriguez

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The Villages, Florida

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Why not simply unplug the chargers when not in use ???Been there, done that and old enough to know better.....
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09-29-2018 07:11 PM  10 months ago
wjvail

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Meridian, Mississippi

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JuanRodriguez...
Why not simply unplug the chargers when not in use ???
That is a more than fair question... In fact, both power supplies have On/Off switches. I could just turn them off. That is exactly what I used to do.

The problem is that my iCharger doesn't tolerate the ramp-up in power very well. My chargers are completely reliable if I plug them into a power supply that is already powered up. They don't like to be plugged into a power supply that is subsequently switched on.

More than that, the chargers are connected to the laptop setting next to them. I get pretty graphs that way. Every time I power-off my charger, the computer obviously looses connection. It's a small matter to re-establish the USB connection but it's all because the fans on the power supplies seem to be trying to cool the radiator of a V-8.

As it stands now, in order to get rid of the fan noise I have to unplug the charger using the EC-5 and then turn the power supply off. To get back to charging I have to turn the power supply on, wait a moment, plug the charger back in using the EC-5 (which usually includes a zesty spark), and then re-open the laptop software.

Being fundamentally lazy, and using my charger nearly daily while I'm home, I'd like to just fix these ludicrous fans.
"Well, nothing bad can happen now."
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09-29-2018 07:20 PM  10 months ago
JuanRodriguez

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The Villages, Florida

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I know that you're a very handy fellow..... what about wiring a switch to the fans themselves to shut them off when not charging ??Been there, done that and old enough to know better.....
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09-29-2018 09:08 PM  10 months ago
Dan Minick

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Columbus, WI

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my iCharger doesn't tolerate the ramp-up in power very well.
Funny, when I fried two 4010 duos in a row no one at progressive or icharger had ever heard of voltage issues.

I have my main power supply below a deck in a pelican case. Then larger 110mm fans venting the case. This really cuts the noise of the small fans in the power supply. Perhaps you could mount them in a more permanent location and "hide" the noise
Team Synergy, Team FBL Rotors-------if its not broke...it will be!
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09-30-2018 01:22 AM  10 months ago
Ace Dude

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USA

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I use industrial grade Cosel and MeanWell power supplies. My chargers are always connected to the power supply. At the field I plug the power supply into the generator and start it (Honda EU2000i). At home the power supply is plugged into a power strip with switched outlets so I can turn individual items on and off.

https://www.grainger.com/product/PO...let-Strip-1A945
  
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10-03-2018 03:15 AM  10 months ago
Rojoalfa

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Punta de Mata, Monagas-Venezuela

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/
/
Don't mess with fans...

/
Saludos cordiales,
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10-13-2018 10:36 PM  10 months ago
wjvail

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Meridian, Mississippi

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Sorry to start this thread and then leave it unattended so long. There has been some learning, some setbacks, some distractions and some triumphs.

First, I opened the case and found the fans had created a blanket inside sufficient to keep a small child warm in the winter. Note to self: take an air hose to this thing more often. I'm putting that in the learning category.

I found the fans were connected to the main board using a JST connector. My plan was to disconnect the fans and see if they were really required for very light duty use. I gave the wires a gentle tug and broke the wires going to the plug. I would put that in the setback category.

The plugs were lightly glued into their sockets but I was able to remove the now damaged connectors without injury to the board. I'm calling that a win.

Alright.. Now the fans are out, I can find out if their constant howling is really needed. All I need to do is do a light cycle of a 2,200 3S battery and see if they are essential.

They are. The unit overheated and shut down. It seems the act of powering the charger, even if it's not charging, is enough for the SOB to get really hot. That goes in the fail category.

OK. The fans were old and now they are damaged. I bought new fans from Amazon. 20 bucks. See links. Actually, I first ordered fans that wouldn't work for my application and had to return them (That goes in the distraction column).
https://www.amazon.com/gp/product/B...0?ie=UTF8&psc=1
https://www.amazon.com/gp/product/B...0?ie=UTF8&psc=1

All that was left to do was plug the new fans in and put it back together. Except the new fans didn't work. They wouldn't cycle on and the unit got hot. (Setback).

After considerable trouble shooting I discovered that the new fans were perfect for this application except the JST connectors were wired backward. All I needed to do was carefully reverse the pins on the new fan connectors. (Clearly a triumph.)

As it is, the power supply is back together and working 100%. It now has two new upgraded fans. I learned that this unit just makes heat and that the fans are a necessity. All-in-all an educational, if not frustrating, project.

Hope someone can use the information...
"Well, nothing bad can happen now."
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10-14-2018 12:25 AM  10 months ago
JuanRodriguez

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The Villages, Florida

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After going through all that, you didn’t add a switch to turn them off when not needed ? Shame on you !!! Been there, done that and old enough to know better.....
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10-14-2018 12:40 AM  10 months ago
wjvail

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Meridian, Mississippi

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JuanRodriguez...
After going through all that, you didn’t add a switch to turn them off when not needed ? Shame on you !!!
Honestly Juan I spent a considerable amount of time considering your suggestion. It was a good idea.

The problem is that the way this unit works, it needs the fans if it's simply connected to an outlet. There would never be a time I could turn them off.

My reason for this post was that the fans on the eFuel charger seem to run when it’s just sitting there - and apparently they need to. I ran the unit with the fans disconnected and the charger connected but at idle and measured the temp at about 70c on a cool day.

In fact, when I ran my simple test with the fans disconnected, the unit didn't overheat and shut down until the charge current dropped below .5 amp.

I really did consider a small switch but decided it would serve no purpose.
"Well, nothing bad can happen now."
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10-14-2018 02:51 AM  10 months ago
BeltFedBrowning

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Kansas City

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This is the most fun thread that I have seen all summer!
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10-14-2018 06:00 AM  10 months ago
Heli Fanatix

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Fountain Valley, CA

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I have a Chargery S1200 & Server PSU modified Units. The fan always ran as long as either PSU was plug into the 120V outlet.

I also have an EFuel 60A purchased in 2012 and it has multiple speed and only comes on when needed. When Charging @ 5A .. fan doesn’t come in till PS gets hot, runs for only 30-60 seconds.

Efuel later on released a 50A model, I’m assuming it’s got the same fan function as my 60A.

This should suit your needs.

BTW
The blanket of lint is just like from our
- PC computer case fan
- dryer lint screen

FYI
- Majority of dust is from dead skin, insect parts & animal dander

* They all gotta go somewhere!!!
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10-24-2018 01:10 AM  10 months ago
wjvail

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Meridian, Mississippi

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Alright. A little time has passed.

I set out to build a "switch" for the charger. It occurred to me that the power supply had three switched power outputs that might be used to power a relay that would in turn switch the main power. Those output look like this:

I bought a relay from Amazon and wired it appropriately. Now switching one of the smaller outputs on throws the relay and allows the larger output to power the charger. The benifit of all this is that I can now power on the power supply and after it has powered up and is stable, I can switch the charger on.

A couple of notes... The relay runs hot. About 50c. It is rated for 300 amps and continuous use but I'll be curious to see how long it runs. Also, I have nothing to suggest this is a safe or effective way of apply power to the charger. It could be damaging - but, I have to believe it is better than fiddling with the EC5. Finally, the relay I bought is a 24 volt unit. The power supply voltage has to be set for 24(ish) volts even though it is capable of putting out 30 volts.

"Well, nothing bad can happen now."
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