Showing posts with label Thermistor. Show all posts
Showing posts with label Thermistor. Show all posts

Tuesday, August 15, 2017

Off-Grid inverter cooling upgrade

I'm current utilizing a PC UPS as my off-grid inverter. The model is BEST FORTRESS UPS 600VA. It produces a clean sine wave and in fact it can power everything (as long as it's within it's power range) including LED lights, halogen lights, fluorescent tubes and even small motors.





It has been in operation for almost 9 years and to be honest I'm really surprised by it's reliability! This UPS was never designed to be in operation/inverter mode for 24/7 with a 50%+ load almost continuously, however it has performed this task for all these years without any hiccups. 
One of the most important upgrades which was required on this UPS to offer all these long years of service was the adding of active cooling. The UPS comes with passive cooling which is just NOT enough!
The cooling system is made up of 6 x 40mm 24v fans. 



I know this from experience, since once the cooling fans stopped working and the UPS went from warm to hot.... in fact the transformer was starting to boil. Thankfully, the protection fuse finally blew, saving the UPS. 

4 fans have been installed on the side (using the existing cooling holes) while another 2 have been installed on top (drilled 2 x 40mm holes), just above the transformer and the power transistors.




The Image below is displaying the power transistors heat-sinks and the power transformer. In between, I placed a thermistor which will record the temperature of both the power transistors heat-sinks and the power transformer.


The image below is displaying the inverter opened without the cover. Instead of the batteries, there is now the fan controlling circuit and a large reservoir capacitor (150,000 uF - 50v). 
The Inverter is taking power from the capacitor which in turn is being fed by 10mm cables. 


The image below is displaying the fan controlling circuit. It's basic function is to switch on the cooling fans when the temperature inside the inverter reaches about 40°C. Details of this circuit can be found here


Inverter cooling circuit


Circuit Description:
The circuit is based around the LM324 quad Opamp configured as differential amplifiers.
QA1a generates a very stable voltage, set to 10v, while QA1b will compare this stable voltage against the voltage difference generated by the thermistor. The thermistor is an NTC 47K. NTC stands for Negative Temperature Coefficient i.e. the resistance decreases when the temperature rises.
Opamp QA1b inverting input (-) is preset to 8v while the non-inverting input (+) is fed from the voltage difference between the 47K preset and the 47K thermistor. When the temperature rises, the thermistor resistance will decrease and therefore the the non-inverting input (+) voltage will rise. Once the non-inverting (+) input is higher than the inverting input (-), the output of the opamp will go high, turning on the transistor Q1 which in turn will turn on the relay RLY1. The relay will in turn switch on the cooling fans.
Capacitors C2, C3, C4 & C6 offer some hysteresis so that the fans will not switch on/off continuously.
U1 is a 7812 voltage regulator. Since the available voltage inside the inverter is 24v and the circuit needs 12v, the regulator is used to step down the voltage, smoothed further by C1.

Parts List:
D1 - 5.6v Zener Diode
D2, D3 - 1N4001
D4 - Red LED
U1 - 7812 voltage regulator
OA1a, OA1b - LM324
R1 - 4.3K
R2 - 5.6K
R3 - 1K
R4 - 5.6K
R5 - 47K Preset
R6 - 1K
R7 - 47K Thermistor (NTC)
R8 - 47K Preset
R9 - 1.2K
C1, C5 - 2200uF
C2, C3, C4, C6 - 1000uF
Q1 - TIP122
RLY1 - Relay