My third time writing this up due to my browser thinking backspace meant to go back in history when I was clearly typing...
Background/Motivation:
Project History until now:
Current Status:
To-Do List:
This is where I will list out my next steps in the progression of this project.
Feedback:
Notes about plans for this mod:
Background/Motivation:
As I'm sure many of us know HDPlex has recently launched the upgrade/replacement to their 300w DC-ATX unit in the form of the gorgeously heatsinked, higher capacity HDPlex 400w DC-ATX unit. While the new design and higher rating are very welcome things there is a bit of a conundrum in the fact that there seem to be now 400w AC-DC power bricks available to power it. This fact has been brought up a few times in the HDPLEX 400W DC-ATX thread and one comment in particular caught my attention:
This combined with @Reldey kindly reaching to me a bit later to craft some cables that would allow him to connect the AC-DC adapter to his HDPlex (in the beautiful S4 Mini by @Josh | NFC) as well as passing through the PWM connection from his mobo to a fan on the adapter, led to the creation of this project.
The guys at HD PLEX told me that if you push "Active air flow" to the 300W AC-DC brick they have, it will support 400w.
This combined with @Reldey kindly reaching to me a bit later to craft some cables that would allow him to connect the AC-DC adapter to his HDPlex (in the beautiful S4 Mini by @Josh | NFC) as well as passing through the PWM connection from his mobo to a fan on the adapter, led to the creation of this project.
Project History until now:
The first idea was to use a 10pin DIN or 'aviation' plug in place of the usual barrel connector that way all 6pins of the DC output of the unit could be passed into the HDPlex 400w inside the case as well as the 4pins for a PWM extension from a fan mounted to the AC-DC unit all the way to the motherboard.
Realizing that this would create more cabling complexity in the S4 Mini I recommended that we find a way to power the fan directly from the adapter itself. After some searching I found a small Step-Down (or buck) converter that would allow me to take the 19v output of the AC-DC unit and convert it into a more suitable voltage for powering a fan.
The next modification was the decision to use two fans on the unit instead of one: a 20mm one (this nice Noiseblocker one more specifically) for intake on the Output side and then another 10mm fan (undecided currently, probably this one with a gasket) as an exhaust on the top above the AC-in side.
Finally the most recent addition to the list is a way to control the speed of the fan via a 3-4 way switch (or similar) that way they can be tuned (i.e. High - Med - Low - Off) based on your needs.(mocked up in sketchup because that what I'm most familiar with and 3D warehouse)
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Notes:
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Notes:
- very rough design, my next step is to move it over to proper CAD (Fusion 360 or Inventor) so that I can model it more exactly and better suited for 3D printing.
- The mockup shows the Buck converter being placed in the ramp/adapter section but as soon as I took the screenshots I realized that a better place would be the top next to the exhaust fan.
Current Status:
So the part you've all been waiting for... (or just skipped to
) the pictures!
Here are the screenshots of the design in it's current state:
Notes:
Here are the screenshots of the design in it's current state:
Notes:
- Since I decided to place the Buck converters on the top I went ahead and designed a top to house them and the fans internally to the unit to keep things clean and protected.
- Need to find a good switch for the speed control of the fans and add the spot for it to the model.
- I'm considering adding on another part to the AC-input side to house the extra cable and attach the socket for the AC power cord as well.
- I might also need to change the top design to make room for the original DC-output cables to be internal so that they don't show. Might be a bit of a tall order tho because of the large 6pin connector.
- I do need to figure out the screws used originally and which ones I'll use for the DC-out mounting plate. Probably will have to wait until my own unit arrives to find out tho.
- Updated measurements of the current design will be edited in later
To-Do List:
This is where I will list out my next steps in the progression of this project.
Convert the design to proper CADI am now using Fusion 360!Accurately model and measure the original AC-DC unitCreate/find fan, fan grill, gasket, and Buck converter modelsNot really neededCreate v0.3 of the design with the converter/switch up top
Figure out if Switch for fan modes can be integratedMay need to design my own PCBToo much work lol- Decide how many converters and what volts to set them at
- Find a good & small switch
- Make Documentation
- Create Wiring diagram
- Create Bill of Materials
(Acquire unit formyself?)Bought one! Should be on its way to me shortly- Prototype
- Test, test, test!
Feedback:
I love feedback so please let me know what you think!
If you have ideas about a better layout for this post please let me know as well. Thx!!
If you have ideas about a better layout for this post please let me know as well. Thx!!
Notes about plans for this mod:
Assuming all goes according to plan and this mod actually is succesful in raising the wattage output capacity of the HDPlex 300w AC-DC unit I would love to be able to provide Mod-Kits to those who would wish to buy one. I am documenting the process here for the opportunity for feedback and in case someone wants to copy the mods that were done for their own use.
Since that is my hope I am trying to make this mod as plug & play as I can for quick and simple installation. I would love and welcome any feedback about the design and idea.
Since that is my hope I am trying to make this mod as plug & play as I can for quick and simple installation. I would love and welcome any feedback about the design and idea.
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