User`s Manual(current)
Contents
1. 4 Assemble a Gently pull push on the wires to bring the PCB up to the case top b Gently align the RGB LED to poke through the case top 13 64 hole c Fasten the case halves together using the case screws 5 Program as desired TRA PLUS Manual 2 5 Page 13 L QO E S n Q E Ova SSA LW ayy 839 bald eva PVva INDOL 094 tad cady cad rad sad 994 294 031 898 O a RGB LED POL val FIGURE 7 TRA PLUS SCHEMATIC AND KEY COMPONENTS Page 14 TRA PLUS Manual 2 5 DIP SWITCH PIC MCU FIGURE 8 TRA PLUS PCB LAYOUT AND KEY COMPONENTS S849 Jid gt x J 1 3 K K KJ KJ K OA HU it HIY LN NCL ONS NU vwu OOD LOL RGB LED Page 15 TRA PLUS Manual 2 5 FIGURE 9 TRA PLUS LAYOUT TEMPLATES PRINTS 1 1 SCALE ON MOST PRINTERS HELPFUL FOR DRILLING HOLES Page 16 TRA PLUS Manual 2 52. new CUSTOM band ranges were permanently stored in non volatile memory ensuring the TRA PLUS retains its values if power is removed or cycled After programming DIP SW 1 may be returned to the ON position if TACHOMETER operation is desired output is the same as the input Be sure not to move DIP SW 1 from ON back to OFF for 20 seconds or additional unwanted programming may occur To eliminate the 20 second waiting requirement simply reset the TRA PLUS using the momentary switch To restore DEFAULT RPM bands follow the above steps but instead start by entering in the LOWEST RPM first then finish by entering in the HIGHEST RPM next The TRA PLUS emits 2 closely spaced sets of 2 short beeps when programming is complete indicating DEFAULTS have been restored TRA PLUS Manual 2 5 Page 8 SOUND The TRA PLUS has 3 sound modes Beep Normally 1 Set DIP SW 3 to ON Moving from OFF to ON will cause the TRA PLUS to beep once Beep Only When Programming 1 Set DIP SW 3 to OFF No beeps will occur during operation Disable All Beeps Set the TRA PLUS DIP SW 3 setting to the OFF position Change the TRA PLUS DIP SW 3 setting from OFF to ON The TRA PLUS will beep once 3 Within 5 seconds change the TRA PLUS DIP SW 3 setting from ON back to OFF The TRA PLUS will beep twice indicating TRA PLUS beeps have all been disabled Enable All Beeps from a Disabled Configuration Set the TRA PLUS DIP SW 3 setting to the OFF position
3. off indicating whether default or user custom parameters were loaded BACKGROUND DC fans are commonly found in computers computer power supplies uninterruptable power supplies DVRs servers and other electrical equipment with active cooling systems Fans can however be noisy due to the speed and volume of air being pulled across its blades A noise reduction technique is to use a larger fan that spins slower thus producing less noise but without compromising air flow due to its larger size Of course there must be room to mount an adapter flange or manifold in addition to the larger fan Given the explosive growth of the computer industry over the last few decades fans are available in a wide variety of sizes speeds and noise levels Other features include built in thermal detection with automatic speed adjustment manually adjustable speed controls LEDs etc Computer DC fans started out as simple 2 wire fans for DC voltage and Ground As computers evolved 3 wire fans emerged DC voltage e g 12V Ground and a third wire called Sense The signal on the Sense wire depends on the fan type Tachometer fan or Rotor Locked fan Tachometer fans produce pulses at a rate proportional to fan speed Rotor Locked fans produce a static signal that is in one of two states FAIL Locked Rotor or GOOD Spinning Rotor Signal waveforms for Tachometer Fans and Rotor Locked Fans are shown in Figures 1A and 1B respectively TRA PLUS Manual 2 5 P
4. Change the TRA PLUS DIP SW 3 setting from OFF to ON The TRA PLUS will beep twice 3 Within 5 seconds change the TRA PLUS DIP SW 3 setting from ON back to OFF The TRA PLUS will beep twice indicating the TRA PLUS beeps have all been re enabled TRA PLUS Manual 2 5 Page 9 BUZZER LOUDNESS To obtain louder sounds the buzzer can be mounted on top of the case instead of inside Ensure when placing the buzzer there is adequate clearance beneath it for the buzzer pins The example in the picture shows the buzzer mounted just above the buzzer location on the PCB To mount drill two small holes on the top of the case for the buzzer pins to poke through and solder wires from the buzzer pins down to the PCB buzzer pads the square pad is positive Double sided sticky tape can be used to hold the buzzer to the case apse Jo kT Za t FIGURE 5 BUZZER MOUNTED ON TOP OF THE CASE For the hobbyist and sound enthusiast sound can be increased with a larger piezo buzzer and more drive current Piezo buzzer must operate with 12VDC Typical Kit piezo is 14mm diameter draws lt 10mA to deliver 86dBA of sound pressure The piezo drive transistor TBUZ is a 2N4401 inside a TO 92 package which drives up to 600mA For even greater current drive e g gt 1 amp room exists to replace the TO 92 with a TO 226 package Darlington Pair transistor ensure compatible pinout for replacement transistor see layout for sirens or sounders TRA PLUS M
5. The Tach Rotor Adapter Plus TRA PLUS works with 3 wire 12VDC fans commonly found in computers computer power supplies uninterruptable power supplies DVRs servers and other electrical equipment with active cooling systems The TRA PLUS is user programmable converts a tachometer signal also known as a speed sensor signal to a rotor locked signal provides fan speed RPM indication using an RGB red green blue LED and provides alarm detection and indication using an RGB LED and sound via a piezo buzzer TACH ROTOR ADAPTER PLUS MANUAL 2 5 M D PENDLETON markdpend aol com December 2012 INTRODUCTION The TRA PLUS improves upon the original TRA by adding sound and programmability The TRA PLUS uses the same microcontroller unit MCU used in the original TRA thus leverages previous hardware and software design development and testing ensuring a stable reliable design The original RPM color schemes and form factor are the same as the TRA and the TRA PLUS fits in the same case In addition to more DIP switch settings the user can now program additional parameters to customize the TRA PLUS to their system The addition of sound enhances visual alerts while providing a convenient feedback mechanism during operation and for quick and easy programming User programming remains stored even if power is removed and defaults can be restored The TRA PLUS smartly beeps during power up assuming all beeps have not been turned
6. age 1 Tach Fan Waveform Rotor Locked Fan Waveform J Hg Vcc Vcc Gnd Ly LI Gnd Spinning Spinning Voltage dependent on final resting position of fan blade Stopped Stopped FIGURE 1A TACH FAN WAVEFORM FIGURE 1B ROTOR LOCKED WAVEFORM Fans with tachometer sensors are commonly used in computers as it s a simple matter for the computer s processor to monitor and compute fan speed For unattended equipment Rotor Locked fans are popular as they integrate easily into alarm systems due to their simpler 2 state outputs Unfortunately Rotor Locked fans generally cost more are not as common as Tachometer fans and are even harder to find in sizes over 92mm making the noise reduction technique of getting a bigger fan tougher to realize So the Tachometer Rotor Adapter TRA was born and given the power of the MCU additional features were added which are described below FEATURES The TRA PLUS provides the following 3 functions 1 Speed Sensing Display and Sound 2 Fault Indication 3 Rotor Locked Conversion Speed Sensing Display and Sound In the same way a computer calculates fan speed the MCU in the TRA PLUS calculates fan speed and illuminates an RGB red green blue LED to a color indicating which one of four RPM ranges or bands the fan is operating User fan speed can be verified against the DEFAULT RPM Band Colors and Ranges or the TRA PLUS can be programmed by the user to allow all four colors to span the range of
7. anual 2 5 Page 10 KIT OVERVIEW The TRA PLUS Kit comes with a custom PCB board components and a case A DIP switch allows user configurability The PCB layout uses only through hole mounting allowing for simple level soldering skills and quick assembly The PIC16F88 microcontroller sits inside a solder mounted DIP socket allowing the PIC to be easily removed and inserted for firmware updates Required Tools or Supplies e PIC16F88 Programmer e Soldering eguipment Iron Solder Flux e Wire cutting and stripping tool e Drill 1 8 drill bit 13 64 drill bit e Small screwdriver slotted or Philips to fit case screws e Needle nose pliers CASE TOP FIGURE 6 CASE DRILL HOLES TRA PLUS Manual 2 5 Page 11 IC MCU PIC16F88 I P 8 BIT 1 NPN 40V 0 6A 100 360 TO 92 5 7 SWITCH PB TACT SPST OFF ON 1 LED RGB WATER CLEAR 1T1 3 4 2 0 1 10 2157159 RES CF 1K OHM 1 4 WATT 5 11 2158864 RES CF 4 7K OHM 1 4 WATT 5 12 690742 RES CF 330 OHM 1 4 WATT 5 13 196357 PIEZO BUZZER 13 8MM 12V 14 101470 10 BAT CONN WIRES FOR EXT BUZ TABLE 2 TRA PLUS CIRCUIT DESIGN QTY TRA PLUS KIT QTY Hi O O ja Notes 1 Representative Kit at time of printing Parts subject to change and availability 2 Similar parts may be substituted Please refer to schematic for design considerations and or limitations TRA PLUS Manual 2 5 Page 12 KIT ASSEMBLY STEPS 1 Prepare Case and Fan Cables a Cut the fa
8. eps Rotor Locked Conversion The TRA PLUS output can be set to follow the input from the fan s sense wire known as a tachometer signal most computers use this type or can be converted to a 2 state rotor locked signal where the signal is LOW when the fan is spinning or HIGH open collector when the fan is below the FAIL threshold 30 RPM Fan output selection is made using DIP switches described in the TRA PLUS Features Table TRA PLUS Manual 2 5 Page 3 LED COLOR RPM based on fan BAND waveform having 2 pulses per revolution at 50 Duty Cycle 3 2 000 RPM BLUE MED HIGH FLICKER SUPPRESSION ee po 1 500 RPM BANDS GREEN MED LOW 1 000 RPM o aiak aa ha ed gt 2000 RPM gt ae gt n W i s gnii 1 gt 1000 RPM lt Fan Speed lt 1500 RPM FIGURE 3 ASSEMBLED KIT amp OPERATING COLORS TRA PLUS Manual 2 5 Page 4 FEATURE DESCRIPTION SELECTION METHOD Output Signal Type LED ON OFF Fan FAIL Fan FAIL Recovery LED Brightness Flicker Suppression RESET Output sense wire matches Tachometer Fan input signal or is converted to a Rotor Locked signal Turns the LED ON or OFF LED turns RED Fan FAIL overrides LED ON OFF setting Beeps for 1 second every 60 seconds until the fault condition is removed Beeps when FAIL condition is removed MEDIUM or HIGH Prevents LED flicker caused by frequency noise a slowly varying fan or when
9. n extension cable into 2 equal halves b Drill holes in case as shown in the Case Drill Holes figure i RESET and BUZZER holes are optional ii Size the RESET hole for intended RESET device e g 1 8 small for toothpick 13 64 medium for small screwdriver etc c Drill 1 one hole for Piezo Buzzer optional if internal mounting OR drill 2 two holes to accommodate the Piezo Buzzer pins for external mounting 2 Install Components a Solder 12 twelve resistors Solder 1 one 18 pin IC carrier Solder 1 one DIP Switch and 1 one Tactile Momentary Switch Solder 1 one Piezo Buzzer to PCB if internal mounting Solder 2 two capacitors Solder 3 three transistors Solder 1 one 5V regulator za n 2 0 o Solder 1 one 2 pin header i Solder 1 one RGB LED to the PCB note mount RGB LED high enough so the LED pokes through the 13 64 hole on case top j Insert PICinto the 18 pin IC Carrier k Set DIP switch to desired settings 3 Install cables a Feedcables through 1 8 holes in top cover i Cable with MALE connector goes through LEFT hole ii Cable with FEMALE connector goes through RIGHT hole Strip 0 5 insulation from the 3 wires on each cable Solder cable with MALE connector to FAN IN pads see label on PCB Solder cable with FEMALE connector to FAN OUT pads Affix the Piezo Buzzer to top of the case e g with double sided sticky tape then nm a n o solder wires from PCB to Piezo Buzzer if external mounting
10. s measured the TRA PLUS changes to the appropriate color TRA PLUS Manual 2 5 Page 7 PROGRAMMING RPM Color Bands For systems that have a fan controller that can change fan speed the TRA PLUS may be able to operate through all 4 DEFAULT RPM COLOR BANDS However because fans come in a wide variety of speeds and fan controllers differ it s possible that not all LED colors will show up with a given system s fan and fan controller combination so the TRA PLUS allows the creation of CUSTOM RPM Band boundaries that utilize all 4 color ranges by allowing the user to simply identify the HIGHEST and LOWEST fan speeds from which the TRA PLUS computes the new ranges To program the TRA PLUS please follow the following steps 1 Place a fan controller between the TRA PLUS and the computer fan as shown in the Test Setup pictures Set the TRA PLUS DIP SW 1 setting to the OFF position if it isn t already there 2 Adjust the fan controller to run the fan at its HIGHEST speed Change the TRA PLUS DIP SW 1 setting from OFF to ON The TRA PLUS will beep once indicating the fan s HIGHEST RPM speed was measured 3 Adjust the fan controller to run the fan at its LOWEST speed Within 20 seconds built in timeout to prevent unintended programming change the TRA PLUS DIP SW 1 setting from ON back to OFF The TRA PLUS will beep three times indicating the fan s LOWEST RPM speed was measured CUSTOM RPM Band Ranges for all 4 bands were computed and the
11. speeds using the fan controller DEFAULT RPM Ranges can be restored at any time TRA PLUS Manual 2 5 Page 2 Using a combination of filtering and hysteresis regions between bands were created to suppress LED flicker caused by a fan slowly crossing a band threshold noise on the voltage ground signals or some other disturbance The RGB LED can be switched ON or OFF and LED brightness can be set to High or Medium using DIP switches described in the TRA PLUS Features Table The TRA PLUS has three sound modes 1 Normal 2 Beep Only When Programming and 3 Disable All Beeps Each mode is permanently stored once programmed and can be re programmed up to a million times The TRA PLUS ships in Normal Sound mode sound ON for operation and programming LED colors are based on the fan s speed and are independent of Output Signal Type selection e g the TRA PLUS will still display color bands representing fan speed even if the TRA PLUS output is set to the 2 state Rotor Locked waveform Fault Indication When the fan falls below 30 RPM the LED becomes RED and a 1 second beep occurs every 60 seconds until the fault condition is removed Sound can be turned ON or OFF using the DIP switches described in Table below Fan FAIL overrides LED ON OFF setting When the FAIL condition is removed the TRA PLUS emits 3 short beeps if it has been CUSTOM programmed If the TRA PLUS is using DEFAULT RPM Band Ranges the TRA PLUS emits 2 sets of 2 short be
12. the fan slowly crosses a band threshold Resets TRA PLUS same effect as cycling power DIP SW 1 OFF ROTOR LOCKED ON TACHOMETER DIP SW 2 OFF LED ON ON LED OFF FIXED lt 30 RPM DIP SW 3 OFF Buzzer OFF ON Buzzer ON FIXED DIP SW 4 OFF MEDIUM ON HIGH FIXED 75 RPM Momentary Button TRA PLUS Manual 2 5 Page 5 DEFAULT RPM BANDS br pon as DEFAULT MED LOW Green gt 1000 RPM RANGES amp COLORS FIXED LOW Blue Red gt 30 RPM RPM Band Ranges RPM values at the color boundaries can be modified where all colors are used USER across the range of speeds created by the PROGRAMMABLE fan controller DEFAULT RPM Band DIP SW 1 Ranges can be restored at any time TABLE 1 TRA PLUS FEATURES TRA PLUS Manual 2 5 Page 6 INSTALLATION Place the TRA PLUS between the computer s fan and computer s motherboard fan header For use with a fan controller connect the fan to the fan controller connect the fan controller to the TRA PLUS and connect the TRA PLUS to the computer or other end use device TEST SETUP 9 S FIGURE 4 TRA PLUS CONFIGURATION USING A FAN CONTROLLER POWER ON At POWER ON the TRA PLUS cycles through all 3 colors beginning with Red then Green then Blue and then OFF Next the TRA PLUS either a emits 3 short beeps if it has been CUSTOM programmed or b emits 2 sets of 2 short beeps if the DEFAULT RPM Band Ranges are stored Once the fan speed i
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