Dilshan R Jayakody’s Web Log

A few years back I purchased Honeywell CL15AE evaporative air cooler and it is15L indoor air cooler manufactured by JMATEK (for Honeywell). Sine last week this cooler became dead, and the only thing which I can see live is its red color power indicator. After disassembling the unit I see that most of the components of the controller PCB are rusted and damaged.  As I observed the main reason for corrosion is the absence of protective varnish on the top side of the PCB. The original control board of CL15AE cooler. At first, I restore all the damaged parts in the PCB with new parts, which including SS8050 , SS8550 , transistors and a few of electrolytic capacitors. After replacing those components, the unit starts to beep during power up but failed to power on. Damaged SS8050 and SS8550 transistors. After some tests, I figured out the problem is in SONiX SN8P2602 8-bit microcontroller.  Due to unavailability of microcontroller and it's firmware I decided to pr...

In my workshop, I got a couple of INGCO power tools. INGCO is a Chinese power tool manufacturer, and this brand is quite popular in Sri Lanka. Out of those tools I frequently used INGCO MG1502.2 mini drill. I purchased this drill three years back and mainly use for engraving and for precision drilling. A few days ago while I'm using this drill, it suddenly stopped. As a first thing, I checked brushes and mains-lead. After a few minutes of inspections, I found out that both brushes and mains lead are in perfect order. To further examine I decided to open the drill. The internal layout of this drill is quite simple. It mainly consists of an AC motor and electronic speed controller circuit. After a few checkups, I determined that the electronic speed controller is dead. In speed controller board I notice some unknown microcontroller, 74HC595 shift register, and Z0409MF TRIAC. As like many Chinese products here also they erased the IC number and other markings of the MCU. After ...

In this post, we describe the fan controller which we designed for our 9U wall mount server cabinet. This fan controller is designed to drive a 12V DC cooler fan with pre-configured intervals or by monitoring the temperature of the server cabinet. The final version of the fan controller with DC brushless fan and 12V - 60W PSU. Core components of this fan controller are CD4060 binary counter, LM35 temperature sensor, and LM358 operational amplifier. In this design, CD4060 has used as long duration timer and it can be configured to trigger cooler fan from 1-minute and up to 4-hour. In this design, an LM35 temperature sensor is used to activate cooler fan in specified temperature. This sensor stage is useful to drive cooler fan when timer stage is in an inactive state. To control the cooler fan we use AP9971 dual N-channel power MOSFET transistor. We design this system to drive 12V cooler fans up to 2A of current. To test this controller we use commonly available 120mm × 120mm...

Due to the advancement of audio technologies reel to reel audio tapes are now classified as a rare item. The biggest problem with the reel to reel tapes is a fungus . The fungus is developed on old unused tapes due to humidity exposure. Also, another problem with old tapes is that the lubrication on the surface of the tape starts to deteriorate and tape starts to stick to itself, and this leads tape to break during the playback. Most of them that have Fungus can be fixed by using a tape cleaner. But these days reel to reel tape cleaners are not available to buy and because of that, we decided to build simple tape cleaner by using parts of old reel to reel tape players. The core component of this player is an induction motor which we got from an old reel to reel player. The motor which we used in this project is the Sony HC-134. HC-134 is 100V single-phase, capacitor run, induction motor with 1500 - 1800 RPM. Recommended auxiliary winding capacitor for this motor is 1.5μF. To delive...

UC3844 is a popular current mode controller which is commonly found on DC-to-DC converter circuits and switch mode power supplies. This motor speed controller is also based on UC3844 and it is specifically designed to drive 20V - 24V DC motors. In this given configuration UC3844 produces (approx.) 50kHz to 240kHz PWM output and this range can be adjusted by changing the value of C2 timing capacitor. As per the datasheet, UC3844 is capable to produce PWM output frequency up to 1MHz. This circuit is quite sensitive to the noises, and to get the accurate output to construct this circuit on PCB. As per our observations, long wires on the oscillator circuit may change the stability of the output signal. According to the ON semiconductors , UC3844 has now discontinued product but it is still commonly available in the market for less than Rs. 40.00 (LKR). For this circuit either DIP (UC3844N) or SMD (UC3844D1) version of UC3844 can be used but the PCB design available with this arti...

This article describe the LMD18245 and PIC16F877A base 16 step bipolar stepper motor driver which is design to work with 12V 18 º bipolar stepper motors. In this design we use pair of LMD18245 DMOS full bridge motor drivers to control 2 phases of the stepper motor and PIC16F877A MCU is used as controller. We test this driver with several stepper motors (including 1.8 º - 12V stepper motors) and all of them provide excellent smooth output with this driver. The supplied firmware of this driver is design for 16 micro-steps but it can be easily change to full-step, half-step, 8, 32 or 40 micro-steps. In this given design LMD18245 current sense resistor is calculated for 200mA and it can be extend to 3A by changing the value of R2 and R4 resistors. For more information refer the LMD18245 datasheet . This project is released as open hardware project. Firmware of this project is released under the terms of MIT License and schematic is released under the terms of Creative Commons ...

While designing some mechanical projects we often have need for easy to build motor speed controllers. Thanks to the SGS-THOMSON Microelectronic’s TDA7274, now we have easy to build, low voltage D.C motor speed controller. TDA7274 provides wide operating voltage range from 1.8V to 6V and in this project we use it to drive small CD-ROM ejection motors. In this project we design entire speed controller with 39.3mm × 28.9mm PCB. While at the prototyping we test this system with 5V power source and successfully control several CD-ROM ejection motors, cassette motors and toy D.C motors. You can obtain all the circuit diagrams, PCB patterns and other information of low voltage motor speed controller from google drive .

In this project we design 2 channel D.C motor controller with pulse width modulation (PWM) based speed and direction control. This module is mainly design to drive 14.4V to 18V electric D.C motors. This motor controller is design to work with 18V - 1.5A D.C power source and it can be directly interface with general microprocessor / microcontroller system (without using any voltage level shifters). While at the prototyping stages we successfully couple this module with several NIDEC D.C fans and blowers which include D1751M24B7AP, E1331K12B7AZ-00, DME37KA, CF24DM506, etc. Control interface for this module is easy to use and at the designing stages we interface it with PIC16F887 and Atmega64 MCUs. Control interface of this module is consisting with 3 inputs (please refer the J3 in the circuit diagram) and using these inputs user may be able to select the motor, apply the brakes and also change the rotational directions of the motor(s). When constructing the circuit it is recommend...