Sub-Ohm Pass-through Concept

[Signal20]

Hey guys, I am working on a design for a 100 watt pass-through device. The parts I am using are listed below. If anyone who has made something similar could provide some input and or suggestions for the project, especially in regards to safety measures, please let me know. I am also looking for some ideas for housings. The idea is to have the button and 510 connector to be placed in a handheld enclosure with the power supply and other components separate.
Parts include:

1. 5v 20a PSU
2. vandal switch w/ dual pol red/green led
3. sealed 510 connector
4. 30a rated relay (A relay is used so I can pass low current through the vandal switch to activate the relay and pass high current to the mod, as the vandal is designed for low current)
5. 15-20a fuse (for current surge/short circuit protection)
6. 3.5a fuse (temporary until I figure out the exact draw of the led/needed activation current of the relay, smallest fuse I have atm)
7. 3x either MOV,TVS, or Zener diode (for voltage surge protection)
8. 12AWG cable (connected to mod)
9. 18AWG cable (connected to 510 connector)
10. 22AWG cable (connected to vandal/led)

Pseudo schematic:
Note: ">" and "->" indicate direction of travel.

 

[Visus]

The PSU has a lot of protection built in, the master on/off switch is usually on the psu. If not a power rail.

You only need a mosfet for the switching and your stuck at 5v output. A really good pt would be to use a regulator fed by the psu then you have a variable vaping range.

The psu may regulate its output so adding another reg may be moot, some psu's have a pot that allows you to adjust the output and that would be awesome..

I use a computer battery backup 12v 12aH battery feeding a Ti 08100 reg
Its rated for 50w, I have had it up to 120w but just for silly millisec test
I vape it at 45w to 80w daily..
Over a year old and not a single problem out of it..

 

[Signal20]

@visus, The psu does have surge and short circuit protection built in, this is all for the sake of redundancy. The psu also has a variable voltage pot, which is why I didn't add one to the design (plus I don't plan on deviating much from 5v). I may relocate the pot from onboard to a more easily accessible location. I will look into using a mosfet as a switch, thanks!

edit: Just briefly looking into mosfets, I found a diagram for a "complementary mosfet motor controller" which may solve the issue I was having with how to reverse the polarity of the led. So double thank you!

 

[Visus]

Yeah I also stay around 5-5.6v vapin its the sweet spot for .7-1Ω 27ga kan coils.

Not familiar with reverse polarity of leds, how does that work? I do know it becomes a zener if blown but reversed?

 

[Signal20]

@visus, Honestly, I am not exactly sure about that. This is the first time I ever messed with this kind of led. I have used 3 legged dual color before, but never 2 legged dual color.

 

[Signal20]

edit: chrome crashed/double post

 

[Visus]

Yeah I did a google, I understand its just a bi directional and color led. Really cool led for red/green on mom sw.. Didn't look at how to wire it tho I will when I do lol. Seems in my head it would need a tranny or nc sw in there to make it work right.. dang technology makin me learns boooo...

 

[chefjoosie]

Looks like you have a decent handle on the switches. Take a look at the way I do mine. There might be some ideas on setup you could find useful.

The way I do mine is, I made a 4 port hub of RCA jacks,(3 5V and 1 3.3V) and I use rca plugs on my passthroughs. I attach the hub, and tool hanger clips to my desk, and secure the wires from the hub to posts on the modified atx power supply. Looks like this:


The RCA hub looks like this:


The passthroughs themselves are made from polypropylene test tubes. They are very strong, shatterproof, easy to cut/drill, and very cheap to buy.

 

[Visus]

That is sweeeeeet chef. Lol wow great idea.. Mine is made from a small box enclosure really crappy when dripping and no adjust 510 pin the air hole lines up facing/dripping on me.
The tube solution solves that coincidence by being omni-directional.. I have a bus load of tubes too, back to modding when I do mod again, being uber lazy since China made it so easy/inexpensive to buy high power lol. My son wants a mod and I wanna buy it lol.. Dang Chinamen messed up my bragginz of cloudy hobby @ the vape shop ..

The hacked Ti 08100 beast 1-11v 120w 12v 12aH belkin battery backup passthru