In this article I am going to show you how to add an automatic cooling fan to your G540.

Please note that this upgrade only applies to the CNCCS Advanved Electrics build.

You can add it to ather builds but you will need to add a 12V power source to run the fan.

 

The Parts

The main components are a 60mm 12V fan and a 40c temperature switch.

You can get them here:

60mm Fan

40c Temperature Switch (sensor)

Note that the fan comes with a grill to cover the back. You really dont need one to cover the front.

If you want one you can get them here:

60mm Fan Grill

In addition you will need the following components:

  • 2, 1” Angle brackets

  • 4, 6-32 x 1-1/2” Machine screws

  • 2, 6-32 x 1/2” Machine screws

  • 6, 6-32 Hex nuts

  • 6, #6 lock washers

  • Metal Tape

I do recommend metal tape to hold the temperature switch in-place but, some heavy duty duct tape will works as well.

Note that you can also use hex nuts with integrated lock washers as shown above.

Fan Assembly

Step 1

Start by attaching the grill(s) using two 1-1/2” machines screws as shown here.

Make sure you attach the grill at the top two holes in the fan. These are the holes located opposite of the wires.

Step 2

On the bottom of the fan secure the grill(s) and the angle brackets as shown here …

… and here.

Step 3

Cut the connector off of the two wires and strip about 1/4” from the ends.

Important - Make sure you cut the wires as close to the connector as you can. You need as much of the wire as you can salvage.

Step 4

Leaving about 1” remaining cut the red wire and strip as shown here.

Step 5

Take the sensor and solder one of the wires to the short end of the fan wire. Solder the other sensor wire to the piece of red wire you cut off.

Note that you can cover the solder joints with black tape, but I prefer heat shrink.

Step 6

Attach the fan assembly to the layout board, as shown here.

Step 7

Attach the black wire from the fan to your ground terminal block.

Attach the red wire coming from the sensor to the 12V terminal block.

Notice how I attached mine to the side of the terminal block with the terminal strap.

Step 8

Use a piece of tape to secure the sensor to the G540, as shown here.

Conclusion

That’s it. The fan should kick on whenever the G540 is 40C (104F) or above.