A FLIR One Pro Sees Again, Thanks To Some Nifty Soldering

March 2, 2021 by Jenny List 28 Comments

The Flir One Pro is a thermal camera that attaches to a mobile phone with a USB-C plug. [Gigawatts] has one, and unfortunately managed to drop it, breaking the USB-C plug and rendering the device useless. The plug is separate from the main PCB, an assembly of its own with a flexible cable, but FLIR are not interested in supplying spares. What was the answer? Wire data lines into the device’s charging port, of course!

The One Pro has its own battery, and to avoid draining the phone it is charged through another USB connection, this time a socket. The data lines aren’t connected, which necessitated some very careful soldering of wire-wrap wire to an SMD package to fix. When completed and secured with glue the resulting camera works with a USB-C cable, and there are plans to mount a tripod thread receptacle in the space left by the USB-C plug.

It’s disappointing that Flir choose not to supply replacements for the USB-C plug assembly, seemingly they see the device as a throwaway piece of consumer electronics rather than the expensive instrument that it is. This modification should at lease allow some unfortunate One Pro owners to revive their dead cameras.

If you’re curious about the Flir One series of cameras, perhaps you’d like to read our review.

1938 Radio Has Awesome Dial

February 10, 2021 by Al Williams 19 Comments

[Mr. Carlson] is truly an old radio surgeon. The evidence? He recently restored an 83-year-old DeForest radio by transplanting an identical chassis from another similar radio. The restoration is fun to watch, but the 7D832 radio dial looks amazing. The dial is very colorful and the wooden knobs and preset selector are beautiful. To seal the deal, the center of the dial has a magic eye tube, giving the radio a retro high tech look.

The donor chassis needed some work before the surgery. In addition, [Carlson] makes some improvements along the way. The radio showed signs of previous service work, which is not surprising after 83 years.

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Chasing Down Bad Caps To Save A Troubled PSU

January 26, 2021 by Tom Nardi 36 Comments

We know what you’re thinking. It’s a bad power supply, of course it was capacitors to blame. But even if we all intuitively know at this point that bad caps are almost always the culprit when a PSU gives up the ghost, it’s not always easy to figure out which one is to blame. Which is why this deep dive into a failed ETK450AWT by [eigma] is worth a look.

The first sign of trouble was when the computer would unexpectedly reboot with nothing in the system logs to indicate a problem. Eventually, [eigma] noticed a restart before the operating system even loaded, which confirmed the hardware was to blame. A quick look at the PSU output with a voltmeter showed things weren’t too far out of spec, but putting an oscilloscope on the 12 V line uncovered a nasty waveform that demanded further investigation.

By carefully following traces and comparing with common PSU diagrams, [eigma] was able to identify the SG5616 IC that checks the various voltages being produced by the PSU and generates the PWR_OK signal which tells the motherboard that everything is working normally. As before, all of the DC voltages at this chip seemed reasonable enough, but the pin that was measuring AC voltage from the transformer was showing the same ripple visible on the 12 VDC line.

Even more digging uncovered that the transformer itself had a control IC nestled away. The 13 VDC required by this chip to operate is pulled off the standby transformer by way of a Zener diode and a couple capacitors, but as [eigma] soon found, the circuit was producing another nasty ripple. Throwing a few new capacitors into the mix smoothed things out and got the PSU to kick on, but that’s not quite the end of the story.

Pulling the capacitors from the board and checking their values with the meter, [eigma] found they too appeared to be within reasonable enough limits. They even looked in good shape physically. But with the help of a signal generator, he was able to determine their equivalent series resistance (ESR) was way too high. Case closed.

While swapping out blown capacitors in older electronics is something of a rite of passage for hardware hackers, this case is an excellent example of how even the simplest of fixes can be tricky to troubleshoot.

Repairing 200+ Raspberry Pis For A Good Cause

January 25, 2021 by Tom Nardi 37 Comments

If somebody told you they recently purchased over 200 Raspberry Pis, you might think they were working on some kind of large-scale clustering project. But in this case, [James Dawson] purchased the collection of broken single-board computers with the intention of repairing them so they could be sent to developing countries for use in schools. It sounds like the logistics of that are proving to be a bit tricky, but we’re happy to report he’s at least made good progress on getting the Pis back up and running.

He secured this trove of what he believes to be customer returned Raspberries or the princely sum of £61 ($83 USD). At that price, even if only a fraction ended up being repairable, you’d still come out ahead. Granted all of these appear to be the original Model B, but that’s still a phenomenal deal in our book. Assuming of course you can find some reasonable way to triage them to sort out what’s worth keeping.

To that end, [James] came up with a Bash script that allowed him to check several hardware components including the USB, Ethernet, I2C, and GPIO. With the script on an SD card and a 3.5″ TFT plugged into the Pi’s header for output, he was able to quickly go through the box to get an idea of what sort of trouble he’d gotten himself into. He was only about half way through the process when he wrote this particular blog post, but by that point, he’d found just 40 Pis which wouldn’t start at all. He suspects these might be victims of some common issue in the power circuitry that he’ll investigate at a later date.

A metal ruler made short work of bent pins.

A nasty, but repairable, problem.

The majority of Pis he checked were suffering from nothing worse than some bent GPIO pins or broken SD card slots. Some of the more abused examples had their USB ports ripped off entirely, but were otherwise fine. Another 10 had dead Ethernet, and 4 appear to have damaged traces leading to their HDMI ports. While we’re interested in hearing if [James] can get those 40 dark Pis to fire back up, so far the results are quite promising.

Donating hardware is always a tricky thing, so for now [James] says he’ll be selling the repaired Pis on eBay and donating the proceeds to the Raspberry Pi Foundation so they can continue to develop hardware that will (potentially) accomplish their goal of giving students all over the world a functional computer.

Burned Out SKR E3 Mini Gets New Stepper Driver

January 5, 2021 by Tom Nardi 19 Comments

It didn’t take long to figure out that a dead X axis and an message saying “TMC CONNECTION ERROR” meant that one of the stepper drivers on the SKR E3 Mini 3D printer control board had released the magic smoke. Manufacturer BigTreeTech replaced the board under warranty, and the printer was back up and running in short order. But instead of tossing it in the trash, [Simon] wondered how hard it would be to repair the dead board.

Removing the original stepper driver IC.

The short answer is, not very hard. There was no question as to which of the four TMC2209 drivers was shot, since the X motor was the only one experiencing a problem. The drivers unfortunately aren’t socketed on this board, but after a little kiss with the hot air, the old chip was off.

[Simon] didn’t have any spare TMC2209 chips, but the TMC2208 has the same pinout and is a drop-in replacement. The TMC2208 is rated for a bit less current, but it shouldn’t be a problem under normal circumstances.

Other than the stepper connector getting a little toasty during the installation, the swap went off without a hitch and the board was up and running again. [Simon] ended up putting the now repaired SKR E3 Mini in his Ender 3; a nice 32-bit upgrade compared to the ATmega1284 that was originally running the show. Though in the past, he’s managed to squeeze a bit more performance out of the older 8-bit board as well.

Uncommon Bárány Chair Gets Fixed Up

January 3, 2021 by Anool Mahidharia 23 Comments

Ever heard of a Bárány chair? Neither had [Troy Denton] before he was asked to repair one, but that didn’t stop him from rolling up his sleeves and tying to get the non-functional device back in working order. As it didn’t come with a user guide, manual, schematic or any other information, he had to rely on his experience and acumen gathered over years of practical work. Luckily for us, he decided to document the whole process.

While it’s not well known outside of aviation circles, the Bárány chair is an important piece of equipment in training pilots to get used to spatial disorientation. The device is essentially a motorized revolving chair, the idea being to spin the subject to induce disorientation. Rotation speed and direction can be controlled via a handheld wireless remote terminal.

When [Troy] first powered it up, the error code on the remote indicated “no power to base unit”. That turned out to be a quick fix – he simply had to move the power connection from a switched socket that had been turned off to a different outlet. But while that cleared the error message, the chair still wouldn’t rotate for any of the knob settings.

Manually rotating the chair showed the RPM on the remote, so [Troy] narrowed down his search to the motor related sections. The motor was being driven by a servo type signal, but changing the speed and direction knob on the remote didn’t seem to alter the control signal when he checked it with his scope. Opening up the hand held remote immediately uncovered the failed part – the rotary encoder for setting the speed and direction had physically split in to two pieces.

Since there was a clean split in the encoder, he was able to temporarily hold it back together to confirm that the chair could spin up. The cause was most likely “User Error” – the last person to conduct the test probably turned the knob rather enthusiastically. A new part is on the way, and the chair should be getting back to making prospective pilots dizzy in no time.

We love a good repair story here at Hackaday. Whether it’s patiently rebuilding a snapped PCB with bodge wires or coming up with replacement parts that may well be better than the originals, we never get tired of seeing a broken piece of gear put back together.

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Think Your Laptop Is Anemic? Try An MSDOS One

December 28, 2020 by Al Williams 51 Comments

If someone gifted you a cheap laptop this holiday season, you might be a little put out by the 2GB of RAM and the 400 MHz CPU. However, you might appreciate it more once you look at [Noel’s Retro Lab’s] 4.8 Kg Amstrad PPC512 He shows it off inside and out in the video below.

Unlike a modern laptop, this oldie but goodie has a full keyboard that swings out of the main body. The space below the keyboard contains the LCD screen, which [Noel] is going to have to replace with an LCD from another unit that was in worse shape but had a good-looking screen. In this video, he gets as far as getting video output to an external monitor, but neither LCD shows any sign of life. But he’s planning more videos soon.

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