USB-C Power Supply Pushes Almost 2 KW

When the USB standard was first revealed, a few peripherals here and there adopted it but it was far from the “universal” standard implied by its name. It was slow, had limited ability to power anything, and its plug-and-play capability was spotty at best. The modern USB standard, on the other hand, has everything its predecessors lacked including extremely high data transfer rates and the ability to support sending or receiving a tremendous amount of power. [LeoDJ] is taking that latter capability to the extreme, with this USB-C power supply that can deliver 1.7 kW of power.

The project was inspired by the discovery of an inexpensive USB-PD (power delivery) module which is capable of delivering either 100W or 65W. After extensive testing, to see if the modules were following the USB standard and how they handled heat, [LeoDJ] grabbed 20 of the 65W modules and another four of the 100W modules and assembled them all into an array, held together in a metal chassis that also functions as a heat sink. The modules receive their DC power from two server power supplies wired together in series.

There was some troubleshooting, including soldering difficulty and a short circuit, but with all the kinks ironed out this power supply can deliver nearly 2 kW to an array of USB-capable devices and, according to the amount of thermal testing done, can supply that power nearly indefinitely. It’s an over-the-top power supply with a small niche of uses, but to see it built is satisfying nonetheless. For more information on all of the perks of working with USB-C, check out this tell-all we published last year.

Bringing A Chain Printer Back To Life: The Power Supply

[Usagi Electric] has his Centurion minicomputer (and a few others) running like a top.  One feature that’s missing, though, is the ability to produce a hard copy. Now, a serious machine like the Centurion demands a serious printer. The answer to that is an ODEC-manufactured printer dressed in proper Centurion blue. This is no ordinary desktop printer, though. It’s a roughly 175lb (80 Kg) beast capable of printing 100 lines per minute. Each line is 132 characters wide, printed on the tractor-feed green bar paper we all associate with old computer systems.

This sort of printer was commonly known as a chain printer, as the letters are on a chain that rides over a series of 66 hammers. Logic on this printer is 74 series logic chips – no custom silicon or LSI (Large Scale Integration) parts on this 47-year-old monster.

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An Adjustable High-Voltage Power Supply Built With Safety In Mind

It’s not entirely clear why [Advanced Tinkering] needs a 50,000-volt power supply, but given the amount of work he put into this one, we’re going to guess it will be something interesting.

The stated specs for this power supply are pretty simple: a power supply that can be adjusted between 20kV and 50kV. The unstated spec is just as important: don’t kill yourself or anyone else in the process. To that end, [Advanced] put much effort into making things as safe as possible. The basic architecture of the supply is pretty straightforward, with a ZVS driver and an AC flyback transformer. Powered by a 24-volt DC supply and an adjustable DC-DC converter, that setup alone yields something around 20kV — not too shabby, but still far short of the spec. The final push to the final voltage is thanks to a three-stage Cockcroft-Walton multiplier made with satisfyingly chunky capacitors and diodes. To ensure everything stays safe in the high-voltage stage, he took the precaution of potting everything in epoxy. Good thing, too; tests before potting showed arcing in the CW multiplier despite large isolation slots in the PCB.

Aside from the potting, some really interesting details went into this build, especially on the high-voltage side. The 3D-printed and epoxy-filled HV connector is pretty cool, as is the special wire needed to keep arcs at bay. The whole build is nicely detailed, too, with care taken to bond each panel of the rack-mount case to a common ground point.

It’s a nice build, and we can’t wait to see what [Advanced Tinkering] does with it. In the meantime, if you want to get up to speed on handling high voltage safely, check out our HV primer.

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Repairing An HP Power Supply

One of the interesting things about living in modern times is that a confluence of the Internet and rapid changes in the electronics industry means that test gear that used to be astronomically priced is now super affordable. Especially if, like [Frankie Mashockie], you can do a little repair work. He picked up an HP6038A power supply for $50. We couldn’t find the original list price, but even refurbs from “professional” sources go for around $800. However, the $50 price came with a “for parts” disclaimer.

The power supply is autoranging. You usually think of that as a feature of meters. In a power supply, autoranging means the device can adjust the voltage based on load as you can see explained in the video below.

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A Nicer Controller For Cheap Power Supply Modules

These days, you can get all kinds of cheap power supply modules off a variety of online vendors. A lot of examples from brands like Juntek and Drok often have pretty poor interfaces though, with a couple of tactile buttons and a simple 7-segment display. [rin67630] decided to whip up a better controller with a much more informative display.

The controller is designed to work with programmable buck converter modules like the DPS3806, Buck3603, and BST900. It’s based on a TTGO ESP32 with an integrated color TFT LCD. It displays voltage at the input and output, the same for current, along with current setpoints. It also allows for control of a fan and charge cycles if so desired, and it has the ability to fetch time from an NTP server for proper scheduling.  There’s also a web interface complete with graphs for really diving down into the nitty-gritty. Future plans include adding an MPPT solar charging capability.

If you’ve ever wanted a cheap power supply module with really low-level control and rich data display, this could be just what you need. Meanwhile, you’ve got your own neat power supply in the works, don’t hesitate to drop us a line. 

PC Case Makes Portable Power Supply

Recently, we’ve seen a lot of semi-portable power stations. These have some big rechargeable battery and various connection options. [Dereksgc] wanted to make his own and decided the perfect housing would be a small PC tower case. (Video, embedded below.) It makes sense. There are plenty of easy-to-work front panel inserts, a power supply box with an AC cord (the power supply is long gone), and it is big enough to fit the battery. You can see the result in the video below.

The bulk of the work was installing power supply modules and a charge controller on floppy disk blank panels. The battery — a 50 Ah LiFePO4 unit — fits nicely in the bottom. Some of the buttons and connectors find use in the new incarnation.

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Learning About Ferroresonant Transformers While Fixing A 1970s Power Supply

Ferroresonant (constant voltage) transformer diagram. Secondary side is kept in full saturation with the tank, keeping voltage constant. (Credit: Usagi Electric)
Ferroresonant (constant voltage) transformer diagram. Secondary side is kept in full saturation with the tank, keeping voltage constant. (Credit: Usagi Electric)

While troubleshooting the power supply of a 1970s Centurion system, [Usagi Electrics] came across a fascinating feature of these units: the ferroresonant, or constant voltage transformer (CVT). The main difference between a regular transformer and a CVT is that the former has a quite direct correlation between the input and output voltage, as the magnetic flux induced on the primary side is directly translated to the secondary (output) side.

A CVT adds a second element on the secondary side in the form of a tank circuit (LC circuit) – essentially a large capacitor – along with a magnetic shunt that ‘short circuits’ part of the magnetic flux between the primary and secondary side. The result of this is that even as the primary side is kept well below the saturation point where efficiency plummets, the secondary side is kept within this saturation region, enabling a very constant output voltage across a wide range of input voltages. For the Centurion’s power supply this input range goes from 90 to 130 VAC.

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