It may have been designed for a sewing machine, but [Haris Andrianakis] found his imported DC brushed motor was more than up to the challenge of powering his mini lathe. Of course there’s always room for improvement, so he set out to reverse engineer the motor’s controller to implement a few tweaks he had in mind. Unfortunately, things took an unexpected turn when plugging his AVR programmer into the board’s ISP socket not only released the dreaded Magic Smoke, but actually tripped the breaker and plunged his bench into darkness.
Upon closer inspection, it turned out the board has no isolation between the high voltage side and its digital logic. When [Haris] connected his computer to it via the programmer, the 330 VDC coming from the controller’s rectifier shorted through the USB bus and tripped the Earth-leakage circuit breaker (ELCB). The good news is that his computer survived the ordeal, and even the board itself seemed intact. But the shock must have been too much for the microcontroller he was attempting to interface with, as the controller no longer functioned.
Now fully committed, [Haris] started mapping out the rest of the controller section by section. In the write-up on his blog, he visually masks off the various areas of the PCB so readers have an easier time following along and understanding how the schematics relate to the physical board. It’s a nice touch, and a trick worth keeping in mind during your own reverse engineering adventures.
In the end, [Haris] seems to have a good handle on what the majority of the components are up to on the board. Which is good, since getting it working again now means replacing the MCU and writing new firmware from scratch. Or perhaps he’ll just take the lessons learned from this controller and spin up his own custom hardware. In either event, we’ll be keeping an eye out for his next post on the subject.