Replacing Selenium Rectifiers

September 24, 2024 by Al Williams 14 Comments

Old radios often had selenium rectifiers to convert AC to DC. The problem is that the old units, dating back to 1933, are prone to failure and to release dangerous chemicals like hydrogen selenide. [M Caldeira] has a new board made to fit a particular rectifier and also allows a varying voltage drop. The circuit consists of a few diodes, a MOSFET, and a pot for adjusting the voltage drop. An IRF840 MOSFET provides the adjustment.

Did it work? It did. The good news is that if it fails — which shouldn’t happen very often — it won’t release stinky and noxious fumes

We wondered if he should 3D print a fake case to make it look more the part. If you haven’t seen a real selenium rectifier, they were made of stacks of metal plates coated with bismuth or nickel. Then, a film of doped selenium was annealed to the surface to form cadmium selenide. Each plate could handle about 20 V and the more plates you used, the more reverse voltage the device could withstand.

Selenium was also found in old photocells. If you fancy replacing other parts of an old radio, you might consider a faux magic eye or even one of the main tubes.

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Comparing AliExpress Vs LCSC-Sourced MOSFETs

August 24, 2024 by Maya Posch 26 Comments

The fake AliExpress-sourced IRFP460 MOSFETs (Credit: Learn Electronics Repair, YouTube)

These days, it’s super-easy to jump onto the World Wide Web to find purported replacement parts using nothing but the part identifier, whether it’s from a reputable source like Digikey or Mouser or from more general digital fleamarkets like eBay and AliExpress. It’s hardly a secret that many of the parts you can buy online via fleamarkets are not genuine. That is, the printed details on the package do not match the actual die inside. After AliExpress-sourced MOSFETs blew in a power supply repair by [Learn Electronics Repair], he first tried to give the MOSFETs the benefit of the doubt. Using an incandescent lightbulb as a current limiter, he analyzed the entire PSU circuit before putting the blame on the MOSFETs (IRFP460) and ordering new ones from LCSC.

Buying from a distributor instead of a marketplace means you can be sure the parts are from the manufacturer. This means that when a part says it is a MOSFET with specific parameters, it almost certainly is. A quick component tester session showed the gate threshold of the LCSC-sourced MOSFETs to be around 3.36V, while that of the AliExpress ‘IRFP460’ parts was a hair above 1.8V, giving a solid clue that whatever is inside the AliExpress-sourced MOSFETs is not what the package says it should be.

Unsurprisingly, after fitting the PSU with the two LCSC-sourced MOSFETs, there was no more magic smoke, and the PSU now works. The lesson here is to be careful buying parts of unknown provenance unless you like magic smoke and chasing weird bugs.

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An Open Source 6kW GaN Motor Controller

August 19, 2024 by Dave Rowntree 30 Comments

We don’t know how you feel when designing hardware, but we get uncomfortable at the extremes. High voltage or current, low noise figures, or extreme frequencies make us nervous. [Orion Serup] from CrabLabs has been turning up a few of those variables and has created a fairly beefy 3-phase motor driver using GaN technology that can operate up to 80V at 70A. GaN semiconductors are a newer technology that enables greater power handling in smaller packages than seems possible, thanks to high electron mobility and thermal conductivity in the material compared to silicon.

The KiCAD schematic shows a typical high-power driver configuration, broken down into a gate pre-driver, the driver itself, and the following current and voltage sense sub-circuits. As is typical with high-power drivers, these operate in a half-bridge configuration with identical N-channel GaN transistors (specifically part EPC2361) driven by dedicated gate drivers (that’s the pre-driver bit) to feed enough current into the device to enable it to switch quickly and reliably.

The design uses the LM1025 low-side driver chip for this task, as you’d be hard-pushed to drive a GaN transistor with discrete components! You may be surprised that the half-bridge driver uses a pair of N-channel devices, not a symmetric P and N arrangement, as you might use to drive a low-power DC motor. This is simply because, at these power levels, P-channel devices are a rarity.

Why are P-channel devices rare? N-channel devices utilise electrons as the majority charge carrier, but P-channel devices utilise holes, and the mobility of holes in GaN is very low compared to that of electrons, resulting in much worse ON-resistance in a P-channel and, as a consequence, limited performance. That’s why you rarely see P-channel devices in a circuit like this.

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The 555 As A MOSFET Driver

August 5, 2024 by Jenny List 25 Comments

To drive a MOSFET requires more than merely a logic level output, there’s a requirement to charge the device’s gate which necessitates a suitable buffer amplifier. A variety of different approaches can be taken, from a bunch of logic buffers in parallel to a specialised MOSFET driver, but [Mr. T’s Design Graveyard] is here with a surprising alternative. As it turns out, the ever-useful 555 timer chip does the job admirably.

It’s a simple enough circuit, the threshold pin is pulled high so the output goes high, and the PWM drive from an Arduino is hooked up to the reset pin. A bipolar 555 can dump a surprising amount of current, so it’s perfectly happy with a MOSFET. We’re warned that the CMOS variants don’t have this current feature, and he admits that the 555 takes a bit of current itself, but if you have the need and a 555 is in your parts bin, why not!

This will of course come as little surprise to anyone who played with robots back in the day, as a 555 or particularly the 556 dual version made a pretty good and very cheap driver for small motors. If you’ve ever wondered how these classic hips work, we recently featured an in-depth look.

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Making A Solid State 6AK8 Tube

July 22, 2024 by Al Williams 13 Comments

[M Caldeira] had a project in mind: replacing a common vacuum tube with a solid-state equivalent. The tube in question was an EABC80 or 6AK8 triple diode triode. The key was identifying a high-voltage FET and building it, along with some other components, into a tube base to make a plug-in replacement for the tube. You can see a video about the project below.

These tubes are often used as a detector and preamplifier. Removing the detector tube from a working radio, of course, kills the audio. Replacing the tube with a single diode restores the operation of the radio, although at a disadvantage.

From there, he adds more diodes directly into the socket. Of course, diodes don’t amplify, so he had to break out a LND150 MOSFET with a limit of 500 volts across the device. It takes some additional components, and the whole thing fits in a tube base ready for the socket.

Usually, we see people go the other way using tubes instead of transistors in, say, a computer. If you want real hacking, why not make your own tubes?

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Introduction To MOSFET Switching Losses

May 15, 2024 by Maya Posch 17 Comments

Metal-oxide semiconductor field-effect transistors (MOSFETs) see common use in applications ranging from the very small (like CPU transistors) to very large (power) switching applications. Although its main advantage is its high power efficiency, MOSFETs are not ideal switches with a perfect on or off state. Understanding the three main sources of switching losses is crucial when designing with MOSFETs, with a recent All About Circuits article by [Robert Keim] providing a primer on the subject.

As it’s a primer, the subthreshold mode of MOSFET modes of operation is omitted, leaving the focus on the linear (ohmic) mode where the MOSFET’s drain-source is conducting, but with a resistance that’s determined by the gate voltage. In the saturated mode the drain-source resistance is relatively minor (though still relevant), but the turn-on time (R_DS(on)) before this mode is reached is where major switching losses occur. Simply switching faster is not a solution, as driving the gate incurs its own losses, leaving the circuit designer to carefully balance the properties of the MOSFET.

For those interested in a more in-depth study of MOSFETs in e.g. power supplies, there are many articles on the subject, such as this article (PDF) from Texas Instruments.

Sketchy Logg Dogg Logging Robot Remote Control Hacking

February 20, 2024 by Maya Posch 9 Comments

When we last left [Wes] amidst the torn-open guts of his Logg Dogg logging robot, he had managed to revitalize the engine and dug into the hydraulics, but one big obstacle remained: the lack of the remote control unit. In today’s installment of the Logg Dogg series, [Wes] summarizes weeks of agony over creating a custom circuit based around a microcontroller, a joystick and a lot of relays and other bits and pieces to drive the solenoids inside the logging machine that control the hydraulics.

Giving the remote controller a bench test before connecting to the logging robot (Credit: Watch Wes Work)

Most of the struggle was actually with the firmware, as it had to not only control the usual on/off solenoids, but also a number of proportional solenoid valves which control things like the track speed by varying the hydraulic flow to the final drives.

This requires a PWM signal, which [Wes] generated using two MOSFETs in a closed-feedback system, probably because open loop controls with multi-ton hydraulic machinery are not the kind of excitement most people look forward to.

Ultimately he did get it sorted, and was able to take the Logg Dogg for its first walk since being rescued from a barn, which both parties seemed to rather enjoy. The background details of this machine and the project can be found in our first coverage.

We’re looking anxiously forward to the next episode, where the controller goes wireless and the sketchiness gets dialed down some more.

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