USB-C Power Supply Pushes Almost 2 KW

January 10, 2024 by Bryan Cockfield 40 Comments

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.

USB-C Power For Ham Radio

September 5, 2023 by Bryan Cockfield 28 Comments

Even though manufacturers of handheld ham radios have been busy adding all sorts of bells and whistles into their portable offerings, for some reason, many of them lack a modern USB-C port. In the same vein, while some have USB for programming or otherwise communicating between the radio and a computer, very few can use USB for power. Instead , they rely on barrel jacks or antiquated charging cradles. If you’d like to modernize your handheld radio’s power source, take a look at what [jephthai] did to his Yaesu.

In the past, USB ports could be simply soldered onto a wire and used to power basically anything that took 5 VDC. But the radio in question needs 12 volts, so the key was to find a USB-C cable with the built-in electronics to negotiate the right amount of power from USB-PD devices. For this one, [jephthai] cut the barrel connector off his radio’s power supply and spliced in some Anderson power pole connectors so he could use either the standard radio charger or one spliced onto this special cable.

With this fairly simple modification out of the way, it’s possible to power the handheld radio for long outings with the proper USB battery bank on hand. For plenty of situations this is much preferable to toting around a 12 V battery, which was the method of choice for powering things like QRP rigs when operating off-grid.

Running The Xbox Series S On A USB Powerbank

February 17, 2023 by Lewin Day 9 Comments

Home consoles were never intended to be made portable, though enterprising hackers have always pushed the boundaries with various tricks and innovative builds. [Robotanv] hasn’t built a fully handheld Xbox Series S, but he has demonstrated one neat trick: making one run on a USB powerbank.

The project starts with an Anker USB-C powerbank, chosen for its ability to deliver a mighty 140 watts. It’s hooked up to a ZY12PDN USB-C trigger board, which enables the powerbank and tells it which voltage to output. It’s set up to run at 20 volts, which is too much for the Xbox, which prefers 12 volts. The reason for this is that the only way to get the full power out of the powerbank is to run at its maximum voltage. A buck converter is used to step down the voltage to 12 volts.

As for the console itself, a lot of disassembly is required, but minimal modifications. Just two wires connect the power supply to the Xbox’s motherboard. Subbing in your own 12 volt supply here is enough to run the console without any problems.

Running the Xbox off the powerbank, along with an external screen, [Robotanv] is able to play Cyberpunk 2077 for an about hour before the juice runs out. While we’d love to see the whole setup duct-taped together into a ersatz Xbox portable, it would probably be a little messy. [Robotanv] has big plans for the future of the project, though, and we can’t wait to see what those are. Continue reading “Running The Xbox Series S On A USB Powerbank” →

USB-C Charging On Your ThinkPad, One Step At A Time

January 30, 2021 by Tom Nardi 10 Comments

Hackers love their ThinkPads. They’re easy to work on, well documented, and offer plenty of potential for upgrades. For the more daring, there’s also a wide array of community-developed modifications available. For example, [Berry Berry Sneaky] has recently put together a step-by-step guide on swapping the common ThinkPad rectangular charging port (also used on ThinkBooks and other Lenovo machines) for USB-C Power Delivery.

Now to be clear, this is not a new concept. But between freely sharing the STL for the 3D printed adapter, providing a full parts list, and providing clear instructions on how to put it all together, [Berry Berry Sneaky] has done a fantastic job of making this particular modification as approachable as possible. For the cost of a common PDC004 Power Delivery “trigger” module and a bit of PETG filament, you can add yet another device to the list of things that work with your shiny new USB-C charger.

While not strictly necessary, [Berry Berry Sneaky] recommends getting yourself a replacement DC input cable for your particular machine before you crack open the case. That will let you assemble everything ahead of time, making the installation a lot quicker. It will also let you keep the original rectangular power jack intact so you can swap it back in if something goes wrong or you decide this whole unified charging thing isn’t quite what you hoped for.

Not a member of the ThinkPad Army? No worries. We’ve seen a lot of interest in using these configurable USB-C trigger modules to upgrade all manner of devices to the new Power Delivery standard or sometimes put together custom battery chargers for their older mobile gadgets.

USB-C Programmable Power Supply For Any Project

January 16, 2021 by Danie Conradie 57 Comments

USB-C Power Delivery 3.0 (PD3.0) introduces a new Programmable Power Supply (PPS) mode, which allows a device to negotiate any supply of 3.3-21 V in 20 mV steps, and up to 5 A of current in 50 mA steps. To make use of this new standard, [Ryan Ma] create the PD Micro, an Arduino-compatible development board, and a self-contained software library to allow easy integration of PD3.0 and the older PD2.0 into projects.

The dev board is built around an ATMega32U4 microcontroller and FUSB302 USB-C PHY. The four-layer PCB is densely packed on both sides to fit in the Arduino Pro Micro Form factor. The board can deliver up to 100W (20 V at 5 A) from an appropriate power source and shows visual feedback on the PD status through a set of LEDs.

The primary goal of the project is actually in the software. [Ryan] found that existing software libraries for PD take up a lot of memory, and are difficult to integrate into small projects. Working from the PD specifications and PD PHY chip data sheet, he created a lighter weight and self-contained software library which consumes less than 8 K of flash and 1 K of RAM. This is less than half the Flash and RAM available on the ATmega32U4.

[Ryan] is running a Crowd Supply campaign (video after the break) to get some of these powerful boards out in the wild, and has released all the source code and schematics on GitHub. The PCB design files will be released during the last week of the campaign, around 25 January 2021.

USB-C and power delivery are not simple standards, but the ability to add a high-speed data interface and a programmable power supply into almost any project has real potential.

Continue reading “USB-C Programmable Power Supply For Any Project” →

A Plethora Of Power Delivery Potential

October 23, 2020 by Kerry Scharfglass 17 Comments

Here at the Hackaday we’ve been enjoying a peculiar side effect of the single-port USB-C world; the increasing availability of programmable DC power supplies in the form of ubiquitous laptop charging bricks. Once the sole domain of barrel jacks or strange rectangular plugs (we’re looking at you Lenovo) it’s become quite common to provide charging via the lingua franca of USB-C Power Delivery. But harnessing those delectable 100W power supplies is all to often the domain of the custom PCBA and firmware hack. What of the power-hungry hacker who wants to integrate Power Delivery in her project? For that we turn to an excellent video by [Brian Lough] describing four common controller ICs and why you might choose one for your next project.

A superb illustration from the TS100 Flex-C-Friend documentation

[Brian] starts off with a sorely-needed explainer of what the heck Power Delivery is; a topic with an unfortunate amount of depth. But the main goal of the video is to dive into the inscrutable hoard of “USB C trigger boards.” Typically these take USB on one side and provide a terminal block on the other, possibly with a button or LED as user interface to select voltage and current. We’ve seen these before as laptop barrel jack replacements and TS100 power supplies but it’s hard to tell which of the seemingly-identical selection is most suitable for a project.

The main body of the video is [Brian’s] detailed walkthrough of four types of trigger boards, based on the IP2721, FUSB302, STUSB4500, and Cypress EZ-PD BCR. For each he describes the behaviors of it’s particular IC and how to configure it. His focus is on building a board to power a TS100 (which parallels his TS100 Flex-C-Friend) but the content is generally applicable. Of course we also appreciate his overview of the products on Tindie for each described module.

For another angle on Power Delivery, check out this series of posts by [jason cerudolo], a perennial favorite. And don’t miss his classic project, the USB Easy Bake Oven.

Have JBC Soldering Handle, Will USB-C Power Deliver

April 21, 2020 by Kerry Scharfglass 8 Comments

Frequent converter-of-tools-to-USB-C [Jana Marie Hemsing] is at it again, this time with a board to facilitate using USB Power Delivery to fuel JBC soldering iron handles. Last time we saw [Jana] work her USB-C magic was with the Otter-Iron, which brought Power Delivery to the trusty TS100 with a purpose built replacement PCBA. This time he’s taking a different approach by replacing the “station” of a conventional soldering station completely with one tiny board and one giant capacitor.

If you’ve been exposed to the “AC fire starter” grade of soldering iron the name JBC might be unfamiliar. They make tools most commonly found with Metcal’s and high end HAKKOs and Wellers on the benches of rework technicians and factory floors. Like any tool in this class each soldering station comes apart and each constituent piece (tips, handles, base stations, stands, etc) are available separately from the manufacturer and on the used market at often reasonable prices, which is where [Jana] comes in.

The Otter-Iron PRO is a diminutive PCBA which accepts a USB-C cable on one side and the connector from a standard JBC T245-A handle on the other. JBC uses a fairly typical thermistor embedded in the very end of the iron tip, which the Otter-Iron PRO senses to provide closed loop temperature control. [Jana] says it can reach its temperature setpoint from a cold start in 5 seconds, which roughly matches the performance of an original JBC base station! We’re especially excited because this doesn’t require any modification to the handle or station itself, making it a great option for JBC users with a need for mobility.

Want to make an Otter-Iron PRO of your own? Sources are at the link at the top. It sounds like v3 of the design is coming soon, which will include its own elegant PCB case. Check out the CAD render after the break. Still wondering how all this USB-PD stuff works? Check out [Jason Cerudolo’s] excellent walkthrough we wrote up last year.

Continue reading “Have JBC Soldering Handle, Will USB-C Power Deliver” →