A Smarter PSU Converter Leaves The Magic Smoke Inside

May 24, 2018 by Lewin Day 24 Comments

Over the years, computers have become faster, but at the same time, more power hungry as well. Way back around the 386 era, most PCs were using the AT standard for power supplies. Since then, the world moved on to the now ubiquitous ATX standard. Hobbyists working on older machines will typically use these readily available supplies with basic adapters to run old machines, but [Samuel] built a better one.

Most AT to ATX adapters are basic passive units, routing the various power lines where they need to go and tying the right pin high to switch the ATX supply on. However, using these with older machines can be fraught with danger. Modern supplies are designed to deliver huge currents, over 20 A in some cases, to run modern hardware. Conversely, a motherboard from the early 90s might only need 2 or 3A. In the case of a short circuit, caused by damage or a failed component, the modern supply will deliver huge current, often damaging the board, due to the overcurrent limit being set so high.

[Samuel]’s solution is to lean on modern electronics to build an ATX to AT adapter with programmable current protection. This allows the current limit to be set far lower in order to protect delicate boards. The board can be set up in both a “fast blow” and a “slow blow” mode to suit various working conditions, and [Samuel] reports that with alternative cabling, it can also be used to power up other old hardware such as Macintosh or Amiga boards. The board is even packed with extra useful features like circuitry to generate the sometimes-needed -5V rail. It’s all programmed through DIP switches and even has an OLED display for feedback.

It’s an adapter that could save some rare old hardware that’s simply irreplaceable, and for that reason alone, we think it’s a highly important build. We’ve talked about appropriate fusing and current limiting before, too – namely, with LED strips.

Hybrid Bench Power Supply Can Also Hit The Road

May 18, 2018 by Dan Maloney 4 Comments

Everyone needs a bench power supply, and rolling your own has almost become a rite of passage for hackers. For a long time, the platform of choice for such builds seemed to be the ATX power supply from a computer. While we certainly still see those builds, a lot of the action has switched to those cheap eBay programmable DC-DC converters, with their particolored digital displays.

This hybrid bench and portable power supply is a good example of what can be accomplished with these modules, and looks like it might turn out to be a handy tool. [Luke] centered his build around the DPS3003, a constant current and constant voltage buck converter that can take up to 40-VDC input and outputs up to 32 volts at 3 amps. In bench mode, the programmable module is fed from a mains-powered 24-volt switching supply. For portable work, an 18-volt battery from a Makita drill slips into a 3D-printed adapter on the top of the case. The printed part contains a commercial terminal [Luke] scored on eBay, but we’d bet the entire thing could be 3D printed. And no problem if you change power tool brands — just print another adapter.

Those little eBay power supply modules have proven to be an enabling technology, at least judging by the number of clever ways we’ve seen them used lately. From this combination bench PSU and soldering iron supply to a portable PSU perched atop a battery, these things are everywhere. Heck, you can even reflash the firmware and make them do your bidding.

[via Dangerous Prototypes]

Making Custom Silicon For The Latest Raspberry Pi

April 12, 2018 by Brian Benchoff 75 Comments

The latest Raspberry Pi, the Pi 3 Model B+, is the most recent iteration of hardware from the Raspberry Pi Foundation. No, it doesn’t have eMMC, it doesn’t have support for cellular connectivity, it doesn’t have USB 3.0, it doesn’t have SATA, it doesn’t have PCIe, and it doesn’t have any of the other unrealistic expectations for a thirty-five dollar computer. That doesn’t mean there wasn’t a lot of engineering that went into this new version of the Pi; on the contrary — the latest Pi is filled with custom silicon, new technologies, and it even has a neat embossed RF shield.

On the Raspberry Pi blog, [James Adams] went over the work that went into what is probably the most significant part of the new Raspberry Pi. It has new, custom silicon in the power supply. This is a chip that was designed for the Raspberry Pi, and it’s a great lesson on what you can do when you know you’ll be making millions of a thing.

The first few generations of the Raspberry Pi, from the original Model B to the Zero, used on-chip power supplies. This is what you would expect when the RAM is soldered directly to the CPU. With the introduction of the Raspberry Pi 2, the RAM was decoupled from the CPU, and that meant providing more power for more cores, and the rails required for LPDDR2 memory. The Pi 2 required voltages of 5V, 3.3V, 1.8V, and 1.2V, and the sequencing to bring them all up in order. This is the job for a power management IC (PMIC), but surprisingly all the PMICs available were more expensive than the Pi 2’s discrete solution.

The MXL7704, with four switching power supplies. The four symmetric gray and brown bits are inductors.

However, where there are semiconductor companies, there’s a possibility of having a custom chip made. [James] talked to [Peter Coyle] of Exar in 2015 (Exar was then bought by MaxLinear last year) about building a custom chip to supply all the voltages found in the Raspberry Pi. The result was the MXL7704, delivered just in time for the production of the Raspberry Pi 3B+.

The new chip takes the 5V in from the USB port and converts that to two 3.3V rails, 1.8V and 1.2V for the LPDDR2 memory, 1.2V nominal for the CPU, which can be raised and lowered via I2C. This is an impressive bit of engineering, and as any hardware designer knows, getting the power right is the first step to a successful product.

With the new MXL7704 chip found in the Raspberry Pi 3B+, the Pi ecosystem now has a simple and cheap chip for all their future revisions. It might not be SATA or PCIe or eMMC or a kitchen sink, but this is the kind of engineering that gives you a successful product rather than a single board computer that will be quickly forgotten.

Converting Power Supplies For Antique Computers

March 22, 2018 by Bryan Cockfield 16 Comments

Just because something is “never used” doesn’t mean it’s good. [Inkoo Vintage Computing] learned that lesson while trying to repair an Amiga 500 and finding parts online that were claimed to be “new” in that they were old stock that had never been used. The problem was that in the last 30 years the capacitors had dried out, rendering these parts essentially worthless. The solution, though, was to adapt a modern PSU for use on the old equipment.

The first hurdle to getting this machine running again was finding the connector for the power supply. The parts seemed to have vanished, with some people making their own from scratch. But after considering the problem for a minute longer they realized that another Commodore machine used the same parts, and were able to source a proper cable.

Many more parts had to be sourced to get the power supply operational, but these were not as hard to come across. After some dedicated work with the soldering iron, the power supply was put to use running the old Amiga. Asture readers will know that [Inkoo Vintage Computing] aren’t strangers to the Amiga. They recently were featured with a nondestructive memory module hack that suffered from the same parts sourcing issues that this modification had, but also came out wonderfully in the end.

DIY Power Supply And TS100 Outlet Combo Shows Off Great Layout

March 19, 2018 by Donald Papp 18 Comments

Here’s a combination of two important electronics workbench tools into a single, cleanly-assembled unit. [uGen] created a DC power supply complete with a plug for the popular TS100 soldering iron, and it looks great! Most of the main components are familiar offerings, like a LM2596 DC to DC buck converter board and a DPS3003 adjustable DC power supply unit (we previously covered a DIY power supply based around the similar DPS5005.) The enclosure is an economical, featureless desktop instrument case whose panels were carefully cut to fit the necessary components. There’s one limitation to the combo: the unit uses a switch to either power an attached TS100 iron, or act as a general DC power supply. It cannot do both at once. So long as one doesn’t mind that limitation, it’s a nice bundle made from very affordable components.

It’s easy for something to look like a hack job, but to look clean and professional involves thoughtful measurement, planning, and assembly. Fortunately, [uGen] has supplied all the drawings and bill of materials for the project so there’s no need to start from scratch. Also, don’t forget that if the capabilities of the DPS power supply units leave you wanting a bit more, there is alternative firmware in the form of OpenDPS; it even offers a remote control feature by adding an ESP8266.

A DIY 5V-3V Switching Converter In The Space Of A TO-220 Package

March 13, 2018 by Dan Maloney 33 Comments

We’re suckers for miniaturization projects. Stuff anything into a small enough package and you’ve probably got our attention. Make that something both tiny and useful, like this 5-volt to 3.3-volt converter in a TO-220 sized package, and that’s something to get excited about. It’s a switch mode power supply that takes the same space as a traditional linear regulator.

Granted, the heavy lifting in [Kevin Hubbard]’s diminutive buck converter is done by a PAM2305 DC-DC step-down converter chip which needs only a few supporting components. But the engineering [Kevin] put into this to squeeze everything onto a scrap of PCB 9-mm on a side is impressive. The largest passive on the board is the inductor in 0805. Everything else is in 0603, so you’ll be putting your SMD soldering skills to the test if you decide to make this. Check the video after the break for a speedrun through the hand soldering process.

The total BOM including the open-source PCB only runs a buck or two, and the end result is a supply with steady 750-mA output that can handle a 1-A surge for five seconds. We wonder if a small heatsink tab might not help that; along with some black epoxy potting, it would at least complete the TO-220 look.

[Kevin]’s Black Mesa Labs has a history of turning out interesting projects, from a legit video card for Arduino to a 100-watt hotplate for reflow work that’s the size of a silver dollar. We’re looking forward to whatever’s next — assuming we can see it.

Continue reading “A DIY 5V-3V Switching Converter In The Space Of A TO-220 Package” →

What Are Those Hieroglyphics On Your Laptop Charger?

February 2, 2018 by Bob Baddeley 93 Comments

Look on the back of your laptop charger and you’ll find a mess of symbols and numbers. We’d bet you’ve looked at them before and gleaned little or no understanding from what they’re telling you.

These symbols are as complicated as the label on the tag of your shirt that have never taught you anything about doing laundry. They’re the marks of standardization and bureaucracy, and dozens of countries basking in the glow of money made from issuing certificates.

The switching power supply is the foundation of many household electronics — obviously not just laptops — and thus they’re a necessity worldwide. If you can make a power supply that’s certified in most countries, your market is enormous and you only have to make a single device, possibly with an interchangeable AC cord for different plug types. And of course, symbols that have meaning in just about any jurisdiction.