DIY – VoltLog

Victron BlueSolar MPPT Repair | Voltlog #487

Are you a DIY enthusiast or a renewable energy hobbyist? If you’ve ever encountered issues with your Victron BlueSolar MPPT75/10 charge controller, this repair guide is just what you need. In this comprehensive tutorial, we’ll walk you through the process of disassembling, diagnosing, and fixing a common problem with these popular charge controllers – a blown fuse.

The video begins by introducing the Victron BlueSolar MPPT75/10, a budget-friendly yet capable charge controller that can handle up to 75V solar panel input and 10A of current. Despite its affordability, this unit packs a punch with features like a serial interface for configuration and compatibility with the Victron Connect app.

The disassembly process is meticulously explained, highlighting the challenges of working with a glue-sealed enclosure. Using a spudger, the presenter carefully separates the blue plastic case from the black acrylic back panel, revealing the internal components and the conformal coating that protects the PCB.

Upon closer inspection, the root cause of the issue becomes apparent – a blown 20A automotive fuse responsible for protecting the battery port. The presenter replaces the fuse, and voilà, the charge controller springs back to life, much to the relief of DIY enthusiasts everywhere. But the tutorial doesn’t stop there.

It also addresses a potential design flaw in the terminal arrangement, which could lead to accidental polarity reversal and subsequent fuse blowouts. The presenter offers valuable insights and tips to avoid such mishaps in the future.

Raspberry Pi 5 on Steroids: The NVMe Upgrade | Voltlog #477

Are you looking to supercharge your Raspberry Pi 5’s performance? Look no further than upgrading to an NVMe SSD drive! In this comprehensive guide, we’ll walk you through the simple steps to configure and boot your Pi 5 from a blazing-fast Samsung MVME Drive. Forget the sluggish performance of traditional SD cards – an NVMe SSD will take your Pi 5 to new heights of speed and reliability.

While there are different tutorials out there, we’ll provide you with the most up-to-date method for March 2024, ensuring a seamless and hassle-free experience. We’ll be using the Raspberry Pi 5, along with the official cooling kit and power supply, the Geekworm P580 metal case, and the Geekworm X1002 PCIe shield.

These accessories, designed to work seamlessly together, will make the entire process a breeze. However, feel free to use alternative hardware, as the instructions provided should apply to most setups. The Raspberry Pi 5 is the first Pi to officially expose a PCIe interface, enabling a significant performance boost.

While not as fully-featured as desktop PCIe interfaces, the single PCIe 2.0 lane is still a game-changer. We’ll guide you through adapting the Pi 5’s flat flex connector to the M.2 form factor using the Geekworm X1002 shield, supporting various SSD sizes. One caveat to note is the current issue with Phison-based SSD controllers.

While progress is being made, for a plug-and-play solution, we recommend using a Samsung SSD or other reported-working drives. We understand the temptation of cheaper Phison-based options, but a little extra investment ensures a smooth sailing experience. Once the hardware is assembled, we’ll walk you through the software configuration, including updating your Pi OS, flashing the image to the NVMe drive, and setting the boot order to prioritize the PCIe drive.

We’ll even cover an experimental step to switch to PCIe Gen3 for an additional speed boost (though results may vary). By the end of this guide, you’ll have a Raspberry Pi 5 running at blistering speeds, perfect for demanding tasks or simply enjoying a snappier overall experience. We’ll share benchmark results, community comparisons, and tips for ensuring your setup runs optimally.

Designing An Automated PCB Test System | Voltlog #475

In this captivating project, Voltlog takes us on a journey to revolutionize the testing and programming process for their VoltLink boards. Tired of the repetitive and time-consuming manual approach, they set out to design a semi-automated test and programming fixture called VoltHub7. The VoltLink, a reliable USB-to-Serial adapter designed to solve the inconsistencies of cheap alternatives, is a crucial component in Voltlog’s electronics design work.

However, manually testing and flashing each board one by one proved tedious and error-prone, leading to the need for an automated solution. Enter the VoltHub7, a ingenious system that combines a custom-designed USB hub and a Raspberry Pi Zero 2W. At the heart of the design lies the Microchip USB2517, a configurable 7-port USB 2.0 Hi-Speed hub controller, carefully chosen for its capabilities and minimal external circuitry requirements.

Voltlog meticulously crafted the USB hub PCB, incorporating features like power distribution switches, status LEDs, and multiple power input options for flexibility. The integration of the Raspberry Pi Zero 2W directly onto the PCB, with its GPIO interfacing with the hub controller, streamlines the setup and enhances reliability.

But the true innovation lies in the use of pogo pins to interface with the Pi Zero’s test pads, eliminating the need for fiddly micro-USB cables and ensuring a robust connection. Voltlog’s attention to detail in the mechanical design, ensuring precise component alignment and fit, is a testament to their commitment to excellence.

The assembly process, complete with a black soldermask and yellow silkscreen for a visually striking result, culminated in a successful power-on and initialization of the hub and Pi Zero. Voltlog’s joy at witnessing the seamless integration of the components is palpable, inviting viewers to share in their excitement.

With the VoltHub7 up and running, Voltlog demonstrated its capability to connect and flash six VoltLink boards simultaneously, a task that would have been significantly more time-consuming with manual intervention. The future holds the promise of a custom test jig, further streamlining the process and eliminating the need for individual USB cables.

High Current Cigarette Lighter Connector Test | Voltlog #473

In the quest for reliable power accessories, Voltlog embarked on a comprehensive testing journey to evaluate the performance of various cigarette lighter connectors. These unassuming components play a pivotal role in powering our on-the-go devices, but cheap options from online marketplaces often fall short of their advertised current ratings, posing potential safety risks.

The lineup consisted of five connectors, ranging from budget-friendly AliExpress offerings to reputable brands from distributors like Digikey. Through a series of rigorous tests, each connector was subjected to its claimed current rating, with temperatures meticulously monitored using a thermal camera.

The results were eye-opening. Connectors rated for 10A and 15A from AliExpress quickly succumbed to the heat, emitting foul odors and melting within minutes. Even the Digikey connector, boasting a 20A rating and a datasheet, struggled to maintain safe temperatures, with internal components soldering themselves together due to the excessive heat.

Surprisingly, an unassuming AliExpress connector, rated for 20A, emerged as the unexpected winner. Its robust construction and thick middle pin seemed to dissipate heat more effectively, outperforming its pricier counterparts. However, the true lesson learned was that for continuous usage at high currents, a heavy-duty female socket with ample heatsinking capabilities is essential.

Voltlog discovered sockets designed specifically for this purpose, featuring ceramic bases, double metal shells, and extended lengths to maximize heat dissipation. This comprehensive testing underscores the importance of scrutinizing advertised specifications and prioritizing safety when it comes to electrical components, especially those handling high currents.

Voltlog’s dedication to uncovering the truth behind these unassuming accessories is a valuable contribution to the DIY electronics community.

InTheMail | Voltlog #472

Welcome to the first InTheMail episode of 2024 on Voltlog! In this installment, we dive into the latest gadgets and tools that have arrived at the lab, perfect for DIY enthusiasts, electronics hobbyists, and tech explorers alike. Kicking things off is a handy 24-pin ATX power supply on/off switch, a game-changer for anyone working with ATX PSUs.

No more fumbling with paperclips or risking short circuits – this nifty device features a dedicated on/off switch and even an LED indicator to signal when the PSU is powered on. Next up, we explore the world of cable sleeving with a nylon braided variety that can transform a mundane wiring job into a professional-looking masterpiece.

While not heat-resistant, these sleeves come in various diameters to accommodate different cable sizes, adding a touch of elegance to your projects. Continuing the theme of project essentials, we have mains voltage neon lamps in panel mount and glass bead variants, perfect for power presence indicators or test fixtures.

And speaking of testing, PTC thermistors offer a convenient way to simulate valve behavior when developing projects like the underfloor heating multi-channel valve controller board. Wireless enthusiasts will appreciate the crimpable N-Type RF connectors compatible with LMR400 cables, along with a press-fit variant that eliminates the need for a crimp tool.

And for those seeking a rugged, magnetic connector solution, the magsafe-style connector with its keyed design and solid construction is sure to impress.

Adding WiFi Connection To Rigol DHO800 Series | Voltlog #470

Unleash the Full Potential of Your Rigol DHO800 Series Oscilloscope with this Simple WiFi Hack! If you’ve been frustrated by the lack of built-in WiFi connectivity on your Rigol DHO800 series oscilloscope, fear not! Thanks to the ingenuity of the eevblog forum community, there’s a straightforward solution that will allow you to add wireless connectivity to your device with minimal effort.

The key to this hack lies in the Android operating system running underneath the Rigol DHO800 series oscilloscopes. By leveraging the pre-installed drivers for the Realtek RTL8188 chipset, you can transform your oscilloscope into a WiFi-enabled powerhouse with just a simple USB WiFi adapter. To accomplish this, you’ll need to acquire a TP-Link TL-WN725N USB WiFi Adapter (version 2 or 3), which is widely available and affordable.

These adapters are specifically designed with the Realtek RTL8188 chipset, ensuring seamless compatibility with the Android drivers on your oscilloscope. Once you have the adapter, simply connect it to your oscilloscope using a USB hub (along with a keyboard for initial setup), and follow the step-by-step guide provided in the video.

By accessing the Android operating system’s settings through keyboard shortcuts, you can easily connect to your desired WiFi network and enjoy wireless connectivity. While this hack may not be officially supported by Rigol and may exhibit some quirks (such as the GUI showing “network disconnected” despite being connected), the benefits far outweigh the minor inconveniences.

With WiFi connectivity, you can access the oscilloscope’s web control interface, transfer screenshots seamlessly, and even adjust the display brightness – a feature previously unavailable through the GUI.

Mastering PCB Cleaning with an Ultrasonic Cleaner! | Voltlog #467

Keeping your Printed Circuit Boards (PCBs) in pristine condition is crucial for ensuring optimal performance and longevity. While no-clean solder products are available, many fluxes and soldering materials leave residue that can corrode components, cause leakage currents, and compromise the overall aesthetics of your projects.

Fortunately, an ultrasonic cleaner offers a convenient and effective solution for thorough PCB cleaning. In this comprehensive guide, we’ll explore the benefits of using an ultrasonic cleaner, essential safety precautions, and a step-by-step process for achieving impeccable PCB cleaning results. The principle behind ultrasonic cleaning is a phenomenon called cavitation.

High-frequency sound waves create rapid pressure changes within the cleaning solution, generating countless microscopic bubbles that form and implode. As these bubbles collapse near the surface of the PCB, they release intense energy, dislodging dirt, contaminants, and residue from even the most hard-to-reach areas.

Before diving into the cleaning process, it’s crucial to observe a few safety precautions. Firstly, never run an ultrasonic cleaner dry, as it can overheat and damage the unit. Secondly, avoid using flammable liquids, as they pose a fire risk when heated. Lastly, consult component datasheets to ensure that the parts can withstand ultrasonic cleaning and submersion in liquids.

To achieve optimal cleaning results, choose a high-quality ultrasonic cleaner like the VEVOR Ultrasonic Cleaning Machine, which offers adjustable temperature, cleaning time, and ultrasonic power settings. Pair it with a suitable cleaning solution and deionized water for best results. The cleaning process itself is straightforward: fill the cleaner with the appropriate solution, submerge the PCB, and let the ultrasonic waves work their magic.

Post-cleaning steps include rinsing the PCB in deionized water and drying it with compressed air. One of the significant advantages of ultrasonic cleaning is its ability to dislodge residue from hard-to-reach areas, such as between component leads and under IC packages, ensuring a level of cleanliness unachievable through manual brushing alone.

Underfloor Heating Valve Actuator Board revD | Voltlog #466

In this captivating video, Voltlog unveils the latest iteration of their revolutionary ESP32-based Valve Actuator project – Revision D. Designed to streamline manufacturing and offer improved functionality, this enhanced version is a testament to the project’s ongoing evolution. Originally conceived as an open-source solution for controlling underfloor heating systems, the Valve Actuator project has gained a loyal following due to its compatibility with popular platforms like Tasmota, ESPHome, and Home Assistant.

With over a couple of hundred units already in operation, the RevD promises to further elevate the user experience and simplify assembly. One of the most notable updates in this revision is the ability to power the valves with a separate AC voltage, such as 24V AC. This feature caters to users with pre-existing underfloor heating systems, providing greater flexibility and compatibility.

Additionally, Voltlog has optimized the PCB design by transitioning from through-hole components to surface-mount technology (SMT) wherever possible, improving manufacturability and reducing potential errors during assembly. The RevD also introduces an innovative LED control feature, allowing users to turn the output status LEDs on or off via GPIO16.

This not only conserves power but also enhances the device’s versatility, making it suitable for discreet installations where visible LEDs are undesirable. Voltlog’s commitment to quality is evident in their collaboration with PCBWay.com, the official provider of printed circuit boards for the channel.

The limited-edition first batch of RevD boards boasts a stunning red solder mask with gold-plated ENIG finish, showcasing exceptional craftsmanship and attention to detail.

New 50Hz Thermal Camera Thermal Eye XH09 | Voltlog #464

The Thermal Eye XH09 from Xinfrared is a game-changer in the world of affordable thermal imaging cameras. With its impressive 256×192 resolution and a groundbreaking 50Hz refresh rate, this camera sets a new standard for outdoor enthusiasts and hunters seeking fluid and accurate thermal imaging capabilities.

The doubled refresh rate is the XH09’s standout feature, significantly enhancing the fluidity and real-time responsiveness of the thermal image. When tracking fast-moving targets or observing dynamic scenes, this rapid refresh rate ensures minimal lag, offering a seamless and detailed view of the surroundings.

Imagine being out in the woods, tracking wildlife or scouting for game – the XH09’s enhanced refresh rate ensures that even the slightest movements are captured swiftly and accurately, allowing for precise detection and tracking, giving you a notable advantage. While maintaining the high resolution and quality expected from Xinfrared, the XH09 also boasts practical features like an adjustable lens, allowing focal length adjustments from 9 to 13mm, and an observable distance of up to 500m for a 2m wide deer.

The included hard EVA carry case, USB Type-C cable, and mounting handle make it a convenient and portable solution for outdoor adventures. Beyond its outdoor prowess, the XH09 excels in household inspections, enabling you to detect potential insulation issues, check underfloor heating, or inspect electrical wiring with ease.

Its versatility and high-performance imaging capabilities make it a valuable tool for a wide range of applications.

2023’s Best Electronics Engineer Gifts | 462

As an electronics engineer, having the right tools can make all the difference in productivity and efficiency. With the 11.11 Shopping Festival just around the corner, it’s the perfect time to upgrade your workbench or surprise your engineer friend with a thoughtful gift. In this guide, we’ve curated a list of top-notch products that are sure to delight any tech enthusiast.

First on the list is high-quality ESD protection from Welectron. Their anti-static mats are not only durable and chemical-resistant but also free from unpleasant odors, ensuring a comfortable working environment. Whether you need a large mat for your workbench or a compact one for your computer desk, Welectron has got you covered.

Next up is the highly anticipated Raspberry Pi 5, a true powerhouse for any electronics engineer or hobbyist. With a significant performance boost and new features like PCIe Gen2 and an RTC module, this little computer packs a punch. As an official Raspberry Pi distributor, Welectron is the go-to source for snagging one of these coveted devices.

For those in need of a thermal camera, the options are diverse and tailored to different use cases. The DytSpectrumOwl is a top choice for PCB inspection on your workbench, while the UNI-T UTi260B and Infiray P2 PRO offer portability and macro lens capabilities, respectively. Whichever you choose, a thermal camera can unlock new levels of productivity and troubleshooting prowess.

The Sugon 8650 Hot Air Station is a game-changer for soldering and rework tasks. With its precise temperature regulation, massive power output, and user-friendly interface, this station can handle even the most demanding jobs with ease. Investing in this top-of-the-line tool is a surefire way to elevate your soldering skills.

Last but not least, the FNIRSI USB power monitors (FNB58 and FNB48) are sleek and highly capable tools for measuring USB power delivery. With their exceptional resolution, cable chip detection, and Bluetooth data logging, these monitors are a must-have for any engineer working with USB-C and power delivery protocols.