Category Archives: Electronics

Posts about electronics. Usually meaning electrical gadgets smaller than a proper computer.

Makergear M2 Upgrades

M2UpgradeComplete

The lab Makergear M2’s heated bed power supply died a few weeks ago, so we decided it was time for a serious upgrade, and set out to equip it with basically the best parts currently on the market, as we’re convinced the M2’s mechanical construction is still about as good as it gets.

Our M2 was a very early M2 from early 2013, with a split-voltage 19v/12v power supply setup, was on its second RAMBo after the first one melted around some connectors (high-current 12V is not a good idea), and RAMBo #2 was already abused with an external transistor on a heatsink wired in to the bed heater. It was also on its second hotend after the first one failed catastrophically during a sensor-separation incident some years ago, and was running a mutant Makergear V3b w/ 12V cartridge custom ordered to suit our machine.

So, shopping list:

Plus a whole boatload of connectors. For reasons known only to themselves, Panucatt doesn’t (or at least didn’t at the time) actually document which kind(s) of connectors are on the board, or offer a wiring kit. Some measurement and educated dead-reckoning got us there, so for anyone else looking, it uses Molex KK connectors in 2.54mm with both keys and locking ramp, in 2,3,and 4 positions. Specifically:

  • Motor (4x): 4 position, Molex p/n:0022013047 (Digikey)
  • Endstops/Probes (4x): 3 position, Molex p/n:0022013037 (Digikey)
  • Thermistors (2x): 2 position, Molex p/n:0008500114 (Digikey)
  • Crimp pins for the above (>32x): Molex p/n:0008500114 (Digikey)
  • Fan (2x): Standard 100mil pinheader, 3 positions. We used generic 3pos Dupont connectors from a Chinese kit.

I’d suggest buying at least one extra housing in each size, and a substantial number of extra crimp pins (They’re like a dime each in quantity, we bought 50 and had plenty to spare). I got a bit of a chuckle that they use 2.54mm molex KKs with locks and keys for everything except the fans, while standard PC fans use 3p molex KKs with locks and keys, but we’re running a 24V system so PC fans would be inappropriate anyway. I personally bought myself an Engineer PA-09 crimp tool because this crossed the line on crimp terminal projects where I’m willing to do it by futzing around with pliers.

M2PartsPile

The parts for this little project could have bought us a second low end printer, but that wouldn’t have given us any interesting new capabilities (particularly since we already have a Wanhao i3), and the machine we ended up with is approximately as capable as any FDM printer on the market.

The Makergear specialty parts are lovely, and improved in various ways as compared to even the newer M2 the lab PI owns personally; the power supply is in a ridiculously nice metal case and has ferrule-tipped color coded wires, the new bed heater covers the aluminum spreader more fully, is constructed with a very nicely machined wire and thermistor bracket, and includes a semi-rigid split-loom to keep it clear. I built a couple slightly weird cables and did some aggressive polish and longevity tweaks, including putting ferrules on everything going into a screw terminal (I did it partially because I decided I wanted an excuse to own a ferrule crimper and assortment). Probably the weirdest bit is that all the fans have male 2pos Dupont connectors on them, and the always-on cooling fans around the head are connected via a Y cable that terminates in a 4-position female dupont wired +24,Gnd,+24,Gnd (Picture has the wires routed wrong).
M2FanFork

All the cabling then retreated into the awesome mesh split-loom wire guides Makergear uses, and went on in more or less in the same configuration as the original cabling, including the weird little ball of wire at the back of the frame.

M2InitalElectronics

We also printed a number of parts for the upgrade, including a set of thingiverse user Neo Usagi’s E3D v6 40 mm Fan Duct and Extruder for MakerGear M2, which is an excellent design, though ours came out seriously over-tight and had to do a bit of grinding then perform the install with a vise – the dominant theory is that it was our fault for using 3 walls. Once fitted, it’s proven to be an excellent assembly with very good well-focused airflow and no tendency to bump into parts or the machine. The area around the head in this setup is extremely congested, and you must run the hot-end wires to the X+ side (the same side as the fan shroud mount) or they will hit the frame before the X endstop triggers, but once everything is situated it makes a nice package with no dangly bits. Even though it isn’t showing much noticeable difference in performance relative to late-model Makergear heads, I’m thoroughly impressed with the E3D hotend; the machining, the quality of the accessories in the kit, the efficacy of the heatbreak, the ease of assembly, everything is excellent, and in the mount we used, it only eats about 3mm of Z travel. They richly deserve their reputation.

M2E3DAssembly

As for the X5 Mini, two of the Makergear original mounting holes are close enough (though not perfectly aligned) to mount the board in a reasonable way with a pair of standard brass threaded standoffs, and a pair of those little barbed plastic motherboard standoffs trimmed to size to prevent tilting, all taken from the lab’s vast collection of PC assembly hardware. Leaving it exposed didn’t seem like a good plan, and we were seeing a slightly uncomfortable amount of warming on the motor drivers, so it needed a case and fan shroud. To that end we designed our own cover/enclosure/fan duct/bracket for the X5 Mini V3 and Viki2 (visible in the header picture – it has a 24V 40mm fan facing the Z motor blowing into the case, powered directly from an extra pair of PSU taps), a more detailed post about which will probably appear on profhankd’s thingiverse page shortly. We did all the printed components for the upgrade in our new favorite material, MakerGeeks’ “Raptor” PLA, incidentally in blue.

Software-wise, I’m satisfied but not enthused by Smoothieware. We’re now running this config.txt, which assumes 32x microstepping on all axes and produces very smooth, quiet motion with a minimum of idle heating. The major tuning efforts are just in the heater PIDs and on the Z movement, as the M2 design tends to make terrible noises if the Z movement is outside of a very narrow velocity window.

I wanted to like Smoothieware a lot more, and it is working well enough for the most part, but it is frankly kind of a garbage fire once you start looking at the code. It’s “modular,” but in an entirely ad-hoc way, so the parts don’t interact in entirely reasonable ways (Ex: AFIK it is currently incapable of setting up a “prevent cold extrusion” behavior, and would take pretty substantial changes to make it able to), with random parser fragments spread throughout the code. It also fails silently on unknown configuration keys, so I wasted the better part of a day on the extruder not responding after I wrote extruder.head.module_enable instead of extruder.head.enable because I misunderstood their half-updated documentation from when they hacked it to support multiple extruders. It looks and smells like a Reprappy hacker/hobbyst “move fast and break things” software, which is fine, but is so much so that I really don’t have high hopes for it maturing into something survivable without a complete redesign. This does make me feel better about sticking with LinuxCNC for my latest personal CNC project (Which I will eventually get to writing up and posting…).

Is ridiculously quieter than even the 24V stock M2, prints nicely at 150mm/s in PLA, heats up almost as fast as you can get a file loaded up and sliced, and can do so more or less independent and minimally attended. From a working current-gen 24v M2, none of the changes we made are particularly substantial upgrades, but from it’s state before the improvement is spectacular.

Posted in DIY, Electronics, General, Objects, School | 4 Comments

Macintosh LC Recap

I’ve done some invasive repairs on the Macintosh LC from my small fleet of vintage computers. I figure it’s worth writing up because there is a lack of detailed information about this kind of work on the ‘net.
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Posted in Computers, DIY, Electronics, General | 7 Comments

TP-Link Archer C7 with OpenWRT

I bought myself a TP-Link Archer C7 because the 2.4Ghz congestion in my apartment has become so terrible that my good old TP-Link WR1043ND (no 5Ghz radios) is no longer adequate, and the C7 was very well spoken of among reasonably-priced 802.11ac routers. It also has some nice perks like two on-board USB ports, so I can use it as a print server (with p910nd) and have USB storage for logs (vnstat & co.) and such attached without a separate hub. I wasn’t feeling quite motivated enough to buy and set up one of the NUC-like cheap SFF Intel boxes as a router like Ars Technica and Jeff Atwood have recently noted is an increasingly good plan, based largely on the dearth of ac WiFi cards that work reliably in host mode.

Some notes that may be of use to others, particularly about firmware replacement on recent models and throughput:
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Posted in Computers, Electronics, General, Objects | 14 Comments

Breaking In to your Own Devices

I gave an informal talk for the IEEE student branch about breaking in to your own devices this evening. I did the low-postable-content notes with live examples and links thing, but at least one person wanted to watch the video links, so here are the notes. There is something delightful about giving talks that require legal disclaimers. I don’t think there is anything in here that will get me in trouble…

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Clevo P650SE/NP8651

P650SET510Flat_web

My 5-year-old T510 has been showing its age, mostly by falling apart (speakers died, parts held on with gaffers tape, occasional probably-thermal GPU lockups, etc.) and I decided it was time for a replacement. Unfortunately, the laptop market right now has absolutely nothing appealing (clickpads everywhere!) so I gave up and bought a closest-match Clevo P650SE chassis that I could kit out myself. There are a couple annoyances, but overall it’s a nice machine. Really long detail notes including a bunch of Linux tweaking below.

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RFID Exploration

I recently picked up a USB RFID reader/writer pod to play with, partly to learn enough to be dangerous about the tech, and partly hoping to tamper with the RFIDs in the current university ID cards. I’m pretty sure I failed on the latter point, but am succeeding at the former in the process.

RFIDKit

Notes from the first round of fiddling with it follow.

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Galaxy S5

MyTouch 4G Slide vs. SGS5, flat dimensions.

MyTouch 4G Slide vs. SGS5, flat dimensions.

I got a Samsung Galaxy S5 (The T-Mobile flavor, SM-900T) a week ago. I’m pretty pleased with it overall, but many of the impressions worth sharing are not positive, particularly of the small-but-stupid variety. Much of the animus (and credit) is really for Google, not Samsung.
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New Chorder

I’ve been playing with chorded input devices for years, and got the itch again recently.

CNChorder
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3D Printing KC Talk

I gave a quick primer on 3D printing as a Keeping Current (CS departmental) seminar yesterday.

It’s not a great standalone deck but posted (in reduced quality, gs -sDEVICE=pdfwrite -dCompatibilityLevel=1.4 -dPDFSETTINGS=/ebook -dNOPAUSE -dQUIET -dBATCH -sOutputFile=/path/to/output.pdf /path/to/input.pdf is good magic).

It seemed to be well-received, printed objects were played with, thoughtful questions were asked, I think this is the first time I’ve given a 3D printing primer to a wider group and not been asked the “guns” question.

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WNR3500L Repair

Some years ago the KAOS lab bought a number of Netgear WNR3500L routers to use as network glue. A pair of them have been in constant service since 2011 in the lab and machine room, and both of those died in the last two weeks. I’ve finally satisfactorily tracked down the culprit, and figure it’s worth a quick write up.

The WNR3500L is a bit of a false-promise machine; it was sold as an “open router” with excellent community firmware support, but it has some pretty extensive blobs that mean it really only runs versions of DD or Tomato with a small range of 2.6 kernels.

I initially just swapped the first one to die out for a spare (which happened to be flashed with Tomato instead of DD, it was an experiment when they were first set up), and reloaded most of the settings by hand (we failed to save or document many of the settings elsewhere. Our fault.) until I had time to investigate. When the second one died, it became urgent.

WNR3500LScrew

Conveniently, the WNR3500L has a 3.3V RS-232-like serial port (115200/8/n/1) under an easily removed panel, retained by one small torx screw/pin thing (Both are out in the picture while I was figuring out which side was which).

WNR3500LBP

This leads to another victory for the Bus Pirate. Any 3.3V compatible UART adapter would work, but the bus pirate has much nicer cables for this sort of thing. In retrospect, those headers are correctly sized to just plug the female harness ends directly, but I used clips out of habit.

It turns out they were booting right up with only warnings, but the configuration was sufficiently garbled that neither the WLAN nor the Ethernet ports were coming up. I blew the first one’s settings away (note: at least on the old version these were running, reboot TWICE after clearing the NVRAM to get back to a consistent state: the first time it writes default values, the second time it boots cleanly). With the software-only nature of the problem established, I took more time to investigate the second one, at which point…

nvram show
[1310 lines excluded]
size: 32782 bytes (-14 left)

Well, There’s Your Problem.

Turns out the tiny little log fields for monthly traffic statistics filled up the nvram and were causing configuration corruption, and thus failures.

There are some forum threads and bug reports on the matter, and it was fixed about two years ago with a test to prevent writing past the end of the file, a default setting to automatically delete traff logs after 12 months, and various other enhancements. Now that we’re up and running again it isn’t desperate, but it looks like there is a DD release from mid-2013 with the fixes applied that still supports these things, and they are probably due to be re-flashed to keep this from happening again.

Lessons:

  • My home OpenWRT on a TP-Link 1043ND uses a connected USB key for logging and such. This is a much better behavior (like most things in OpenWRT: DD-WRT appears to be kind of an unmaintainble mess).
  • Keep an eye on appliances like routers, they’re still just computers.
  • Back up your damn configurations, or at least retain copies of the information required to regenerate them. Regenerating settings, especially when it involves manual tasks like MAC address hunting, sucks.

Other notes:

  • These things’ bootloaders appear to always look at 192.168.1.2 through the non-WAN ports for a tftp payload named vmlinuz. There may be a way to disable that, but I think I’d prefer to leave it on, since it only enables local attacks and provides a rescue mechanism.
  • The WNR3500L has a documented weakness about WAN-LAN throughput with various firmwares. Our uplink is actually good enough for it to matter, so perhaps one of the newer versions will improve that.
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