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How to Hack a Computer Atx Power Supply

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http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/ Food Living Outside Play Technology Workshop How to Hack a computer atx power supply by jmathews on December 3, 2011 Table of Contents How to Hack a computer atx power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Intro: How to Hack a computer atx power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Step 1: Removing the power supply from a computer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Step 2: Getting the PSU to work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Step 3: Mutilating the PSU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Step 4: Marking and drilling holes in the container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Step 5: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Step 6: Crimping and soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Step 7: Connecting all the wires up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Step 8: Hoooooray Your DONE :P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Step 9: Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Transcript
Page 1: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Food      Living       Outside        Play        Technology       Workshop

How to Hack a computer atx power supplyby jmathews on December 3, 2011

Table of Contents

How to Hack a computer atx power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro:   How to Hack a computer atx power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Step 1:   Removing the power supply from a computer case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 2:   Getting the PSU to work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 3:   Mutilating the PSU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 4:   Marking and drilling holes in the container . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 5:   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 6:   Crimping and soldering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Step 7:   Connecting all the wires up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 8:   Hoooooray Your DONE :P . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Step 9:   Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Page 2: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Intro:  How to Hack a computer atx power supplyHi everyone, this is my first instructable and it's about how to Hack an ATX computer power supply and then put it in a nice little case so it's ready for use. I have madeseveral of these before and decided to make an instructable about it. I will try to include as much detail in this instructable so sorry if I'm abit too wordy.

Yes i am aware that there are plenty of other hacks of this type but mine will be in lots of detail for anyone who has never hacked one before. This hack is paticularlyuseful when experimenting with motors, arduino or other mico controller circuits, to power a battery charger and any other electronic project that requires external power.I used the first one I made for about a year and it is still going strong, this is just V2.

First of all I would just like to say that the steps in this instructable are based around an Eagle DR-A350ATX power supply, unless you are useing the same power supplythen the information in the instructable should be used as a guide only. I also take no responsibility for any injuries, property damge caused by steps given in thisinstructable, however if you follow the steps correctly you shouldn't have any problems. Also one final not you are working with potentially high voltages (paticularly insidethe PSU its self) don't make the same mistake as me and work inside the PSU case while it is switch on or you may get a nasty shock.

TOOLS:philips head screw driverwire cutterswire stripperssoldering ironcrimpersfilesdrill with drill bitsDremel (Optional)

MATERIALS : COST1 ATX switching power supply $20 for a used one or pull one out of an old comp1 switch $212 banana plugs $ 14 (at jaycar)1 project box/ tupaware container $ 5 (at jaycar)heat shrink tubecrimping connectorsvarious bit's of wireziptiessuperglue or epoxy

all of these materials can be bought online at jaycar.com.au

Plese forgive my spelling it is rather bad :(

Thanks and have fun

Page 3: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Step 1: Removing the power supply from a computer caseYou can skip this step if you already have your PSU out of the computer case if not then read on.

Firstly you will need to remove the side pannel of your computer which is usually held in place by several screws on the rear of the case. Once these screws have beenremoved slide the panel towards the rear of the case and then lift it up and out (Your case may be different). Next identify the PSU and disconnect all of the wires leadingfrom it, now remove the four screws that hold the psu in place on the rear of the computer case. Now just pull the power supply out and your done.

Image Notes1. Remove this screw2. And this one

Page 4: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Image Notes1. Pull the case back towards the rear ports

Image Notes1. Now lift it up

Image Notes1. remove this one2. remove this one3. Remove these two4. Remove these two5. remove the one in here

Image Notes1. Remove these two

Page 5: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Image Notes1. Drape these cords over the side

Image Notes1. Remove this screw2. Remove this screw3. Remove this screw4. Remove this screw

Image Notes1. now just pull it out and then up.

Image Notes1. Your removed Atx power supply ready to be hacked

Step 2: Getting the PSU to workNow that you have your PSU plug it into the wall and try to turn it on. WOW IT DOESN'T WORK , that's perfectly normal, because there is no load being placed on thePSU. To fix this take a piece of shielded wire, strip the ends and place one end into the a black wire pin on the biggest plug. Now place the free end into one of the othercoloured wires and turn on the PSU, if the fan spins up then it is working if not then take the end in the coloured wire terminal out and place it in another port. Try thegreen wire first ! also sorry about the picture quality, not sure what went wrong.

(On a Standard ATX power supplyyellow =12v,red = 5v,orange = 3.3v,white = - vblue =- vpurple = vgreen = load wire ( the one that we need to turn it on)

Now that we have eablished the load wire connect a multimeter set to VDC to the psu pins to be sure that the voltages listed above are correct, if they aren't write themdown on a piece of paper.

Page 6: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Image Notes1. Any pin that leads to a common or negative wire

Image Notes1. Pluged into the green wire, to turn it on

Step 3: Mutilating the PSUNow it's time for the fun step, where we get to cut apart the PSU. Begin this by taking the wire cutters and cutting off all of the computer connectors as close to the top ofthe terminal as possible. Then cut away any zipties holding the cables together. With this done open the PSU case by undoing the four screws in the top (Make sure youunplug the PSU before you do this!) , now seperate the two halves of the case and then remove the cables from the black fitting that is holding them in the case. Now ifyou DON'T want to use negative voltages or the +5vsb (as in my example) cut them off inside the case and the place a piece of heatshrink tube over the top to preventshort circuits. If you do want to have negative voltage then just make sure in later steps you follow the additional instructions.

Once again sorry for the picture quality

Page 7: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Image Notes1. USE WIRE CUTTERS NOT TIN SNIPS

Image Notes1. All the connectors cut off

Image Notes1. Zipties removed

Image Notes1. Undo this screw2. Undo this screw3. Undo this screw4. Undo this screw

Page 8: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Image Notes1. These are the wires to cut short so they fit inside the case

Step 4: Marking and drilling holes in the containerNow just put your PSU aside for a moment while we work on the case that will house the banana plugs and the power switch. You can use any old tupaware container, Ijust found it easier to by one from jaycar because they have a pre marked drill grid that makes drilling the holes quick and easy. I will post a picture of my layout howeverit is entierly up to you. Once you have marked out your holes drill them out with the recomended drill bit size slowly to avoid cracking the plastic on the other side. thengive then a quick once over with a smooth file just to remove and burs. Do the same for your switch hole however if it is a square hole, you can use a smaller drill bit andthen file out the hole using a square or triangular file or use a dremel.Now see how your container is going to be positioned along with the PSU and drill a hole large enough for the cables to fit through. Once done file it to remove any burs.

If your adding the negative voltage wires in add in extra holes for them, you will also need extra banana plugs.

Image Notes1. Drill here2. Drill here3. Drill here4. Drill here5. Drill here

6. Drill here7. Drill here for your switch8. Drill here9. Drill here10. Drill here11. Drill here12. Drill here13. Drill here

Page 9: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Image Notes1. Expand this hole using a file of a dremel

Image Notes1. The hole for the cables

Step 5: Now take all of your banana plugs and screw them into the holes you have just made being sure to tighten them completely. Then add in the switch and super glue orexoxy it in.

Image Notes1. I broke the banana plug for this hole :(2. I also broke this one :(

Page 10: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Image Notes1. Gluing in the switch with super glue

Image Notes1. The switch glued in

Step 6: Crimping and solderingSelect three orange, red, yellow and six black wires as well as one more thin black wire and feed them through the hole in the side of the case. Now add a small circularcrimping connector to each of the wires accept the thin black one. Once you have crimped all of the wires pull out the unnecissary wires and then arrange them in theirrespective colour groups, leaving the green wire in the case. Place all of the wires back in the black wire guard and then put the PSU case back together. Now take thegreen (or what ever your load wire was) and the thin black wire and solder them to the switch in any order, it doesn't matter.

Image Notes1. My first attempt at organising the wires

Image Notes1. My second attempt was much better2. Place the wires back in the guards

Page 11: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Image Notes1. make sure all the wires are in the guard or you could get a short circuit

Image Notes1. Soldering the switch wires in

Step 7: Connecting all the wires upNow the real fun begins, NOT . When it comes to connecting the wires it turns out there is a right and a wrong way to do it, my first attempt was the wrong way. I will nowtell you the way to do it that works and looks neat.

Start closest to the switch with the three terminals working from left to right1.go to the first negative terminal and connect up two of the black wires2.then move to the next row of three terminals3.so on and so forth.... you get the idea4.

with this completed you will have a lid half attached and a lot of cables dangling around every where. Feed these cables in to the box in an orderly fassion and ly them inthe bottom. Now seperate them agian into colour groups and then place some heat shrink over the wire, pushing it pown. then fold the top of the wire so it forms a sort ofoval circle and contacts the rest of the wire, slide the heat shrink over the top and then shrink it inplace. Repeat this with all the loose wires and then ziptie them togetherjust to be safe.

Page 12: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Image Notes1. Ignore the three wires connected to this terminal... there should only be two

Image Notes1. Mess of wires

Image Notes1. The wires heat shrunk and ziptied together

Step 8: Hoooooray Your DONE :PWell almost the last thing you need to do is place the lid on and then screw it in place and then your done, that's all there is to it. Just turn it on and hook up a multi meterto be sure it's working.

Go on to the next step if your having problems.

thanks very much for reading my instructable and enjoy your new hacked PSU :P

Page 13: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

Step 9: Trouble shootingWell your obviously here if your having problems getting your PSU to work,

SO have you tried turning it off and on again ?- The IT CROWDwell have you?if you havethenusing a multi meter to check if it's working

check the switch on the rear off the PSU unit, ensure that it is on1.Check the switch on the switch pannel ensure that it is on2.unscrew the top pannel and using a wire bridge short between the two switch terminals ( if this makes it work replace the switch)3.check all of your connections and that they are correct4.

If this check list fail to fix your problem post in the comments below, with,

What the problem isyour power supply specshow old it isany other relevant information (stuff that occured whilst building, anything that may be a possible cause, dropping the PSU or extreme levels of dust.

If you follow these steps i will be more than happy to help :P

Jack

Page 14: How to Hack a Computer Atx Power Supply

http://www.instructables.com/id/How-to-Hack-a-computer-atx-power-supply/

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