Xbox test power supply
This is one of my Xbox projects.
I'm gonna build a power supply which I can use to power and test Xbox motherboards and HDD/DVD drives with less risk of electrocuting myself...
There are three different types of power supplies used in Xboxes, and I'm planning to emulate support for all three, perhaps, eventually. Gonna start with 1.0 - 1.5 compatibility, then maybe 1.6.
Power board types
According to the guy from Everything I've Ever Learned About the Original Xbox Part 2- Motherboard Revisions there are three versions of powerboards:
- Type A: v1.0 - v1.1
- Type B: v1.2 - v1.5
- Type C: v1.6
I'm gonna start by making a Type B power supply. I should be able to reuse the Type B supply with a different external cable for Type A support. Type C I will do last and will make a whole new power supply for (if I have to, I will use a cable if I can, this will be reviewed later).
Plans
This is a quick drawing of how I intend to layout the components in the enclosure:
The divets for nuts will be put into the PVC sheet so it can clear the attached fans which will be bolted into one side. The PVC sheet will also need some other notches cut in order to accommodate the enclosure.
There will be two 20pin MOLEX pin headers attached to the epoxy laminate board (on the back left in the drawing on the right side), one internally to connect to the power board and one externally for attaching the external cables.
External power cable
An IEC C8 male Figure 8 power cable will run out of the enclosure on a short cable from the back right for use as the power inlet. Internally the inlet cable will be attached to an IEC C7 female adapter which will plug into the internal wiring. The internal wiring will take in power from another IEC C8 male adapter which will be wired to the switch and plugged into the power board. The power board is taken from an old Xbox (use a v1.2 - v1.5 Xbox for this purpose) and receives its power from a C7 female adapter, might need a right angled one?
Internal power wiring
The internal power wiring will connect the external power cable to the power board via the power switch. I got one of these 1Pc IEC 320 2-Pin C7 Female To C8 Male Right Angled AC Power Adapter Converter adapters for use on the power board.
Power switch
The power switch will be an E-TEN 1021 Handle High end Quality Silver Contact E-TEN(C)1321 DPDT 12MM 15A 250V AC ON-ON 6Pin Reset Rocker Toggle Slide Switch Waterproof switch. The switch will be attached to the internal wiring with two 6.3mm female lugs.
Enclosure
I ordered a bunch of enclosures so I could evaluate them. The ones I got are:
- 263x182x95 Black Box Outdoor Waterproof Case Plastic Box Electronic Project Case Instrument Waterproof Junction Box Housing
- 230x150x85 Outdoor Waterproof Case Enclosure Plastic Box Electronic Project Case Waterproof Junction Box for Electronics
- 250x150x100 Waterproof Plastic Enclosure Box Electronic ip67 Project Instrument Case Electrical Project Box ABS Outdoor Junction Box Housing
- 230x150x85 Transparent Cover Electrical Outdoor Electronic Power Sealed Case Enclosure Plastic Box Project Case Waterproof Junction Box
I'm gonna try with the first one (the black one). I got the PVC sheet to fit in that one.
PVC sheet
I'm gonna attach the internals to a PVC sheet, which I will bolt into the enclosure using spacers and probably some countersunk screws from the bottom.
I got 8 pieces of PVC cut to size from Plastics Online.
PVC Sheet - Cut Size Thickness : 4.5mm Side : 254 x 174(mm) Colour & Features : Clear Nanya PVC
A thickness of 4.5mm was a mistake, I should have got smaller.
Epoxy laminate board
I want some unclad (no copper) PCB material to mount my MOLEX 39-30-1200 Pin Header, Power, Wire-to-Board, 4.2 mm, 2 Rows, 20 Contacts, Through Hole Right Angle pin headers to.
Apparently PCB material is often glass-reinforced epoxy laminate, also sometimes called FR-4 (Fire Retardant 4). I searched for epoxy laminate board and found a bunch of options:
- 10pcs Clear Acrylic Sheet Transparent Plastic Board for Picture Frame Glass Replacement Project Display Painting Thickness 1.0mm
- Black Yellow Glassfibre Template Board Sheet Epoxy Glass Fiber G10 FR4 Fibreglass Plate For DIY Knife handle material 300x170mm
- 100x100x2.8mm Transparent Acrylic (PMMA) Tinted Sheets/plexiglass plate/acrylic plate black/white/red/green/orange
- Black Yellow Glassfibre Template Board Sheet Epoxy Glass Fiber G10 FR4 Fibreglass Plate For DIY Knife handle material 300x170mm
- Black White Clear abs plastic board solid flat sheet for sand table model making 200x300mm 1mm 2mm 3mm 5mm thickness
- 10x15cm Epoxy Fiber FR4 Copper Clad Plate Laminate Circuit Board Double Side PCB 150 x 100 x 1.5mm 10*15cm DIY
- PVC Hard Rigid Board White Black Gloss Plastic Sheet Waterproof Laminate Vinyl Flexible Soft Film Model Handmade Pad Panel Plate
- PVC Hard Rigid Board White Black Gloss Plastic Sheet Waterproof Laminate Vinyl Flexible Soft Film Model Handmade Pad Panel Plate
- 0.5mm Thick FR4 Glass Fiber Board 3240 Epoxy Board Yellow Epoxy Glass Cloth Laminate High Temperature Insulation Board Custom
I purchased:
- 100mmx100mm 2pcs, 1.5mm FR-4 Water Green G10 Insulation Board FR-4 3240 Epoxy Resin Board Glass Fiber Board 3D Printing
- 100mmx150mm 2pcs, 1.5mm FR-4 Water Green G10 Insulation Board FR-4 3240 Epoxy Resin Board Glass Fiber Board 3D Printing
External power cable
The external power cable will be of two parts, one part for motherboard power and the other part for hard drive power. Each part will be 1m long and connect to the enclosure with a single plug.
Inside the enclosure I will secure two MOLEX 39-30-1200 Pin Header, Power, Wire-to-Board, 4.2 mm, 2 Rows, 20 Contacts, Through Hole Right Angle pin headers to some epoxy laminate board, one exposed externally, and each attached to each other. The internal power board will connect to one of these pin headers, then an external cable will be made to connect to the other one. The external cable will have a MOLEX 39-01-2200 Connector Housing, Pull Tabs, UL 94V-2, Mini-Fit Jr. 5557, Receptacle, 20 Ways, 4.2 mm on one end with two cables attached:
- 4 cores, 18 AWG 0.75mm 1 meter, Shielded cable UL2464 18AWG 2 3 4 5 6 7 8 core 26 24 22 20AWG 10-24 core shielded wire Pure copper RVVP control wire signal wire
- 16 cores 2meters, 18 AWG 0.75MM, PVC cable wire14 16 20 24 40 30 cores RVV control wire 26 24 22 20 18 17 AWG pure copper core power cord sensor signal wire
The 4 core wire will be attached to a AMP - TE CONNECTIVITY 1-480424-0 Connector Housing, Commercial MATE-N-LOK, Plug, 4 Ways, 5.08 mm and there will be two ends for Type A and Type B support: