________________________________________________________________________ / \ | HOW TO TURN AN AMIGA 500 INTO A TOWER OF POWER (Mega Hack) | | UPDATE VER 1.5 By: Thomas Weeks 10-14-96 | | tweeks@texas.net and http://lonestar.texas.net/~tweeks | \________________________________________________________________________/ Ok Folks... You all (well not all, but quite a few of you) asked for it so here it is! Please excuse spelling errors and type-o's. I did this on a floppy based 1200 via "ed" on a FRENCH KEYBOARD no less! This updated version corrects the case dimensions that I had previously given from memory in V1.1 (and were wrong), fixes errors in PAL HACK, shows some digitized pictures of the final product (and a picture of ME to boot!), and also includes a schematic and PCB mask for making your own CDTV/A2000 KB to A500 adaptor that will allow a normal "Three Finger Salute" warm boot with a CDTV/2000/3000 keyboard. It also reveals an error found in the original C= A500 schematics regarding the _KB_CLK and _KB_DATA lines (they were backwards!). John Baker and I came to this conclusion after much email discussion and final verification with Dave Haynie. This version also includes my corrected (from 1.4) NTSC/PAL switch hack. Although this hack COULD be reduced to a SIMPLE SPDT switch, I added a bit to it to give switch deboucing, TTL buffering, and a nice LED indicator to show what mode you are in (LED ON=PAL). I decided to include this small hack because it works PERFECTLY with the tower hack and allows one to use the tower case's RESET switch to change video modes, and the TURBO LED as the PAL/NTSC indicator. ARCHIVED FILES: --------------- -NOW!......... This TEXT Document file. Sorry it's so unpolished. -ARTICLE...... A funny article that I wrote and submitted upon request to OACES Amiga Users Group of OK city and which was also published in Amiga Report 3.04 (Feb. 12, 1995). -HACK_PICS.... Slide Show of the hacks themselves & the NTSC/PAL switch hack. (use arrows and esc. to move around and quit) includes: -TOP_1.PIC.... Full Page IFF Documentation File. 1 of 2 -TOP_2.PIC.... "" "" 2 of 2 -NTSC-PAL_Switch_hack.iff...The NTSC/PAL hack to allow switching between the two video modes in lieu of using PAL "boot disks". -PCB_&_SCHEMS. Slide Show of the CDTV/A2000->A500 KB Reset circuit hack (NOTE: Schematic by John Baker(jdb8042@blkbox.com), PCB layout by me). Also shows a 741 op-amp version prototype. includes: -PCB_KBRST_LM339.iff...PCB Mask for the etching of the PCB -PCB_KBRST_SCEHM.iff...The schematic by John Baker and I -PCB_741_RESET.jpg.....A JPEG of my 741 prototype -PICS......... Slide Show of the digitized pictures of the completed hack and then a picture of me... (oh joy...) includes: -AMY-2.JPG.... A front shot of the completed tower hack -AMY-3.JPG.... A side shot with case off (shows old A500 KB) -AMY-4.JPG.... A side shot showing final appearance -ME.jpg....... Yours truly... ;v) Please do not modify or separate any of these files in any way. I maintain full copyrights on this material under the Shareware Agreement. (Allowing only for forms of distribution (e.g. Fred Fish, Aminet, etc.) ) If you USE my hack docs to make your own tower, and feel obliged to thank me in monetary form... Heck.. I ain't too proud to take yer money! DESCRIPTION: ------------ The HACK_PICS images that are included in this archive step you through the process of putting your Amiga 500 into a Black Diamond Mid Tower Klone Case. The use of the DIAMOND CASE I mention is important in that the dimensions were specifically selected so that everything fits nicely. In fact, after cutting into my machine and actually starting the hack I was PLEASED to find how nicely the case I had chosen fit the A500 mother board! The two screw holes next to the Zorro I connector matched up PERFECTLY to two of the cases mother board mounting holes and positioned the board DEAD against the upper inside part of the case! This left me a little room to possibly add a Zorro II adaptor some time in the future and maybe add a 24 bit graphics board and an Emplant (an A500 geeks dream!). Now as I have begun researching it, it does not appear that this is possible while running an A530 due to bus congestion. Oh well... An A4000T is looking better all the time... Anyway... Continuing... This specific case was chosen for it's nice roomy dimensions. There is plenty of room to mount an A500 mother board vertically and have room horizontally (in the BOTTOM of the case) to mount an A530 or other A500 type expansion device(s). The PCB_KBRST_LM339.iff and PCB_KBRST_SCEHM.iff pics show how to construct a small 1 chip PCBoard or air hack to generate the _KB_RESET signal that the CDTV/A2000/A3000 keyboards lack. The signal is derived from the _KB_CLK line and then in fed into the A500 mother board (pin 3) where the stock KB signal was hooked up. The actual construction of the project can be done in one of two ways. The first is to go ahead and use the PCB mask I have made up to print out (at 360x360 DPI resolution for correct pin dimensions). After printing it out, you can either use the photo-chemical method or use the iron on method (using special Copier/Laser Printer transfer paper that allows the ironing on of the PCB mask). This special Laser Printer/Copier acetate can be purchased from Digi-Key (800-344-4539) for around $1.50/sheet in packs of 10. This substance allows you to copy PCB masks onto a special acetate which can THEN be ironed directly onto the copper PCB and etched! No holes need to be drilled in the PCB using this method. I simply "bent" the lower portion of the chips pins and mounted the chip and components onto the PCB as one would a surface mount devices. This method is easy and very stable. I have included a JPEG image of one of my 741 version prototypes (the last picture in the KB_HACK slide show) in which I used this "iron on" etching method. It should be noted, that although the schematic HAS been tested, the LM339 PCB mask I created has not as I used the second "in air" method for the LM339 version of the circuit. The second method is a simpler and quicker method for small one chip projects. This method allows one to simply build the circuit "in air" on no form of PCB (except a ground and Vcc Plane if you wish: see below for a rough example). Copper GND Plane ==========> <---Shorts to both sides of copper / || | \ Components & GND/Vcc Jumpers R C| R C | / | \ | --|-|--|---|-|-- LM339 CHIP | || || || || || | -||-||-||-||-||- \ | | / Components & Vcc leads R C | R | | | | Copper Vcc Plane ============> <--Shorts to both sides of copper Hot glue can be used for both a strengthening and insulating material. It may SOUND like a kludge... and it is.. but for a simple one chip project, it works very well and is MUCH faster than etching a whole PCB for one chip and a few components. SUPPLIES YOU WILL NEED:(Main T.O.P.Hack) ---------------------------------------- (Tried to keep it mostly available from Rat Shak) -An A500 Like... Huh... Huh huh... yea.. -Diamond Tower Case Texas Computer Whse:409-693-6635 And it has to be BLACK! You want people to know that "Dis Ain't No Kolne"! (yea it comes w/250W pwr sply) -Soldering Iron A adjustable iron is best, but a 35W weller is fine. -Solder Duhhh -Liquid Weld Epoxy Great stuff... JB Weld can't TOUCH this stuff! -Diag. Cutters A basic -Needle Nose Pliers I use my leatherman (they blow away swiss army knives!) -Phillips Screw Drv. "" "" -Xacto Knife "" "" -Wire Wrap Wire Rat Shak (I like the blue colored stuff best) -Metal Cutter Nibbler will do, but I HIGHLY RECOMMEND getting a nice (or cheap) Dremel Moto tool! It has been a REAL SWEET investment that I have used the HELL out of! I really can't over emphasize the convenience of this multi purpose tool! If you use the Nibbler, you will Also need a drill to create holes to start the nibbler. -Wire Strippers yea.. -16 Gauge Stranded For doing the Power Adaptor thingie (IFF 2, Fig 4.1) -Female Zorro I Edge Connector I did not HAVE one so I built one using a Rat Shak supplied ISA slot that I dremeled to death and epoxied. Sounds nasty, I know, but it's damn solid and works great! See IFF 1 for more info. -Connectors IDC DSUBs: 4 25pin M, 4 25pin F, 2 9pin M, 2 9pin F 2 RCA in line Males, 2 RCA Case mount F 1 "AT" Mother Board Power Connector (removed of course) (no source known. I just ripped one of a dead AT) 2 IBM AT keyboard extension cables (3ft each) 50 pin IDC SCSI connectors if you're doing SCSI -Heat Shrink Grab bag available at Duh Shack. -50 Cond Rib.Cable About 30-40 inches to be safe (Not Incl. SCSI routing) -220 Ohm 1/4W Res For Power LED reroute to front of case -3.5" to 5.25" Drive Adaptor Kit With Floppy Drive Face Plate -2 3ft AT Key Board Extension Cables For bringing the keyboard out into the daylight whilst (for A500 KB mod) keeping it usable. I got mine from PC Accessories for like 2 bucks each. -Hmmmm I know that I'm forgetting something... SUPPLIES YOU WILL NEED:(CDTV/A2000 KB HACK) ------------------------------------------- -SS Copper PCB This is only if you are planning on dumping my PCB mask to copper PCB and etching your own little board. I tried this method using 741 op amps but it seems to much of a pain to justify. The second version I made used the illustrated LM339 Quad Op-Amp and just built it "in air" which is actually very stable and reliable for such single chip projects. -LM339 Quad Op-Amp Can be had at Rat Shack -Connectors For CDTV KB: 5 Pin Female Mini-DIN. Hard to find. For A2000/3000 KB: 5 Pin Female DIN. -5 Cond. Cable Should use shielded cable to keep out those pesky EMPs! -Project Case Since it will be internal, you can improvise. I used a little Rat Shack project case on my 741 version. On the LM339 "air" version I used a little plastic case that looked like a 35mm film bottle with a hinged top. -1k 1/4 watt res qty:5 -10k 1/4 watt res qty:1 -47k 1/4 watt res qty:1 -22uF Elec. 16V Cap qty:2 -0.1uF Disc Cap qty:1 -1n4148 Diode qty:1 I have had a lot of questions about the tower cases price, and where to get it, so to be on the safe side; I will tell you where I got MINE. I did some tech work for a friend of mine in College Station Texas who owns his own computer place and had him track down this case SPECIFICALLY for it's dimensions. I hear that there are SEVERAL various "Diamond" cases, so to be safe, you may want to just stick with this source... Unless you're feeling lucky and have a fetish for digging through Computer Shopper. As I mention in the IFF's, I do not have access to the REAL dimensions (or any of my schematics) and so this whole thing (& listed values) is from memory. [UPDATE: Dimensions in schematics are now corrected from previous versions.] The case its self is VERY nice and built like a tank! It is nicer than any case that I have seen in any PACKAGE Klone deal (I've assembled and worked on many PC's over the years). If you decide to take the plunge and build this project, the guy to contact is Ollie at Texas Computer Warehouse at phone 409-693-6635. He usually only does big contract related sales, but if you tell him that you are an Amiga user and that *I* sent you his way, he'll take care of you. I'm not sure what the case is going for but it should be between $140 and $160 and I have no idea about the shipping costs. The best thing to do is call him about that. Please don't leave me email about this stuff... He could tell you WORLDS more than *I* could about availability and pricing. Well, lets see... ***Now would be a good time to multitask yer way to the IFF picture files*** (Like you already HAVEN'T!) POSSIBLE PROBLEMS: ------------------ (Assume that you WILL have problems... That way you won't be surprised...) The Zorro I bus extension for the A530 (or other device) connects to the Amigas Zorro I bus and is soldered to the expansion device. This is very touchy and should be done with extreme care! When I did my A530, the A530's leads were too close together to get even a small pencil iron's tip into, so each pin had to be BENT slightly to the side before soldering could be attempted. Just THIS part of the soldering job took me a couple hours of straight, sweat drenched, teeth clenching, lead breathing, agony (I'm always more nervous when I'm working on my own baby!). Since the A530 is a multilayer board, bending a soldered lead TOO far or leaving the heat on TOO LONG could possibly break a trace DOWN INSIDE the multilayer board making the whole thing inoperative. I guess a fake MALE CONNECTOR could be used in the expansion device's side, but I did not have access to any such board when I did this project and I was in a rush (it being a finals week and all). If you *DO* have access to an old totally dead A500 mother board, I guess you could cut off the male edge connector of the Zorro I and make a fake PLUG in solution to the above kludge. Mine works fine though and I ain't messing with it! There is ONE point where I mention that you have to DRILL THROUGH the mother board to create a third mounting hole. If I remember correctly, the hole was drilled just in front of the GARY chip (this area was dictated by the alignment of the other two holes by the Zorro connector). On the backside of the board, the hole simply penetrated a ground plane (rev 5 mother board) but on the top side, I think I went through like 3 address lines. But this was a must due to alignment. So I merely cleared enough room for the mounting of a metal screw (i.e. cut the traces back further from the hole edge) and rerouted the lines with insulated wire wrap wire. All ran smoothly and worked fine. NOTE: THIS LAST STEP IS A MAJOR NO NO TO THOSE OF YOU WITH MULTI-LAYER MOTHER BOARDS (newer revs are multi-layer)! CHECK TO SEE IF YOURS IS OR IS NOT MULTILAYER *BEFORE* DRILLING! This case also worked nicely because the point at which the mother board rests, places the adapted power connector solder job (see IFF 2, Fig 4.1) against open air (as apposed to facing the harsh METAL right hand inside of the case). This was a nice relief as I am always paranoid of potential "Easy Short" areas that could kill an entire machine while tripping your breakers. __Whhoa!__Check_Out_the_Sparks!__ / BvO Although I doubt that anyone else will have THERMAL (Shea!)problems, I found that I had to mount TWO EXTRA internal fans (the second A530 micro fan is not shown in the diagrams) due to the fact that I was running an old 5.25" HH Miniscribe 160M SCSI drive that puts off a *LOT* of heat. When the platters got hot enough, thermal calibration would fail and the drive would go into a thermal recal FRENZY with constant R/W errors until I shut her down and let her cool off. I think that it was also due to the fact that the home made AC power supply I made for the Internalized Line Link was dissipating like close to 3-5 watts of overhead voltage (times the operational current). The modem needed a 9V AC Xformer and I was feeding it via a 12V Xformer and using recitfiers as clippers and they were getting rather warm... In fact, I had to mount them (3 of them) together, shoot 'em up with heat sink spooge and make a little aluminum heat sink. I still don't know why that modem sucks so much current. Poor design I guess. CONCLUSIONS: ------------ I have seen other hacked Tower systems and mine is the only one that I have seen that could pass for commercial... Well... Except for the Epoxy I guess... But What is a finished plastic, but merely a type of squared off epoxy?! Anyway... It came out looking really nice. A nice finishing touch I decided to do was to tape off and paint in BIG, CLEAN CUT, FLAT BLACK, the letters "A M I G A". You can also get ahold of rub on white stencil letters to add final touches to any outside lettering you want do. I blanked out (with Mr.Dremel) the letters for the RESET switch and put PAL/NTSC. It too looks nice. The lettering also came in handy for labeling the LEDs and extras appearing on the front of the Line Link modem. The case also comes with a few sheets of little silver stickers for things such as VIDEO, AUDIO, MOUSE, GAME, COM1, 2, POWER, etc... This a pretty big project here. IF you are not very mechanically inclined OR have not played around electronics a LOT (i.e. Have good soldering experience), this is probably not for you. And please don't ask me how much I would charge to do it for you. Looking back, I don't think that I would WANT to do it again. And if I did, you couldn't afford my time anyway. This was more of just an technical outcry of my lowly financial status in lieu of upgrading than a planned mega-hack. Keep your eyes open for a possible future A530 RAM HACK to take it PAST it's hardware designed 8M of RAM! Well... If I don't loose interest and go get that A4000 first. Or 486 DX... NOT! [UPDATE: I ended up breaking down and buying a GVP 4M SIMM from a company called HCo. Another tech friend of mine sent them a GVP SIMM and got them to clone them. I got a 4M (1Mx32) SIMM for $158!! Even less if you buy more than one! Besides.. looks like I may be going to an A4000T anyway. If you want what info I have, email me... I have the SIMM pinouts (GVP) and some of the A530 info.. all I was lacking was the A2000 50MHz Combo PAL Eq's... If you have the PAL Eq's TELL ME!!! Or if you can yank your PALs and GET the EQ's.. Email me!] A Little About Me: ------------------- (If Anyone cares) ;u) I was raised in Groton/Ledyard Connecticut. Went to a technical high school (Ella Grasso S.E. Tech) and took Electronics there for 3 years. Went on from there to Thames Valley St. Tech School for an AS in Electrical Engineering Technologies. Transferred to Texas A&M in Spring of '92. It's now late '94 (boy I'm feeling long in the tooth) and I've finished all my engineering classes. Have to go back this spring to take a patchwork of classes to finish up my BS in EET/Telecom if I wanna get out by the end of this summer. [UPDATE: It is now Oct '96 and I have graduated and have a job in San Antonio.] I have been a Commodore Technician for about 7 years. Have been authorized Amiga Technician (by Commodore for what ever THAT'S worth now!) since '91 (but been working on them since '89). Have also done classified peon stuff for Tracor Applied Sciences/N.U.S.C, been a Pro Audio Tech (twice), and a computer tech (at like... uhhh.. 5 official places through time.) Oh... My System includes: A500 (tower of course), A530, 9M RAM(1C8F), 800M SCSI, 44Meg SyQuest, HD Internal Floppy, Line Link 144e, Cannon BJ-200, 1084-SP, Home Made 8 bit Stereo Digitizer, Ext. Floppy, KS 2.05, WB 2.1 and a PC286 shoved in the GVP. Email is now: tweeks@texas.net My Web Page: http://lonestar.texas.net/~tweeks Welp... Good Luck! Tom D Tek **************************************************************************** ****************************** DISCLAIMER ********************************** **************************************************************************** *I ASSUME NO RESPONSIBILITY FOR ANY DAMAGES THAT OCCUR FROM ANYONE ATTEMPT-* *ING ANY OF THE SYSTEM MODIFICATIONS MENTIONED ABOVE OR AS SEEN THE * *ACCOMPANYING GRAPHIC DOCUMENTATION IMAGES. IT SHOULD BE NOTED THAT NONE * *OF THESE MODIFICATIONS ARE AUTHORIZED BY ANY PART OF COMMODORE AND THAT * *OPENING YOUR MACHINE VOIDS ANY WARRANTY YOUR MACHINE MAY CURRENTLY HOLD! * *ALL OPINIONS AND EXPRESSED IDEAS IN THESE DOCUMENTS ARE MY OWN AND SHOULD * *NOT BE ASSOCIATED WITH ANY OTHER PERSON AND/OR ORGANIZATION. * ****************************************************************************