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Salvaging the Commodore 64 'Brick-of-Death' epoxied power-supply and rebuilding it. (many pictures)

GearTechWolf

Experienced Member
Joined
Apr 24, 2015
Messages
264
Location
Washington
First off, I know many don't find this to be a worthwhile project, preferring to build/buy an all-new or pre-rebuilt supply instead.
I respect that. It's a money-versus-time issue and most people have more money to put into this hobby than I currently do.
However, I have lots of time and enjoy nearly-lost-cause projects! So I purchased a second brick from a user on here.
I addition to recording the process of salvaging as many original component from within the epoxy as possible,
I will document difference between the two version of this supply that I currently own, the 13-'83 and the 3-'83.
Both are P.S.25 P/N251053-02, made in Singapore, marked with CSA and NLS, and "SHOCK HAZARD DO NOT OPEN" in English and French.
The 3-83 version is also UL-listed, marked 13J5 and "FOR USE WITH COMMODORE COMPUTER".
The 3-83 is rated at 117V 50/60 Hz 40VA input, and 5VDC 7.5W 9VAC 6.7VA output.
The 13-83 is rated at 117V 50/60 Hz 46W input, and 5VDC 8.5W 9VAC 9VA output.
The 3-83's markings are molded into the casing while the 13-83's marking are printed on the underside with the date on a metalized sticker and a label duplicating some information on the top.
The 3-83 has ribs running up both sides and across the top with a molded Commodore symbol in a blank square on top.
The 13-83 has a sticker on top with the C symbol, Commodore, Power supply, the input-output data, and the part number on it. Single row of narrow ribs along sides.
Of particular note is the slight difference in included electrical components within each unit. Both have the same count, but one component the other lacks.
The 3-83 has a 5A 250V fuse in-line with the 9VAC output and lacks the 2.2Uf 16V tantalum between pins 1 + 2* of the regulator. (but has the holes for it)
*(input and ground, respectively)
Now, for what you're all here for, the pictures!
BC64PS-1.png
As found, after cracking the case open, a nice minty-green epoxy!
BC64PS-2.png
The bottom cover, slightly different in design from the one on the later case.
BC64PS-3.png
Close-up shot for wire-connections reference, and the fuse can be seen poking out of the epoxy here. (it didn't survive disassembly)
BC64PS-4.pngBC64PS-5.png
When I saw this line-voltage connection I though it had been burned out and was only hanging on by a couple strands!
(but I was wrong, that was the hollow space left in the jacket by the ground-wire, the line-wire is deeper. Can't explain the marks/discoloration though)
BC64PS-6.png
Here you can see where the three conductors of the line-cord were split, leading to my confusion with the one.
BC64PS-7.png
Input/output cords removed, fuse exposed*, and PCB cleaned off, de-soldered, removed.
*(scratched the glass, may have contributed to its destruction, but I doubt it would have survived excavation regardless)
BC64PS-8.png
Back of the embedded regulator. I partially backed the screw out by gripping the exposed threads, cut off the stub with a hacksaw, and drilled it out until the heat-sink was free.
BC64PS-9.png
The transformed in the 3-83 unit was wrapped with a single layer of masking-tape around the edges of the laminations, unlike the 13-83 unit.
Made it much easier to pull the epoxy away from it in large chunks!
BC64PS-10.png
Close-up of the embedded components exposed after removing the PCB. Four large legs are the two diodes, two thin legs are the .22uF 35V tantalum across the +5V output, three rectangular legs are the regulator, and the two resistors (100Ohm and 22Ohm) can be seen through air-bubble gaps in the epoxy. (no second, 2.2uF 16V, tantalum)
All component were nominally functional before tear-down.
On to page two!
 
BC64PS-11.png
Next, the simple and inefficient heat-sink. Just a featureless aluminum plate bent into a U-shape ang given a relief near the regulator's legs.
Drill-bit slipped off the screw into the soft aluminum so I had to chew it out from multiple angles to free it.
BC64PS-12.png
Another close-up of the underside of the components-block, I forget why.
BC64PS-13.pngBC64PS-14.png
Couple close-ups of the old masking-tape that protected the sides of the transformer.
BC64PS-15.png
Close-up of the regulator with its drilled-off screw and the spot of epoxy that chipped out when I backed the screw in.
BC64PS-16.png
Ye olde transformer, showing the epoxy that I don't bother to remove for fear of damaging the windings.
Again, tape (clear, maybe Kapton?) makes it easier to clean the epoxy off. In not for the tape, the winding would be inextricable from the epoxy!
BC64PS-17.pngBC64PS-18.pngBC64PS-19.pngBC64PS-20.png
Four exposures of the intact, yet-to-be-cleaned, PCB, showing how the epoxy removed half or more of the solder-mask from it.
Fortunately, this time the PCB wasn't heavily bonded to the epoxy on either side, like the later unit I first salvaged, where the board got broken.
Also of note, this PCB is marked "PNE-5" with the characters etched into the copper, the later board is unmarked.
On to the third, and penultimate page!
 
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Highlights from the breakdown and rebuild of the 13-83 power-brick, resulting in a stable +5V and 9VAC with 90% original components!
C64PS-1.png
The partially-exposed brick, as it was when I picked the project back up after years spent in a shed after my first de-potting attempts.
C64PS-5.pngC64PS-7.pngC64PS-8.png
Removing the resistors, still embedded in the cool-grey epoxy, and showing the damage to the PCB.
C64PS-26.pngC64PS-29.pngC64PS-32.png
Bottom-markings, top-label, and disappointingly-small side-ribs.
C64PS-34.png
The rebuilt board, with new 7805 regulator, better heat-sink, otherwise original components, plus PCB rebuilt with superglue and baking soda.
Now, onto the fourth and (this time for real) final (for now) page!
 
BC64PS-21.png
First off, maker's-mark on both transformers: MP Miles-Platts England.
BC64PS-22.pngBC64PS-23.pngBC64PS-24.png
Then the transformer from the 13-83 power-supply, with the residual cool-grey epoxy I'm leaving between the windings and laminations, and the patch on the edges of the plates that I couldn't remove fully due to the lack of masking-tape protecting them.
BC64PS-25.pngBC64PS-26.pngBC64PS-27.png
Finally, a few pictures showing the damages that can occur during de-potting of the transformer.
I snapped off one of the line-in terminals, also severing the wire attached to it.
I'll glue it back on (reinforced with superglue/baking-soda) and jumper the wire, easy fix.
In the second image I snapped one of the 9VAC secondary wires while removing epoxy from around its terminal, again easily jumper-wired.
The wire previously attached to the now-destroyed fuse is also seen there, hovering above the windings, it fortunately escaped damage.
In the last image is the thermal fuse running between one end of the primary winding and the other line-in terminal.
I removed enough epoxy there to de-solder the stump of the power-cord wire and re-attach the cord later, the rest of the epoxy will remain there.
That's all for now, folks! Merry Christmas, Happy New Year, and may you enjoy success with your projects in the new year!
 
I went through this very process back when the C64 was a current machine for a friend of mine who was unemployed and had zero money for a replacement at the time. I confess when I said I would have a look at it, I did not realise the PSU was embedded in resin but I went ahead anyway, not the easiest job I have ever done.
 
Nicely done. Appreciate you taking pictures during your process.

I have done the same (chipping the epoxy) and carefully do away with the electronics and just save the Transformer. I said “carefully “ as I learned that you could possibly break the Transformer output wire so short from doing connections. Luckily I was OK .
As for the electronics I used the following.
1 - 4A rectifiers
2 - UBEC 5V/3A ( these are rated 5.2v so I did a mod to bring it down to ~5.11 at no load)
3 - 2 filter capacitors ( one after the rectifiers, one after the UBEC 5V output
4 - cheap Digital 3digit voltmeter panel
I have done 4 so far and I have 3 more ready to put the electronics on

The attached file shows the latest rebuild with 5.2V from UBEC before it was readjusted ( change a resistor value) to ~5.11v at no load
 

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I went through this very process back when the C64 was a current machine for a friend of mine who was unemployed and had zero money for a replacement at the time. I confess when I said I would have a look at it, I did not realise the PSU was embedded in resin but I went ahead anyway, not the easiest job I have ever done.
Wow! Now that's friendship! Out of curiosity, do you recall what had failed?
Nicely done. Appreciate you taking pictures during your process.
I have done the same (chipping the epoxy) and carefully do away with the electronics and just save the Transformer.
Ah yes, I saw your post in another thread, very clean repair/upgrade!
Pictures really make a great difference, don't they? Though it's hard to get in the habit of taking them! XD
 
Welcome to my world.

I have spent a considerable amount of time digging circuits out of rock hard epoxy resin.

This is because I am interested in automotive electronics and everything was potted. But the manufacturers like Lucas and Bosch didn't publish the circuits, which left everyone in the dark. And made repairs difficult.

Years ago I was trying to fix the air con module in my wife's (then vintage) XJ6 Jag. It was made easier because the Prof of Radiology at the hospital I was working at (as a house officer) agreed to Xray it for me. That made it a lot easier to safely, slowly, grind away the resin.

Bosch used a rock hard black resin, that made concrete look soft and Titanium look like putty. It was "fun" to grind it out and document the circuit diagram.

 
Welcome to my world.
I have spent a considerable amount of time digging circuits out of rock hard epoxy resin.
Bosch used a rock hard black resin, that made concrete look soft and Titanium look like putty. It was "fun" to grind it out and document the circuit diagram.
Dang, that's an impressive conversion! Sounds like the newer (90's+?) rubbery potting (silicone?) is far preferable to the hard-setting stuff.
I just did a bit of dremeling to extract the still-functional GL1016 without snapping the heat-sink tang away from the body like last time.
Man, that stuff stinks when cut with a whiz-wheel! Worth it though, would have taken hours or days to cut deep enough slots to safely chip the epoxy away from the sides of the regulator so it could be gently pried free.
Chipping is definitely preferred over grinding! But unfortunately poses its own risks of damaging components and connections.
I suppose the accidentally de-capped one could be sent off to one of those places that do microscopic photographs of component circuits...
Anyhow, thanks for weighing in and sharing your experience with this type of frustrating salvaging/repairing operation!
Repairing (and documenting) unknown/unrepairable circuits/devices and sharing/preserving that information is an awesome help to future tinkerers!
 
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