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Tool-less UK Mains Plug

Plug Bottom
Plug Bottom

This is a standard 13A UK main power plug – with a twist. This one requires no tools to open or connect.
The top cover is slid off the top, after turning the red cam with a coin to unlock it.

Plug Top
Plug Top

Manufactured by Plugco – a Google search of this company returns no results.

Cover Removed
Cover Removed

Top cover removed from the plug, as is standard with UK mains plugs the live conductor is fused – 3A in this case. The conductors are clamped into the fittings in a row along the top edge of the plug.

Wire Clamps
Wire Clamps

Closeup of the wire clamps. Conductor is placed in the slot & snapped closed.

This is an old plug & they do not appear to be available these days, for unknown reasons. Being able to change a plug without a screwdriver has it’s advantages 🙂

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LED Lighting Part 1

Here I will document progress in replacing standard halogen MR10 lights with LEDs.

3x1W LED
3x1W LED

These units are from TruOpto, available through Rapid Electronics in the UK. They are 3W total, from 3x 1W emitters on an aluminium back plate.

LED Test Rig
LED Test Rig

Here is the LED attached to a heatsink for testing purposes – these units dissipate nearly 2W in heat at full output.

As the lights are to be run from a 12v battery bank, for simplicity a master regulator is required to provide a stable 11.4v rail for LED supply.

Regulator Module
Regulator Module

I have used a Texas Instruments part – PTN78020WAH. This is a 6A capable adjustable regulator module.

The LED lights are to be fully dimmable – the low voltage PWM dimmers are in progress of being built.

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Camcorder CRT Viewfinder

CRT Assembly
CRT Assembly

Here are the viewfinder electronics from a 1984 Hitachi VHS Movie VM-1200E Camcorder. These small CRT based displays accept composite video as input, plus 5-12v DC for power.

Screen
Screen

Here is the front face of the CRT, diameter is 0.5″.

Power Board
Power Board

Closeup view of the PCB, there are several adjustments & a pair of connectors. Socket in the upper left corner is the power/video input. Pinout is as follows:

  1. Brown – GND
  2. Red – Video Input
  3. Orange – +12v DC
  4. Yellow – Record LED
The potentiometers on the PCB from left:
  1. H. ADJ
  2. V. ADJ
  3. BRIGHT
  4. FOCUS
PCB Part Number reads: EM6-PCB
This unit utilises the BA7125L deflection IC.
Solderside
Solderside
Reverse side of the PCB, very few SMT components on this board.
Tube Assembly
Tube Assembly
Here is an overall view of the CRT assembly with scan coils. Tube model is NEC C1M52P45.
Electron Gun
Electron Gun

Closeup view of the CRT neck, showing the electron gun assembly.

 

CCTV Camera
CCTV Camera

The old CCTV camera used to feed a composite signal to the CRT board. Sanyo VCC-ZM300P.

CCTV Camera Connections
CCTV Camera Connections

Connections at the back of the camera. Red & Black pair of wires lead to 12v power supply, Green & Black pair lead to the CRT board’s power pins. Seperate green wire is pushed into the BNC video connector for the video feed. video ground is provided by the PSU’s ground connection.

Connections
Connections

Finally the connections at the CRT drive board, left to right, +12v, Video, GND.

Screen Operation
Screen Operation

Display taking video signal from the CCTV camera.

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Sigma Mini Keychain LCD Photoframe

Front
Front

This is a cheap Sigma branded keychain photoframe. User buttons for power & selecting photos are on the left.
There are two white LEDs on the bottom edge that function as a torch as well.

Display
Display

Front of the unit removed, showing the LCD module. The USB jack is bottom left, next to the pair of white LEDs & above that is the 32kHz watch crystal that the CPU uses for timekeeping.

Back Removed
Back Removed

Here the back has been removed showing the 3.7v Li-Ion cell used to provide power.

Display Folded Back
Display Folded Back

Here the display has been removed from the PCB exposing the chipset.

Chipset
Chipset

Here the CPU blob-top chip & a flash memory IC are visible. The CPU is a Sitronix ST2205U.

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XM2000 Marine VHF Radio

Radio
Radio

Here is an old XM2000 marine VHF tranciever.

Internal View
Internal View

Here is the casing split, with the main CPU board & display on the right, & the RF tranciever board on the left.

Main CPU
Main CPU

View of the main CPU board, with the mic & loudspeaker on the right hand side.
The channel display is on the reverse side of the PCB.

RF Board
RF Board

View of the RF board, with it’s brass shielding attached. This radio will transmit at 5W max.

RF Shields Removed
RF Shields Removed

Shielding removed, power regulation bottom right corner of the board, tranciever on the left.

PCB Front
PCB Front

CPU board removed from the casing, showing the LCD & the user buttons to the left.

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PSi 150 Power Inverter

Front
Front

This is a small 120W power inverter, intended for small loads such as lights, fans, small TVs & laptop computers.

End Cover
End Cover

End cover of the unit, 12v DC input cord at the top, power switch & indicator LEDs at the bottom.

Mains Output
Mains Output

Opposite end of the unit, with the standard 240v AC 50Hz Mains output socket.

Cover Removed
Cover Removed

Cover removed from the top of the unit. Main power transformer is visible in the centre here, MOSFET bank is under the steel clamp on the left, the aluminium case forms the heatsink.

PWM Controllers
PWM Controllers

On the right is a KA3525 switchmode PWM controller & on the left is a LM324N quad Op-Amp IC. The buzzer on the far left is for the low battery warning.

PCB Removed
PCB Removed

PCB removed from the casing, with the MOSFET bank on the right hand side. Two potentiometers in the centre of the board tweak the frequency of the switcher & the output voltage.

 

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Monox Compact-S CO Sensor Cell

Top
Top

Here is an old electrochemical type carbon monoxide detector cell, from Monox. Hole in the centre is the inlet for the gas under test.
DO NOT TRY THIS AT HOME! Electrochemical cells contain a substantial amount of sulphuric acid, strong enough to cause burns.

This is a type of fuel cell that instead of being designed to produce power, is designed to produce a current that is precisely related to the amount of the target gas (in this case carbon monoxide) in the atmosphere. Measurement of the current gives a measure of the concentration of carbon monoxide in the atmosphere. Essentially the electrochemical cell consists of a container, 2 electrodes, connection wires and an electrolyte – typically sulfuric acid. Carbon monoxide is oxidized at one electrode to carbon dioxide while oxygen is consumed at the other electrode. For carbon monoxide detection, the electrochemical cell has advantages over other technologies in that it has a highly accurate and linear output to carbon monoxide concentration, requires minimal power as it is operated at room temperature, and has a long lifetime (typically commercial available cells now have lifetimes of 5 years or greater). Until recently, the cost of these cells and concerns about their long term reliability had limited uptake of this technology in the marketplace, although these concerns are now largely overcome. This technology is now the dominant technology in USA and Europe.

Rear
Rear

Rear of unit with connection pins. Hole here is to let oxygen into the cell which permits the redox reaction to take place in the cell when CO is detected, producing a voltage on the output pins.

Disassembled
Disassembled

Cell disassembled. The semi-permeable membrane on the back cover can be seen here, to allow gas into the cell, but not the liquid electrolyte out. Cell with the electrodes is on the right, immersed in sulphuric acid.

Platinum Electrode
Platinum Electrode

Closeup of the electrode structure. Polymer base with a precious metal coating.

Membrane
Membrane

Membrane & filter on the test gas input port.

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BigBen DSi Inductive Charging Dock

Front
Front

Here is a Inductive charger designed for the Nintendo DSi. Cheap Chinese build, but it does work!

Overview
Overview

Top has been removed from the unit here. Most prominent in the centre is a solid steel bar, simply there to give the device some weight.
Pair of Tri-colour LEDs at the front indicates charging status.
Induction coil is on the left, with the controller & oscillator PCB at the top.

PCB Closeup
PCB Closeup

Closeup of the PCB, ICs have had their markings ground off.

Coil
Coil

Induction coil. This couples power into a coil built into a special battery, supplied with the base, to charge it when the DSi is placed on the dock.

Label
Label

Information Label on the base.

Power Input
Power Input

Standard DSi charger port, connects to the charger you get with the DSi. Power switch is on the right.

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Brother P-Touch 80 Label Maker

Touchpad
Touchpad

Here is a label maker, bought on offer at Maplin Electronics. Full Qwerty keyboard with 1 line dot matrix LCD display visible here. Power is 4 AAA cells or a 6v DC Adaptor.

Rear
Rear

Rear cover removed. Battery compartment is on the left hand side, space for the tape cartridge on the right. Ribbon cable leading to the thermal print head is on the far right, with rubber tape drive roller.

PCB
PCB

PCB under the top cover with the main CPU, a MN101C77CBM from Panasonic. This CPU features 48K Mask ROM & 3K of RAM. Max clock frequency is 20MHz. 32kHz clock crystal visible underneath a Rohm BA6220 Electronic speed controller IC.
This is used to drive the printer motor at a constant accurate speed, to feed the tape past the thermal head. Miniature potentiometer adjusts speed.
Ribbon cable at the bottom of the board connects to the print head, various wiring at the left connects to the battery & DC Jack.

Printer Drive
Printer Drive

Printer drive mechanism. Small DC motor drives the pinch roller though a gear train. DC Jack & reverse polarity protection diode is on the right.
This unit uses a centre negative DC jack, which is unusual.

Cartridge
Cartridge

Thermal tape cartridge, black text on white background.

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USB-IDE/SATA Adaptor

Front
Front

This is a device to use an IDE or SATA interface drive via a USB connection. Here is the front of the device, IDE interface at the bottom, 2.5″ form factor.

PCB Top
PCB Top

PCB removed from the casing. USB cable exits the top, 12v DC power jack to the left.
SATA interface below the DC Jack.
Molex connector below SATA is the power output for the drive in use. This unit has a built in 5v regulator.

PCB Bottom
PCB Bottom

Bottom of the PCB showing the interface IC.

Drive Adaptor
Drive Adaptor

Adaptor to plug into the 44-pin 2.5″ form factor IDE interface on the adaptor, converts to standard 40-pin 3.5″ IDE.

Power Cable
Power Cable

Power pigtail with standard Molex & SATA power plugs.

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Combo Microwave

Electronics Bay
Electronics Bay

Here are the internals of a cheap Microwave/Convection Oven combo. Electronics bay is pretty much the same as a standard microwave, with the magnetron, transformer & diode/capacitor voltage doubler, with the addition of an extra fan & a pair of nichrome elements to provide the convection oven function.

Convection Fan
Convection Fan

Convection blower which keeps the cooking vapours & smoke away from the elements, & circulates the hot air around the cooking chamber. This is a 12v DC centrifugal type blower.

Convection Element
Convection Element

The elements are inside this steel shield, air duct extends from the centre.

Thermal Cutouts
Thermal Cutouts

This oven has a pair of thermal switches on the magnetron.

Capacitor & Diode
Capacitor & Diode

The usual capacitor/diode voltage doubler in the magnetron power supply. The transformer is visible to the left.

Controller
Controller

Electronic controller PCB. This has a pair of relays that switch the elements & the magnetron transformer.

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Grand Hand View

Front
Front

This is an adaptor to convert computer VGA to composite & S-Video output for a normal TV.

Bottom
Bottom

Bottom of the unit with option select switch.

PCB Top
PCB Top

PCB removed from the casing, CPU in centre, buffer RAM on the right.

PCB Bottom
PCB Bottom

Reverse side with the VGA connections at the top & the S-Video/composite outputs on the bottom.

VGA
VGA

Inputs. USB connector provides power, pair of VGA connectors provides passthrough function.

S-Video & Composite
S-Video & Composite

Outputs. Standard S-Video on the left & composite video on the right.

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Belling Microwave


Front
Front

Here is a cheap no frills microwave oven, which died after a few weeks of normal use.

Electronics Bay
Electronics Bay

Cover removed, showing the internals. Front of the microwave is on the left.

Timer
Timer

Closeup of the timer unit. Cheap & nasty.

Magnetron
Magnetron

Magnetron removed from the oven. Antenna is on the top,  cooling fins visible in the center. White conector at the bottom is the filament terminals.

Magnetron Chokes
Magnetron Chokes

Chokes on the magnetron’s filament connections. These prevent microwave energy from feeding back into the electronics bay through the connections.

Magnetron Assembly
Magnetron Assembly

Magnetron cooling fins, tube & magnets removed from the frame.

Magnetron Tube
Magnetron Tube

Bare magnetron tube.

Power Input Board
Power Input Board

This PCB does some rudimentary power conditioning, power resistors are in series with the live feed to the power trasformer, to prevent huge power up surge. When the transformer energizes the relay, which is in parallel with the resistors, switches them out a fraction of a second after, providing full power to the transformer.
Standard RFI choke & capacitor at the top of the board, with the input resistor.

Transformer
Transformer

Power transformer to supply the magnetron with high voltage.
Power output is ~2kV at ~0.5A. Pair of spade terminals are the low voltage filament winding.

Capacitor
Capacitor

HV Capacitor. This along with the diode form a voltage doubler, to provide the magnetron with ~4kV DC.

Diode
Diode

HV diode stack.

Fuse Element
Fuse Element

Internals of the HV fuse. Rated for ~0.75A at 5kV. The fuse element is barely visible attached to the end of the spring. Connects between the transformer & the capacitor.

Cooling Fan
Cooling Fan

Cooling fan for the magnetron. Drive is cheap shaded pole motor.

Fan Motor
Fan Motor

Fan motor. Basic 240v shaded pole induction type.

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Hot Laminator

Top
Top

Here is a cheap no brand hot laminator. This pulls the paper, inside a plastic pouch through a pair of heated rollers to seal it.

Heater
Heater

Top removed, heater assembly visible. PCB attached to the top cover holds LEDs to indicate power & ready status.

Switch
Switch
Thermostat
Thermostat

Here is the thermostat & thermal fuse, the thermostat switching the indicator on the front panel to tell the user when the unit is up to temperature. This has a self regulating thermostat. Thermal fuse inside the heat resistant tubing is to protect against any failure of the heater.

Motor
Motor

5 RPM motor that turns the rollers through a simple gear system.

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Audi TT Roof Hydraulics

Pump
Pump

This is the hydraulic system from an Audi TT that would power the soft top. Here is the hydraulic pump unit. Oil Tank is on the left. Power is 12v DC at ~20A

Cylinders
Cylinders

The pair of hydraulic cylinders that attached to the roof mechanism.

Limit Switch
Limit Switch

One of the cylinders has a limit switch built in. The brass bolt coming out of the side of the head is one contact. The other contact is the cylinder body.

Hose
Hose

Marking on the hoses. This is Parker Polyflex hydraulic hose. 1/8″ ID.

Motor
Motor

Drive motor for the hydraulic pump. Standard DC permanent magnet motor.

Motor Suppression
Motor Suppression

Motor power terminals & suppression capacitors. As the reversing relays actually short the motor out when de-energized, there is a lot of arcing at the brushes without some suppression.

Reversing Relays
Reversing Relays

Reversing relay stack. Each relay is a SPDT configuration. The pair are arranged as a DPDT bank to reverse the motor, depending on which relay is energized.

Tank
Tank

Detail of the oil tank showing the level markings.

Power Valve
Power Valve

Solenoid valve on top of the unit. This valve provides full pump pressure to the cylinders when energized.

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455nm Laser Head

Aixiz Module
Aixiz Module

Here’s my prototype 455nm laser head, constructed from the front section of an Aixiz module threaded into a heatsink from an old ATX power supply. This sink has enough thermal mass for short 1W testing.

Connection
Connection

Connection to the laser diode at the back of the heatsink. Cable is heat shrink covered for strain relief, & hot glued to the sink for extra strain relief.

Beamshot 1
Beamshot 1

Looking down the beam, laser is under the camera. Operating around 1.2W here

Beamshot 2
Beamshot 2

Camera looking towards the laser. Again operating at ~1.2W output power.

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Power Pack Regulator Update

7.5v Regulator
7.5v Regulator

To help make my system more efficient, a pair of switching regulators has been fitted, the one shown above is a Texas Instruments PTN78060 switchmode regulator module, which provides a 7.5v rail from the main 12v battery pack.

A Lot like the LM317 & similar linear regulators, these modules require a single program resistor to set the output voltage, but are much more efficient, around the 94% mark at the settings used here.

The 7.5v rail supplies the LM317 constant current circuit in the laser diode driver subsection. This increases efficiency by taking some voltage drop away from the LM317.

5v Regulator
5v Regulator

The 7.5v rail also provides power to this Texas Instruments  PTH08000 switchmode regulator module, providing the 5v rail for the USB port power.

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Portable Power Pack Charger

A quick update to my portable power pack, a mains charging port. Uses a universal DC barrel jack.

Connection to the battery. 1N4001 reverse protection diode under the blue heatshrink tubing. I used a surplus PC CD-ROM audio cable (grey lead). Seen here snaking behind the battery to the DC In Jack.

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Uniden Stalker Radar Detector

Top
Top

An early speed radar detector from the early 90’s. Pictures showing the front of the unit with the option buttons.

Bottom
Bottom

Bottom of the unit showing label. Unlike the newer plastic detectors, the whole casing of this unit is cast aluminium.
Model Uniden Stalker RD-6000W.

PCB Top
PCB Top

PCB removed from the casing. Volume/power control on the left. Option tactile switches on the edge of the PCB, with the indicator LEDs. Power input jack on the right hand side of the PCB. Large aluminium can is the detector assembly, containing the detector diodes. Waveguide horn is at the top.

Waveguide Horn
Waveguide Horn

Shot down the waveguide, showing the detector diodes at the end.

LEDs
LEDs

Indicators on the front of the unit, X, K & Ka band detection LEDs on the left, Power & detection level (1-4) LEDs in centre. City (C) (Audio (A) & Mute (M) LEDs on the right.

PCB Bottom
PCB Bottom

Bottom of the PCB, showing detection logic. Piezo buzzer top left.

CPU
CPU

Custom Uniden CPU. Marking UC1465.

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Laser Diode Driver

Connection

Closeup
Closeup

The parts arrived for my adjustable laser diode driver! Components here are an LM317K with heatsink, 100Ω 10-turn precision potentiometer, 15-turn counting dial & a 7-pin matching plug & socket.

Driver Schematic
Driver Schematic

Here is the schematic for the driver circuit. I have used a 7-pin socket for provisions for active cooling of bigger laser diodes. R1 sets the maximum current to the laser diode, while R2 is the power adjustment. This is all fed from the main 12v Ni-Cd pack built into the PSU. The LM317 is set up as a constant current source in this circuit.

Installed
Installed

Here the power adjust dial & the laser head connector have been installed in the front panel. Power is switched to the driver with the toggle switch to the right of the connector.

Regulator
Regulator

The LM317 installed on the rear panel of the PSU with it’s heatsink.

Connection
Connection

Connections to the regulator, the output is fully isolated from the heatsink & rear panel.

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Portable Power Supply

Battery
Battery

This is detailing my portable multi-purpose power pack of my own design. Here is an overview, mainly showing the 4Ah 12v Ni-Cd battery pack.

Front Panel Right
Front Panel Right

Panel Features – Bottom: Car cigar lighter socket, main power keyswitch. Top: LED toggle switch, provision for upcoming laser project, Red main Power LED, 7A circuit breaker.

Front Panel Left
Front Panel Left

Top: Toggle switch serving post terminals, USB Port.
Post terminals supply unregulated 12v for external gadgets. USB port is standard 5v regulated for charging phones, PDAs etc.
Bottom: Pair of XLR connectors for external LED lights. Switches on their right control power & the knob controls brightness.

Additions are being made to this all the time, the latest being a 2W laser diode driver. Update to come soon!

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Bandridge VA-315

Front Panel
Front Panel

This is a small audio mixer, marketed for camcorder audio dubbing.

Rear Panel
Rear Panel

I/O Panel on the rear of the unit. Contains a small preamp, but will not drive speakers directly. Power is a 9v battery or plugpack.

PCB Front
PCB Front

Front of the PCB removed from the case. Mic preamp bottom right corner. Each channel has it’s own Preamp IC between the faders.

PCB Rear
PCB Rear

Rear of the PCB.

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PSP Slim

Front
Front

Here is a PSP Slim that recently died.

Label
Label

For those that are interested, here is the ID label, this is a PSP-2003.

Front Removed
Front Removed

Here the front of the unit has been removed, showing the first internal components.

Screen Removed
Screen Removed

Here is the unit with the LCD removed, here the mainboard is partially visible.

Left Pad
Left Pad

Left pad unit removed from the PSP, with the left speaker & the memory stick slot cover.

Left Pad Rear
Left Pad Rear

Rear of the left pad assembly, showing the speaker.

Joypad
Joypad

Joypad removed from the casing. Resistive unit.

Output Jack
Output Jack

Headphone/data board removed from the casing. This also has TV-Out on the PSP-200x series.

Mainboard
Mainboard

Mainboard removed. Main CPU is at the top. Sockets around the bottom connect to the UMD drive & UMD Drive.

CPU & GPU
CPU & GPU

Closeup of the main chipset. CPU is the top IC.

Mainboard Rear
Mainboard Rear

Rear of the mainboard, Memory Stick socket on the right.

WiFi Chipset
WiFi Chipset

Closeup of the WiFi chipset & the charging power socket on the right.

Charging Chipset
Charging Chipset

Closeup of the bettery connector & the charge controller IC.

UMD Drive
UMD Drive

UMD Drive removed from the rear of the casing. This is a miniature DVD style drive, using a 635nm visible red laser.

UMD Drive Back
UMD Drive Back

Rear of the UMD drive, showing the laser sled & drive motors. Both the spindle motor & the sled motor are 3-phase brushless type. The laser diode/photodiode array is at the top of the laser sled.

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Southwestern Bell Freedom Phone

Phone
Phone

This is an old cordless landline phone, with dead handset batteries.

Handset Radio Board
Handset Radio Board

Here’s the handset with the back removed. Shown is the radio TX/RX board, underneath is the keyboard PCB with the speaker & mic. All the FM radio tuning coils are visible & a LT450GW electromechanical filter.

Handset Radio Board Bottom
Handset Radio Board Bottom

Radio PCB removed from the housing showing the main CPU controlling the unit, a Motorola MC13109FB.

Keypad Board
Keypad Board

The keypad PCB, with also holds the microphone & speaker.

Handset Keypad Board Bottom
Handset Keypad Board Bottom

Bottom of the keypad board, which holds a LSC526534DW 8-Bit µC & a AT93C46R serial EEPROM for phone number storage.

Base Main Board
Base Main Board

Here’s the base unit with it’s top cover removed. Black square object on far right of image is the microphone for intercom use, power supply section is top left, phone interface bottom left, FM radio is centre. Battery snap for power backup is bottom right.

Power Supply Section
Power Supply Section

PSU section of the board on the left here, 9v AC input socket at the bottom, with bridge rectifier diodes & main filter capacitor above. Two green transformers on the right are for audio impedance matching. Another LT450GW filter is visible at the top, part of the base unit FM transceiver.

ICs
ICs

Another 8-bit µC, this time a LSC526535P, paired with another AT93C46 EEPROM. Blue blob is 3.58MHz crystal resonator for the MCU clock. The SEC IC is a KS58015 4-bit binary to DTMF dialer IC. This is controlled by the µC.

Base Main Board Bottom
Base Main Board Bottom

Underside of the base unit Main PCB, showing the matching MC13109FB IC for the radio functions.

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Co-Op Bank Card Reader

Keypad
Keypad

This is a little security measure you get with Internet Banking with the Co-Op, generates codes to confirm your identity using your bank card. About the size of a pocket calculator, this is the keypad & screen.

Card Slot
Card Slot

The rear of the unit, the card slots into the top, manufactured by Gemalto Digital Security.

Card Contacts
Card Contacts

Outer back cover removed, showing the 8 contacts for the chip on the bank card, the 2 contacts below that switch on power when a card is inserted. Power comes from 2 lithium coin cells in the compartment on the lower left.

PCB Rear
PCB Rear

PCB removed from the casing, showing the internal components. Two large pads at top left are battery connections, while the only IC on the board is the main CPU, under the card connector. 6MHz oscillator & 32Khz crystal on board for processing & timekeeping. LCD screen connection at far right.

Keypad Contacts
Keypad Contacts

Reverse side of the PCB, with the keypad contacts. LCD on right, with programming interface pads at side of keypad.