How to fix a sync and charge cable

Snerkel · 08-06-05, 07:28 PM

Having bought a sync cable for the X50V from Ebay, I came up against the problem that the current required by the X50V exceeded the limit for my USB port, this caused the USB port to shutdown, leading to loss of the connection. This continued cycling through connected, disconnected.

This modification has cured the sync problem, and also allows the X50V to charge from any USB port while switched off.

Before you start the instructions here worked for me, but you carry them out at your own risk.

You will need a soldering iron to make one simple joint, and a hot glue gun or similar to make the connections robust and reduce the chance of a short circuit.

Firstly disassemble the X50V plug end of the cable, on the version I have this just meant removing two screws, and unclipping two small clips.

Once in you should see something like this. The yellow circle shows the wires we will be dealing with.

Image 100_0237.jpg

1. Using snips you need to cut the loop of wire that goes between the two pins (circled in yellow).

2. Cut the red wire that comes from the cable, cut it as close to the pins as you can.

3. Cut the (in this case red but maybe different on your plug) wire that runs to one of the central pins, again cut as close to the left hand pins as you can (circled in yellow).

4. Connect the wire cut in step 2 to the wire cut in step 3, preferably this should be soldered together.

5. Position the jointed cable towards the middle of the plug so that it is clear of all the pins.

Image 100_0238.JPG

6. Hot glue gun the wire cut in step 1, and the wires you joined in step 4

7. Re-assemble the plug

You should now be able to sync without charging the X50V, or with the X50V off it should charge at less than 500mA.
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tmn72 · 08-06-05, 07:52 PM

Wow, that's a pretty impressive mod. Funny, Snerkel doesn't conjure images of bravery, yet you are far more brave than I to tackle such a project! :D

Snerkel · 08-07-05, 06:46 AM

I am an electrical engineer, so I guess its more stupidity than bravery :rolling: and a bit of educated guess work.

I have been doing some experiments using a sync and charge cable compared to the modified "sync or charge" cable.

Both tests with battery at about 24% and x50v switched off

Standard cable draws 930mA this is way too much for a standard USB port.

Modified cable draws 460mA this is within the limits for a standard USB port (500mA).

Obviously the charge time will be approx double with the modified sync cable, but it will work with virtually any USB port. This charging method is also in theory better for the battery and should give it a slightly longer life. :)

08-07-05, 06:49 AM

good work.

the other thing you can do is with those two wires, hook another usb plug onto them, then on a motherboard that has multiple usb hub's ( some only have 1 with 2 usb ports, other have more, mine has 4 seperate usb hubs so the are powered seperately) then you can feed 1amp into your pda and charge/use at the same time.

Snerkel · 08-07-05, 06:57 AM

Originally Posted by stevodude

good work.

the other thing you can do is with those two wires, hook another usb plug onto them, then on a motherboard that has multiple usb hub's ( some only have 1 with 2 usb ports, other have more, mine has 4 seperate usb hubs so the are powered seperately) then you can feed 1amp into your pda and charge/use at the same time.

Yes that should work, though I would make a double USB male to one USB female adaptor, it would keep it neater. Not sure about being able to operate the x50v at the same time though as the charge + operating current is over 1A in certain circumstances.

Snerkel · 08-10-05, 02:16 AM

I have been doing further tests with an out of the box sync and charge cable.

At the start of charging the X50V had approx 24% charge, this time I made the X50V really work hard to see what the maximum current requirement was.

The processor was set to Auto speed, screen brightness full, WiFi and Bluetooth on, various software was being run, including streaming radio and a Bluetooth GPS. The X50V has the standard 1100mA battery, and is fitted with a 1GB SD card.

The typical current draw was around 950mA often increasing to 1100mA. On occasion the current draw peaked at 1360mA. The current being drawn by the X50V is very unstable while being used with high peaks as a program starts for instance.

From the these figures the minimum current available from a power supply when charging and running the X50V should be at least 1.5A (1500mA). As reported elsewhere a power supply of at least 2A (2000mA) is recommended to ensure sufficent capacity.

forests_gump · 09-13-05, 09:32 AM

Snerkel, great work... on risking it and getting it right!

For the sake of the rest of us, which is less knowledgable, you mind save us the guesswork by giving us the pinouts related?

It would be great if you can describe:

1. The usual pinout of the problematic power hungry sync charge cable.

2. The final pinout of the modified less power hungry sync charge cable.

By the way, your modified cable, if the battery is removed, the battery cover still on, can the x50v power on from the USB?

Snerkel · 09-13-05, 01:56 PM

With the plug in the X50V (screen towards you) pin 34 and 36, possibly 35 will have the red wire from the USB cable connected to them, the same wire will also connect to pin 16.

You need to keep the red wire connected to pin 16, all other connections from that red wire need disconnecting.

Note in the plugs I have looked at they have a few red wires, the only red wires you are interested in are the ones connected to the red wire coming from the USB cable. The only pin this wire should connect to when you have finished is to pin 16 (pin 16 is near middle, all other connections for this wire are on the pins at the right hand end).

I have also seen one plug wired with a PCB, the pin out is the same, to modify the PCB type you should be able to saw through the tracks to these pins with a fine junior hacksaw etc.

Just to add with regard your final point, I am 99% sure it wouldn't work.

d0pefish · 09-13-05, 03:28 PM

Nice one Snerkel! :)

I wrote a similar tutorial a while back that does the same only for the Brando sync 'n charge cables or similar. These ones have the small circuit boards where you cut through the tracks. Take a look if you like:

http://www.aximsite.com/boards/showthread.php?t=79985

:)

Snerkel · 09-13-05, 06:13 PM

Wow yet another different design, nice instructions. The PCB one I have is double sided so both tracks that need cutting are on opposite sides.

I actually have a couple of cables moded for sync or charging (I never use the cradle). I also have two un-moded one used with a high powered USB socket in my car, makes a neat installation and works a treat for operating the X50V.

I suppose the next step for me is to fit a switch in the plug so I can select "burn baby" charging or the nice gentle charging that this mod produces.

d0pefish · 09-14-05, 07:15 AM

Nice idea. I was also thinking of trying to squeeze a little DC power socket into the plug so that I could plug in the charger brick when I want to sync + charge at the same time without spazz attacks. ;)

Either that, or if one couldn't fit in (probably won't) have a little extra cable trailing back. Probably wouldn't be as elegant though... Hmm.

09-14-05, 11:21 AM

I opted for the dell travel sync cable in my x50v buddle. It has the usb plug and a separate hole for the powerplug so the axim is not tricked into drawing too much power from the usb port.

One thing I'm testing out is using a usb->4mm_powerplug cable: link so the axim can be powered by two usb ports.

I have an old 4 port usb 1.1 hub that I use solely for charging purposes. The powersupply is rated for 2500mA so I assume that is good enough to give 500mA to each port.

It would be cool if there is a program on the axim that can show the electrical characteristics of the input power so we know if it's getting enough input power or not.

I'm also playing around with running my axim on an external batterypack such as this one: link

With the axim being so power hungry, they should make a slip-on case that is itself a big battery (ala the old ipaq slipcases).

expresspotato · 12-10-05, 11:28 AM

GREAT JOB Snerkel!!!!

I managed to apply this modification to both my USB/Charge cable & my External Battery Extender (AA's). Prior to this mod, the light on my Axim would continually cycle from green to orange indicating a charger fault. Now, things work perfectly and I'm able to charge my unit thanks to YOU!

UnLoGiC · 12-13-05, 10:38 AM

I bought a synch & charge cable from ebay a while ago for the enormous price of 1.50$ but it charged from USB port even when the X50v was turned on so here is my fix:

http://www.canit.se/~unlogic/PICT3781.JPG

maddoctor · 12-24-05, 09:44 AM

Hi, this seems to be a great mod.
But after the mod, will the cable, when used with a "car to usb adapter" still charge the axim while it is ON or only if it is off?I'd like to use it to power the PDA without battery drain while GPS navigating...
Thanx