[comp.sys.misc] UNIX-PC Hardware modifications

cmv@ihuxz.ATT.COM (Craig Votava) (01/20/88)

This is my 3rd try, again excuse duplicates...
------
I (re)posted all of this stuff last week, but our machine lost all of
the articles, so I don't know who got it and who didn't. Please excuse
all duplicates.

All the articles that I talk about reposting, will appear in
unix-pc.general and att.sys.unixpc ONLY. If you cannot get these
groups, let me know what groups you do get, and I'll try and get
you a copy somehow...

----- News saved at 5 Jan 88 21:29:26 GMT
Many people have asked me to repost a number of upgrades that I've done
to my unix-pc to make it do more than it originally could. I will try to
summarize some of the upgrades that I've done, here in this article and
then repost the original articles as well.

I started with a used 7300 (0.5MBytes RAM, 20Mbyte Disk) in February of 1987
(bought just before the blowout sale... darn!) and have ended up with what is
really a 3b1 I guess, 2.5MBytes RAM, 86Mbyte Hard Disk (I could have gone up
to a 191Mbyte Disk, but didn't have the money!), DOS-73 board, and a Voice
Power Board (These are really neat, I'd recommend them to anyone!). In order
to get my machine to this point, I had to learn a lot about a wide variety
of upgrades.


EXPANSION MEMORY BOARD UPGRADE:
The first problem I tried to solve with my system was to increase the amount of
main memory I had in order to speed up the response time. I bought a used 0.5MB
memory expansion board (thanks Gary!) which increased my total memory to 1 Meg.
Then I found out that the exact same board populated with 256k chips instead of
64K chips (as mine was) could provide 2.0 Mbytes of memory! So, after some
research into how to accomplish this, and screwing up my courage to do some
hardware hacking, I ripped out all of the old memory chips, installed sockets
and populated them with the higher density memory chips. Then I changed some
jumpers on the board, installed it in my machine, and I ended up with a total
of 2.5 Mbytes in my machine. I will re-post the original description of this
upgrade.

MOTHERBOARD MEMORY UPGRADE:
During the course of my research into the above upgrade, I found out that the
motherboard can be upgraded to hold a maximum of 2.0 Mbytes as well (that's a
grand total of 4.0Mbytes in the machine). Early machines (like mine) were
shipped with 0.5Mbytes of memory where all the available memory chip locations
were populated with 64K chips. Later versions were shipped with 1.0Mbytes of
memory where only half of the available memory chip locations were populated
with 256K chips (the rest of the locations were left blank). For me to upgrade
my machine, I'd need to rip out all of the 64K chips, and re-populate with 256K
chips. This I was too scared to do initially, but am feeling better about it
now, maybe someday I'll do this. To modify one of the later 1.0 Mbyte versions,
all you have to do is add in the rest of the 256K chips. There are also jumper
changes on any of these modifications.  I will re-post the original
description of this upgrade.

EIA-RS232 RAM MEMORY EXPANSION BOARD UPGRADE:
The eia-rs232 ram memory expansion board can be purchased in a number of
different memory configurations from 0K memory, up to 1.5Mbytes of memory.
It is also possible to upgrade a board on your own from any configuration
up to 1.5Mbytes. I don't have any "official" upgrades on this, but I put
together what I think would help to upgrade it. Back in August,
ethos!fubar!cliff was trying to upgrade a 0K board (howze it going, Cliff?)
I don't have a recent status on this. I will re-post the original description
of this upgrade.

7300 TO 3B1 POWER SUPPLY UPGRADE:
The second problem that I attacked in order to speed up response time, was to
get a new Hard Disk. I decided to go with the Full-Height CDC WrenII 86Mbyte
(9 heads, 925 cylinders) mainly for price reasons (thanks again, Gary!).
I was worried about the power supply, since I'd heard rumors that the 7300
power supply was different than the 3b1 power supply, so I did some
investigation to see what was what. According to the technician that I talked
to, the 7300 and 3b1 power supplies are the same in every way except in how
they deliver the power to the Hard Disk. On the 7300, all power is routed
through the motherboard, so you have cables from the power supply circuit board
to the motherboard, then other cables from the motherboard to the hard disk
(as well as the floppy). On the 3b1, power for the hard disk comes off
of a cable on the power supply circuit board directly into the hard disk,
bypassing the motherboard totally. So I took my machine apart and looked at the
power supply circuit board, and found that the holes for the cable to the
hard disk are there and labeled! All you'd need to do is to remove the HD
power supply cable from the motherboard and install it on the power CB, and
you'd be all set! I decided to keep this as a last resort though, and simply
connected my HD to the existing cable from the motherboard. I've had no
problems, or unusual behavior, so never needed to perform this upgrade.

HARD DISK CYLINDER CAPACITY UPGRADE:
One limitation of the machine that can become a problem with all of the
different sizes of ST-506 hard disks available now, is the maximum number
of cylinders it can access. The hard disk controller chip originally installed
in most unix-pc's was the Western Digital 1010 hard disk controller (WD1010).
This chip physically cannot access more than 1024 cylinders on a hard disk.
After talking with WD I found that they had a new chip that can replace the
WD1010 and access more than 1024 cylinders - the WD2010. So, what this means
is that if I went out and bought, say the MAXTOR XT2190 hard disk, installed
it and tried to format it following the manufacturer's specifications (which
indicate the drive has 1224 cylinders), the format program on the diagnostic
disk would bomb out since the hard disk controller chip cannot access cylinders
greater than 1024. The solution is to go to your friendly neighborhood
electronics shop, and buy a WD2010 hard disk controller chip ($40.00), bring
it home and replace your existing WD1010 chip with the new WD2010 chip.
Since my hard disk has only 925 cylinders, I did not do this upgrade. I did
however, try is out in a stock 7300 with the 20Mbyte hard disk, and everything
worked properly - but that test didn't try formatting cylinders above 1024.
I will re-post the original description of this upgrade.


HARD DISK HEAD SELECT CAPACITY UPGRADE:
Another limitation of the machine, that can be solved, is it's inability to
access more than 8 heads on a hard disk. This problem hit me where I live,
since the hard disk I installed in my machine had 9 heads; for a couple of
months I had about 10Mbytes that I couldn't access! This upgrade took the most
work to drag out of Convergent, and the most work to implement. Basically it
involves installing a pre-programmed PAL chip in an unused location on the
motherboard, and running jumper wires from the new chip to various locations
on the motherboard. Since the upgrade fairly involved, and the equations to
program the PAL chip with are proprietary to Convergent, I can/will not provide
the upgrade via the net, but the upgrade instructions are not hard to acquire
if you're persistent enough, and is not difficult to do, if you know your way
around a soldering station. I will re-post the original description of this
upgrade.

BATTERY BACK UP REPLACEMENT:
There have been a bunch of articles on how to do this, so I won't go into it
in detail, but it involves going to Radio Shack and buying some re-chargable
batteries and a battery holder and replacing the existing battery on the
motherboard. Total cost is about $6.00 (Thanks Steve!)

2-WAY DATAKIT PORTS:
A lot of very smart folks (thanks summit!) did a good deal of work to get
2-way datakit ports working on many AT&T machines (3b1,3b2,3b20,etc.).
There are no hardware modifications, but I wanted to mention this because of
the many questions I've seen on the net concerning this topic. The software
is now available, for the 7300/3b1 through THE STORE (nice job Jonathan!).

*******************************

Some other projects that I'm looking at are:

*******************************

STREAMER TAPE UPGRADE:
While talking with a buddy of mine, I found out that the streamer tape designed
for the unix-pc has an interface that makes it look like a floppy disk drive.
When you spend the megabucks to buy the streamer tape backup system from AT&T,
you get the free standing streamer tape (with box and power supply) and a
circuit board to connect it to. This circuit board must simply supply the
unix-pc with another set of floppy disk connections, which we connect the
streamer tape to and use the streamer tape software to drive the device.

In theory then, I could rip out the floppy drive, and substitute a streamer
tape, install the streamer tape software, create the /dev files with the
appropriate major and minor numbers (if the software was written correctly)
and be able to backup my hard disk to the streamer tape!

If this assumption is true, what I'd like to do is to get the "Black Box
Corp." to fabricate a switch box for me that will switch both the power,
and the ribbon cable between 2 devices. Then I'll buy the streamer tape itself
and connect it to one side of the switch, connect the internal floppy disk
drive to the other side of the switch, and connect the cables from the
motherboard to the "common" part of the switch. With this arrangement, I can
select the floppy when I want to use it, or select the streamer tape when I
want to do backups! Feel free to send me comments if you have any comments
that could help me.

1200-2400 BAUD MODEM UPGRADE:
I'm looking for a 2400 baud pin compatible modem chip to replace the 1200 baud
modem we have in the unix-pc. This would be nice, but I don't know if it's
feasable. Help here would be appreciated.


That's all I have for now, feel free to send me questions, or send me help
at [ihnp4!]looney!cmv or [ihnp4!]ihlpm!cmv

Craig "looking-for-a-new-job" Votava
IH 4G-324 x2542

richard@islenet.UUCP (Richard Foulk) (01/20/88)

> If this assumption is true, what I'd like to do is to get the "Black Box
> Corp." to fabricate a switch box for me that will switch both the power,
> and the ribbon cable between 2 devices. Then I'll buy the streamer tape itself
> and connect it to one side of the switch, connect the internal floppy disk
> drive to the other side of the switch, and connect the cables from the
> motherboard to the "common" part of the switch. With this arrangement, I can
> select the floppy when I want to use it, or select the streamer tape when I
> want to do backups! Feel free to send me comments if you have any comments
> that could help me.

Floppy drives are designed to be bussed together.  They normally have
a couple of lines for drive-enable which is probably all you need to
switch. That's why most multi-floppy systems connect the drives together
via the same ribbon cable.

So the job is much easier than it seems at first.






-- 
Richard Foulk		...{dual,vortex,ihnp4}!islenet!richard
Honolulu, Hawaii
-- 
Richard Foulk		...{dual,vortex,ihnp4}!islenet!richard
Honolulu, Hawaii