Thomson Sky-HD (and Sky+) PSU failure

admin · Posted: Tue Feb 12, 2008 11:27 pm Post subject:

I'm just waiting for our repairer to type up the list of parts that we need to order. He's been too busy doing repairs for the past couple of days and tomorrow is his day off. Also I have to test the heat shield material, which hasn't arrived yet. So it will take a few more days.

UPDATE: May 1, 2009
We are now supplying special heat-resistant card with every kit and PSU.

Ragnarok · Newbie Joined: 03 Feb 2008 Posts: 12 Location: UK

ooooooh Heat shield material, I like the sound of that considering a number of the caps are right next to hot voltage regulators and their heatsinks.

Seems you and your crew have really tried to put this reliability problem to bed.

admin · Posted: Wed Feb 13, 2008 12:19 am Post subject:

We aim to give a 3 year guarantee on our rebuilt PSUs. I think it only fair that people can expect at least that from the kits, although we won't be offering a guarantee on kits - except that the parts will be of high quality.

Unfortunately, we are struggling with price. I'd hoped to stay below £10 but I don't think that will be possible.

Ragnarok · Newbie Joined: 03 Feb 2008 Posts: 12 Location: UK

I personally wasn't expecting the price to be that low. then again if an extra few quid saves me from needing to open up the box again for possibly another year or 2 it's money well spent.

admin · Posted: Thu Feb 14, 2008 8:13 pm Post subject:

Hooray! We finally have a list of parts. These will (hopefully) be ordered tomorrow (Friday 14th) and we'll have a price by Monday. Kits should be ready by Wednesday.

The "heat shield" material arrived but, unfortunately, it was useless. However, we think the capacitors will survive without it.

Update: if you'd like to extend the life of the capacitors and you can locate some thin "Nomex" card, put a strip between the heatsink and the capacitors. "Nomex" card is used in the manufacture of transformers and also (as a soft, woven fabric) in the manufacture of racing driver fireproof under garments. Unfortunately, we have not been able to find a supplier of small quantites.

Ragnarok · Newbie Joined: 03 Feb 2008 Posts: 12 Location: UK

. Put me down for a pre order. It's a shame the heat shield was a failure but I have seen some poorly placed caps last over 3 years and still going strong.

beats my current time bomb!

admin · Posted: Fri Feb 15, 2008 3:53 pm Post subject:

Another darn setback. Sad

One of the capacitors is completely sold out in the UK so we're trying to order it from a stockist in the USA.

I think that puts Wednesday target out of the window.

I'm going away on Thursday so I've put up the order form so that people can place advance orders. They'll be sent out as soon as stock arrives. Credit cards won't be charged until the day of despatch.

http://www.SatCure.net/accs/page12.htm#HD

admin · Posted: Fri Feb 15, 2008 6:58 pm Post subject:

OK, the order is placed. We are shipping a thousand of the special capacitors in by UPS. Darn, why does everything always cost more and take longer? Sad

But I'm optimistic that we might still make the Wednesday deadline. UPS are usually pretty fast.

Oops: I forgot to note down the PCB designations for the capacitors When I had a unit in my hands so I've had to work from photographs and guesswork. This means that I might have got a couple of numbers wrong. For example, I might have transposed C41 and C51. This really shouldn't matter but it might confuse. I'd appreciate it if someone could check.
http://www.SatCure.co.uk/tech/images/33j_layout.gif

(It's lonely here. Is anyone reading this? I've never been keen on "blogs" but it's turning into one. If I'm not careful, I'll be telling you what I had for breakfast. A banana, actually. Oops.) Embarassed

Taomyn · Newbie Joined: 13 Feb 2008 Posts: 9 Location: Luxembourg

Do you have any idea when you'll have rebuilt PSUs in stock again? I definitely don't want an original built one.

I'm in Luxembourg, but I have a friend visiting me from the UK 2nd week of March, so I was hoping to get one shipped to him to bring over for me, I would then replace mine in my SKyHD, make sure it was okay and get him to take back and return the old one to you.

Cheers,
Fernando

admin · Posted: Fri Feb 15, 2008 9:24 pm Post subject:

We should have a few more PSUs next week. Place your order and get in the queue!

Ragnarok · Newbie Joined: 03 Feb 2008 Posts: 12 Location: UK

satbreak · Moderator Joined: 05 Oct 2005 Posts: 190

Checked on 3 boards, 2 from Sky+160's, one from Sky HD.

14 OK
20 OK
21 OK
71 OK
61 OK
43 OK

On gif -> On my PCB(s).

33 -> C52
52 -> C81
41 -> C60

Some obscured on all my boards by yellow epoxy. I'm loath to chip away at a working board.

Following numbers derived by cross referencing from Nigel's list (He lists suggested replacement values with cap number).

81 -> C33
60 -> C41

51 balance of probability suggests this is OK, same value as C41 so these *could* be reversed.

Happy to double check this information when gif is corrected.

admin · Posted: Sat Feb 16, 2008 5:34 pm Post subject:

Thanks, I've changed the GIF. Now I'll change it on the instruction sheet.

satbreak · Moderator Joined: 05 Oct 2005 Posts: 190

Checked. All looks OK.

I keep planning to draw a circuit diagram for the thing. I assume none is available?

Ragnarok,

Useful if you could check if 41 and 51 are transposed when you swap them out if you have the curiosity.

Taomyn · Newbie Joined: 13 Feb 2008 Posts: 9 Location: Luxembourg