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majortom

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Reply with quote  #1 
Woke up this morning to the S9 Constantly rebooting.
Like OK here we go. If ya removed the load on the power supply,
by disconnecting the cable from Pwr supply output, to main board input, the power supply output voltages seemed stable with no load.
So it was still fundamentally functional. They are labelled +24V, +12V and +5V at the output ribbon cable connector.
If ya monitored any of the output voltages while loaded, none of them were stable. They all followed they same pattern as the rebooting. Closed loop feedback shutting er down under load.

Found C19 on the Pwr Supply Board was toast.
C19 and C17 are in parallel, next to each other so they add up for a total of 3000 uF.
C17 measured OK, while C19 Measured only 100 UF on my Triplett DMM.
For now I replaced C19 with a 1000 uF 35 V, all I had handy in the parts bin,
and for now it's working. Should be OK while I await new caps from Digikey.
Popped the new Littlefuse resettable Fuse / Posistor in while I was in there.
Cleaned up all the mung underneath the Main Board with denatured alchohol while I had it all apart.
Looked like brown flux mung left over from the factory post wave bath.
Anyway, it's all back together scannin the sky again till I get the correct new caps.

For future reference here is a list of all the electrolytic caps on the Power Supply Board of the Openbox S9.

Openbox S9 Power Supply
Constant Reboot

Electrolytic Caps
These two are in parallel on the +5V output line if I remember correctly. So if ya ever need to replace one, maybe assume the inevitable and replace em both at the same time.
C19 1500 uF 10 V 105 deg C    Toast             Digikey P14379-ND
C17 1500 uF 10 V 105 deg C    looks and measures OK    Digikey P14379-ND

rest of these just because they are also on other output voltages.
C12 470 uF 35V 105 deg C    Digikey P12415-ND
C13 220 uF 35V 105 deg C    Digikey P5552-ND
C14 220 uF 25V 105 deg C    Digikey P12383-ND
C15 100 uF 25V 105 deg C    Digikey P5540-ND
 
Not as likely needing to be replaced save for catastrophic failures.
C4 33uF 50V 105 deg C        Digikey P5567-ND
Main AC Rectifier Filter Cap
C2 33uF 400V 105 deg C        Digikey 565-1464-ND

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Perfect 10 7.5' mesh Chapparal C/Ku Co-Rotor feed, Norsat 8115 CBAND, Norsat 4106A Ku Thomson Saginaw Actuator, Vbox positioner,
Home Brew Polarotor683 Servo circuit. Openbox S9, Prof7500, v4l-updatelee linux drivers installed.
Pixl

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Reply with quote  #2 

Interesting find, most S-9 power problems end up being the polyfuse or the LNB voltage regulator, not the supply itself. This is the first I've read of the S-9 power supply actually bad. Now the S-10 supplies are poorly designed with undersized parts.
I'm saving the info from this fix.


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Location: Traverse City, Michigan
C: 8' Andrew w/orthomode feeding twin Norsat 8515, Atemio Nemesis
Ku: 1.2m Channel Master w/orthomode feeding twin NJR universal lnbs, Manhattan RS-1933
DBS: Motorized DTV Slimline, Jynxbox Ultra V3
4:2:2 AZminiMe slaved off C/Ku
majortom

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Reply with quote  #3 
the original caps all say they are mfr'd by some "Econd" never heard of 'em.
Must be some chinese cap mfr. 

here's a pic of the pwr supply caps.
should be able to tell which one is the bad C19.

http://db.tt/AMG2CzJL

https://db.tt/SzRhV8HP

and the flux mung, not sure how well ya can see.

http://db.tt/NEqh1vaZ

Edit: after a little googlin, looks like "Econd" is a Russian Capacitor manufacturer.

 
Quote:
The major foreign manufacturers are: the United States Maxwell company, Russia’s Econd company, Elit company, 
Japan’s Elna Company, Panasonic Corporation, Nec-Tokin Corporation, 
Korea Ness companies, Korchip company, Nuintek companies.
 
 

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Perfect 10 7.5' mesh Chapparal C/Ku Co-Rotor feed, Norsat 8115 CBAND, Norsat 4106A Ku Thomson Saginaw Actuator, Vbox positioner,
Home Brew Polarotor683 Servo circuit. Openbox S9, Prof7500, v4l-updatelee linux drivers installed.
majortom

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Reply with quote  #4 
got the new caps and finished this up today.
I wound up replacing all of the Russian Caps, only because I've never heard of them. Normally I wouldn't bother replacing all. They are cheap enough.

http://db.tt/WyjTbASr

While only C19 was actually bad (measured 59 uF out of circuit) , C17 it's identical twin in parallel measured >2000uF, which is ~ +33%. Possibly how it limped along with a bad cap for so long (2 years or so?)...

Box is back up and working.


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Perfect 10 7.5' mesh Chapparal C/Ku Co-Rotor feed, Norsat 8115 CBAND, Norsat 4106A Ku Thomson Saginaw Actuator, Vbox positioner,
Home Brew Polarotor683 Servo circuit. Openbox S9, Prof7500, v4l-updatelee linux drivers installed.
WellerTip

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Reply with quote  #5 
One of my S9's found dead today. Opened it up and C13 had exploded. Blew its guts everywhere, unable to even read the label on the can that was floating around the chassis. But Tom's post from years ago quickly answered that question.
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majortom

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Reply with quote  #6 
Nice...just noticed your post. Got it working OK by now I assume?
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Perfect 10 7.5' mesh Chapparal C/Ku Co-Rotor feed, Norsat 8115 CBAND, Norsat 4106A Ku Thomson Saginaw Actuator, Vbox positioner,
Home Brew Polarotor683 Servo circuit. Openbox S9, Prof7500, v4l-updatelee linux drivers installed.
WellerTip

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Reply with quote  #7 
Yepper, and thanks again!
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