Corsair HX-520W - orange glow results in burned components

[retiredcaps]

I got this used unknown condition Corsair HX-520W about 3 weeks ago. Since I didn't know if it was working or not (and out of warranty), I opened it up to look for bad caps and obvious signs of damage.

I was excited to see that UCC KY caps were used throughout (after getting sick of seeing UCC KZGs on 3 motherboards - all non working of course). I also noticed the power supply looked like it was coated in fine sand? It wasn't normal dirt, but light brownish like sand.

I cleaned it all out carefully and put the cover back. I hooked it up to my power bar (with on/off switch) with power off. I readied my multimeter to test the 5V SB rail. I put a paper clip in the green and black power connector. I double checked everything before hitting the power button.

I put my safety glasses on and as soon as I hit the power on, the fan spun, and through the spinning blades I could see an orange glow. I immediately shutdown the power and about 1 second later I could smell the burnt electronic odor.

In retrospect now, I should have been very suspicious of the glue that turned brown and scraped it off before power on. Anyway, you can see the damage to a resistor, coil, and possibly more items.

Anyway, I would like to try and save this power supply if possible. A new 450W Corsair, on sale, will cost around $40 CDN. More importantly, this is an opportunity for me to learn more about ATX PS.

I can provide more pictures to help id the components if required.

[kc8adu]

Re: Corsair HX-520W - orange glow results in burned components

might be as simple as scraping away the crud.be sure to get any carbon tracks while you are in there.
i would have figured that the brown glue would have been dumped in the 70's when the first problems came up.
like the quasar tv sets with huge globs of it on the crt socket board.and missing traces under it.

[Toasty]

Re: Corsair HX-520W - orange glow results in burned components

Doesn't look like damage, per se. Looks more like it just flashed across the glue remains. Do what kc8adu said and clean it up. Then go and clean the rest of it out.

[retiredcaps]

Re: Corsair HX-520W - orange glow results in burned components

Okay, I finally got around to cleaning this out and I noticed:

1) There is a nice crater (that isn't obvious in the pic) in the pcb right by the leg of the diode.

2) The diode that was covered in black soot still tests good in circuit (.397V and 0L on diode check).

3) I'm not sure if that is copper sitting behind the diode. It is almost like the top layer pcb peeled backwards to reveal copper?

4) Because of the AC plug and modular connectors are soldered into the unit, it is almost impossible for me, but not others, to remove this board from the metal casing. Any work done by me will be very limited.

Q1) Should I have take a chance of powering this thing up in the present condition?

Q2) If the damage is beyond my repair skill level, does anyone want this? I can ship it from Canada, but the cost of shipping it may be unwarranted due to high costs.

[hardwareguy]

Re: Corsair HX-520W - orange glow results in burned components

The "sandy" material you speak of....could it be conductive metal oxide shavings? Check that before you apply power. Use high pressure air to clean it out. (take necessary personal protective precautions...its nasty to breathe and seems to love to get stuck in eyes)

[Toasty]

Re: Corsair HX-520W - orange glow results in burned components

If shipping to the US could be kept reasonable, I'd take it on as a 'science project'.

LOL

[retiredcaps]

Re: Corsair HX-520W - orange glow results in burned components

If shipping to the US could be kept reasonable, I'd take it on as a 'science project'.

LOL

Give me a few days to get an estimated shipping weight. I'll box it and take it to the post office. I don't have an accurate scale at home to weigh it myself.

Should I even try to power it on again?

[Toasty]

Re: Corsair HX-520W - orange glow results in burned components

>>Should I even try to power it on again?<<

Why not? Just keep your distance...

[retiredcaps]

Re: Corsair HX-520W - orange glow results in burned components

Why not? Just keep your distance...

Looks like you and kc8adu were right (like there was any doubt?). I put on the safety glasses, plugged the psu into a power bar with finger ready to turn off, and turned on the psu.

No flames or burning smell so I started measuring voltages and got everything (3.3V 5.0V, and 12.0V DC).

I'm still not 100% comfortable with its operation so I will test it on a low end board and monitor it very carefully. I'll also do a bit more cleaning of the board.

Thanks for all the help.

[hardwareguy]

Re: Corsair HX-520W - orange glow results in burned components

Desolder the inductor and clean the brown glue off underneath the unit.

Use a non-acid curing silicone such as GE Silicone II to replace the glue.

[Toasty]

Re: Corsair HX-520W - orange glow results in burned components

I am concerned with the foil you may have lifted:

>>3) I'm not sure if that is copper sitting behind the diode. It is almost like the top layer pcb peeled backwards to reveal copper?<<

Clean the area well with isopropyl alcohol and an old toothbrush. Use silicone caulk to fix/insulate the board 'crater' area too.

Get the rest of that glue out of there!

Good work!

.

[retiredcaps]

Re: Corsair HX-520W - orange glow results in burned components

Clean the area well with isopropyl alcohol and an old toothbrush. Use silicone caulk to fix/insulate the board 'crater' area too.

Get the rest of that glue out of there!

Okay, I finally got around to do all the suggestions with the isopropyl alcohol, silicone caulk, and old glue removal. I let everything dry for 3 or 4 days (even though I didn't have to) and let the silicone caulk sit for 36 hours.

I also lubricated the fan bearing with 5W30 motor oil so it runs a lot quieter now.

I put the cover on and all voltages appear within spec. No burning smell or glowing components.

I need to run some longer tests on it before I gain confidence in my repair job.

[retiredcaps]

Re: Corsair HX-520W - orange glow results in burned components

I need to run some longer tests on it before I gain confidence in my repair job.

It has been over a year and the PSU is in daily use now and things are still fine. The PSU isn't very stressed though.

Thanks again to kc8adu, Toasty and hardwareguy for all the feedback and help.

[Behemot]

Re: Corsair HX-520W - orange glow results in burned components

Interesting to see something like that happening in Seasonic PSU's.

Anybody else encountered this in PSU's from this era? S12II/M12II, OEM models?

[ben7]

Re: Corsair HX-520W - orange glow results in burned components

Maybe a bug walked inside of it. Not uncommon

[retiredcaps]

Re: Corsair HX-520W - orange glow results in burned components

Maybe a bug walked inside of it. Not uncommon

Since I buy used stuff or get them for free, I'm very careful to check for unwanted visitors before I bring them into the house. There was no visitor on this one.

[ben7]

Re: Corsair HX-520W - orange glow results in burned components

Since I buy used stuff or get them for free, I'm very careful to check for unwanted visitors before I bring them into the house. There was no visitor on this one.

Maybe there was a 'visitor' inside, hidden behind the PFC choke

[retiredcaps]

Re: Corsair HX-520W - orange glow results in burned components

Maybe there was a 'visitor' inside, hidden behind the PFC choke

That is a possibility since these PSUs are all tightly packed and I can't see/clean every crevice.

I did find an unwanted visitor in an old Fluke 25+ year multimeter.

I realize, buying new, is also no guarantee.

[ben7]

Re: Corsair HX-520W - orange glow results in burned components

That is a possibility since these PSUs are all tightly packed and I can't see/clean every crevice.

I did find an unwanted visitor in an old Fluke 25+ year multimeter.

I realize, buying new, is also no guarantee.

I once had a pioneer radio/amplifier which all of a sudden started sizzling and popping. Under the circuitboard was a well toasted cockroach! It must have already been dead, so no roaches in my house!

[tom66]

Re: Corsair HX-520W - orange glow results in burned components

I have had an insect invite itself onto a plasma TV buffer board (high voltage... around 500Vp-p.) This lead to the insect's unfortunate cooking, and also that of the buffer board. Luckily a new board was cheap.