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Dell Optiplex GX150 PSU Recap Done!

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    Dell Optiplex GX150 PSU Recap Done!

    Hey guys,

    So as you may/may not be aware, I was having some problems with my Optiplex GX150 (Pentium III). Turns out there were a crapload of G-Luxons and Teapos in the power supply, two of which had notably failed. So after quite a bit of questioning regarding parts, I finally made an order. They came yesterday, and I now have it finished.

    Caps I used:

    Panasonic FC: I used these for all of the large Low-ESR filtering caps on the secondary side. I also used FCs predominatley for the coupling capacitors and other small-ish capacitors. They are a good median between low-ESR and GP, and are suitable for power supply filtering.

    Nichicon PW: I used these for a few stray coupling caps that I could not find in Panasonic FC (which I initially planned on using for the entire supply). PWs are also on the line of low-ESR/GP.

    Nichicon PJ: I used only one of these because I could not find the value in either FC or PW. I used it to replace a coupling-type capacitor.

    Panasonic CE: I used these "big cans" for the voltage doubler/PFC-type circuit on the input. These are rated for 200V and 330uF. I chose these over UCC KMH because of their higher ripple current rating.


    All capacitors are rated at 105*C.

    I did run into one issue though. The one Panasonic FC at the end of the PCB is too tall and hits the power supply's slanted enclosure. It was kind of too late for me to try to alter it's position after I got it soldered in already and leads cut, so I hammered away at the metal enclosure until it fit.

    Another problem formed. The fan that lays on this slanted part of the enclosure is now too close to the lid of the Optiplex's case, so...out of pure laziness. I'm leaving the Optiplex's case cracked open a little bit. Honestly, I think it would be better off with a little bit more air in that poor oven of a case. And it's not getting heavy use, so whateverrr....

    If anyone plans on doing the same, make sure one of your 2200uF 10Vs are a bit shorter than the others OR bend it horizontally so it lies on it's side.

    Otherwise, it was a great success. The computer, which was running horrendously slow before the recap is now up to the mind-boggling speed that it held in 2003...Well not quite...but it sure as hell isn't as bad as it was before.

    Total cost wound up being about $20...so you decide if you want to invest in it or not. I think it's a decent investment, not the best, not the worst. But it was very satisfying.

    Cheers. Enjoy the pictures.
    Attached Files
    Last edited by TheLaw; 04-08-2011, 08:46 PM.

    #2
    Re: Dell Optiplex GX150 PSU Recap Done!

    ALL RiGHT! - Now you're down to 999 projects!

    Good skill to have.
    The next one might be some proprietary POS where a complete unit replacement costs in the 100's or simply doesn't exist at all.

    There are proprietary socket 7 boards [and even 386/486] used in industrial equipment that cost in the $500-$1000 range to replace because they are so hard to find and using a newer board isn't an option.
    .
    Mann-Made Global Warming.
    - We should be more concerned about the Intellectual Climate.

    -
    Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind.

    - Dr Seuss
    -
    You can teach a man to fish and feed him for life, but if he can't handle sushi you must also teach him to cook.
    -

    Comment


      #3
      Re: Dell Optiplex GX150 PSU Recap Done!

      The Panasonic 200V units are actually ED Series, not CE Series ("CE" is the French acronym for Electrolytic Capacitor).
      My first choice in quality Japanese electrolytics is Nippon Chemi-Con, which has been in business since 1931... the quality of electronics is dependent on the quality of the electrolytics.

      Comment


        #4
        Re: Dell Optiplex GX150 PSU Recap Done!

        Ah thanks to both of you. Japlytic, I had it down as ED originally, but then I edited my post and changed it to CE. Funny you should say that.

        Comment


          #5
          Re: Dell Optiplex GX150 PSU Recap Done!

          Originally posted by PCBONEZ View Post
          ALL RiGHT! - Now you're down to 999 projects!

          Good skill to have.
          The next one might be some proprietary POS where a complete unit replacement costs in the 100's or simply doesn't exist at all.

          There are proprietary socket 7 boards [and even 386/486] used in industrial equipment that cost in the $500-$1000 range to replace because they are so hard to find and using a newer board isn't an option.
          .
          Yeah fortunately (or unfortunately?), just about everything else I have uses pretty good caps. My other Dells have very robust PSUs. UCC KYs, Rubys and more and UCC LXZ/Sanyo/OSCON on the motherboard....

          So I won't be able to do any repairs. Shucks. But I do have a giant amp/speaker build underway that is prettyyy intimidating. Who knows when I'll finish that.

          Comment


            #6
            Re: Dell Optiplex GX150 PSU Recap Done!

            Most of the smaller caps were actually silk screened for larger diameters, but of course the bean counters decided that they weren't actually going to use anything good, so they used small 4mm caps instead. The silk screens could have accommodated 5-6mm.

            Comment


              #7
              Re: Dell Optiplex GX150 PSU Recap Done!

              TheLaw - Congratulations.

              Glad to hear of yor success. I am just about to recap a PSU (Also P3/P4 era).

              Nichicon PW is actually equal in ESR to Panasonic FC but have better ripple suppression and longer MTBF. I like to use them whenever I can.

              Nothing beats FM though. I don't know how they're spec'd so good.

              By the way, you didn't mention if your fan started spinning again or not.
              "We have offered them (the Arabs) a sensible way for so many years. But no, they wanted to fight. Fine! We gave them technology, the latest, the kind even Vietnam didn't have. They had double superiority in tanks and aircraft, triple in artillery, and in air defense and anti-tank weapons they had absolute supremacy. And what? Once again they were beaten. Once again they scrammed [sic]. Once again they screamed for us to come save them. Sadat woke me up in the middle of the night twice over the phone, 'Save me!' He demanded to send Soviet troops, and immediately! No! We are not going to fight for them."

              -Leonid Brezhnev (On the Yom Kippur War)

              Comment


                #8
                Re: Dell Optiplex GX150 PSU Recap Done!

                There is no difference between FC and PW ripple suppression.

                Just where did you come up with MTBF because it doesn't have much [if anything at all] to do with Endurance.
                Endurance is an amount of time abused with NO FAILURE resulting at the end of the test.
                An Endurance test is nothing at all like a time to failure test used to find a MTBF.
                .
                Last edited by PCBONEZ; 04-10-2011, 12:11 AM.
                Mann-Made Global Warming.
                - We should be more concerned about the Intellectual Climate.

                -
                Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind.

                - Dr Seuss
                -
                You can teach a man to fish and feed him for life, but if he can't handle sushi you must also teach him to cook.
                -

                Comment


                  #9
                  Re: Dell Optiplex GX150 PSU Recap Done!

                  PW is a little more expensive and the specs always rate them for more hours. For example go to digikey and search for FC and PW only, value 16V 2200uF. Actually, in this case the PW is a little cheaper (But usually it is a little more than FC), and in this case the ripple suppression is exactly the same, like you said, but it clearly states that the PW is "7000 Hrs @ 105°C" and the FC is "5000 Hrs @ 105°C".

                  It's possible that you're right, and it's not actually superior even if they claim it to be, but then why would Nichicon charge more for most of the PW when they are usually much more affordable than Panasonic?
                  "We have offered them (the Arabs) a sensible way for so many years. But no, they wanted to fight. Fine! We gave them technology, the latest, the kind even Vietnam didn't have. They had double superiority in tanks and aircraft, triple in artillery, and in air defense and anti-tank weapons they had absolute supremacy. And what? Once again they were beaten. Once again they scrammed [sic]. Once again they screamed for us to come save them. Sadat woke me up in the middle of the night twice over the phone, 'Save me!' He demanded to send Soviet troops, and immediately! No! We are not going to fight for them."

                  -Leonid Brezhnev (On the Yom Kippur War)

                  Comment


                    #10
                    Re: Dell Optiplex GX150 PSU Recap Done!

                    The Endurance Lifetime tells you nothing about Useful or Expected Life Span.
                    Several long threads explaining that already and as it's 3:30 AM here I'm not going to write it -all- out again.

                    Some people think you can get from one to the other with math but the equations are only +/-40% accurate.
                    -
                    Working backwards from Expected Life Span to Endurance AND taking the +/-40% into account.
                    "7000 Hrs" => Anywhere from 4200 Hrs to 9800 Hrs
                    "5000 Hrs" => Anywhere from 3000 Hrs to 7000 Hrs
                    -
                    100% of those advertised for 7000 Hrs could fail at 4200 Hrs
                    100% of those advertised for 5000 Hrs could fail at 7000 Hrs
                    - - And BOTH would be FULLY within their advertising claims.

                    Is the Endurance Lifetime a useful number in estimating Life Span in the real world?
                    --> Not even a little bit.

                    ~~~~~

                    As I recall the Nichicon P_ series' are certified for use in medical life support equipment and FC are not.
                    That doesn't mean FC aren't good enough it just means Panasonic didn't bother with getting them certified.
                    -- And that's why PW generally cost a little more.

                    I don't remember EVER seeing [or hearing about] a failed FC.
                    - There might have been one case I heard about but the cap was put in backwards so that one doesn't count. - Neiner Neiner...

                    From any -practical- standpoint FC and PW are exactly the same.
                    If both are available in the size I need I get whichever is cheaper.

                    [And a digikey tip]
                    Which is cheaper at the 'each' price isn't always the same as which is cheaper at the '10 piece' price.
                    FC and PW prices flip back and forth a lot that way and so do some others.
                    - So price things on the pages that list the price breaks. [Not the search result page that only shows the 'each' price.]
                    .
                    .
                    Last edited by PCBONEZ; 04-10-2011, 05:07 AM.
                    Mann-Made Global Warming.
                    - We should be more concerned about the Intellectual Climate.

                    -
                    Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind.

                    - Dr Seuss
                    -
                    You can teach a man to fish and feed him for life, but if he can't handle sushi you must also teach him to cook.
                    -

                    Comment


                      #11
                      Re: Dell Optiplex GX150 PSU Recap Done!

                      Thanks for the clarification.
                      As I recall the Nichicon P_ series' are certified for use in medical life support equipment and FC are not.
                      This is interesting. So in essence, Nichicon is just charging a fortune for these because of this? They're usually pretty good about prices with their high-end caps. I actually bought recently from my local electronics shop an AC adapter that claims to be "For Medical Use". It has some heft to it, and I'd love to know now what's inside.
                      There might have been one case I heard about but the cap was put in backwards so that one doesn't count. - Neiner Neiner...
                      I will do the mocking around here.

                      Did you notice the odd series you sometimes get during a search which claims "Up to 130C". Generally speaking, they're GP caps. Are they worth the money?
                      "We have offered them (the Arabs) a sensible way for so many years. But no, they wanted to fight. Fine! We gave them technology, the latest, the kind even Vietnam didn't have. They had double superiority in tanks and aircraft, triple in artillery, and in air defense and anti-tank weapons they had absolute supremacy. And what? Once again they were beaten. Once again they scrammed [sic]. Once again they screamed for us to come save them. Sadat woke me up in the middle of the night twice over the phone, 'Save me!' He demanded to send Soviet troops, and immediately! No! We are not going to fight for them."

                      -Leonid Brezhnev (On the Yom Kippur War)

                      Comment


                        #12
                        Re: Dell Optiplex GX150 PSU Recap Done!

                        Originally posted by mockingbird View Post
                        TheLaw - Congratulations.

                        Glad to hear of yor success. I am just about to recap a PSU (Also P3/P4 era).

                        Nichicon PW is actually equal in ESR to Panasonic FC but have better ripple suppression and longer MTBF. I like to use them whenever I can.

                        Nothing beats FM though. I don't know how they're spec'd so good.

                        By the way, you didn't mention if your fan started spinning again or not.
                        The original stock fan stopped working about 4 years ago. I replaced it with a cheap Antec 80mm and it has worked ever since, even with the bad caps.

                        Comment


                          #13
                          Re: Dell Optiplex GX150 PSU Recap Done!

                          Originally posted by mockingbird View Post
                          Thanks for the clarification.

                          This is interesting. So in essence, Nichicon is just charging a fortune for these because of this?
                          Not the only industry that works that way.
                          -
                          I've had to pay $10+ for Nitrile O-rings that were certified for use in Nuke plants while the same damned thing [same manufacturer even] less the 'paper trail' and the cert# costs under 25 cents at the hardware store.
                          -
                          If you look at Kingston RAM PN's those that end in an I are "Intel Certified" and usually cost more as new.
                          -
                          There's even some kind of a certification for fry pans. - Gezz!
                          There are many examples, those are just the first I thought of.

                          Originally posted by mockingbird View Post
                          Did you notice the odd series you sometimes get during a search which claims "Up to 130C". Generally speaking, they're GP caps. Are they worth the money?
                          Possibly for 4-5mm caps in a PSU hot-spots but I've been pretty happy using FC, PW, LXZ, KG and the likes there. Haven't had any of those fail [yet].
                          .
                          Mann-Made Global Warming.
                          - We should be more concerned about the Intellectual Climate.

                          -
                          Be who you are and say what you feel, because those who mind don't matter and those who matter don't mind.

                          - Dr Seuss
                          -
                          You can teach a man to fish and feed him for life, but if he can't handle sushi you must also teach him to cook.
                          -

                          Comment


                            #14
                            Re: Dell Optiplex GX150 PSU Recap Done!

                            If you look at Kingston RAM PN's those that end in an I are "Intel Certified" and usually cost more as new.
                            A few months ago there was a report of a massive counterfeiting operation of Kingston SD Cards in China. Eventually the investigation took the inquisitive researcher to some back alleys in China where he saw vendors enthusiastically opening up genuine Kingston products and replacing them with the counterfeited product. My opinion is that there is some sort of collusion involved here.

                            This guy actuall slices chips very thin and then washes away residue with strong acids so he can look at the core. He posted pictures of the Kingston die and the counterfeit die.
                            "We have offered them (the Arabs) a sensible way for so many years. But no, they wanted to fight. Fine! We gave them technology, the latest, the kind even Vietnam didn't have. They had double superiority in tanks and aircraft, triple in artillery, and in air defense and anti-tank weapons they had absolute supremacy. And what? Once again they were beaten. Once again they scrammed [sic]. Once again they screamed for us to come save them. Sadat woke me up in the middle of the night twice over the phone, 'Save me!' He demanded to send Soviet troops, and immediately! No! We are not going to fight for them."

                            -Leonid Brezhnev (On the Yom Kippur War)

                            Comment


                              #15
                              Re: Dell Optiplex GX150 PSU Recap Done!

                              ^ i've seen that guys website too. can't find the link at the moment though..

                              Comment


                                #16
                                Re: Dell Optiplex GX150 PSU Recap Done!

                                Hmm that's interesting. How the hell do you "slice" a chip? Deli slicer? O.o

                                Comment


                                  #17
                                  Re: Dell Optiplex GX150 PSU Recap Done!

                                  he used nitric acid to dissolve the microSD casing

                                  found the link
                                  http://www.bunniestudios.com/blog/?p=918

                                  edit: it's from feb 2010.. so quite a bit older than "a couple months".. but i think it's the same thing mockingbird was talking about
                                  Last edited by Scenic; 04-12-2011, 08:59 PM.

                                  Comment


                                    #18
                                    Re: Dell Optiplex GX150 PSU Recap Done!

                                    Yes, good work German guy, that's exactly the article I was refering too. Wow, has it been that long?
                                    "We have offered them (the Arabs) a sensible way for so many years. But no, they wanted to fight. Fine! We gave them technology, the latest, the kind even Vietnam didn't have. They had double superiority in tanks and aircraft, triple in artillery, and in air defense and anti-tank weapons they had absolute supremacy. And what? Once again they were beaten. Once again they scrammed [sic]. Once again they screamed for us to come save them. Sadat woke me up in the middle of the night twice over the phone, 'Save me!' He demanded to send Soviet troops, and immediately! No! We are not going to fight for them."

                                    -Leonid Brezhnev (On the Yom Kippur War)

                                    Comment

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