Corroded Wires Caused Intermittent Contacts In Computer ATX SMPS
This Computer SMPS was brought to me with the complaint that it works intermittently and if the multiple wire connector is shaken, it comes on and off. So, it was a clear indication of loose contacts in the wire. Now, there is a problem, as this connector has 24 pins in one connector:
As you can see there are 8 black wires (ground), 5 red wires (+5V), 2 yellow wires (+12V), 4 Orange wires (+3.3V), 1 green wire (PS-ON), 1 Blue Wire (-12V); 1 White wire (-5V), 1 Grey wire (Power Good sensor) and 1 Violet wire (+5V Standby) totaling to 24.
Then there are 12 more connections going to Hard Disks, CD drives, SMPS Fan etc. totaling to 36 wires! So, how to know which wire is the culprit? All these are soldered very closely on the Board and it is very difficult to comb the area or check the broken wires. The only way was to transplant another set from a salvaged SMPS and that is what I did. I selected a good set of wires from an old SMPS and removed the 36 wires ensuring that no damages are caused to the tips. Then started from one end and replaced the wires on the Board, keeping the choice as colours.
First I replaced all the Yellow, then black, then red, then orange, and the others one by one. The method was : remove same colour wires and clean up the area, insert the replacement of same colour wires and solder them one by one ensuring proper bonding! Well, it took some time for sure. But the net result was good!
After finishing this work, I rechecked what I did thoroughly (one wrong connection is enough to have the PC mother board or other parts damaged) cleaned the board and powered the SMPS on to find that the Tester was indicating
all voltages and SMPS fan was running well! A job well done to my satisfaction, result of which as you might all know by now that it jumps itself to its collection bag! (LOL)
This article was prepared for you by Parasuraman Subramanian from India. He is 71 years old and has more than 30 years’ experience in handling antique equipment like Valve Radio, Amps, Reel Tape Recorders and currently studying latest tech-classes conducted by Kerala State Electronics Technicians’ Association. He has done graduation in BBA degree, private diploma in Radio Engineering and retired as MD of a USA company. Presently working as Consultant to Hospital and other institutions.
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You may check on his previous repair article below: https://jestineyong.com/rejuvenated-a-weak-crt-tube-of-samsung-model-ks9a21m16-and-fixed-broken-back-cover/
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Albert van Bemmelen
March 16, 2021 at 8:46 pm
A good but tedious job you again undertook and with success! In case the problem wasn't in the wires but in the 24 female pin connector it could have been a lot of work for nothing? In the past I have bought a special set of tools to be able to disassemble those female pin headers more easily from a cable wire. I noticed those cables are also sold as power adapter cables. Click Here for more details.
Parasuraman S
March 17, 2021 at 9:38 am
Many thanks. You are right. The replacement included the connector. As the SMPS is working well, the problems got resolved! Many thanks for the link. Import is now restricted and I cannot make use of it. Moreover, these are available plenty in salvage collection!
Robert Samuel
March 17, 2021 at 2:38 pm
Wow, this would be a very time consuming task. It takes great patience.
You should consider buying a much larger "Satisfaction Bag".
Parasuraman S
March 17, 2021 at 9:38 pm
Many thanks! The size of the bag has been enlarged! (LOL)
Waleed Rishmawi
March 17, 2021 at 2:59 pm
man, that is a lot of work for cheap power supply but the satisfaction of the repair sometime is beyond any cost or tiredness. have a blessed day
Parasuraman S
March 17, 2021 at 9:39 pm
Many thanks for your intimate comments!
Yogesh Panchal
March 17, 2021 at 11:08 pm
Sir,
Good Job!
Parasuraman S
March 18, 2021 at 11:15 pm
Many thanks, Yogesh Bhai!
Mark
March 20, 2021 at 10:15 am
Well done on your diagnosis and repair!
In the Automotive industry, we find many wiring issues due to mice eating the wires. They love to eat the insulation to keep their teeth size in check! 🙂
Parasuraman S
March 21, 2021 at 7:26 am
Ha!Ha! Enjoyed the reasons for mice bites! Many thanks!