DLINK GLB 802C ADSL Broadband Router Repaired
The complaint of this router was irregular behavior like frequently line dropout / slow web page opening / on pinging IP web page pinging but web site page is not opening in any Browser .i.e. Firefox, Google Chrome or internet explorer. I am facing the stated problem since last two to three months. For this problem I have contacted my ISP (Internet Service Provider) they have physically checked the line and they found everything seems to be OK.
Most of the time the above problem is due to oxidation on ADSL Line wire terminal. I have cleaned and rejoin the cable terminal in my house but no success. Meanwhile I got the call from my service provider that they have checked entire line and line up to my house was OK.
I have observed while browsing internet; when I put ON the Router for few minutes it works fine and after 15 to 30 minutes it starts irregular behavior (Even though all LED Indication are showing Normal Operating) as stated above. I have decided to change the location of router, may be due to poor air circulation this happening; while moving the router on holding in my hand I realized that modem is Overheating. So what next?
Because I do not have circuit diagram for fault finding anyway I have opened the router and started with visual inspection but everything seems to be ok there was no physical damage or burn marks. I have turned the Router On by giving power supply and after few minutes I am trying to find out which area was overheating with the touch of my finger while touching I found CONEXANT Main big square IC was too hot to be touched by finger.
I have kept router On for few Hours and then checked web browsing while PCB is open and out of BOX it works fine so the problem is COOLING?? So why not go ahead with some ideas to provide better cooling and try!!
First of all I have replaced all the electrolytic capacitors.
And then decided to put some holes on casing of router which provides better air circulation so I did the same with the help of hand drill machine.
And brought Aluminum Heatsink for main Square IC which was overheating.
Once done I reassembled the router connected to my pc for testing purpose and I found web pages are now opening with good speed without any problem.
This article was prepared for you by Yogesh Panchal who works as a Computer Hardware Engineer in Mumbai India.
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Waleed Rishmawi
May 19, 2015 at 10:05 pm
good idea of adding holes and the heat sink..usually that fixes the problem. i have seen it before in my line of work. thanks for sharing.
Yogesh Panchal
May 22, 2015 at 1:17 am
Thanks waleed for your comment.
Andre Gopee
May 20, 2015 at 12:46 am
Thanks for sharing, but will not the IC fail after some time? What is the cause of the problem.
Robert Calk
May 20, 2015 at 11:40 am
That's what I was thinking. Aren't the IC's designed to operate without a heatsink? Maybe some other problem is causing it to overheat.
Yogesh Panchal
May 22, 2015 at 1:22 am
Sir thanks for your Comment.As i have already said i do not have any reference circuit diagram so i could not able to finger it out but router is working fine since last one month.
Bernie Scott
May 20, 2015 at 1:14 am
very good article.....I do have a question...how did you attach this heat sink to the surface of the chip??....Is there a special bonding agent that you have to use??
Thanks,
Bernie
Frank Seldevig
May 20, 2015 at 8:01 pm
Special thermal conductive double sided tape. Its relatively cheap.
Yogesh Panchal
May 22, 2015 at 1:26 am
Sir, thanks for your comment. Heat sink comes with thermal adhesive tape which hold the heat-sink on the place.
Yogesh Panchal
May 22, 2015 at 1:30 am
Sir, thanks for comment. please find your answer as follow.
Davide
November 9, 2015 at 3:18 am
Watch ebay for "heatsink glue" if you reuse old heatsinks..
beh
May 20, 2015 at 1:18 am
Thanks YOGESH very intelligent.
Yogesh Panchal
May 22, 2015 at 1:28 am
your welcome sir.
Albert
May 20, 2015 at 1:34 am
Nice repair Yogesh!
I had a Wifi stick from Sitecom that became hotter everyday until it just quit. Luckily they gave a very long guarantee and because that model wasn't available anymore I did get my money back. And I bought another Wifi dongle from another manufacturer.
And a good thing those routers IC's do not use Ball Grid solder connections and still have pins.
Because in laptops heat is playing a destructive way with BGA chips like CPU and GPU. Mostly because these are soldertin grids from 600 to 800 Ball Grid contacts or even more underneath the ic's. And there is no telling when it will mean the end of a working laptop or notebook. And the begin of a HOTFIX with special equipment other than the standard 'paint remover hot air gun'. (works only temp.)
My boss had a pc controlled IR hotfix machine but I don't think that even a good hotfix is working for an unlimited period.
And as long that you have the time to repair the more difficult cases, it pays off.
And well done on the article!
Albert.
Yogesh Panchal
May 22, 2015 at 1:32 am
Sir, I agree with you Ball grid and BGA are worst Technology.
Luciano
May 20, 2015 at 4:08 am
Mr. Yogesh,
This is Creativity at its best blended with experience!!! Thanks for sharing!!!
Luciano
Yogesh Panchal
May 22, 2015 at 1:32 am
your Welcome sir.
Mark
May 20, 2015 at 5:20 am
Hey Yogesh,
Thanks for your article. It is easy to forget the basics and get bogged down with the details.
Great idea to encourage cooling with your methods!
Yogesh Panchal
May 22, 2015 at 1:33 am
your welcome sir,
Anthony
May 20, 2015 at 7:11 am
Nice repair, Thanks for sharing !
Yogesh Panchal
May 22, 2015 at 1:33 am
sir, your welcome
Florin
May 20, 2015 at 7:48 am
Drilling the case of the router is a very ugly solution.
Yogesh Panchal
May 22, 2015 at 1:37 am
Thanks for your comment. can you have better solution then this ? without spending more time and money ??..........
lescort
May 22, 2015 at 10:16 am
mmmm, i repaired one like this, a tank capacitor failed, voltage too low for the processor increase in ampers, :::)) ic gets too hot
Dave T
May 28, 2015 at 1:34 am
I think its a rather clever solution and who looks at their router anyway its usually hidden away.
Vishnu
May 20, 2015 at 8:39 am
Thanks Yogesh. Great idea!
Yogesh Panchal
May 22, 2015 at 1:37 am
Thanks Vishnu.
Robert Calk
May 20, 2015 at 11:42 am
Good job Yogesh. Let us know if the IC fails.
Yogesh Panchal
May 22, 2015 at 1:38 am
Sir, It working fine since last one month without any problem.
Amir Mukhtar
May 20, 2015 at 2:01 pm
Thank you Yogesh to Sharing important Issue solution.
Good Work and Keep Sharing your Expertise.
Thanks you
Amir Mukhtar AShrafi
Yogesh Panchal
May 22, 2015 at 1:39 am
Sir, thanks for your Comment.
Frank Seldevig
May 20, 2015 at 7:58 pm
Good job Yogesh.
I have on several occasions added a fan to a router with great success (my own included), but next time I will add a heatsink too.
To Florin: drilling holes in the case is a really nice touch. Making a router which is not cooled enough is ugly.
To Bernie Scott : Heat sinks are added with special heat conductive double sided tape.
Good article Yogesh
Yogesh Panchal
May 22, 2015 at 1:40 am
yes sir FAN is also good Solution.Thanks for reply
Davide
November 9, 2015 at 3:26 am
For me cooling with holes not self asking why it gets hot now and not when was new is hiding the dust under the carpet..
reza
May 21, 2015 at 2:29 pm
hi dear Yogesh Panchal
thank u for sharing this article.
m.reza from iran
Yogesh Panchal
May 22, 2015 at 1:41 am
your welcome sir,
elkenani
May 21, 2015 at 3:23 pm
very good article but want to know why ic become hot what is the reason
Yogesh Panchal
May 22, 2015 at 1:42 am
sir thanks for your Comment. please refer above for your answer.
ZED
May 21, 2015 at 3:46 pm
nice share of this ideas in thi articles yogesh. thanks
Yogesh Panchal
May 22, 2015 at 1:43 am
your welcome sir.
Humberto
May 21, 2015 at 8:13 pm
Hi Yogesh Panchal, I've really enjoyed reading your article. I have one sugestion and one question.
Suggestion: could you connect a little fan in the casing of router?
Question: how did you attach the heatsink to the overheating IC?
Have a good day and waiting for your answer, Humberto
Yogesh Panchal
May 22, 2015 at 1:47 am
Humberto thanks for suggestion, Connecting FAN also good idea ; by the way heat-sink comes with thermal conducive tape.