Sony Laptop Charger Repair- Intermittent Problem
Customer walked in to my workshop wanted me to repair his Sony Laptop. The complaint was the charger because sometimes it can charge the battery and sometimes not charging. What I did was to connect the power adapter to the Laptop and powered it ON.
I found the LED power indication on power adapter was ok but power indicator LED on Laptop was not lighted up. Hence I have used my multimeter to test the power output of the power adapter. As per specification on the adapter the output is 19.5 V DC.
Testing voltage of the output jack of the power adapter, I’d got .03V instead of 19.5 V DC, so this reading confirms the problem with the adapter.
After this result I have decide to open the adapter for further troubleshooting. After opening the adapter, as usual I found pastry cream spilled on components (Ha ha hah!!!!…………….. Just joking). This white substance is used as Thermal Paste Glue on the components where chances of overheating are high on applying the Load.
On visual inspection I have not seen any Burnt marks and physical damage. As power LED light indicator is working on the adapter this means some voltages are available up to the LED area hence it is time to test voltages on the other end of the DC Pin wire on the PCB where they are soldered.
Here I got 19.8 V DC that means adapter is ok and problem is in between adapter DC wire and DC Pin. Now the job starts here to find break in between.
On testing the cable I found cut type twist near cable grommet of the adapter, so I have again tested output voltage on DC pin by twisting and shaking the cable but no effect on reading. Hence I cut the wire for further testing and tested wire to the pin by continuity tester one wire is showing continuity and other wire does not (Wire is open circuit somewhere) that means culprit is not grommet area but somewhere else.
Now what? Because I can arrange the wire if found bad but what about the pin. Because this type of DC Pin is difficult to find in the market and buying it on line is not worth. So here I have two options one give back the adapter to the customer unrepaired or try “something else” so that I also make some money and customer is also be happy by retaining the original power adapter.
So what is that something else?
With the help of Non Contact Voltage Detector pen I have traced the wire by applying AC 230 V (while doing this please use insulation tap on other side end of the wire under test) in this process the device shows full continuity till the end of the wire DC Pin. Hence chances of the damaged DC pin is high,
Hence I have cut the DC Pin from the wire and again I have tested the continuity on the wire by using multimeter. Now I got the continuity on both the wires that mean wires are OK and DC pin (output jack) itself is culprit. As you can see the pin is molded and sealed in plastic grommet. Now this is time to modify the pin.
I have used nail remover pliers for cutting the plastic grommet and removed the metal unit and removed old solder and wire from the pin and soldered the cable which I have tested for the continuity again on the pin. After solder I tested again this cable from pins to the other end of wire found OK. Now it is time to reallocate everything back hence prepared the wire with grommet-for final work.
Now till here every thing is smooth now what about the DC Pin. How to cover the pin because you cannot use the same grommet back which you have removed so I have used a product called M-Seal to cover the pin. Sorry for not covering the photograph of the process because I have to use my both the hand and palms are become sticky while mixing up the material of M-seal and making clay out of that and here is final touch up on the pin.
Now the things are totally modified and ready for the final test.
On final testing I’d got 20V DC without load that means the Sony laptop charger (power adapter) is repaired.
This article was prepared for you by Yogesh Panchal who works as a Computer Hardware Engineer in Mumbai India.
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Note: You can check his previous repair articles on LCD Monitor in the link below: