failed – Experimental Engineering

Posted on May 1, 2018April 29, 2018 by The Engineer — 10 Comments

Sterling ProCharge Ultra PCU1210 Teardown & Repair

The Sterling charger we’ve had on board nb Tanya Louise since Feb 2014 has bitten the dust, with 31220 hours on it’s internal clock. Since we’re a liveaboard boat, this charger has had a lot of use while we’re on the mooring during winter, when the solar bank isn’t outputting it’s full rate. First, a bit of a teardown to explore the unit, then onto the repair:

There’s the usual mains input filtering on the left, with the bridge rectifier on it’s heatsink.
Underneath the centre massive heatsinks is the main transformer (not visible here) & active PFC circuit. The device peeking out from underneath is the huge inductor needed for PFC. It’s associated switching MOSFET is to the right.

On the other side of the PFC section is the main DC rail filter electrolytic, a 450v 150µF part. Here some evidence of long-term heating can be seen in the adhesive around the base, it’s nearly completely turned black! It’s not a decent brand either, a Chinese CapXon.
The PCB fuse just behind it is in the DC feed to the main switching supply, so the input fuse only protects the filter & Active PFC circuitry. Luckily this fuse didn’t blow during the failure, telling me the fault was earlier in the power chain.
The logic circuits are powered by an independent switching supply in the centre, providing a +5v rail to the microcontroller. The fan header & control components are not populated in this 10A model, but I may end up retrofitting a fan anyway as this unit has always run a little too warm. The entire board is heavily conformal coated on both sides, to help with water resistance associated with being in a marine environment. This has worked well, as there isn’t a single trace of moisture anywhere, only dust from years of use.
There is some thermal protection for the main SMPS switching MOSFETS with the Klixon thermal fuse clipped to the heatsink.

The DC output rectifiers are on the large heatsink in the centre, with a small bodge board fitted. Due to the heavy conformal coating on the board I can’t get the ID from this small 8-pin IC, but from the fact that the output rectifiers are in fact IRF1010E MOSFETS, rated at 84A a piece, this is an synchronous rectifier controller.
Oddly, the output filter electrolytics are a mix of Nichicon (nice), and CapXon (shite). A bit of penny pinching here, which if a little naff since these chargers are anything but cheap. (£244.80 at the time of writing).
Hiding just behind the electrolytics is a large choke, and a reverse-polarity protection diode, which is wired crowbar-style. Reversing the polarity here will blow the 15A DC bus fuse instantly, and may destroy this diode if it doesn’t blow quick enough.

Right on the output end are a pair of large Ixys DSSK38 TO220 Dual 20A dual Schottky diodes, isolating the two outputs from each other, a nice margin on these for a 10A charger, since the diodes are paralleled each channel is capable of 40A. This prevents one bank discharging into another & allows the charger logic to monitor the voltages individually. The only issue here is the 400mV drop of these diodes introduce a little bit of inefficiency. To increase current capacity of the PCB, the aluminium heatsink is being used as the main positive busbar. From the sizing of the power components here, I would think that the same PCB & component load is used for all the chargers up to 40A, since both the PFC inductor & main power transformer are massive for a 10A output. There are unpopulated output components on this low-end model, to reduce the cost since they aren’t needed.

A trio of headers connect all the control & sense signals to the front panel PCB, which contains all the control logic. This unit is sensing all output voltages, output current & PSU rail voltages.

The front panel is stuffed with LEDs & 7-segment displays to show the current mode, charging voltage & current. There’s 2 tactile switches for adjustments.

The reverse of the board has the main microcontroller – again identifying this is impossible due to the heavy conformal coat. The LEDs are being driven through a 74HC245D CMOS Octal Bus Transceiver.

Now on to the repair! I’m not particularly impressed with only getting 4 years from this unit, they are very expensive as already mentioned, so I would expect a longer lifespan. The input fuse had blown in this case, leaving me with a totally dead charger. A quick multimeter test on the input stage of the unit showed a dead short – the main AC input bridge rectifier has gone short circuit.

Here the defective bridge has been desoldered from the board. It’s a KBU1008 10A 800v part. Once this was removed I confirmed there was no longer an input short, on either the AC side or the DC output side to the PFC circuit.

Time to stick the desoldered bridge on the milliohm meter & see how badly it has failed.

I’d say 31mΩ would qualify as a short. It’s no wonder the 4A input fuse blew instantly. There is no sign of excessive heat around the rectifier, so I’m not sure why this would have failed, it’s certainly over-rated for the 10A charger.

Now the defective diode bridge has been removed from the circuit, it’s time to apply some controlled power to see if anything else has failed. For this I used a module from one of my previous teardowns – the inverter from a portable TV.

This neat little unit outputs 330v DC at a few dozen watts, plenty enough to power up the charger with a small load for testing purposes. The charger does pull the voltage of this converter down significantly, to about 100v, but it still provides just enough to get things going.

After applying some direct DC power to the input, it’s ALIVE! Certainly makes a change from the usual SMPS failures I come across, where a single component causes a chain reaction that writes off everything.

Unfortunately I couldn’t find the exact same rectifier to replace the shorted one, so I had to go for the KBU1010, which is rated for 1000v instead of 800v, but the Vf rating (Forward Voltage), is the same, so it won’t dissipate any more power.

Here’s the new rectifier soldered into place on the PCB & bolted to it’s heatsink, with some decent thermal compound in between.

Here is the factory fuse, a soldered in device. I’ll be replacing this with standard clips for 20x5mm fuses to make replacement in the future easier, the required hole pattern in the PCB is already present. Most of the mains input filtering is also on this little daughterboard.

Now the fuse has been replaced with a standard one, which is much more easily replaceable. This fuse shouldn’t blow however, unless another fault develops.

Now everything is back together, a full load test charging a 200Ah 12v battery for a few hours will tell me if the fix is good. This charger won’t be going back into service onboard the boat, it’s being replaced anyway with a new 50A charger, to better suit the larger loads we have now. It won’t be a Sterling though, as they are far too expensive. I’ll report back if anything fails!

Posted on August 5, 2017August 3, 2017 by The Engineer — 3 Comments

Wheelchair Motor Service Part 1: Teardown & Inspection

Trolley Propulsion System: Wheelchair Motor Units

So it’s time to get the propulsion system underway for the trolley, a pair of wheelchair motors were sourced for this, from HacMan. Since I don’t know how many hours are on these units, or how they’ve been treated in the past, I’m going to do a full service on them to ensure reliability. I decided on wheelchair motors due to their extreme ruggedness & heavily built components – this project when complete is going to weigh in at about 150kg!
I suspected something was amiss with one of the motors from running them under no load: the left hand wheelchair motor was heating up to the point of being too hot to touch, so this one at the very least needed some investigation.

Motor Disassembly & Assessment

With the back cover removed from the motor the electromagnetic brake is revealed. This engages when power is removed to stop the motor freewheeling, which even though it’s a wormdrive box, it will do readily if backdriven.

The brake is rated 6.7W at 24v DC.

The brake disc is just visible between the plates of the brake here, with some green dust worn off the disc. When power is applied, the top disc, just under the magnet on top, is pulled upward against spring pressure away from the brake disc, which is attached to the motor armature.

Here’s the brake disc, removed from the motor. There’s only a little wear here, as I’d expect – these brakes don’t engage until the motors have come to a complete stop.

The steel disc above the magnet acts as one of the friction surfaces of the brake.

Finally, the solenoid is at the back, partially potted in resin. The strong coil spring in the centre applies the brakes when power is disconnected.

Removing the top of the gearbox reveals the state of the internals – There’s no wear at all on the gearset, but the lubricant is totally manky. The external oil seals have been leaking for some time, letting water in and grease out. The emulsified result is revolting! These gearboxes have a wormdrive first stage, the worm gear is underneath the left hand gearset. Steel spur gears then do the final gearing to the output shaft. The output gear is splined onto the output, and can slide along the shaft out of mesh – this is the freewheel clutch mechanism. At the moment it’s all obscured by the disgusting lubricant.

Here’s the failed seal on the left hand gearbox, the face damage was done by petrol immersion to clean everything up. (The seal is already compromised, so I’m not fussed about solvents eating the remaining rubber). The motor shaft is joined to the gearbox input by a rubber coupling.

The output shaft seals seem to be still OK, there has been some seepage past the collar that the shaft rides in, but nothing more. This can be resealed with some Loctite bearing sealant. The sleeve is held into the gearbox by the wheel hub when in operation, but this doesn’t seal the gap unfortunately. I don’t know why the manufacturer didn’t just machine the shaft to that larger diameter, instead of using an extra sleeve to accommodate the seal.

The bore seals covering the ends of the shafts are also fine, which is a good thing, since I can’t seem to find replacements for these anywhere. The input shaft seals will be replaced on both gearboxes though.

The oil seal must have been leaking for a long while! This is the gearbox end of the wheelchair motor frame, completely clogged with grease. Luckily only a small amount has made it down past the armature to the brushgear.

The commutator of this motor is badly damaged, and the brushes are very worn. This has been caused by the gearbox oil seal failing, and contaminating the motor internals with lubricant. The undercut between the segments is all but gone – filled with an abrasive mixture of brush dust, copper dust & old lubricant. Some repair work will be required here.

Here’s the brushgear removed from the second wheelchair motor, this one looks much more normal, and there’s not as much wear on the brushes or the commutator. Just the usual coating of brush dust.

Here’s both armatures together, with the contaminated one on the right, after some cleaning to remove most of the greasy old grok & brush dust from everything. The windings on the damaged left hand wheelchair motor haven’t darkened, which I would expect from severe overheating damage, so I’m hoping this armature is OK, and won’t require a rewind. Using an ohmmeter on these windings doesn’t tell me much – there’s only 7 turns of 0.86mm (20AWG) magnet wire in each coil, so they read as a dead short anyway. There was some leakage between the windings and the core before I cleaned things up – this was in the high (28+) megohms range, but this seems to have cleared now I’ve given things a real good cleaning.

More to come when new bearings & seals arrive!

Posted on July 2, 2017 by The Engineer — Leave a comment

nb Tanya Louise – Gas Locker Corrosion Part 1 – Removing The Old Locker & Replacing the Deck Plate

This is a part of the boat that hasn’t really had much TLC since we moved aboard, and finally it’s completely succumbed to corrosion, opening a rusty hole into the engine space below. I’ve already used a grinder to remove the rest of the locker – and even this had corroded to the point of failure all around the bottom just above the welds. The bulkhead forming the rear of the locker has also corroded fairly severely, so this will be getting cut out & replaced with a new piece of steel.
This was originally a 1/8″ plate, but now it’s as thin as foil in some places, with just the paint hiding the holes.

I’ve cut out as much of the corroded deck plate as possible – it’s supported underneath by many struts made of angle iron, and got the new 3mm replacement tacked in place with the MIG. I’ve not yet cut out the rotten section on the bulkhead, this will come after we’ve got the steel cut to replace it, as electrical distribution is behind this plate – I’d rather not have weather exposure to the electrical systems for long! Unfortunately more corrosion has showed itself around the edges of the old locker:

Around the corner the steel has pretty much totally failed from corrosion coming from underneath – applying welding heat here has simply blown large holes in the steel as there’s nothing more than foil thickness to support anything.

Some more extensive deck replacement is going to happen to fix this issue, more to come when the steel comes in!

Posted on April 5, 2017April 24, 2017 by The Engineer — Leave a comment

Blog Housekeeping & More Of The Same

Since I’ve been working on the backend servers a lot over the past few days, I’ve decided it was time to get some broken things on the blog fixed.

Firstly, the radiation monitor graphs. Originally I was using a Raspberry Pi to grab the data from the local monitor, and that was connecting via FTP to the server over in the datacentre to push it’s graph images. Since the server is now on the same local network as the monitor, there’s no need to faff about with FTP servers, so I’ve rejigged things with some perl scripts from cristianst85 over on GitHub, running on the web server itself.
I deviated from the suggested place to put the scripts on the server & opted to store everything within the Experimental Engineering hosting space, so it gets backed up at the same time as everything else on a nightly basis.

This is also accessible from the menu at top left, the script pulls data from the monitor & updates the images every 60 seconds via a cron job.

I’ve removed a couple of dead pages from the blog system, along with some backend tidying of the filesystem. Over the years things have gotten quite messy behind the scenes. This blog is actually getting quite large on disk, I’ve hit the 15GB mark, not including the database!

Caching is enabled for all posts on the blog now, this should help speed things up for repeat visitors, but as most of my content is (large) image based, this might be of limited help. I’m currently tuning the MySQL server for the load conditions, but this takes time, as every time I change some configuration settings I have to watch how things go for a few days, before tweaking some more.

Server Control Panels – More Of The Same

Sorry Sentora. I tried, and failed to convert over to using it as my new server control panel. Unfortunately it just doesn’t give me the same level of control over my systems, so I’ll be sticking with Virtualmin for the foreseeable future. Sentora stores everything in, (to me at least), very odd places under /var/ and gave me some odd results with “www.” versions of websites – some www. hosts would work fine, others wouldn’t at all & just redirect to the Sentora login interface instead. This wasn’t consistient between hosting accounts either, and since I didn’t have much time to get the migration underway, this problem was the main nail in the coffin.

Just storing everything under the sun in /var/ makes life a bit more awkward with the base CentOS install, as it allocates very little space to / by default, (no separate /var partition in default CentOS), giving most of the disk space to /home. Virtualmin on the other hand, stores website public files & Maildirs under /home, saving /var for MySQL databases & misc stuff.

The backup system provided is also utterly useless, there’s no restore function at all, and just piles everything in the account into a single archive. By comparison, Virtualmin has a very comprehensive backup system built in, that supports total automation of the process, along with full automatic restore functionality for when it’s needed.

Sentora did have some good points though:
It handled E-Mail logins & mail filters much more gracefully than Virtualmin does, and comes with Roundcube already built into the interface ready to use. With Virtualmin the options are to use the Usermin side of the system for E-Mail, which I find utterly awful to use, or install a webmail client under one of the hosted domains (my personal choice).
Mail filtering is taken care of with Sieve under Sentora, while Procmail does the job under Virtualmin.

Sentora does have a nicer, simpler, more friendly interface, but it hides most of the low-level system stuff away, while under Virtualmin *everything* on the system is accessible, and it provides control interfaces for all the common server daemons.

Posted on February 15, 2017March 27, 2017 by The Engineer — Leave a comment

16-Port SATA PCIe Card – Cooling Recap

It’s been 4 months since I did a rejig of my storage server, installing a new 16-port SATA HBA to support the disk drives. I mentioned the factory fan the card came with in my previous post, and I didn’t have many hopes of it surviving long.

The heatsink card has barely had enough time to accumulate any grime from the air & the fan has already failed!

There’s no temperature sensing or fan speed sensing on this card, so a failure here could go unnoticed, and under load without a fan the heatsink becomes hot enough to cause burns. (There are a total of 5 large ICs underneath it). This would probably cause the HBA to overheat & fail rather quickly, especially when under a high I/O load, with no warning. In my case, the bearings in the fan failed, so the familiar noise of a knackered sleeve bearing fan alerted me to problems.

A replacement 80mm Delta fan has been attached to the heatsink in place of the dead fan, and this is plugged into a motherboard fan header, allowing sensing of the fan speed. The much greater airflow over the heatsink has dramatically reduced running temperatures. The original fan probably had it’s bearings cooked by the heat from the card as it’s airflow capability was minimal.

Here’s the old fan removed from the heatsink. The back label, usally the place where I’d expect to find some specifications has nothing but a red circle. This really is the cheapest crap that the manufacturer could have fitted, and considering this HBA isn’t exactly cheap, I’d expect better.

Peeling off the back label reveals the back of the bearing housing, with the plastic retaining clip. There’s some sign of heat damage here, the oil has turned into gum, all the lighter fractions having evaporated off.

The shaft doesn’t show any significant damage, but since the phosphor bronze bearing is softer, there is some dirt in here which is probably a mix of degraded oil & bearing material.

There’s more gunge around the other end of the bearing & it’s been worn enough that side play can be felt with the shaft. In ~3000 hours running this fan is totally useless.

Posted on February 1, 2017January 24, 2017 by The Engineer — Leave a comment

nb Tanya Louise Heating System – Oxide Sludge

I wrote a few weeks ago about replacing the hot water circulating pump on the boat with a new one, and mentioned that we’d been through several pumps over the years. After every replacement, autopsy of the pump has revealed the failure mode: the first pump failed due to old age & limited life of carbon brushes. The second failed due to thermal shock from an airlock in the system causing the boiler to go a bit nuts through lack of water flow. The ceramic rotor in this one just cracked.
The last pump though, was mechanically worn, the pump bearings nicely polished down just enough to cause the rotor to stick. This is caused by sediment in the system, which comes from corrosion in the various components of the system. Radiators & skin tanks are steel, engine block cast iron, back boiler stainless steel, Webasto heat exchanger aluminium, along with various bits of copper pipe & hose tying the system together.
The use of dissimilar metals in a system is not particularly advisable, but in the case of the boat, it’s unavoidable. The antifreeze in the water does have anti-corrosive additives, but we were still left with the problem of all the various oxides of iron floating around the system acting like an abrasive. To solve this problem without having to go to the trouble of doing a full system flush, we fitted a magnetic filter:

This is just an empty container, with a powerful NdFeB magnet inserted into the centre. As the water flows in a spiral around the magnetic core, aided by the offset pipe connections, the magnet pulls all the magnetic oxides out of the water. it’s fitted into the circuit at the last radiator, where it’s accessible for the mandatory maintenance.

Now the filter has been in about a month, I decided it would be a good time to see how much muck had been pulled out of the circuit. I was rather surprised to see a 1/2″ thick layer of sludge coating the magnetic core! The disgusting water in the bowl below was what drained out of the filter before the top was pulled. (The general colour of the water in the circuit isn’t this colour, I knocked some loose from the core of the filter while isolating it).

If all goes well, the level of sludge in the system will over time be reduced to a very low level, with the corrosion inhibitor helping things along. This should result in much fewer expensive pump replacements!

Posted on January 5, 2011January 3, 2011 by The Engineer — Leave a comment

Chicom “500W” ATX PSU

Here is a cheapo 500W rated ATX PSU that has totally borked itself, probably due to the unit NOT actually being capable of 500W. All 3 of the switching transistors were shorted, causing the ensuing carnage:

Here is the AC input to the PCB. Note the vapourised element inside the input fuse on the left. There is no PFC/filtering built into this supply, being as cheap as it is links have been installed in place of the RFI chokes.

Main filter capacitors & bridge rectifier diodes. PCB shows signs of excessive heating.

Filter capacitors have been removed from the PCB here, showing some cooked components. Resistor & diode next to the heatsink are the in the biasing network for the main switching transistors.

Heatsink has been removed, note the remaining pin from one of the switching transistors still attached to the PCB & not the transistor 🙂

Output side of the PSU, with heatsink removed. Main transformer on the right, transformers centre & left are the 5vSB transformer & feedback transformer.

Output side of the unit, filter capacitors, choke & rectifier diodes are visible here attached to their heatsink.

Comparator IC that deals with regulation of the outputs & overvoltage protection.