Repairing a Faulty Power PCB

If the voltages on your power supply are out of tolerance it is likely that a few of the critical electrolytic  capacitors have aged and are out of spec. The capacitors that we are interested in are usually Samwha RD Series 1000uF 16V 105°C radial types - or the same spec/type from another brand. It is common to find different brands of capacitors on the one board. Ideally you could upgrade the power supply by replacing them with 1200uF 16V capacitors like the RS Components pack of 5 that retails for $7.48 (part number 3150489). Or get the low ESR capacitors from Jaycar (in Australia), as low ESR capacitors give off less heat under load and are rated for higher temperatures. Unfortunately Jaycar only has 1000uF 16V low ESR electrolytic capacitors, though this is still an improvement on the original 1000uF 16V capacitors.

The capacitors you will normally need to replace are C17, C18, C22 and C23. If you buy a pack of 5 you may as well also replace C19. If you have a 6th capacitor you may as well also replace C25, though it's normally not required.

If you look carefully at the photo below you can see the orientation of the capacitors. The circuit board should also have markings indicating the polarity of the capacitors. Just make sure you fit the new ones the correct way around.

Photo by Peter Hagarty

Resurrecting a Dead Power PCB
If the power PCB is completely dead, or has more serious problems than just high and/or low voltages, you will need to replace more than just a few electrolytic capacitors. After testing the board and components you will then need to source suitable replacement components using the circuit diagram above and the markings on the circuit board and the components themselves to determine the type and specifications. Availability and price will determine whether it is better to purchase a new replacement PCB or repair the old one.

 
Life Expectancy
The life-span of the standard -45° to +105°C rated capacitors depends on their average temperature. At a constant 105°C the capacitor would only last 2,000 hours (12 weeks if left on 24/7). At 55°C the capacitor would only last 32,000 hours (96 weeks or 1.8 years, if left on 24/7). Not surprisingly many Toppys' power supplies fail after only 1.5 years. If you only leave your toppy turned on for 8 hours a day the capacitors could fail after 5.4 years.

Changes
Sometime between June 2005 and April 2006 Topfield changed the type of the connectors used where the Power PCB connects to the Main PCB. The new type of connector has a retaining clip that requires you to squeeze the clip towards the plug to remove it from the socket on the Main PCB. The Power PCB has 2 cables that connect to the main PCB (one small and one large). They are keyed to only fit in one orientation (though you can force them to fit in the wrong way) and all wires are white except for one black wire at one end of the connector. This black wire is at the top in the photo.

Replacing
If you are ordering a replacement Power PCB, or Main PCB, you need to order one of the correct vintage to make sure that the connectors match your existing mating part. Of course if you order both a new Power PCB and a new Main PCB then the type of connector does not matter as you will be buying matching PCBs with the new connector type.

Mix & Match?
Old type plugs will fit, with a bit force, into new type sockets. But new type plugs require modifying to fit into old type sockets. Be aware that unmatched connectors may work loose if you transport the Toppy to a different location.

Modifying
If required you can unsolder both existing cables on a new Power PCB and solder in the old type cable from your original Power PCB. In a worst case scenario you can even cut off the retaining clip and the 2 lugs (on the same side as the clip) on each end of a new Power PCB's cables' plugs to make the plugs fit into old type sockets on an old Main PCB.

Top  

 Warning!

240v can kill! Be very careful when working inside any 240 Volt appliance. Double check that you have unplugged the power cord before starting. And do NOT reconnect the power cord until the top cover has been securely re-attached. Keep children and pets away while working with electricity or electronics. Beware that for some time after you remove the 240 volt power source the 240 volt side of the power board circuit (especially the very large capacitor) can still contain a charge large enough to injure or kill you. Pressing the Standby button on the toppy, after unplugging the 240 volt power, should be enough to drain the capacitor.
 

 Disclaimer

You should only remove the cover of your Toppy if it is no longer under warranty. If you are not the owner of the Toppy you must get the owner's permission before you start. If you are under 18yr you must get an adult to supervise. While all possible due care and thought has been put into the writing of this guide, ToppyTools, myself, and any business or person associated with me or ToppyTools, will not be held responsible if something goes wrong. By following this guide you are accepting this disclaimer and agree that the only person responsible for your actions is you.