What's Inside a BROKEN Dixell Refrigeration Controller?

[@flowerpt]

This was super helpful for understanding how these work. Thanks!

[@randacnam7321]

A good load for inrush current testing is incandescent lamps.

[@MetaphysicalEngineer]

I agree that would have been better. Unfortunately didn't have 10 amps worth of lightbulbs on hand. Good news: I have nonzero budget now. Bad news: I'm a long way from home so don't have a lot of my old equipment available.

[@ntag411]

Thanks for the internal view of the controller. Like many things that use relays/switches, the relay is a failure point. Typically I just clean the contacts of a air compressor relay or do a refinish of sorts using emery type cloth. My Logitech Pro (M70) PC mouse is giving me left/right button issues. My intent is to clean the contacts of the switches by running printer paper within the closed contacts and then with a cleaner/lube. IMO, the Pro has exceptional internal/external build quality. I dislike tossing things in the trash.

[@MetaphysicalEngineer]

Unfortunate how the bean counters decided saving $2 on a relay was worth it, even when it makes a $200 controller fail so quickly. Worse when the same cost cutting is applied to an $800+ proprietary control board which is months backordered. Those are the ones I've rebuilt! How did the mouse repair work out? Didn't think those tiny switches were serviceable but I may be wrong.

[@ntag411]

@@MetaphysicalEngineer the mouse fix attempt did not work. The contact lever of the switch is also the spring for the lever. I've had the same issue with some air compressors. The pressure switch is integrated with the relay. The better units have the relay and pressure switch as separate assemblies. I most likely distorted the fragile arm contact and spring. I think the switch is available. Meanwhile I have identical mouses as backup. I might play with the switch's once replaced. But most likely may not still work properly, too delicate to work on.

[@MetaphysicalEngineer]

Ah, unfortunate. That was my fear that the tiny switches would be too small to service. If you can get matching parts, rebuilding the mouse is a great plan B!

[@ntag411]

@@MetaphysicalEngineer just like to say the switch's were not removed from the board and cleaning the lever contact caused the lever to come apart from the switch. The integrated spring of the lever also acts as retention of the lever to the switch. Toying with the switch removed from the board might work better. Just dislike desoldering because of the added work and it can only be done a limited number of times. I miss some of the test instruments made by Tektronix of the 80s. The active components were socketed flush to the PCB. Kind of like it wasn't made for a price point. I mean the stuff looked beautiful. 😁

[@MetaphysicalEngineer]

Everything's been cheapened to the point of absurdity. And that's assuming the actual assembly is done right! Check out how a cheap PCB with a defect took down that nice Maytag dryer I refurbished a few months back. Or that Sylvania TV where I added fans to stop an engineered failure by overheating. If a million units are produced and somebody finds a way to save one dollar per unit, the company just made a million bucks. Not their problem if the gadget that used to last 8 years now fails in 3. Out of warranty, so not their problem, and can generate even more revenue when the customers come back to buy replacements.