A928 cable melting fix
Hi,
This problem you have has been found by many other people, and it is a design fault by ECS (although they won't recognise it).
You are in North America and can afford it, I would suggest you to send your unit to David in Canada (you'll find the person who's been fixing this problem for everyone in the PCreview thread).
If you are not (like me), and you have some skill on disassembling electronic things and doing proper hot-soldering, you can fix the problem yourself. Basically, the problem is that the female plug in the A928 was not really designed to put up with the high current going through it. With time, the plug starts to melt (particularly in hot days or when the ventilator vents become dirty), and run (by gravity) away from the pin. This increases resistance, which increases the generation of heat, leading to the eventual melting of the plug (or the pin coming out of the female plug). Replacing the power supply is not good, since the heat generated in the female plug will melt the new one very quickly.
The solution is to disassemble the unit (a LONG proccess, which includes taking out HD, memory, keyboard and LCD screen, and some 50 screws of different sizes - I recomend you to see the threads at PCreview for instructions on how to do that) and to resolder the plug. This is not ordinary soldering. You need first to remove all debris and oxidation from the pin (when you disassemble the unit you will see what I mean), and then use a good (min 80W, earthed) soldering iron to heat the metal exterior of the plug and put a lot of solder from the metal exterior (which is the conection from the third pin to the motherboard) to the third pin, at the same time avoinding producing a short with the other two pins (you should verify it first with a magnifying less, and then with a multimeter - the resistance between the bottom and the two top pins (which are conected to each other, by the way), should be above 40 ohms).
The whole procedure took me about 4 hours, but now my unit is running cool and I'm happy again with it.
One important thing: do NOT try to run the computer the way it is now. It will become each time worse, and eventually one of the ICs in the motherboard will be ruined, which will cost you much more money to fix.
I have also added another connection to the third pin (a parallel bypass) to one female plug (one of those banana jacks, capable of coping with over 6 Amperes) which I inserted just beside the power plug in the A928. I soldered an extra lead to the shielding of the cable that comes from the power supply to the desknote, and I can, now, connect the power supply to the computer using the regular lead AND the banana pin (so as to reduce the amount of power runing through the third pin). This plug is conected to the metal casing of the original one. But this is not really necessary, and it doesn't look as nice as the original one. Nevertheless, I decided to add it just to to be sure I won't be having this kind of heating problems again!
I hope this will help some of you living too far away or in countries with unreliable postal systems or complicated customs proceedures, but who are stuck with this A928 problem. I still find it amazing that ECS could get away with this design problem! I won't ever buy things from them again.
cheers,
Antonio