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Geek Culture / laptop DC in jack overheating

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PAGAN_old
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Posted: 22nd Mar 2009 06:19
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it started about half a year ago, The plug in my DC in jack was horribly overheating. Just did it at completely random times. This problem was also accompanied by a problem of my DC jack loosing contact. this is also extremely random. Like at one point i cant find a stable contact no matter how much i rotate the wire, and then all of a sudden the problem stops. I tried figuring it out by rotating the wire again but the contact seemed to have absolutely no problems. this didn't bother me too much until it started noticing the deformation of the plastic case around the jack. the weird thing is the jack itself is fine, but as the time went on, the plastic around the jack along with the rubber around the DC plug started melting when they overheated.

today it overheated so much, i could see the smoke coming from the melted plastic/rubber. When that happens i usually unplug it and let it cool off and plug it back in. Well the hole melted so much that the dc jack barely fits now.

has anyone had this problem before? because, its pretty bizzar

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NeX the Fairly Fast Ferret
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Posted: 22nd Mar 2009 17:35
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Well, see, thing is, if a jack is loose and making partial contact with the motherboard, it increases the resistance so a great deal of heat might be generated. I would advise you either resolder it yourself (if you have the technical skill) or get it repaired.

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PAGAN_old
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Posted: 23rd Mar 2009 01:26
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thats the only explanation i can find., the thing is i took this laptop apart before when the problem occured and the jack was not loose at all, and even now when i wiggle the plug insiside, it does not feel loose, I have dealt and fixed this problem before on another laptop, so i know stuff thats supposed to happen, but the jack just doesn't seem loose at all.

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NeX the Fairly Fast Ferret
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Posted: 23rd Mar 2009 01:36
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Perhaps the issue is not that the jack is loose but that either swarf has shorted out the contacts or there is a bad solder joint.

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PAGAN_old
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Posted: 23rd Mar 2009 05:31
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swarf?

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NeX the Fairly Fast Ferret
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Posted: 23rd Mar 2009 10:25
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Waste metal. Little chips of broken metal. Often left over from cutting metal, usually removed.

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PAGAN_old
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Posted: 23rd Mar 2009 14:11 Edited at: 23rd Mar 2009 14:44
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oh i see, Well, yesturday it got hot for too long and melted the whole jack shut, i had to use a knife to cut out the hole again. The good news is the jack is melted solid to the motherboard, (so thats not loose or going anywhere. Some contacts on the inside of the jack were bent in too far. One of the problems as it turned out the contacts bent too far in so the plug was only touching the pin. Thats fixed for now (dont know how long) but i still dont understand why it overheated so much.

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mamaji4
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Posted: 3rd Apr 2009 00:02
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Excessive heat on the power line is generally because the current rating of the DC jack(female) is lower than the DC current being supplied by the rectifier(adaptor).
Are you using the adaptor supplied by the manufacturer or using another one? An adaptor of a different current or voltage rating can cause overheating.
If its the manufacturer's adaptor then its possible there is an internal short and some of the AC current is leaking onto the DC output of the adaptor. If you have a multimeter, put it on the AC setting, and check if there are any stray AC voltages on the male DC plug of the adaptor. If so change the adaptor immediately or you'll fry your mobo and everything else.
The contact problem you're having is because the jack is deformed due to the excess heat.
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PAGAN_old
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Posted: 3rd Apr 2009 16:14
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yeah, mu PSU is the one supplied by the manufacturer

The jack is deformed, but i bent some contacts inside it, and both of the issues went away for 2 weeks already. This is a temporary solution but ill replace the jack soon.

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mamaji4
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Posted: 3rd Apr 2009 17:56
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Yeah, its a good idea to replace the jack.
In case there is an intermittent short between DC out and ground, that would also explain the overheating. Also, if there is a short, you could damage the adaptor due to current overload.
If you can measure the DC voltage with the adaptor plugged in you could make out if there is a shorting problem. If the DC voltage on no load(without connecting the adaptor to the jack), corresponds to the voltage rating shown on the adaptor, but it drops off drastically on full load(when connecting the adaptor to the jack) then there is either a short in the jack, or the mobo is pulling too much current. This can also happen if your battery is defective and is pulling too much current from the adaptor during the trickle charging. To eliminate this, remove your battery and then see if the overheating occurs.
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