Bones Service - Homepage

History of some of our work.

Not all of our Portfolio, as our clients repairs are confidential.

Please excuse the quality of photography, as this is not one of our in-house skills.

Computers

Laptops

Clients daughter dropped laptop

Memory backup battery voltage not quite high enough. Replaced it.

Fan vents blocked by dust bunny, been used on furnishings

Many broken plastic parts holding bolt ferrules.

Processor heatsink compound dried out. Replaced.

Hot gluing ferrules back in place.

Hot glue used, as will break under stress. Protects other components from shock.

Lots to glue

Corner ferrules need extra glue, as under most stress.

Peripherals

Someones favourite optical mouse, left mouse button stopped working

Disassembled for testing

Button indeed, was faulty

Replaced button with modern equivalent

Electronics

Anti-lock Braking System Modules

VW Golf GTi ABS

Standard VW ABS unit causing faults on VAG diagnostics

Dry joints on press fit connector & a blown transistor MOS-FET. Not easy to get into as it has to be cut apart :(

Audio Visual

Cambridge FMJ AVR400 DOA goes to standby.

Having a quick look.

Main transistor on Front left dead Q5170

Q5540 SOT-323 BC856BW shorted be, C5544 50v 10uF replaced (reading 89 ohms), R5542 0603 150ohm open CCT.

Q5130 BC846BW short be, complementary Q5131 BC856BW short ce.

Destroyed R5155 0825.

R5155 0825 100ohm replaced, replaced also R5150 0603 56ohm, R5131 0603 10ohm, R5132 0603 150ohm, R5182 0603 100ohm, all open CCT

Q5141 SOT-323 BC846BW 1k8 across be. Replaced.

R5175 0.22ohm 5W dual power resistor, blown on one side.

R5175 replaced with 2 single 0.22ohm 5W non inductive power resistors (as the dual version if very expensive)

Pre-assembly test.

Mid-assembly test.

Full and final assembly.

Basic modular amplifier power CCT to assist repairs.

Basic bias CCT to assist repairs.

Batteries

eBike battery 36V 15A

Check function of BMS

Check circuits of BMS

Get new cell to replace dead cell in pack

Reassemble pack

Load test pack with new cell

eBike 24v rebuild test & rewrap Battery, test PSU

PSU tested for load and NTC operation.

eBike 24v NiMH 9AH rebuild, test NTC and rewrap.

MacAllister MP18 Multi tool battery.

Battery no charge or output.

Cells dead below 2.5v, signs of water damage.

Re-Celled battery

Tested BMS for correct charging & discharging, after Re-Cell.

Scooter battery recover & test cells.

Remove protective wrap & heat-shrink to trace fault.

Faulty BMS removed.

Removed bottom protection for strip down.

600 odd Nickel spot welds removed.

600 odd Nickel spot welds removed on top side, to access cells for testing.

Luggie battery failed BMS & cells, due to water damage.

Faulty BMS removed for testing of 7 lots of 4 parallel packs.

2 dead cells replaced along with 6 iffy cells. New BMS with better temperature management & balancing installed.

Solax battery complete rebuild.

Evidence of water damage.

Further evidence of water damage.

BMS blown, BER.

BMS PCB tracks damaged.

BMS tracks & components destroyed.

Ready to assemble with 2 new cells, existing cells all validated.

Cells spot welded into 7s2p, with monitor wires.

BMS mounted & connected to input/output & monitor wires.

Pack secured in fresh barley paper.

Shrink wrapped & ready for final sealing into casing.

Rockwell 18V drill pack: water damaged.

Dismantling pack. Water damage obvious.

Water damage has removed some connections.

Stripping welds.

Welds removed, ready for new cells & testing.

Solax battery, no output & cannot charge.

Found MOSFET to be faulty on BMS.

Testing cells to prove charge & load potential.

Pack assembled with new MOSFET.

Shrink wrapped & tested.

Dead 24v Pack 7s12p 84 cell

Initial testing showed 1 cell array very low, attempted to bring array back up to usable, which failed.

Removed cells from faulty array.

Replaced with good cells & tested.

Re-wrapped for return to client.

Gogo 13s2p dead, rebuild as 13s3p

Completely dead Gogo battery (Water damage) All cells EOL

Test & modify BMS ready for upgrade.

Pack rebuilt as 13s3p, increased range for scooter.

Battery chargers

Pihsiang 24v lead acid battery charger dead.

Output side of charger tests ok.

Mains not connected to switch mode section, found faulty dual coil toroid choke.

Choke core stripped ready for rebuild.

Choke rewired.

Choke potted.

Reinstalled rebuilt choke, tested ok.

STL Transtech TGA 24v 8a lead acid battery charger.

Faulty charger no output. Caused by three capacitors black & white on the left side of image.

Replaced capacitors, tested ok.

Triple battery charger, 3 circuit faulty.

Faulty circuit, has broken toroidal choke, repaired.

All three circuits had problems with 15k smds in parallel & serial to make 4 x 15k with not enough wattage to handle charger load. Evidence of burnt PCB.

Replaced SMD resistors with higher wattage through hole resistors on all three circuits.

Body Control Modules

Ford Mondeo MKIV BCM

Check BCM for water ingress, corrosion & dry joints. Multi symptomatic faults.

CCTV

CCTV 4 way monitor no power

Checking main voltage regulators etc.

Checking for broken tracks.

All working, cable connector issue.

Development

Solar array low voltage battery WiFi monitor

Client requested this ESP8266 programmed using LUA to remote monitor solar array station, with Over The Air Updates.

Developed basic test circuit for job

Built board to program & test with a LDR rather than solar array.

HTML output for test server accessible securely worldwide.

Pedestrian crossing button unit.

Client wants unit to light up when button pressed & emit beeping after timeout. Also client wants to use a as a lamp. ie. press & hold button to keep the light on, without timeout & beeping, tap to turn off.

Inside, new micro mains SMPSU 12v 400ma. Beeper installed bottom right. New micro processor PCB installed under reflector top right.

Micro controller PCB, with 5V buck converter for PIC12F508, contains programming for operation. Transistor to drive beeper & MOSFET to drive LED back-lights.

Ignition Control Units

Triumph Triple Sport ICU faulty Coil output

ICU under test.

Faulty transistor found in circuit.

Testing output on Oscilloscope, after transistor replaced.

Reverse engineered circuit diagram to trace faults.

Replaced TR5 to effect repair.

Board cleaned & tested.

Measurement & Test

LeCroy WaveAce 202. Complete trash recovery.

Missing all knobs, 3 broken rotary encoders, broken power switch & button, faulty PSU. Calibrated & tested, to be used for training.

Broken power switch.

Broken pulse encoder.

Another broken pulse encoder.

Zepiu H60 bench battery tester. 24V+ applied to channel B, disastrously.

First replace main channel fuse.

Found TVS diode to be blown on channel B

Replaced with appropriate diode.

Found blown MOSFET

Replaced MOSFET, new silicon mount.

Old MOSFET with new mount also.

SMD fuse blown 1.5A

Replaced with temporary fuse in Dark red at the top.

Shorted flyback diode across relay.

Replaced with temp flyback diode.

Found detached load mounting.

Repaired mounting.

Tested current sense ICs out of circuit.

Tested Display Arm CPU with display function.

Bypassed broken display pin.

Reassembled loads for testing.

Upgraded to modern efficient SMPSUs, changed fan to industrial grade.

Unit under stress test, passed.

Zepiu H60 bench battery tester. Dead channel, previous failed repair. Replace fan.

From this image you can see a previous repair with stick on trace, insufficient for current.

Repaired with 1mm Solid copper rod sufficient for the 10a required.

Tested both channels ok.

Musical instruments

Yamaha D65 Electone Organ

Faulty middle C on top keyboard

Start process of opening chassis to trace fault.

Faulty diode found & repaired, under visible blue tape. Otherwise whole keyboard would need to be stripped to access old faulty diode.

Office equipment

OKI MC362W Multi-function printer copier. PSU fault, intermittent.

Found faulty capacitor on primary side of SMPSU, replaced with equivalent.

Chinese equivalent capacitor failed explosively.

Causing damage to main PSU PCB

Replaced with uprated 400v 1000uf & repaired PCB damage.

Reverse engineering

HiCam web interface repair, not booting.

Reverse engineering faulty IP Cameras to fix bootup failing for web interface.

Decoded capture & converted, now to start decompiling software/firmware

Scooters

Breeze scooter PCBs damaged.

Blown PCB track.

Track repaired.

Track damage with an attempt at repair visible.

First track laid.

Remaining tracks laid & protected.

Track damage between J7 & J9 repaired on reverse. Modification to MOSFETs U1, U6, U3, U5 to get indicator circuits to work correctly.

Rhino 2 DS160 controller, problem with brake.

Found to have 5 detached & faulty capacitors on main output rail.

Replaced with 5 new 1000uf 35v capacitors.

Signal Acquisitions Modules (SAM)

Mercedes ML360 Auxiliary control board. No fuel Gauge, missing rear lights.

No obvious damage, previous repairs covered with PCB sealer.

After removing connectors; water damage/ingress evident.

Replaced left hand 3321 resistor for 332 resistor, within spec, to resolve fuel level sensor not working.

Replaced 430 ohm, 2k2 ohm & 15 ohm resistor in power MOSFET section to resolve all other faults. No water damaged tracks or vias found.

Transmission Control Modules

Dennis Elite II TCM (Transmission Control Unit)

TCM for Alison AT6 Intermittent fault. Top cut off, damage visible.

Close up of vibration damage (worn varnish on touching fly wires, visible under microscope)

How they should look; separated

Fly wires stress tested and positioned correctly.

Right side stress tested and positioned

Both sets of fly wires potted securely against vibration stress. Reassembled, client left to waterproof unit, after testing on vehicle.

Game systems

xBox

xBox 360 PSU Model: Liteon PE-2151-03MX Rev:A

No Output. Dead components Bridge rectifier, 4A fuse & a Metal oxide varistor.

Complete & tested.

xBox One S

Suffering overheating issues. Heatsink compound found to be dry & ineffective. Removed, cleaned through & reapplied new heatsink compound.

Telephone Systems

PBX CCUs

Samsung OfficeServ 7030 (no Boot)

System powers, boot-loader works, read only file system on /dev/j2ffs

Using SIO port (serial) backup database, reflash boot-loader to V4.63, TFTP system files to V4.63. Test

FTP client database onto system and do full test.

Samsung OfficeServ 7030 (no Power)

Low voltage on +12v and +5v rails, caused by 6 faulty aluminium electrolytic capacitors. You can see the capacitor bases have popped off.

PSU repaired, system would not boot, was stuck in upgrade cycle with faulty MMC. Reflashed to V4.63 bool-loader and system to V4.63. All ok.

Engineering

Vehicles

Cars

Range Rover Autobiography 2006 faulty heated drivers seat.

Found broken wire in back heater (swab)

Soldered new wire end to swab heater.

Restitched swab together, stitched swab to leather. Thinly hot glued new stitching & new wire to prevent further breakage & electrical safety.

eBikes

Thin bike multiple faults causing intermittent drive.

Thin bike controller.

Controller under test.

Wire damage found at frame boundary.

Additional wire damage found at hub entry point.

Found faulty hall effect device in hub.

New hall device installed.

Reassembled with anti vibration glues, tested all ok.

Motorcycles

Triumph Triple Sport ICU faulty Coil output

ICU under test.

Faulty transistor found in circuit.

Testing output on Oscilloscope, after transistor replaced.

Reverse engineered circuit diagram to trace faults.

Replaced TR5 to effect repair.

Board cleaned & tested.

Server

Programming

SSH Blacklist to track BOTs & intrusion detection using F2B, PHP, NMap & more

SSH Blacklist site; HoneyPot to track BOTs & intrusion detection, using Fail2Ban, PHP etc.

Javascript 3d using JQuery and Canvas; No VRML, pluggins or any other library.

Proof of concept for a US engineer. To convert 3d data live to a 2d projections using focal length. Uses Matrices for move, rotate & transpose functions.

Genealogy Site

Genealogy site, using weighted dynamics to display data of a family tree, order & sized per device. With Genealogical search & navigation functions

Barcode reader testing site

Testing barcode readers. Live updating barcode & products from mobile barcode scanners: test site.

Live site to calculate ingredients, allergens & calorific content of Bakery products.

To comply with HSE & Local government changes. A bakery needed a method or printing labels for their products. Uses NUT tables & manufacturers data to compile information for labelling.

Pandemic work from home IP telephony.

TABS (Telephone Accounting & Billing System). Live site programmed for use by clients, after installing many end user IP phones at home. Uses Asterisk for IP telephony interconnect. Clients & Users needed a system for tracking, billing & directory updates across handsets at multiple locations.

Prices from:
£55 call out.
£33 hourly rates.
See here for details.