VP-1000 Power Supply unit for Yaesu Quadra amplifier repair

I use a second hand Quadra amplifier S/N 7M030041 for about 10 years. After initial problems (controller board replacement, because of faulty microcontroller - fault temperature protection pin), the amplifier was reliable and robust, I am satisfied.

Problem 1 - electrolytic capacitors

Recently I spotted some strange behaviour of power supply VP1000: strange sound a also smells unusually. So I immediately stopped the operation (but up to that moment the HF power was still present, protection circuitry reported no problems).
I dismounted the unit (it is hard work, the circuitry is nicely shielded, but is means I had to unscrew lot of screws). Finally I got inside and started search for problems. What was suspicious was the dirty PCB close to some capacitors. Electrolyte capacitors often cause problems by old radios and computer parts - they lose capacity or electrolyte liquid leaks outside. So I took them out of PCB and cleaned the PCB by ethanol.
Here you can see the detail:

What happened: after some time the capacitor became non hermetic, the electrolyte liquid got off the components to the PCB. Because the liquid is conductive, it created conductive path between certain pins. The current started to flow there, resulting in PCB heating. Finally it started to burn, creating audible sound and smell. Bad is the damage is only visible when you remove the capacitor. Not very funny... The capacitors are in positions C34 (the critical point), C8, C21, C22, C23 and C33, value 100uF 25V, in component list of Power Supply Unit PB1 stated MFR'S DESIGN CEBSM1E101M, Yaesu P/N K40149056. I checked the capacity of all capacitors, it is still good (in tolerance). So capacity value cannot be used as indicator of leakage.

Repair.
Fortunately I stopped the PCB burning soon, so only few millimeters burned. I removed the burned PCB surface using knife and cleaned the PCB. As final step I applied a protection enamel. I bought a brand new capacitors 100uF/25V 105C and replaced all 7 pieces (check polarity).

Hopefully this article can help someone to locate similar problem, but more generally it points again to known problem with old capacitors. As we see the 105C class is no guarantee it cannot happen, but can be expected that 85C capacitors are ever worse. So the only way is to replace them by new ones. I hope the recent capacitors are better in this view as manufacturers know better about that phenomena than years ago, but of course nobody can tell what happens with the components after 10 years and also no manufacturer guarantee is valid for such long time period...

Problem 2 - startup resistor

Symptoms: Amplifier completely dead, PA display dark, no voltage on supply connectors.
Reason: faulty resistor (one of three) R0002A (board PB1) in startup circuit. When AC power is applied to power supply, the resistors are connected in series in order to reduce startup current. After short time capacitors are charged and the logic activates a relay X1 that short circuits the resistors. Each startup resistor (value 5.6 Ohm 5 watts) must survive short peak overload (500W each !). Unfortunately one of them burned. No smoke, no visual damage, just ohmmeter shows infinite resistance. As result the AC line supply is interrupted and all is dead.

Repair: again the most difficult task is disassembly/assembly of the VP1000 unit. I recommend to follow instruction pictures in service manual. You have to search for suitable resistor replacement(not just the values but also the dimensions, the most important is peak current - thermal conductivity and capacity). Ceramic wire type or better wire in metal enclosure is recommended. Good choice could be to install robust 18 ohm 15W (or more) resistor outside the PCB (not verified) to replace all 3 resistors in series.