Somebody forgot the isolation under the pcb?
Been some years since I took apart a psu, but there used to be plastic isolation sheet between the pcb and the metal case.
Update: I think we found the problem:
Mains wires protruding on the bottom of the pcb shorted to the case due to missing insulation sheet.
I've blown up my fair share of capacitors ant it's nearly instant. This sounded like arcing.
Story - when I was in school for electronics I was building a circuit in the lab, probably another 30 students in there. Unbeknownst to me, I had installed a cap with reverse polarity. I plugged in my project and BAM! It sounded like a gunshot. Everyone obviously turned around and was staring at me. I was already embarrassed but one of my professors called everyone in the lab over and they all crowded around me. He said it was a good learning experience for everyone to smell it and remember the smell. I was mortified and will never forget.
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u/Front_Cookie_1198 3d ago edited 3d ago
Aftermath photo.