Quoted from MRudowsky:Yesterday, I was able to borrow a known good PDB (from a Foo pro coincidentally). With the replacement power supply and the borrowed PDB, I’ve gone through 5 power cycles (power up, play a game, power off) with anywhere from 20 minutes - 6 hours between cycles. No clicks outside of the initial click when the PDB gets power. Just swapped the power supply back to my original to show Stern it’s the PDB, not the power supply. First 2 cycles, no clicks. Capacitor lot number on clicky PDB is 2245P. Borrowed non-clicky PDB is 2236P.
My plan is to write it all up, return the replacement power supply, and hope Stern will send a PDB with good caps. Thanks PinMonk and everyone else who’s chimed in with their info!
Yeah, it's not impossible to get a non-clicky PDB with 2022 caps, it's just that when about half of the 2022 caps are low-spec in my (limited) testing, you're rolling the dice with a 50% probability each cap is insufficient (below 8500uF on a 10k uF spec), and you have to win that roll three times to get a single good PDB set with 2022 caps. The math on that says you have 12.5% odds of that happening, so the odds are ever <not> in your favor.
With 2021 CDE caps the odds are close to 100% of getting a good set of caps.
I don't have the balls to do it, but it would be interesting to cut open a cross-section of a 2021 CDE cap and a 2022 one to see what material(s) inside CDE changed that made the 2022 ones .3 oz heavier and way less reliable. Maybe something more like benheck might investigate.