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    Fixed

    Fixed
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    All 5 grounds work together, the return current...

    All 5 grounds work together, the return current is distributed across them. If you put 4.5A on one rail you cannot put another 4.5A on another rail (the total should not exceed 7.5A)

    Might I...
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    Absolutely, the first half

    Absolutely, the first half
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    Interesting that Aris still feels "In power...

    Interesting that Aris still feels
    "In power supplies, the two most important parts are the capacitors and the cooling fan."
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    You will get it, but at the risk of damaging the...

    You will get it, but at the risk of damaging the connector; 7.5A max if you don't want to take a risk.

    It is very simple, no pin should exceed 1.5A, the rest you can work out for yourself.
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    1.5A per SATA pin, 4.5A per rail (3 pins).

    1.5A per SATA pin, 4.5A per rail (3 pins).
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    You are scaring me!

    You are scaring me!
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    1.5A per SATA pin, so 4.5A per rail and 7.5A...

    1.5A per SATA pin, so 4.5A per rail and 7.5A overall since there are only 5 ground pins.

    So each cable carries up to 4.5A (assuming 2 ground cables as in the attached picture)
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    Which begs the question: what do other supplies...

    Which begs the question: what do other supplies do at out-of-spec under voltage? hopefully not self destruct.
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    Recall...

    Recall
    https://digilander.libero.it/hibone/UPS/PSU_and_UPS_Compatibility_Test_Report.pdf
    where the bus voltage is anything but constant

    Perhaps something of the sort is happening here;...
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    It's actually the PWM FET that fails (but your...

    It's actually the PWM FET that fails (but your point remains valid)
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    So most of the power transistors have built in...

    So most of the power transistors have built in fly-back diodes?
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    I meant in the component list

    I meant in the component list
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    Where would it be in the list of components you...

    Where would it be in the list of components you gave?
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    The idea of using a 'better' transistor is to see...

    The idea of using a 'better' transistor is to see if that solves the issue; if not the problem might indeed be with the transformer.

    One other question, for an expert like you: is the fly-back...
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    Ah, thanks for the clarification.

    Ah, thanks for the clarification.
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    Perhaps I misunderstood, but I thought you were...

    Perhaps I misunderstood, but I thought you were trying to understand why the power transistor failed, and there is the possibility it was due to the transformer saturating and not the transistor...
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    My point was that the link I found had 150W max,...

    My point was that the link I found had 150W max, which also means 150VA max and so it might be hard to get 750W from the same form factor. It seemed a reasonable line of reasoning to me, but I am...
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    I wonder if a better MOSFET could hold up, for me...

    I wonder if a better MOSFET could hold up, for me it is not obvious as the transformer may have gone into saturation.
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    Yes, I did already ask

    Yes, I did already ask
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    Tell that to ...

    Tell that to

    http://transformers.en.hisupplier.com/product-2307022-ERL-series-ERL39-High-frequency-transformer.html

    Perhaps your point was VA rather than W?
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    ERL39...

    ERL39
    http://transformers.en.hisupplier.com/product-2307022-ERL-series-ERL39-High-frequency-transformer.html

    Now it does suddenly change to ERL28
    Output Power: 30 to 150 W


    what am I missing?
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    Why another unit? just get a box of identical...

    Why another unit? just get a box of identical power transistors, and some that are superior; replacing the whole unit limits testing. Are there separate fly-back diodes and if so, did they survive?
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    Just a thought... if the voltage is down, the...

    Just a thought... if the voltage is down, the main transformer may get saturated (the modulation trying to compensate) and short the transistor? One could watch the voltage on the bulk capacitor as...
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    At full load? Q2 is a main switching...

    At full load?

    Q2 is a main switching transistor? or PFC control

    a few details seem to have been left out
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