Hi Everyone,
Font, i agree with your comments so have informed my manager and am awaiting further notice. We have been informed that if the device passes all tests then it is ok to go back into service. But also from the same source that it is preferred the codemasters are replaced with newer models. We are in the process of identifying all capacitors exhibiting this popping noise.
As R. Ling says, once you get breakdown of electrolyte, then loss of capacitance, more leakage, further breakdown etc. This accelerates the failure of the capacitor.
Font, as your HV caps are showing visual signs of electrolyte leakage i would assume it is at a further stage of failure and might have failed the calibration anyway in which case RFS would be the solution.
Ill keep you informed on our position here when i know anything.