It had nothing to do with the coil in that case. The damaged channel was shorted via the relay's contacts.
Sounds like you dug into it. I watched the video and it sounds like Dave never found the root cause. He stated that he was using the relay to short CH1 but had no video of it. If we assume that is correct, did he have enough lead inductance to cause it or is there some sort of sneak path on the other channel driving the coil and the BEMF caused it? I had used some crap power supplies for work once that would go up in smoke during radiated susceptibility testing. The RF would cause the supply to go unstable and the output would swing high enough to trip the crowbar which could not handle the power and would short. Is there enough crap from switching the relay that could have caused it? What were your thoughts about the root cause?
Yeah I watched the entire video. At the end of it Dave demonstrated the exact same arrangement that he had in place when CH1 went dead and he could not reproduce the issue after the successful repair. He could not reproduce it when he randomly shorted bare ends of the leads directly by hand, either. The current regulation circuitry in the PSU consistently did its job and dropped the output voltage respectively every time the output was shorted.
What was the root cause of the pass transistor failing short initially? I have no idea other than a dodgy transistor (maybe partially damaged with ESD when it was hand-soldered at the factory?)
What else could it be? The rest of the components remained the same, nothing else was broken. I don't think it was inductive kickback, either, as there are some protection diodes there close to the pass transistor that are supposed to (I don't know how they're connected, but what else can it be) clamp any overvoltage on the pass transistor's terminals.
Was there something radiated by the coil onto the contacts that could cause issues? That sounds too fantastic to me, but I can't disregard it entirely as I do not know everything :).
p.s. I've been wondering about the BJT that was getting hot when the blown pass transistor was letting current through when it was supposed to be off. What is its purpose? It's apparently placed after the pass transistor, so can it be there to create load across the output terminals to quickly bleed off any residual charge when the pass transistor is being turned off or partially off? Does that make sense?