Repair and Refurbishment of Powerline Electronics LTD Model ER200 Power Supplies

Nuclear Electronic Solutions (NES) recently undertook the repair and refurbishment of six obsolete Powerline Electronics LTD Model ER200 power supplies from a nuclear power plant. These power supplies, which deliver regulated outputs of ±12Vdc, ±5Vdc, and +24Vdc with a current sourcing capability of up to 20A, had exhibited various failures. These issues included no output, poor regulation, and high AC ripple.

Upon receipt, our initial inspection and testing identified a range of faults across the power supplies. With no available schematics, NES engineers meticulously developed a schematic and Bill of Materials (BOM) by analyzing the power supply's circuit card assembly (CCA) and wiring. During this process, we discovered that three diodes had been installed with their anode/cathode orientation reversed relative to the PCB silkscreen. Additionally, a thermal cutout switch was improperly installed on the inductor it monitored. These discrepancies were documented and corrected during the refurbishment.

To ensure the reliability and compliance of the repaired units, we developed and executed a comprehensive test plan. This included a 100-hour burn-in period, followed by rigorous acceptance testing to verify proper operation. After passing all tests, the power supplies were returned to the customer in fully operational condition.

This project highlights NES’s expertise in extending the life of critical electronic components in the nuclear industry, ensuring continued operational reliability and safety.