Modification of Cimdor 1.2kW Power Supply
Initial Problem
The electrical connections between the high-voltage transformer and the underside of the insulating board were originally designed with female push-on connectors. Over time, these connections tend to loosen, becoming electrically intermittent, which results in excessive localized heating.
This degradation has an avalanche effect, damaging surrounding components and leading to total failure of the power supply. Repairs in such cases are typically time-consuming or require complete unit replacement, both of which are costly and disruptive.
Objective
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Eliminate failure-prone push-on connections between transformer and insulating board.
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Improve electrical integrity and thermal performance of the power supply.
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Reduce failure rates and simplify future maintenance.
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Extend the overall life and reliability of the power supply.
MES Solution
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Replaced the insulating board to ensure a clean and undamaged working surface.
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Replaced all wiring on the high-voltage capacitors, rectifier assembly, and the upper section of the insulating board.
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Removed all push-on connectors from the transformer interface and re-terminated the leads with ring-type terminals secured using lock washers and double nuts for improved mechanical and electrical integrity.
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Upgraded the high-voltage rectifier assembly with a modern version offering higher voltage and current ratings.
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Thoroughly cleaned both the outer enclosure and internal chassis of the power supply.
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Tested the refurbished power supply under load to verify stable and safe operation.
Results
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More reliable operation of the power supply under full load.
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Significant reduction in unplanned downtime.
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Improved thermal and electrical efficiency.
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Extended service life of the power supply and its key components.
Before
After
