Omicron CMC 356 Protection Relay Test Set Repair - Utilities, Nashik
Fault Analysis
The Problem
AC output stuck at 150V regardless of setpoint commands (0-300V range non-functional)
"Output Filter Fault" error code recurring in calibration mode, preventing relay synchronization tests
THD (Total Harmonic Distortion) measured at 18.5% at 50 Hz fundamental versus spec <5%
Failed capacitor unit measured 32µF capacitance instead of rated 100µF (68% degradation)
ESR (Equivalent Series Resistance) spike from 0.085Ω to 1.24Ω detected via internal CMC 356 memory logs
Money Saved
Cost Savings Breakdown
What this customer saved by repairing instead of buying new
* Govt. taxes extra as applicable · Shipping charges extra as applicable on the repair quote.
This Repair's Journey
From Inquiry to Delivery
Completed in 103 hours
Inquiry Received
Equipment details logged, initial assessment scheduled
Diagnosis & Evaluation
Component-level fault analysis with detailed report
Repair Work
Expert component-level repair using OEM-grade parts
Testing & QC
Full-load testing under operating conditions, QA sign-off
Delivery & Warranty
Dispatched with test report and 6-month warranty
Inquiry Received
Equipment details logged, initial assessment scheduled
Diagnosis & Evaluation
Component-level fault analysis with detailed report
Repair Work
Expert component-level repair using OEM-grade parts
Testing & QC
Full-load testing under operating conditions, QA sign-off
Delivery & Warranty
Dispatched with test report and 6-month warranty
Technical Details
Our Repair Approach
Non-Invasive AC Frequency Sweep Analysis
Performed sine-wave injection across 10 Hz to 5 kHz to characterize output filter response and identified 50 Hz attenuation coupled with 18.5% THD, indicating capacitor degradation.
Thermal Imaging and Capacitance Measurement
Isolated the three parallel 100µF/63V output filter capacitors via thermal camera (67°C hot spot) and in-circuit ESR measurement confirmed one unit at 32µF with 1.24Ω ESR versus spec 100µF and <0.1Ω.
Desoldering and Component Replacement
Desoldered all three output filter capacitors from main AC output PCB (Assembly P/N: 1G-CMC-D002) and replaced with OEM-equivalent Panasonic FR-A series 100µF/63V capacitors using nitrogen-purge wave soldering.
AC Output Linearity and Frequency Response Validation
Calibrated AC output across 10-300V setpoint range confirming <0.3% error and performed frequency sweep 10-10 kHz verifying <5% THD at 50 Hz fundamental within specification.
48-Hour Soak Test Under Rated Load
Operated repaired unit at 150 VA load for 48 hours with continuous thermal monitoring (steady-state 38°C) and ESR trending to validate capacitor stability and thermal management.
Synchronization Module Live Relay Test Certification
Injected live 22 kV test signal from MSEDCL sub-station protection console and verified all three-phase relay synchronization markers aligned within ±1.2° accuracy for Siemens 7SJ64 distance relay certification.
Mission Accomplished
The Result
MSEDCL commissioned the repaired CMC 356 within 4 days (103 hours turnaround including soak testing and shipping buffer), enabling completion of all three backlogged protection relay projects and maintaining CEA compliance certification. The repair cost of Rs. 7,30,000 versus OEM replacement of Rs. 38,50,000 yielded a facility saving of Rs. 31,20,000 (81% cost reduction) while preserving equipment continuity and avoiding 6-8 week procurement delays.
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