Omicron CMC256 Protection Relay Test Set LCD Backlight & Touchscreen Repair - Utilities, Pune
Fault Analysis
The Problem
Complete LCD display blackout with no backlight illumination despite device power-on and successful firmware boot confirmation
Intermittent touchscreen phantom touches and erratic menu navigation, unresponsive to deliberate user input, reproducing consistently under thermal stress cycling
Backlight inverter voltage measurement: 0V (expected 60V nominal) indicating ICN2053B boost converter failure
Cold-solder joints detected on FT6236 touchscreen controller IC (40-pin QFP) confirmed via thermal imaging and X-ray inspection
Elevated ESR values (8+ ohms) measured on backlight inverter electrolytic capacitors, indicating capacitive performance degradation and inverter circuit instability
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 71 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
Comprehensive Diagnostic & Root Cause Analysis
Executed full bench testing protocol including visual PCB inspection under 40x magnification, DC bias measurements across all major IC supply pins, thermal imaging of backlight inverter circuit, and thermal cycling stress test (-10 to +50°C/100 cycles) to reproduce touchscreen intermittency.
Backlight Inverter Circuit Restoration
Desoldered and replaced four failed electrolytic capacitors (2200 µF/16V) in the ICN2053B boost converter stage and reflowed gate driver IC SI8210BB isolator connections, restoring inverter output voltage to specification (60V ±2V).
Touchscreen Controller & Solder Joint Remediation
Removed FT6236 touchscreen controller IC via precision micro-soldering, inspected BGA pad integrity, and re-flowed using selective wave soldering with automated flux penetration verification to eliminate cold-joint defects.
Power Distribution Via Network Re-flow
Identified and re-flowed 32 micro-fractured solder connections in the main power distribution via array using thermal profiling and micro-soldering technique to restore robust power integrity across all supply rails.
Post-Repair Functional & Safety Validation
Conducted 8-hour continuous operation burn-in testing, calibrated 2048-point touchscreen coordinate mapping, verified LCD brightness stability across 0-50°C temperature range, executed all 47 internal self-test parameters (PASS status), and confirmed IEC 61010-1 electrical safety compliance.
MSEDCL Protocol Baseline & Warranty Documentation
Validated repaired CMC256 against utility's specific relay testing procedures (relay communication protocol, analog injection accuracy ±0.1%, waveform capture fidelity, relay timing measurement within ±1 ms), generated complete repair traceability documentation, and issued 6-month component warranty certificate.
Mission Accomplished
The Result
The Omicron CMC256 was restored to full operational status and returned to MSEDCL's testing laboratory within 71 hours (2 hours 58 minutes under the 72-hour emergency deadline), enabling completion of Wednesday morning protection scheme commissioning on schedule with zero production delay. The utility achieved cost savings of Rs 16,60,000 (79% reduction) by choosing component-level repair at Rs 4,40,000 instead of OEM replacement quotation of Rs 21,00,000, while maintaining factory-equivalent reliability and receiving a 6-month repair warranty.
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