HI-REL Repair Services India
HI-REL Electronics specializes in high-reliability power supplies, converters, and DC-DC modules designed for aerospace, defense, medical, and harsh industrial environments. Founded in 1965, HI-REL has built a reputation for mil-spec quality and ruggedized electronics that operate in temperature extremes and demanding conditions. Their presence in Indian industrial sectors—particularly aerospace manufacturing, railways, and oil-gas—continues to grow.
HI-REL Electronics specializes in high-reliability power supplies, converters, and DC-DC modules designed for aerospace, defense, medical, and harsh industrial environments. Founded in 1965, HI-REL has built a reputation for mil-spec quality and ruggedized electronics that operate in temperature extremes and demanding conditions. Their presence in Indian industrial sectors—particularly aerospace manufacturing, railways, and oil-gas—continues to grow.
Synchronics Electronics repairs the complete HI-REL power electronics portfolio, including enclosed power supplies, chassis-mount converters, and military-grade DC-DC modules. Our 180+ engineers have deep expertise in HI-REL's hybrid and encapsulated designs, potted assemblies, and conformal-coated circuit boards. We handle burn-in failures, capacitor degradation, transformer faults, and thermal management issues specific to HI-REL's high-density packaging—with turnaround times faster than factory service.
Expert repair of HI-REL mil-spec power supplies and ruggedized DC converters across India.
HI-REL Equipment We Repair — By Category
HI-REL Product Lines We Repair
Our engineers are trained on the full HI-REL product range. Below are the major product families we service.
Enclosed Power Supplies (EPS Series)
HI-REL's enclosed AC-DC and DC-DC power supplies rated for military and aerospace use. Common failures include transformer primary-winding insulation breakdown, rectifier bridge failure under thermal stress, and capacitor leakage in potted modules.
Chassis-Mount Converters (CMC Series)
Hybrid and thick-film DC-DC converters designed for high-reliability applications. Repair challenges include solder joint fatigue in hybrid substrates, MOSFET gate-drive failures, and thermal cycling damage in conformal-coated assemblies.
Military-Grade Regulators (MGR Series)
Linear and switching voltage regulators with mil-spec filtering and EMI suppression. Typical faults involve output transistor leakage, feedback network capacitor degradation, and PCB trace corrosion under humid storage.
Potted Module Assemblies (PMA Series)
Fully encapsulated power conversion modules for vibration-prone and corrosive environments. Failures stem from potting compound micro-cracking, internal lead-frame oxidation, and input filter capacitor electrolyte leakage in sealed cavities.
Filtered Input Modules (FIM Series)
Input filters with integrated EMI/RFI suppression for HI-REL power supplies. Common repair needs include ceramic capacitor cracking, inductor core delamination, and filter element saturation after thermal cycling.
Redundancy and Backplane Assemblies (RBA Series)
Dual-supply switching, cross-strapping diodes, and distribution modules for mission-critical systems. Repair issues include Schottky diode forward-voltage rise, backplane trace fatigue, and redundancy circuit sensing-line corrosion.
Why Choose Synchronics for HI-REL Repairs?
PCB-Level Expertise
We repair down to the component level — not just swap boards. Our engineers identify root causes, replace failed IGBTs, capacitors, processors, and gate drivers on HI-REL equipment.
Fast Turnaround
Standard 7–10 working days. Express 3–5 days available for critical breakdowns. Emergency same-day/next-day service for unplanned downtime.
6-Month Warranty
Every repaired unit ships with a 6-month comprehensive warranty on parts and labour. Our repair success rate is over 94% across all brands.
All-India Service
Couriered repairs accepted from any city in India. Doorstep pickup available in Vadodara, Mumbai, Pune, Ahmedabad, Surat, Chennai, and more.
Common HI-REL Equipment Faults We Fix
Based on 30+ years of repair data, these are the most frequent failure modes we see in HI-REL equipment arriving at our workshop.
- ✓Potted assembly internal capacitor leakage — HI-REL's potted modules contain aluminum electrolytic capacitors in sealed cavities. Moisture ingress and thermal cycling cause electrolyte breakdown, reducing capacitance and increasing ESR, leading to output ripple and regulation loss.
- ✓Conformal coating peeling and trace corrosion — HI-REL conformal coatings (acrylic, urethane) degrade in high-humidity Indian climates and thermal shock. Peeling exposes PCB traces to moisture and salt spray, causing dendritic growth and short circuits on feedback networks and sense lines.
- ✓Hybrid substrate solder joint cracking — HI-REL's hybrid DC-DC converters use thick-film ceramic substrates with hand-soldered components. Vibration in Indian railways, oil-rig equipment, and textile machinery, combined with thermal cycling, causes fatigue cracks in solder fillets connecting high-current leads and transformers.
- ✓MOSFET gate-drive circuit failure — HI-REL switching supplies use discrete MOSFET drivers operating at high frequency. Gate-drive transformer core saturation, bootstrap capacitor leakage, or optocoupler degradation causes gate voltage collapse, leading to MOSFET thermal runaway and short-circuit failure.
- ✓Transformer primary insulation breakdown — HI-REL power supply transformers are pot-cast with tight primary-secondary spacing for compact design. High-voltage stress, moisture-induced insulation degradation, and dielectric breakdown from corona discharge cause primary winding short-circuits, triggering input fuse failure or current-mode regulation loss.
- ✓Output voltage drift and regulation failure — HI-REL's feedback dividers and error amplifiers use thin-film resistors and precision capacitors. Aging of film resistors, capacitor leakage in humid conditions, and operational amplifier bias current drift cause output voltage to drift beyond specification (typically 5-10%), affecting downstream equipment.
How We Repair Your HI-REL Unit
Receive & Log
Your unit is logged into our tracking system with a unique job number. You receive WhatsApp / email updates at every stage.
Fault Diagnosis
Board-level diagnosis using oscilloscopes, LCR meters, and thermal cameras. Root cause identified before any repair begins.
Component Repair
Faulty ICs, capacitors, MOSFETs, IGBTs, and gate drivers replaced with genuine or equivalent-spec components.
Full-Load Test
Unit tested under rated load with original or equivalent motor. All parameters verified. 6-month warranty issued.
Industries Using HI-REL Equipment
We serve plant maintenance teams across all major industries where HI-REL automation is deployed.
Frequently Asked Questions — HI-REL Repairs
Do you repair HI-REL equipment anywhere in India?+
Yes. Synchronics repairs the complete HI-REL power supply and converter portfolio across India. We offer PAN-India door pickup and delivery from all metro cities—Mumbai, Delhi, Pune, Bangalore, Chennai, Hyderabad, Ahmedabad, Jaipur, and beyond. Your equipment is transported securely to our Vadodara facility, repaired, tested, and returned within 7-10 working days. We also support on-site repairs for aerospace and defence OEMs.
What makes HI-REL power supplies difficult to repair?+
HI-REL equipment is engineered for extreme reliability and mil-spec performance, which means potted assemblies, hybrid substrates, conformal coatings, and tightly integrated circuits. Standard repair shops lack the expertise and test equipment to safely depot modules, identify root causes in sealed assemblies, and re-qualify to original specifications. Synchronics has invested in depotting ovens, X-ray inspection, and mil-spec component sourcing specifically for high-reliability repair work.
Can you repair HI-REL potted modules without destroying them?+
Yes, but only with specialized equipment and experience. Synchronics uses controlled thermal depotting (gradual heating to soften potting compound without damaging internal components), careful mechanical removal, component-level repair, and aerospace-grade re-potting with epoxy that matches the original potting material specifications. We then perform electrical characterization and burn-in to restore the module's reliability rating. This approach saves the cost of replacement in critical installations.
Do you stock HI-REL spare parts and components?+
Synchronics maintains inventory of common HI-REL replacement parts—military-grade capacitors, high-reliability optocouplers, precision resistors, and MOSFET drivers. For rare or obsolete components, we source through authorized distributors and trusted suppliers within 48 hours. We prioritize mil-spec and space-grade equivalents to maintain equipment reliability and avoid performance degradation.
How long does a typical HI-REL power supply repair take?+
Most HI-REL repairs—capacitor replacement, solder joint repair, regulator adjustment—are completed in 3-5 working days. Complex failures (potted module depotting, transformer winding) take 7-10 days. We provide daily status updates and offer expedited service for critical downtime situations. All repairs include full electrical testing, load testing, and a 6-month warranty on parts and workmanship.
How do I send my HI-REL unit for repair?+
Pack the unit securely and courier it to our Vadodara workshop. Include a note with the fault description and your contact details. We will log it into our system and WhatsApp you a job number within 24 hours of receipt. Doorstep pickup is available in Vadodara, Ahmedabad, Surat, Mumbai, and Pune.
What is the cost of repairing a HI-REL drive or PLC?+
Repair cost depends on the model and the fault. We offer a free diagnosis — once we identify the fault, we provide a fixed quotation before proceeding. Typical repairs cost 20–40% of the new unit price. We will never repair without your approval.
What warranty do you provide on HI-REL repairs?+
All repaired units carry a 6-month comprehensive warranty covering the same fault and related issues. If the fault recurs within the warranty period, we repair it free of cost.
Do you provide a no-fix, no-fee guarantee?+
Yes. If we cannot repair your HI-REL unit after diagnosis, you pay only the diagnosis fee (₹500–₹1,500 depending on the product). The unit is returned to you at no additional charge.
HI-REL Repair Catalog
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Send us your faulty industrial electronics. Our engineers will diagnose it and provide a detailed quote within 24 hours — with no obligation to proceed.
Free Evaluation
No obligation
48hr Turnaround
Fastest in India
6-Month Warranty
Every repair
No Fix, No Charge
Zero risk policy
Pan-India Pickup
Doorstep service