Power Supply Repair
Industrial SMPS, UPS, servo stabiliser, and panel power supply repair — all ratings, component-level, load tested before dispatch.
A failed power supply can cascade into damage across your entire production line — we fix the root cause and load test every repair at full rated current.
Industrial power supplies are the silent backbone of every automated facility — when an SMPS fails, it can trigger a cascade of faults across PLCs, drives, sensors, and HMIs connected downstream. Synchronics repairs industrial power supplies at the component level — MOSFETs, IGBTs, PWM controller ICs, isolation transformers, rectifier bridges, and output filter capacitors — across all topologies including flyback, forward converter, half-bridge, full-bridge, and LLC resonant designs. Every single repair is load tested at full rated current with efficiency and ripple measurements before dispatch.
Diagnosis Guide
Common Power Supply Problems We Fix
Experiencing any of these symptoms? Our engineers have diagnosed and repaired thousands of these faults.
SMPS No Output
Power supply is dead — no output voltage, no LED indication, no fan spin. Connected equipment is completely offline.
Input fuse blown due to shorted MOSFET/IGBT, failed bridge rectifier, or dried-out input filter capacitors causing startup circuit failure
UPS Not Charging / Not Switching
UPS shows charging fault, batteries not charging, or UPS fails to switch to battery during power cut — load drops instantly
Charger thyristor/MOSFET failure, battery management IC fault, relay contact welding, or transfer switch driver circuit failure
Servo Stabiliser Motor Failure
Output voltage not regulating, motor buzzing but not correcting, or stabiliser trips repeatedly on overload
Servo motor brush wear or bearing seizure, motor drive TRIAC failure, voltage sensing resistor drift, or control card relay fault
Panel PSU Voltage Drift
Output voltage slowly drifting from 24V to 22V or 26V, causing intermittent PLC and sensor faults downstream
Feedback resistor value drift due to thermal ageing, optocoupler CTR degradation, or TL431 reference IC failure
MOSFET / IGBT Blown
Loud pop at startup, burning smell, input fuse blown immediately, or output pulsing on and off (hiccup mode)
Switching transistor avalanche breakdown from voltage spike, gate driver IC failure causing shoot-through, or inadequate snubber network
Electrolytic Capacitor Failure
Output ripple increased, audible buzzing from transformer, intermittent shutdowns under load, or visibly bulged/leaking capacitors
Capacitor ESR increase from thermal ageing (especially near heat sinks), exceeding rated temperature or ripple current, or poor ventilation
How It Works
Our Power Supply Repair Process
A systematic, schematic-driven repair process — from receipt to dispatch.
Receive & Log
Power supply received with nameplate details, fault history, and application context logged. Unit is photographed for reference.
Visual & Smell Test
Physical inspection for burnt components, bulged capacitors, discoloured PCB areas, cracked solder joints, and signs of liquid ingress or overheating.
Input / Output Measurement
Input section tested — fuse continuity, bridge rectifier diode check, bulk capacitor voltage. Output section tested — DC output under no-load and light-load conditions.
Topology Analysis & Signal Tracing
Power supply topology identified (flyback, forward, half-bridge, full-bridge, LLC) and critical signals traced — PWM output, gate drive waveforms, feedback loop, and current sense signals.
Component-Level Repair
Faulty MOSFETs, IGBTs, diodes, capacitors, PWM controller ICs, optocouplers, and gate driver ICs replaced with original-spec or upgraded components.
Full Load Test & Dispatch
Repaired unit tested at full rated output current using programmable electronic load bank. Voltage regulation, ripple, efficiency, and thermal rise measured and documented.
Thorough Inspection
Power Supply Inspection Checklist
Every unit goes through a comprehensive inspection checklist before and after repair.
Input Filter & Rectifier
Switching MOSFETs / IGBTs
PWM Controller IC
Output Filter & Rectification
Feedback Loop & Regulation
Protection Circuits
The Synchronics Advantage
Why Choose Us for Power Supply Repair
All Topologies — Flyback to Full-Bridge
Our power electronics team is trained on every SMPS topology in use today — from simple flyback converters in 50W panel PSUs to complex full-bridge and LLC resonant converters in multi-kilowatt UPS systems. We understand the magnetics, control loops, and failure modes unique to each topology.
Load Tested at Full Rated Current
We do not dispatch any repaired power supply based on a no-load voltage check. Every unit is connected to our programmable electronic load bank and tested at 100% rated current for a sustained duration. We measure voltage regulation, ripple, efficiency, and thermal rise — and include the test report with your unit.
UPS Battery System Expertise
Beyond board-level UPS repair, we assess battery health, charger circuit calibration, and transfer switch timing. For online UPS systems, we verify seamless zero-transfer-time switchover. For large UPS installations, we provide on-site commissioning support after repair.
Troubleshooting
Common Power Supply Fault Symptoms We Repair
Seeing one of these error codes? We diagnose and repair the root cause.
Power supply completely dead — no output voltage, no standby LED
Blown input fuse from shorted MOSFET, failed startup resistor, or open primary winding on transformer
Output voltage below rated value (e.g. 24V supply reading 18-20V)
Feedback optocoupler CTR degradation, TL431 reference drift, or output capacitor ESR increase causing voltage drop under load
Output voltage above rated value — risk of damaging connected equipment
Feedback loop open (broken optocoupler), voltage divider resistor gone open, or shorted output rectifier in multi-output supply
Supply starts briefly then shuts down, or enters hiccup/retry mode
Output short or overload, current sense resistor drift, PWM controller OCP threshold shifted, or secondary rectifier leaking
Cooling fan not running, supply overheating and tripping on thermal protection
Fan bearing seizure, fan driver transistor failure, blocked air filter, or thermal switch/NTC open circuit
UPS reports battery not charging, battery low, or fails to support load on mains failure
Charger thyristor/MOSFET failure, battery management IC fault, battery connector corrosion, or end-of-life battery cells
Power supply faults manifest as symptoms rather than alphanumeric fault codes. We diagnose based on the behaviour observed and the topology of your specific unit. Send us a photo of the nameplate and a description of the fault for a free repair estimate.
Industries Served
Where Power Supplys Are Used
Factory Automation
24V DC panel power supplies for PLCs, sensors, solenoid valves, and field instruments. SITOP, QUINT, and PULS DIN rail PSU repair across manufacturing plants.
IT Infrastructure & Data Centres
Rack-mount UPS systems, server power supplies, and PDU repair. Online double-conversion UPS main board repair and battery management for Emerson, APC, and Schneider systems.
Healthcare & Medical Equipment
Medical-grade SMPS repair for diagnostic equipment, patient monitors, and imaging systems. Compliance with safety isolation requirements and leakage current standards.
Telecom & Broadcasting
-48V DC rectifier module repair, telecom power plants, and DC-DC converter repair for base stations and exchange equipment. N+1 redundancy system commissioning.
Process Control & Petrochemical
Redundant 24V power supply repair for DCS and SCADA systems. Intrinsically safe power supply repair for hazardous area applications in refineries and chemical plants.
Textile & Packaging Machinery
Servo stabiliser and panel PSU repair for looms, knitting machines, and packaging lines where voltage stability is critical for consistent product quality.
Trusted Brands
Brands We Service
Component-level repair for all major manufacturers
FAQ
Frequently Asked Questions
Yes — without exception. Every repaired power supply is connected to our programmable electronic load bank and tested at 100% rated output current for a sustained period. We measure and document output voltage regulation, ripple voltage, efficiency, and thermal rise. The load test report is dispatched with your unit as proof of performance.
Yes. We maintain a database of pin-compatible and functionally equivalent PWM controller ICs. If the original IC (e.g. UC3842, TOP-Switch, or proprietary ASIC) is obsolete, we identify a suitable replacement and modify the peripheral circuit values if needed to match the original switching parameters. This is one of our core competencies in power supply repair.
For large-frame UPS systems (above 10kVA) where shipping is impractical, we offer on-site diagnosis and board-level repair at your facility. Our engineers carry portable test equipment and common replacement components. For smaller UPS units, we recommend shipping to our Vadodara facility where we have complete test infrastructure including battery load banks.
Electrolytic capacitors fail primarily due to thermal stress — operating near a heat source, poor ventilation, or exceeding rated ripple current. During repair, we replace failed capacitors with higher-temperature-rated (105 deg C) and higher-ripple-rated units where possible. We also check heat sink mounting, fan operation, and airflow paths to address the root cause of premature capacitor ageing.
Industrial Power Supply Repair Specialists — All Brands, All Ratings
Synchronics Electronics Pvt. Ltd. is a leading industrial power supply repair company in India, operating from our well-equipped facility in Vadodara, Gujarat. We repair SMPS units, online and line-interactive UPS systems, servo voltage stabilisers, DIN rail panel power supplies, and custom power conversion equipment across all ratings from 50W panel PSUs to 500kVA UPS installations. Our power electronics team has repaired over 8,000 units for factories, data centres, hospitals, telecom facilities, and process plants across India.
What makes Synchronics the preferred choice for power supply repair is our commitment to full load testing. While many repair shops check output voltage at no-load and call it done, we connect every repaired unit to a programmable electronic load bank and run it at full rated current — measuring voltage regulation, output ripple, conversion efficiency, and thermal behaviour. This rigorous testing, combined with our use of genuine replacement components from authorised distributors and a 6-month warranty, ensures that your repaired power supply will perform reliably in the demanding conditions of an industrial environment.
Get Your Equipment
Back in Action — Fast
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