Saturday, December 8, 2018

Repairing a Tripp-Lite PR-40 DC Supply

TrippLite power supplies are well made, high quality supplies, but that negative lead regulation is a little odd and difficult to wrap your head around when it comes time to repair them. This supply to me inoperative, so I had to dig in deep to see what was wrong. 

First: TrippLite keeps the schematics for these close to their chest, so it took a bit of searching online to locate someone with an electrical schematic. FYI, there's a great site on yahoogroups for power supplies,  you should join it if you think you'll ever need a schematic or info on a power supply. The link to it is:

https://groups.yahoo.com/neo/groups/powersupplies/

I also uploaded a copy of the schematic in the [Schematics & Manuals] section of my website at:

http://www.WB4IUY.net


I discovered the remaining insulators on the output terminals had failed, and the rest were totally missing, shorting the output/crowbar board to the chassis. This took out all of the pass transistors and a few other bits. I replaced the pass transistors, fabricated new feed-thru insulators to protect the output studs from shorting to the case again, and rebuilt the crowbar circuit. Now, it'll go from no load to 40 amps @ 13.8 VDC with only 0.2 VDC shift. Solid supply! 

 Just cracking it open to take a look...

 Output / Crowbar board removed for inspection...

 Broken insulator...

 The only insulators left... There should be a feedthru insulator and a backup insulator in each stud...

 The PR-25, PR-40, and PR-60 use the same schematic... 2 pass transistors for the 25, 4 for the 40, and 6 for the 60.

 One pass transistor tacked in and boards jumped in place for testing...

 New insulators fabricated...the outside insulator is T-shaped and passes through the chassis, the inner parts are counter bored so they fit together. 

 Outside view with the new insulators in place...

All finished and ready to rock!!


Dave WB4IUY
http://www.WB4IUY.net