661G + 665E Power Supplies + CF82E98 Regulator Cards

[marcmozart]

This is a "Power Supply Thread" - let's bring together documents and pictures around that!

UPDATE:
- Side by side pictures of Console and Computer PSU added.
- Part Numbers for Fan Replacement added.
- Infos about recapping of 82E331 Trip/Driver Card added.

... I just cleaned and recapped a bunch of the CF82E98 Regulator Cards inside the PSUs. The 661 Power Supply is using 5 of them, and the 665 Mix Computer Power Supply has 4 (+1 thats different), all the exact same cards.

Recapping them is an easy and quick job. 2 x 220uF 50V, 1x 47uF 25V, 2x 1.5uF 35V.

Before you start... know that swapping out one of these regulator cards requires an alignment procedure on the Power Supply which is NOT a trivial thing.

One of my Power Supplies had a card from 2005 that still looks like new, the other ones are still the original ones from 1991. The ones from 1991 have been recapped before, but the dust on the cards and the caps tell me that it's been a while.
You can see on the back of the PCB that the heat in the Power Supplies is doing its job...

First step is to remove the old capacitors with a vacuum desoldering tool. After that I'm cleaning the PCB and the components with a Q-tip and Isoprop.
Finally the new caps come in - I'm using Panasonic FR Series for the 220uF and 47uF, they have very high specs - better than the Panasonic FC and FM Series.
I am replacing the 1.5uF Electrolytic Capacitor with a WIMA MKS Film Capacitor. They have an operational life of > 300 000 hours vs. 10 000 hours for the Panasonic FR.

http://de.mouser.com/Search/ProductDetail.aspx?R=MKS2B041501E00KSSDvirtualkey50520000virtualkey505-MKS21.5/50/10

Perhaps one of the Power Supply Specialists on the forum can chime in on this - any other parts that should be replaced on these cards?

Power supply replacement part numbers:

The 2 Fans in 661G are
ebm-papst 4500N
Mouser Part No: 5912-4500N
115V, Airflow 99.5CFM, Noise 48dBA, Speed 3000RPM, Power Rating 15W, Size 119x119x38mm
http://mouser.com/ProductDetail/ebm-papst/4500N/?qs=%2fha2pyFaduifyChYrQOQW1eUMHfBW8eU8MIP8hGMO8Y%3d

There is a modern replacement for those with better specs in all areas. I haven't tested it, but would probably go for this one in case of replacing the fans:
ebm-papst ACi4410HH
Mouser Part No: 5912-ACI4410HH
115V, Airflow 106CFM, Noise 42dBA, Speed 3350RPM, Power Rating 4.4W, Size 119x119x38mm
http://mouser.com/ProductDetail/ebm-papst/ACi4410HH/?qs=%2fha2pyFaduh%2fjL%2fzmMye2CdXK8%2ffZQYAOttqcteNLAAQEaxIPYMmZA%3d%3d

Spare Card tested by SSL in 2005:




Original 1991 Card from my Power Supply, cleaned and recapped (note the red 1.5uF WIMA Film Capacitors replacing the Electrolytic Cap)


Backside of 1991 Card, note how the heat inside the Power Supply has done its job...

[Artur D'Assumpção]

Great log Marc, has always!!

This is awesome info! Keep it coming!

Cheers,

Artur

[marcmozart]

Upon request, here are side by side comparisons of the 661G Console Power Supply and 665E Computer Power Supply. These are both from 1991. There was an earlier version of the Console PSU (661E). Not sure if the 665E was ever upgraded to a 665G?

LEFT: Console PSU CF661G / RIGHT: Computer Power Supply CF665E
Note: Regulator Cards are not fitted on these pictures. You can see the 5 empty slots near the rear of the cases.


Larger view of the Console PSU CF661G


Larger view of the Computer PSU CF665E

[sintech]

Marc, does that computer supply have an AC fuses?

[Showcase]

Marc, does that computer supply have an AC fuses?

Seems they are fitted down on the right side

The left must be the computer PSU and Right the Console PSU, hmm weird...

[waltzingbear]

none of them have AC fuses, the AC is controlled by contactors, how else could you have such a small switch to turn the psu on!

The fuses that are discussed in various places here are in the rectified unregulated supplies.

Cheers
Alan

[michaeldtech]

Such a great pic of the supplies side by side.  Thanks!  It shows the good getting better.

I know you have some isopropyl there, so clean the flux off those re-capped boards ;-)  SSL did it, so why shouldn't we?

Mike

PS: why the wimp poly's in place of electrolytics?

[marcmozart]

PS: why the wimp poly's in place of electrolytics?

You tell me if this makes sense? My thinking is - the WIMA's are better and last longer so I put them in wherever I can.

And yes, Toothbrush with Isopropyl cleaning the boards is always the last step before putting the recapped boards back in!

Still looking for a place in Germany that sells Caig Pro Gold... for the final icing on the cake

[waltzingbear]

you may have more luck finding EML products that come from England. Equally as good and effective, and easier to apply (less wastage and overspray).

Caig built their name on the original red caig product that they no longer produce. DeOxit R5 is a different product with a different formulation that does not work as well. Only the color is the same.

Things such as "preservative" are a light oil that seals the surface from oxidation. Many companies that works well there.

Alan

[michaeldtech]

I used to agree about electrolube (EML) but have since shunned. I have a client with a mint Neve 8078 who used EML1 on eight year old isostats and now they are all crunchy and have to be replaced. Not a smoke filled dirty studio he figures it was the EML.
My can got zapped into the cornfield. BAD man!
Mike

[waltzingbear]

strange, never had a problem with it.

Alan

[marcmozart]

The 82E331 Trip/Driver Card is a subassembly attached to the right side of the 661G Power Supply Case. The Console Service Manual explains what it does on page 9-2.
I have replaced the two caps, 1x 220uF 50V (using Panasonic FR-Series) and 1x 100uF 100V (using Nichicon HE-Series as this value wasn't available from Panasonic FR-Series).
The Heatsink has some Thermal Paste between it's backside and the Power Supply Case. I've removed the old Thermal Paste easily using Isopropyl.

Before you remove the card, make sure to make a photo of the connectors. They are color-coded, and if you have a photo, not much can go wrong when reassembling. Don't forget to apply Thermal Paste again!

BEFORE cleaning and recapping...


Recapped and Cleaned Card






Back in the case AFTER recapping and cleaning.


Note the Thermal Paste between Heatsink and Case Wall