Autopilot dig-220 - about 8 years old
SC-60 cell - about 3.5 years old
Was getting low amps warning and that "bad electrical" smell from the unit as if something is overheating. Disassembled and had several caps blown, tops popped and covers overheated and black/brown. Fans had seized due to corrosion which might have started the failure process. Removed all of the 1000, the 3000, and the 2 10000 microfarad caps and tested, a few had 0 capacitance, a couple had minimal, and a couple were good. Main board was discolored on top left but no signs of burning or broken traces. Tested coil for continuity, all 4 windings had continuity, no shorts between windings. Replaced all of the caps listed above and the fans.
After reassembly initially worked and tested fine. Then when I checked it again later that day had same symptoms as before my "fix" - low amps warning and that "bad electrical" smell from the unit as if something is still overheating. Voltage was low, about 4v, amps varied but were low under 4. Cell had some calcium deposits, cleaned it and the tri-sensor per manual. Now have check cell warning and 0v with amps varied between 4 and 5. Similar results on power levels 1, 2, and 3.
Is there anything else I can test in the power supply or do I just have to give up and buy a new one? I hate doing that because it appears to be a pretty simple design and I suspect it just needs one or more other failed components replaced. But reading here I'm afraid this is the end as apparently no circuit documentation is available.