Computer uninterruptible power supply repair. Repair of uninterruptible power supplies (UPS repair). Such a useful and necessary UPS
Uninterruptible power supplies provide stable power supply to desktop computers and important electronic systems of the enterprise. An uninterruptible power supply (UPS) ensures a stable supply of electricity to devices during a short-term shutdown of the main source.
Most often, the battery in an uninterruptible power supply requires repair, since this unit in the UPS takes on the main load. In most cases, the cause is natural wear and tear of the battery.
There are also other malfunctions that are typical for uninterruptible power supplies of all types and brands:
- Capacitors: stop working due to the electrolyte drying out.
- Fans: their operation may be disrupted by drying out of the lubricant.
- Inverter: very sensitive to load and voltage changes, and in conditions of unfavorable network operation and battery failure, it often stops functioning.
Sometimes the uninterruptible power supply itself creates interference, in which case it must be equipped with filters against radio frequency and electromagnetic interference. Natural wear and tear of the unit as a result of long-term operation can also lead to failure of the UPS.
Uninterruptible power supply failures are very diverse; unfavorable operating conditions can also trigger premature UPS repairs - in particular, dust getting into the unit housing. Therefore, the place where the uninterruptible power supply is installed must always be clean.
UPS repair prices:
| Manufacturer Cyberpower | ||
|---|---|---|
| Model | Ah batteries | Price, rub |
| dx650e | 4,5 | 1500 |
| dx850e | 7,2 | 1600 |
| dl650elcd | 4,5 | 1500 |
| dl850elcd | 7 | 1600 |
| ex650e | 4,5 | 1500 |
| ex850e | 7,2 | 1600 |
| bu600e | 5 | 1500 |
| br850elcd | 9 | 2200 |
| br1200elcd | 5,8 | 2200 |
| ut850ei | 7 | 1600 |
| br1000elcd | 9 | 2200 |
| bs850e | 7 | 1600 |
| bs650e | 4,5 | 1500 |
| value600elcd | 7 | 1600 |
| value800elcd | 9 | 2200 |
| value1000elcd | 9 | 2200 |
| value1200elcd | 7x2 | 3000 |
| value1500elcd | 9x2 | 4200 |
| value2200elcd | 9x2 | 4600 |
| value1200eilcd | 7x2 | 3000 |
| value1500eilcd | 9x2 | 4200 |
| value2200eilcd | 9x2 | 4600 |
| value600ei | 7,2 | 1600 |
| value800ei | 9 | 2200 |
| value1000ei | 9 | 2200 |
| value400ei | 4,5 | 1500 |
| value500ei | 4,5 | 1500 |
| value700ei | 7,2 | 1600 |
| cp1350eavrlcd | 8x2 | 4200 |
| cp1500eavrlcd | 8.5x2 | 4600 |
| pr750elcd | 7x2 | 3000 |
| pr1000elcd | 12x2 | 5800 |
| pr1500elcd | 17x2 | 6200 |
| pr1000elcdrt1u | 6v9ahx4 | 6300 |
| pr1000elcdrt2u | 7x4 | 5800 |
| pr1500elcdrt2u | 7x4 | 5800 |
| pr3000elcdrt2u | 9x4 | 8800 |
| pr1500elcdrtxl2u | 9x4 | 8800 |
| pr2200elcdrtxl2u | 9x4 | 8800 |
| pr2200elcdrt2u | 9x4 | 8800 |
| pr3000elcdrtxl2u | 9x4 | 8800 |
| pr6000elcdrtxl5u | 9x16 | 32000 |
| pr750elcdrt1u | 6v9ahx4 | 6400 |
| or600elcdrm1u | 6v9ahx2 | 3200 |
| or1000elcdrm1u | 6v7ahx4 | 5600 |
| or1500elcdrm1u | 6v9ahx4 | 6400 |
| ols1000e | 7x3 | 4500 |
| ols1500e | 9x3 | 6600 |
| ols2000e | 7x6 | 7800 |
| ols3000e | 9x6 | 13200 |
| ols1000ert2u | 7x3 | 4500 |
| ols1500ert2u | 9x3 | 6600 |
| ols2000ert2u | 7x6 | 7800 |
| ols3000ert2u | 9x6 | 13200 |
| ols6000e | 7x20 | 25000 |
| ols10000e | 9x20 | 40000 |
| ol1000ertxl2u | 9x3 | 6600 |
| ol1500ertxl2u | 9x3 | 6600 |
| ol2000ertxl2u | 9x6 | 13200 |
| ol3000ertxl2u | 9x6 | 13200 |
| ol6000ert3ud | 7x20 | 25000 |
| ol8000ert3ud | 9x20 | 40000 |
| ol10000ert3ud | 9x20 | 40000 |
| ol6000ert3udm | 7x20 | |
| ol8000ert3udm | 9x20 | |
| ol10000ert3udm | 9x20 | |
| ol6000e | 7x20 | |
| ol8000e | 9x20 | |
| ol10000e | 9x20 | |
| ol1000exl | 7x3 | |
| ol1500exl | 9x3 | |
| ol2000exl | 7x6 | |
| ol3000exl | 9x6 | |
| Manufacturer Ippon | ||
| Model | Ah batteries | Prices, rub |
| Back Office 400 | 4,5 | 1500 |
| Back Office 600 | 7 | 1600 |
| Back Office 1000 | 7.2x2 | 3000 |
| Back Verso New 400 | 4,5 | 1500 |
| Back Verso New 600 | 5 | 1500 |
| Back Verso New 800 | 7 | 1600 |
| Back Verso 400 | 4,5 | 1500 |
| Back Verso 600 | 7 | 1600 |
| Back Verso 800 | 9 | 2200 |
| Back Comfo Pro 400 | 4,5 | 1500 |
| Back Comfo Pro 600 | 7 | 1600 |
| Back Comfo Pro 800 | 9 | 2200 |
| Back Power Pro LCD Euro 600 | 7,2 | 1600 |
| Back Power Pro LCD Euro 800 | 9 | 2200 |
| Back Basic 650 | 7 | 1600 |
| Back Power Pro LCD 400 | 7 | 1600 |
| Back Power Pro LCD 500 | 7 | 1600 |
| Back Power Pro LCD 600 | 7 | 1600 |
| Back Power Pro LCD 800 | 9 | 2200 |
| Back Power Pro 400 | 7,2 | 1600 |
| Back Power Pro 500 | 7,2 | 1600 |
| Back Power Pro 600 | 7,2 | 1600 |
| Back Power Pro 700 | 7,2 | 1600 |
| Back Power Pro 800 | 9 | 2200 |
| Smart Power Pro 1000 | 7x2 | 3000 |
| Smart Power Pro 1400 | 9x2 | 4200 |
| Smart Power Pro 2000 | 9x2 | 4200 |
| Smart Winner 1000 | 9x2 | 4200 |
| Smart Winner 1500 | 9x2 | 4200 |
| Smart Winner 2000 | 7x6 | 7800 |
| Smart Winner 2000E | 9x4 | 7600 |
| Smart Winner 3000 | 9x6 | 10800 |
| Smart Winner 1500(2006) | 7.2h2 | 3000 |
| Smart Winner 2000(2006) | 9h2 | 4200 |
| Smart Winner 3000(2006) | 5x8 | 11200 |
| Innova RT 1K | 7x3 | 4500 |
| Innova RT 1.5K | 7x4 | 5800 |
| Innova RT 2K | 9x4 | 7600 |
| Innova RT 3K | 9x6 | 10800 |
| Innova RT 6K | 5x15 | 21000 |
| Innova RT 10K | 9x20 | 36000 |
This is not an official offer.
Diagnostics are free. If you refuse repairs, you will also not be charged for disassembling and reassembling the equipment.
Repair features
The UPS is an important unit that should be trusted only to qualified technicians in case of failure. The consequences of unqualified intervention in the UPS device are unpredictable, since independent repairs can cause:
- additional breakdowns that will increase repair costs;
- complete failure of the UPS without the possibility of recovery;
- unstable operation and failures of the UPS;
- UPS fire.
Self-repair is only possible if the battery is faulty; replacing it is not difficult. Attempts to eliminate other UPS faults, for example the board, can result in the most dangerous consequences.
Modern uninterruptible power supplies are technologically complex and require a professional approach to repair. You can find out the cause of a UPS malfunction using special diagnostic equipment, which is available from a certified electronics repair technician.
In some cases, an uninterruptible power supply cannot be restored - for example, if its housing is damaged by fire or a fall, or water gets inside. Only a technician can reliably judge the repairability of your UPS, as well as the possible cause of the breakdown.
You can order diagnostics and repair of uninterruptible power supplies - APC Back-UPS 500, APC Back-Up ES 700, APC Smart-UPS 1500, etc. - from the Inzhenerik company. We have the necessary equipment and many years of experience at our disposal.
Repair of any complexity
The professionalism of our employees, modern equipment, availability of spare parts and extensive experience allow us to repair the most complex devices: LCD TVs, all types of industrial equipment and microelectronics.
Availability of certified equipment
Thanks to this, even complex soldering of BGA chips using a thermal profile is possible. Soldering chips is necessary when repairing almost any electronics - from recorders to complex electronic control units of industrial equipment.
Time saving
Although the laptop repair service in Moscow is very common, sometimes it is unavailable due to the lack of any spare parts, and the order and delivery last for an indefinite period. We guarantee that our process will go faster. This is guaranteed by reliable suppliers and the availability of scarce spare parts. You don't have to wait weeks for their arrival, as was the case in the past.
Saving
Repair is always cheaper than a new purchase. Even if your TV, a very expensive and ultra-modern one, is broken, it can be repaired for a small amount. Why “give up” good technology because of a minor breakdown? Bring it to us, find out the cause of the breakdown and the time frame for its elimination. Repairs will be performed at reasonable prices. In this case, no advance payment is required - you pay for the WORK DONE.
Guarantee
You will receive WARRANTY DOCUMENTS that provide free repairs in case of repeated breakdown.
Surprising is the complete lack of information about such common devices as uninterruptible power supplies. We break through the information blockade and start publishing materials on their construction and repair. From the article you will get a general idea of the existing types of uninterruptible power supplies and a more detailed, at the circuit diagram level, about the most common Smart-UPS models.
The reliability of computers is largely determined by the quality of the electrical network. The consequences of power outages such as surges, rises, dips and loss of voltage can include keyboard locking, data loss, damage to the system board, etc. To protect expensive computers from troubles associated with the power network, uninterruptible power supplies (UPS) are used. A UPS allows you to get rid of problems associated with poor quality power supply or its temporary absence, but is not a long-term alternative source of power supply, like a generator.
According to the SK PRESS expert and analytical center, in 2000 the sales volume of UPS on the Russian market amounted to 582 thousand units. If we compare these estimates with data on computer sales (1.78 million units), it turns out that in 2000, every third computer purchased was equipped with an individual UPS.
The vast majority of the Russian UPS market is occupied by products from six companies: APC, Chloride, Invensys, IMV, Liebert, Powercom. APC products have been maintaining a leading position in the Russian UPS market for many years now.
UPSs are divided into three main classes: Off-line (or stand-by), Line-interactive and On-line. These devices have different designs and characteristics.
Rice. 1. Block diagram of an Off-line class UPS
The block diagram of an Off-line class UPS is shown in Fig. 1. During normal operation, the load is supplied with filtered mains voltage. To suppress electromagnetic and radio frequency interference in input circuits, EMI/RFI Noise filters are used on metal-oxide varistors. If the input voltage becomes lower or higher than the set value or disappears altogether, the inverter is turned on, which is normally in the off state. By converting the DC voltage of the batteries into alternating voltage, the inverter powers the load from the batteries. The shape of its output voltage is rectangular pulses of positive and negative polarity with an amplitude of 300 V and a frequency of 50 Hz. Off-line class UPSs operate uneconomically in electrical networks with frequent and significant voltage deviations from the rated value, since frequent switching to battery operation reduces the battery life. The power of the Back-UPS model Off-line class UPS produced by APC is in the range of 250...1250 VA, and the Back-UPS Pro model is in the range of 2S0...1400 VA.
Rice. 2. Block diagram of Line-interactive class UPS
The block diagram of a Line-interactive class UPS is shown in Fig. 2. Just like Off-line UPSs, they retransmit alternating mains voltage to the load, while absorbing relatively small voltage surges and smoothing out interference. The input circuits use Metal Oxide Varistor EMI/RFI Noise Filter to suppress EMI and RFI. If an accident occurs in the power grid, the UPS synchronously, without loss of the oscillation phase, turns on the inverter to power the load from the batteries, while the sinusoidal shape of the output voltage is achieved by filtering the PWM oscillation. The circuit uses a special inverter to recharge the battery, which also works during power surges. The range of operation without connecting a battery is expanded due to the use of an autotransformer with a switchable winding in the input circuits of the UPS. The switch to battery power occurs when the mains voltage goes out of range. The power of Line-interactive UPS class Smart-UPS manufactured by APC is 250...5000 VA.
Rice. 3. Block diagram of an On-line class UPS
The block diagram of an On-line class UPS is shown in Fig. 3. These UPSs convert AC input voltage to DC, which is then converted back into AC with stable parameters using a PWM inverter. Since the load is always supplied by the inverter, there is no need to switch from the external network to the inverter, and the switching time is zero. Due to the inertial DC link, which is the battery, the load is isolated from network anomalies and a very stable output voltage is generated. Even with large deviations in input voltage, the UPS continues to supply the load with pure sinusoidal voltage with a deviation of no more than +5% from the user-set nominal value. APC On-line class UPSs have the following output powers: Matrix UPS models - 3000 and 5000 VA, Symmetra Power Array models - 8000, 12000 and 16000 VA.
Back-UPS models do not use a microprocessor, but Back-UPS Pro, Smart-UPS, Smart/VS, Matrix and Symmetna models do use a microprocessor.
The most widely used devices are: Back-UPS, Back-UPS pro, Smart-UPS, Smart-UPS/VS.
Devices such as Matrix and Symmetna are used primarily for banking systems.
In this article, we will look at the design and circuit of Smart-UPS 450VA...700VA models used to power personal computers (PCs) and servers. Their technical characteristics are given in table. 1.
Table 1. Technical characteristics of Smart-UPS models from APC
| Model | 450VA | 620VA | 700VA | 1400VA |
|---|---|---|---|---|
| Allowable input voltage, V | 0...320 | |||
| Input voltage when operating from the network *, V | 165...283 | |||
| Output voltage *, V | 208...253 | |||
| Input circuit overload protection | Resettable circuit breaker | |||
| Frequency range when operating from mains, Hz | 47...63 | |||
| Switching time to battery power, ms | 4 | |||
| Maximum load power, VA (W) | 450(280) | 620(390) | 700(450) | 1400(950) |
| Output voltage when operating on battery, V | 230 | |||
| Frequency when operating on battery power, Hz | 50 ± 0.1 | |||
| Waveform when running on battery | Sine wave | |||
| Output circuit overload protection | Overload and short circuit protection, latching switch off when overloaded | |||
| Battery Type | Lead sealed, maintenance free | |||
| Number of batteries x voltage, V, | 2 x 12 | 2 x 6 | 2 x 12 | 2 x 12 |
| Battery capacity, Ah | 4,5 | 10 | 7 | 17 |
| Battery life, years | 3...5 | |||
| Full charge time, h | 2...5 | |||
| UPS dimensions (height x width x length), cm | 16.8x11.9x36.8 | 15.8x13.7x35.8 | 21.6x17x43.9 | |
| Net weight (gross), kg | 7,30(9,12) | 10,53(12,34) | 13,1(14,5) | 24,1(26,1) |
* User adjustable via PowerChute software.
UPS Smart-UPS 450VA...700VA and Smart-UPS 1000VA...1400VA have the same electrical circuit and differ in battery capacity, number of output transistors in the inverter, power transformer power and dimensions.
Let's consider the parameters characterizing the quality of electricity, as well as terminology and designations.
Power problems can be expressed as:
In Russia, dips, dropouts and voltage surges, both up and down, account for approximately 95% of deviations from the norm, the rest is noise, impulse noise (needles), and high-frequency surges.
The units used to measure power are Volt-Amps (VA, VA) and Watts (W, W). They differ in power factor PF (Power Factor):
The power factor for computer equipment is 0.6...0.7. The number in the designation of APC UPS models means the maximum power in VA. For example, the Smart-UPS 600VA model has a power of 400 W, and the 900VA model has a power of 630 W.
The block diagram of the Smart-UPS and Smart-UPS/VS models is shown in Fig. 4. The mains voltage is supplied to the EM/RFI input filter, which serves to suppress interference from the mains. At the rated mains voltage, relays RY5, RY4, RY3 (pins 1, 3), RY2 (pins 1, 3), RY1 are turned on, and the input voltage passes to the load. Relays RY3 and RY2 are used for the BOOST/TRIM output voltage adjustment mode. For example, if the network voltage has increased and gone beyond the permissible limit, relays RY3 and RY2 connect the additional winding W1 in series with the main winding W2. An autotransformer is formed with a transformation ratio
K = W2/(W2 + W1)
less than one, and the output voltage drops. In the event of a decrease in the mains voltage, the additional winding W1 is reversed by the relay contacts RY3 and RY2. Transformation ratio
K = W2/(W2 - W1)
becomes greater than unity, and the output voltage increases. The adjustment range is ±12%, the hysteresis value is selected by the Power Chute program.
When the input voltage fails, relays RY2...RY5 are turned off, a powerful PWM inverter powered by the battery is turned on, and a sinusoidal voltage of 230 V, 50 Hz is supplied to the load.
The multi-link power supply noise suppression filter consists of varistors MV1, MV3, MV4, inductor L1, capacitors C14...C16 (Fig. 5). Transformer CT1 analyzes high-frequency components of the network voltage. Transformer CT2 is a load current sensor. Signals from these sensors, as well as the temperature sensor RTH1, are sent to the analog-to-digital converter IC10 (ADC0838) (Fig. 6).
Transformer T1 is an input voltage sensor. The command to turn on the device (AC-OK) is sent from the two-level comparator IC7 to the base Q6. Transformer T2 - output voltage sensor for Smart TRIM/BOOST mode. From pins 23 and 24 of processor IC1 2 (Fig. 6), the BOOST and TRIM signals are supplied to the bases of transistors Q43 and Q49 to switch relays RY3 and RY2, respectively.
The phase synchronization signal (PHAS-REF) from pin 5 of transformer T1 goes to the base of transistor Q41 and from its collector to pin 14 of the IC12 processor (Fig. 6).
The Smart-UPS model uses an IC12 microprocessor (S87C654) that:
The EEPROM IC13 memory chip stores factory settings, as well as calibrated settings for frequency signal levels, output voltage, transition limits, and battery charging voltage.
Digital-to-analog converter IC15 (DAC-08CN) generates a reference sinusoidal signal at pin 2, which is used as a reference for IC17 (APC2010).
The PWM signal is generated by IC14 (APC2020) together with IC17. Power field-effect transistors Q9...Q14, Q19...Q24 form a bridge inverter. During the positive half-wave of the PWM signal, Q12...Q14 and Q22...Q24 are open, and Q19...Q21 and Q9...Q11 are closed. During the negative half-wave, Q19...Q21 and Q9...Q11 are open, and Q12...Q14 and Q22...Q24 are closed. Transistors Q27...Q30, Q32, Q33, Q35, Q36 form push-pull drivers that generate control signals for powerful field-effect transistors with a large input capacitance. The load of the inverter is the transformer winding, it is connected by wires W5 (yellow) and W6 (black). A sinusoidal voltage of 230 V, 50 Hz is generated on the secondary winding of the transformer to power the connected equipment.
Operation of the inverter in “reverse” mode is used to charge the battery with pulsating current during normal operation of the UPS.
The UPS has a built-in SNMP slot, which allows you to connect additional cards to expand the capabilities of the UPS:
The UPS has several voltages necessary for normal operation of the device: 24 V, 12 V, 5 V and -8 V. To check them, you can use the table. 2. Measure the resistance from the terminals of the microcircuits to the common wire with the UPS turned off and capacitor C22 discharged. Typical faults of Smart-Ups 450VA...700VA UPS and methods for eliminating them are given in table. 3.
Table 3. Typical faults of Smart-Ups 450VA...700VA UPS
| Brief description of the defect | Possible reason | Troubleshooting method |
|---|---|---|
| UPS does not turn on | Batteries not connected | Connect batteries |
| Bad or faulty battery, its capacity is low | Replace the battery. The capacity of a charged battery can be checked using a high beam lamp from a car (12 V, 150 W) | |
| Powerful field-effect transistors of the inverter are broken | In this case, there is no voltage at the terminals of the battery connected to the UPS board. Check with an ohmmeter and replace the transistors. Check the resistors in their gate circuits. Replace IC16 | |
| Broken flexible cable connecting the display | This problem may be caused by the flex cable terminals shorting on the UPS chassis. Replace the flexible cable connecting the display to the main board of the UPS. Check the serviceability of fuse F3 and transistor Q5 | |
| The power button is pressed in | Replace button SW2 | |
| The UPS turns on only from the battery | Fuse F3 burned out | Replace F3. Check the serviceability of transistors Q5 and Q6 |
| The UPS does not start. Battery replacement indicator lights up | If the battery is good, the UPS does not execute the program correctly. | Calibrate the battery voltage using a proprietary program from APC |
| The UPS does not connect to the line | The network cable is torn off or the contact is broken | Connect the network cable. Check the serviceability of the automatic plug with an ohmmeter. Check the hot-neutral cord connection |
| Cold soldering of board elements | Check the serviceability and quality of soldering of elements L1, L2 and especially T1 | |
| Varistors are faulty | Check or replace varistors MV1...MV4 | |
| When the UPS is turned on, the load is shed | Voltage sensor T1 is faulty | Replace T1. Check the serviceability of the elements: D18...D20, C63 and C10 |
| Display indicators are flashing | The capacitance of capacitor C17 has decreased | Replace capacitor C17 |
| Possible capacitor leakage | Replace C44 or C52 | |
| Relay contacts or board elements are faulty | Replace relay. Replace IC3 and D20. It is better to replace diode D20 with 1N4937 | |
| UPS overload | The power of the connected equipment exceeds the rated power | Reduce load |
| Transformer T2 is faulty | Replace T2 | |
| Faulty current sensor CT1 | Replace ST1. Resistance greater than 4 ohms indicates a faulty current sensor | |
| Faulty IC15 | Replace IC15. Check voltage -8 V and 5 V. Check and replace if necessary: IC12, IC8, IC17, IC14 and inverter power field-effect transistors. Check the windings of the power transformer | |
| Battery not charging | The UPS program is not working correctly | Calibrate the battery voltage using a proprietary program from APC. Check constants 4, 5, 6, 0. Constant 0 is critical for each UPS model. Check the constant after replacing the battery |
| The battery charging circuit is faulty | Replace IC14. Check the voltage of 8 V on the pin. 9 IC14, if it is missing, then replace C88 or IC17 | |
| Bad battery | Replace battery. Its capacity can be checked with a high beam lamp from a car (12 V, 150 W) | |
| Microprocessor IC12 is faulty | Replace IC12 | |
| When turned on, the UPS does not start, a clicking sound is heard | Faulty reset circuit | Check serviceability and replace faulty elements: IC11, IC15, Q51...Q53, R115, C77 |
| Indicator defect | Indication circuit is faulty | Check and replace faulty Q57...Q60 on the indicator board |
| The UPS does not work in On-line mode | Defect of board elements | Replace Q56. Check the serviceability of the elements: Q55, Q54, IC12. IC13 is faulty or will need to be reprogrammed. The program can be taken from a working UPS |
| When switching to battery operation, the UPS turns off and turns on spontaneously | Broken transistor Q3 | Replace transistor Q3 |
In the second part of the article, the On-line class UPS device will be considered,
OFF-LINE CLASS UPS DEVICE
Off-line UPSs from APC include Back-UPS models. UPSs of this class are low-cost and are designed to protect personal computers, workstations, network equipment, retail and point-of-sale terminals. The power of produced Back-UPS models is from 250 to 1250 VA. Basic technical data of the most common UPS models are presented in table. 3.
Table 3. Basic technical data of Back-UPS class UPS
| Model | BK250I | BK400I | BK600I |
|---|---|---|---|
| Rated input voltage, V | 220...240 | ||
| Rated network frequency, Hz | 50 | ||
| Energy of absorbed emissions, J | 320 | ||
| Peak emission current, A | 6500 | ||
| IEEE 587 Cat. Voltage Surge Values Missed in Normal Mode. A 6kVA, % | <1 | ||
| Switching voltage, V | 166...196 | ||
| Output voltage when operating from batteries, V | 225 ± 5% | ||
| Output frequency when operating from batteries, Hz | 50 ± 3% | ||
| Maximum power, VA (W) | 250(170) | 400(250) | 600(400) |
| Power factor | 0,5. ..1,0 | ||
| Crest factor | <5 | ||
| Nominal switching time, ms | 5 | ||
| Number of batteries x voltage, V | 2x6 | 1x12 | 2x6 |
| Battery capacity, Ah | 4 | 7 | 10 |
| 90% recharge time after discharging to 50%, hour | 6 | 7 | 10 |
| Acoustic noise at a distance of 91 cm from the device, dB | <40 | ||
| UPS operating time at full power, min | >5 | ||
| Maximum dimensions (H x W x D), mm | 168x119x361 | ||
| Weight, kg | 5,4 | 9,5 | 11,3 |
The index “I” (International) in the names of UPS models means that the models are designed for an input voltage of 230 V. The devices are equipped with sealed lead-free maintenance-free batteries with a service life of 3...5 years according to the Euro Bat standard. All models are equipped with limiting filters that suppress surges and high-frequency interference in the mains voltage. The devices emit appropriate sound signals when the input voltage is lost, the batteries are low, or there is an overload. The threshold value of the mains voltage, below which the UPS switches to battery operation, is set by switches on the rear panel of the device. Models BK400I and BK600I have an interface port that connects to a computer or server to automatically shut down the system, a test switch, and a buzzer switch.
The block diagram of the Back-UPS 250I, 400I and 600I is shown in Fig. 8. The mains voltage is supplied to the input multi-stage filter through a circuit breaker. The circuit breaker is designed as a circuit breaker on the rear panel of the UPS. In the event of a significant overload, it disconnects the device from the network, while the contact column of the switch is pushed upward. To turn on the UPS after an overload, it is necessary to return the contact column of the switch to its original position. The input filter-limiter of electromagnetic and radio frequency interference uses LC links and metal oxide varistors. During normal operation, contacts 3 and 5 of relay RY1 are closed, and the UPS transmits mains voltage to the load, filtering high-frequency interference. The charging current flows continuously as long as there is voltage in the network. If the input voltage drops below the set value or disappears altogether, or if it is very noisy, contacts 3 and 4 of the relay close, and the UPS switches to operation from the inverter, which converts the DC voltage of the batteries into AC. The switching time is about 5 ms, which is quite acceptable for modern switching power supplies for computers. The load signal shape is rectangular pulses of positive and negative polarity with a frequency of 50 Hz, a duration of 5 ms, an amplitude of 300 V, an effective voltage of 225 V. At idle, the duration of the pulses is reduced and the effective output voltage drops to 208 V. Unlike Smart models -UPS, Back-UPS does not have a microprocessor; comparators and logic chips are used to control the device.
The schematic diagram of the Back-UPS 250I, 400I and 600I UPS is almost completely shown in Fig. 9...11. The multi-link power supply noise suppression filter consists of varistors MOV2, MOV5, chokes L1 and L2, capacitors C38 and C40 (Fig. 9). Transformer T1 (Fig. 10) is an input voltage sensor. Its output voltage is used to charge batteries (D4...D8, IC1, R9...R11, C3 and VR1 are used in this circuit) and analyze the mains voltage.
If it disappears, then the circuit on elements IC2...IC4 and IC7 connects a powerful inverter powered by a battery. The ACFAIL command to turn on the inverter is generated by IC3 and IC4. A circuit consisting of comparator IC4 (pins 6, 7, 1) and electronic key IC6 (pins 10, 11, 12) allows the inverter to operate with a log signal. "1" arriving at pins 1 and 13 of IC2.
A divider consisting of resistors R55, R122, R1 23 and switch SW1 (pins 2, 7 and 3, 6), located on the rear side of the UPS, determines the mains voltage, below which the UPS switches to battery power. This voltage is factory set to 196 V. In areas where the mains voltage fluctuates frequently, resulting in frequent UPS transfers to battery power, the threshold voltage should be set to a lower level. Fine adjustment of the threshold voltage is performed by resistor VR2.
During battery operation, IC7 generates inverter excitation pulses PUSHPL1 and PUSHPL2. Power field-effect transistors Q4...Q6 and Q36 are installed in one arm of the inverter, and Q1...Q3 and Q37 in the other. The transistors are loaded with their collectors onto the output transformer. A pulse voltage with an effective value of 225 V and a frequency of 50 Hz is generated on the secondary winding of the output transformer, which is used to power the equipment connected to the UPS. The duration of the pulses is regulated by variable resistor VR3, and the frequency by resistor VR4 (Fig. 10). Turning the inverter on and off is synchronized with the mains voltage by a circuit on elements IC3 (pins 3...6), IC6 (pins 3...5, 6, 8, 9) and IC5 (pins 1...3 and 11... 13). Circuit based on elements SW1 (pins 1 and 8), IC5 (pins 4...V and 8...10), IC2 (pins 8...10), IC3 (pins 1 and 2), IC10 (pins 12 and 13), D30, D31, D18, Q9, BZ1 (Fig. 11) turns on an audible signal to warn the user of power problems. During battery operation, the UPS emits a single beep every 5 seconds to indicate the need to save user files because Battery capacity is limited. When operating on battery power, the UPS monitors its capacity and emits a continuous beep for a certain time before it is discharged. If pins 4 and 5 of switch SW1 are open, then this time is 2 minutes, if closed - 5 minutes. To turn off the sound signal, you need to close pins 1 and 8 of switch SW1.
All Back-UPS models, with the exception of the BK250I, have a bidirectional communication port for communication with a PC. Power Chute Plus software allows the computer to both monitor the UPS and securely automatically shut down the operating system (Novell, Netware, Windows NT, IBM OS/2, Lan Server, Scounix and UnixWare, Windows 95/98), preserving user files. In Fig. 11 this port is designated J14. Purpose of its pins: 1 - UPS SHUTDOWN. The UPS turns off if a log appears on this pin. "1" for 0.5 s.
2 - AC FAIL. When switching to battery power, the UPS generates a log on this pin. "1".
3 - CC AC FAIL. When switching to battery power, the UPS generates a log at this pin. "0". Open collector output.
4, 9 - DB-9 GROUND. Common wire for input/output signals. The output has a resistance of 20 Ohms relative to the common wire of the UPS.
5 - CC LOW BATTERY. In the event of a low battery, the UPS generates a log at this output. "0". Open collector output.
6 - OS AC FAIL When switching to battery power, the UPS generates a log on this pin. "1". Open collector output.
7, 8 - not connected.
Open collector outputs can be connected to TTL circuits. Their load capacity is up to 50 mA, 40 V. If you need to connect a relay to them, then the winding should be bypassed with a diode.
A regular “null modem” cable is not suitable for communication with this port; a corresponding RS-232 interface cable with a 9-pin connector is supplied with the software.
UPS CALIBRATION AND REPAIR
Setting the output voltage frequency
To set the frequency of the output voltage, connect an oscilloscope or frequency meter to the UPS output. Switch the UPS to battery mode. When measuring the frequency at the UPS output, adjust resistor VR4 to 50 ± 0.6 Hz.
Setting the output voltage value
Switch the UPS into battery mode without load. Connect a voltmeter to the UPS output to measure the effective voltage value. By adjusting resistor VR3, set the voltage at the UPS output to 208 ± 2 V.
Setting the threshold voltage
Set switches 2 and 3 located on the rear side of the UPS to the OFF position. Connect the UPS to a transformer type LATR with continuously adjustable output voltage. Set the voltage at the LATR output to 196 V. Turn resistor VR2 counterclockwise until it stops, then slowly turn resistor VR2 clockwise until the UPS switches to battery power.
Setting the charge voltage
Set the voltage at the UPS input to 230 V. Disconnect the red wire going to the positive terminal of the battery. Using a digital voltmeter, adjust the resistor VR1 to set the voltage on this wire to 13.76 ± 0.2 V relative to the common point of the circuit, then restore the connection to the battery.
Typical faults
Typical faults and methods for eliminating them are given in table. 4, and in table. 5 - analogues of the most frequently failing components.
Table 4. Typical Back-UPS 250I, 400I and 600I faults
| Defect manifestation | Possible reason | Method for finding and eliminating a defect |
|---|---|---|
| Smell of smoke, UPS does not work | Input filter faulty | Check the serviceability of components MOV2, MOV5, L1, L2, C38, C40, as well as the board conductors connecting them |
| The UPS does not turn on. The indicator does not light up | Input circuit breaker (circuit breaker) of the UPS is disabled | Reduce the load on the UPS by turning off part of the equipment, and then turn on the circuit breaker by pressing the circuit breaker contact column |
| Batteries are faulty | Replace batteries | |
| Batteries are not connected correctly | Check that the batteries are connected correctly | |
| Inverter faulty | Check the serviceability of the inverter. To do this, disconnect the UPS from the AC mains, disconnect the batteries and discharge capacitance C3 with a 100 Ohm resistor, test the drain-source channels of powerful field-effect transistors Q1...Q6, Q37, Q36 with an ohmmeter. If the resistance is several ohms or less, then replace the transistors. Check the resistors in the gates R1...R3, R6...R8, R147, R148. Check the serviceability of transistors Q30, Q31 and diodes D36...D38 and D41. Check fuses F1 and F2 | |
| Replace IC2 | ||
| When turned on, the UPS switches off the load | Transformer T1 is faulty | Check the serviceability of the windings of transformer T1. Check the tracks on the board connecting the T1 windings. Check fuse F3 |
| The UPS operates on batteries despite the fact that there is mains voltage | The power supply voltage is very low or distorted | Check the input voltage using an indicator or meter. If this is acceptable for the load, reduce the sensitivity of the UPS, i.e. change the response limit using switches located on the rear wall of the device |
| The UPS turns on, but no voltage is supplied to the load | Relay RY1 is faulty | Check the serviceability of relay RY1 and transistor Q10 (BUZ71). Check the serviceability of IC4 and IC3 and the supply voltage at their terminals |
| Check the tracks on the board connecting the relay contacts | ||
| The UPS hums and/or shuts down the load without providing the expected backup time | The inverter or one of its elements is faulty | See sub-item “Inverter faulty” |
| UPS does not provide expected power backup time | Batteries are discharged or have lost capacity | Charge the batteries. They require recharging after prolonged power outages. In addition, batteries age quickly when used frequently or in high temperature environments. If the batteries are approaching the end of their service life, it is advisable to replace them, even if the battery replacement alarm has not yet sounded. Check the capacity of the charged battery with a 12 V, 150 W car high beam lamp |
| UPS is overloaded | Reduce the number of consumers at the UPS output | |
| UPS does not turn on after replacing batteries | Incorrect connection of batteries when replacing them | Check that the batteries are connected correctly |
| When turned on, the UPS emits a loud tone, sometimes with a decreasing tone | Defective or severely discharged batteries | Charge the batteries for at least four hours. If the problem persists after recharging, the batteries should be replaced. |
| Batteries are not charging | Diode D8 is faulty | Check the serviceability of D8. Its reverse current should not exceed 10 μA |
| Charge voltage below required level | Calibrate battery charge voltage |
Table 5. Analogues for replacing faulty components
| Circuit designation | Faulty component | Possible replacement |
|---|---|---|
| IC1 | LM317T | LM117H, LM117K |
| IC2 | CD4001 | K561LE5 |
| IC3, IC10 | 74С14 | It is made up of two K561TL1 microcircuits, the conclusions of which are connected according to the pinout on the microcircuit |
| IC4 | LM339 | K1401SA1 |
| IC5 | CD4011 | K561LA7 |
| IC6 | CD4066 | K561KT3 |
| D4...D8, D47, D25...D28 | 1N4005 | 1N4006, 1N4007, BY126, BY127, BY133, BY134, 1N5618... 1N5622, 1N4937 |
| Q10 | BUZ71 | BUZ10, 2SK673, 2SK971, BUK442...BUK450, BUK543...BUK550 |
| Q22 | IRF743 | IRF742, MTP10N35, MTP10N40, 2SK554, 2SK555 |
| Q8, Q21, Q35, Q31, Q12, Q9, Q27, Q28, Q32, Q33 | PN2222 | 2N2222, BS540, BS541, BSW61...BSW 64, 2N4014 |
| Q11, Q29, Q25, Q26, Q24 | PN2907 | 2N2907, 2N4026...2N4029 |
| Q1...Q6, Q36, Q37 | IRFZ42 | BUZ11, BUZ12, PRFZ42 |
Gennady Yablonin
"Electronic equipment repair"
The company "Elemont+" carries out repair of uninterruptible power sources power supply (UPS repair) UPS in Moscow and the nearest cities of the Moscow region - Mytishchi, Korolev, Pushkino, Dolgoprudny. We work with both individuals and legal entities. It is possible to conclude a service agreement and repair, How uninterruptible power supplies, and office equipment in general. Payment can be made by bank transfer.
Repair of uninterruptible power supplies (UPS) at Elemont+
Working for a long time at a computer, developing a new program or simply typing text, a person does not always think about the fact that due to problems with the power supply, his many hours of work can go down the drain. A small voltage drop or sudden power outage will not allow time for the results to be saved. For these purposes, uninterruptible power supplies (UPS) are used, which are capable of maintaining the computer for some time without electricity. This time is enough to save the necessary files to your computer’s hard drive or removable drive and shut down the operating system correctly.
Repair of uninterruptible power supplies (UPS repair). General price list
| No. p / p |
Equipment type |
Diagnostics and repair, rub. |
| 1 | Uninterruptible power supplies UPS up to 6 kVA | from 800 |
| 2 | Uninterruptible power supplies UPS from 6 kVa to 15 kVa | from 4400 |
| 3 | Uninterruptible power supplies UPS from 20 kVa to 40 kVa | from 5800 |
| 4 | Uninterruptible power supplies UPS from 120 kVa and above | from 6900 |
| 5 | Replacing UPS batteries | from 300 |
| 6 | Mains voltage stabilizer (depending on power) | from 800 |
Our company also carries out routine maintenance work on uninterruptible power supplies and voltage stabilizers. To estimate the cost of services, send your proposal by email This email address is being protected from spambots. You must have JavaScript enabled to view it.
Typical UPS faults
The main problem with almost all budget models of uninterruptible power supplies is the battery. The lion's share of low-price UPS comes without a voltage stabilization unit. In such models, protection against small voltage surges is provided by short-term switching to battery operation.
If the phenomenon of voltage drops is quite frequent in your network, then replacement battery like this UPS will be needed very soon. However, if such problems are not observed, then it is not advisable to spend money on purchasing a more expensive UPS.
An uninterruptible power supply is a rather complex device, which can be roughly divided into two blocks - a 12V to 220V mains converter, and a charger that performs the opposite function: 220V to 12V to recharge the battery. In most cases, repairing an uninterruptible power supply is very problematic and expensive. But it’s still worth a try - of course, there’s always a chance for a freebie in the form of a blown fuse :)
A friend of mine at the company threw away a non-working UPS model APC 500. But before using it for spare parts, I decided to try to revive it. And as it turned out, it was not in vain. First of all, we measure the voltage on the rechargeable gel battery. For the uninterruptible power supply to function, it must be within 10-14V. The voltage is normal, so there is no problem with the battery.
Now let's inspect the board itself and measure the power at key points in the circuit. I couldn’t find a native circuit diagram for the APC500 uninterruptible power supply, but here’s something similar. For better clarity, download the full version here. We check the powerful left-field transistors - the norm. Power to the electronic control part of the uninterruptible power supply comes from a small 15V mains transformer. We measure this voltage before the diode bridge, after, and after the 9V stabilizer.
And here is the first swallow. The 16V voltage after the filter enters the stabilizer chip, and the output is only a couple of volts. We replace it with a model of similar voltage and restore power to the control unit circuit.
The uninterruptible power supply began to crackle and buzz, but the 220V output was still not visible. We continue to carefully inspect the printed circuit board.
Another problem - one of the thin tracks burned out and had to be replaced with a thin wire. Now the APC500 uninterruptible power supply device is working without problems.
Testing it in real conditions, I came to the conclusion that the built-in buzzer signaling the absence of a network is screaming like crazy, and it wouldn’t hurt to calm it down a little. You can’t turn it off completely - since you won’t be able to hear the state of the battery in emergency mode (determined by the frequency of the signals), but you can and should make it quieter.
This is achieved by connecting a 500-800 Ohm resistor in series with the sound emitter. And finally, some advice to owners of uninterruptible power supply systems. If it sometimes turns off the load, there may be a problem with “dried up” capacitors. Connect the UPS to the input of a known good computer and see if the alarms stop.
The uninterruptible power supply sometimes incorrectly determines the capacity of lead batteries showing the status OK, but as soon as it switches to them, they suddenly run out and the load is “knocked out”. Make sure the terminals fit snugly and are not loose. Do not disconnect it from the network for a long time, making it impossible to keep the batteries constantly charged. Avoid deep discharges of batteries, leaving at least 10% capacity, after which you should turn off the uninterruptible power supply until the supply voltage is restored. At least once every three months, do a “training session”, discharging the battery to 10% and again charging the battery to full capacity.
Discuss the article REPAIR OF A UPS
The Service-Inverter company repairs uninterruptible power supplies in Moscow. Our service center works with all models and uses the recommendations and instructions of the manufacturers in its work.
For most brands represented on the Russian market, the company is an authorized service center. Therefore, the level of our services is higher than in many workshops.
- Firstly, we use original components and spare parts recommended by manufacturers.
- Secondly, equipment whose warranty has not expired is repaired free of charge, provided that the breakdown was not caused by the user’s fault.
- And thirdly, we always provide prompt service because spare parts are delivered without delay.
Prices for professional UPS repair in Moscow
"Service-Inverter" means high quality work, quick solutions to even complex problems, qualified craftsmen and regular training. Our service policy 
center is aimed at continuous improvement of skills and knowledge.
The status of an authorized center allows our specialists to participate in seminars and courses of manufacturers, organized specifically to introduce specialists to new technologies of the equipment itself and its repair, and thereby improve the quality of service.
That is why repairs of APC uninterruptible power supplies are most often ordered from our service center. Our craftsmen regularly train, confirm their qualifications and receive manufacturer certificates. In addition to this brand, we work with companies such as Powercom and Ippon.
Consistently high quality of work is not the only advantage of our service. We also offer our clients favorable terms of cooperation:
- Free delivery of equipment to our service. If you do not have the opportunity to bring the installation, call us and tell us the address - we will send a car.
- Free diagnostics. Within two to three hours after delivery of the equipment, the technician conducts a comprehensive examination of it. After the diagnosis, we will definitely call you and inform you of the results.
To order our services, send a request from the website or call us. Be sure to indicate the presence of a manufacturer’s warranty, because under warranty, repairs of uninterruptible power supplies from APC and other brands are free.
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