Design and repair of uninterruptible power supplies by ars. Design and repair of ars uninterruptible power supplies Download apc rs 500 power supply diagram

APC-500 uninterruptible repair:

The first sign of a malfunction is the darkening of the upper part of the case due to overheating of the elements. The UPS does not charge the battery to the nominal level, the charge voltage is often not higher than 5 - 8 volts. In this case, the battery fails, and the UPS simply does not turn on.

Such a malfunction often leads an inexperienced repairman to a common mistake. The master changes the battery, uninterruptable power source turns on and seems to work fine.

But this continues until the battery is completely discharged, which then has to be replaced with a new one due to a noticeable loss of capacity. Therefore, it is important to check the charge voltage value when replacing the battery. When measuring, the source must be connected to the network, and one of the battery contacts must be disconnected.

Source does not turn on or low battery indicator is on

APC Back UPS RS 500 is a Stand-by type source, the battery is charged from a converter assembled on a UC3843 PWM controller chip.

The circuit starts when the voltage across capacitor C7 reaches 7.8-9.0 volts. This voltage is obtained at the divider R28, R139. After starting, the PWM controller is powered by a transformer through the circuit diode D7, R50. Due to the leakage of this very capacitor C7 (22uF x 16v), the resistor R28 starts to heat up, the output voltage of the source decreases, as well as the battery charge.

It is better to install a capacitor with a higher operating voltage and an operating temperature of 105 degrees. If, after replacing C7, the resistor R28 does not stop heating, you need to check the capacitor C43 or replace the PWM controller chip.

Overcharge voltage, noise during operation

Another malfunction UPS, this is an overestimated charge voltage up to 18 volts. The cause of the defect must be sought in the output voltage stabilization circuit (highlighted in the diagram above). The U2 optocoupler or the IC6 stabilizer chip most often fails.

If U3 is faulty, the converter will not turn off, and the output voltage will rise to 18 - 22 volts. Also, with an overestimated output voltage, you need to check the health of Q34, C61, C41.

If one of the elements listed above is faulty, after the battery is fully charged, the uninterruptible power supply starts to make quite a loud noise. UPSs of earlier releases are still noisy due to the capacitor C22 with a nominal value of 0.1uF x 400v, later it was replaced with 10uF x 400v (see photo above).

Burnt Resistors

In almost every source, you can find burnt 10 ohm resistors. These are R150 and R151. They are connected in RC circuits for extinguishing sparks at relay contacts RY3.

The burned-out resistors do not have any noticeable effect on the operation of the UPS, but so that the relay does not need to be replaced later, the elements must be replaced.

APC-500 UPS battery replacement:

This model of uninterruptible power supply is also a frequent guest on the desktops of service engineers. The APC RS 500 usually works well for two years, after which a defect appears in almost every source. The first sign of a malfunction is the darkening of the upper part of the case due to overheating of the elements. The UPS does not charge the battery to the nominal level, the charge voltage is often not higher than 5 - 8 volts. In this case, the battery fails, and the UPS simply does not turn on.

Such a malfunction often leads an inexperienced repairman to a common mistake. The master changes the battery, uninterruptable power source turns on and seems to work fine. But this continues until the battery is completely discharged, which then has to be replaced with a new one due to a noticeable loss of capacity. Therefore, it is important to check the charge voltage value when replacing the battery. When measuring, the source must be connected to the network, and one of the battery contacts must be disconnected.

Source does not turn on or low battery indicator is on

APC Back UPS RS 500 is a Stand-by type source, the battery is charged from a converter assembled on a UC3843 PWM controller chip.

Overcharge voltage, noise during operation

Also, the stabilization circuit is disabled if the signal CHARGER_EN has a potential greater than 0.8 volts. In this case, the optocoupler U3 should turn on and shunt the capacitor C44, which stops the generator of the PWM chip and turns off the converter. If U3 is faulty, the converter will not turn off, and the output voltage will rise to 18 - 22 volts. Also, with an overestimated output voltage, you need to check the health of Q34, C61, C41.

Burnt Resistors

In almost every source, you can find burnt 10 ohm resistors. These are R150 and R151. They are connected in RC circuits for extinguishing sparks at relay contacts RY3.

The burned-out resistors do not have any noticeable effect on the operation of the UPS, but so that the relay does not need to be replaced later, the elements must be replaced.

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My UPS has failed.
My UPS is APC Back-UPS CS 500, this also applies to slightly younger and older models that have successfully served their life of 3-4 years (they no longer live - it's all about the battery).

As a right citizen, I decided to replace the used battery with an original one recommended by the manufacturer. This model retails from 1500 to 1800 rubles, while I managed to find a new Back-UPS CS 500 for 2000 rubles. It makes no sense to buy a battery separately.

The store advised me to buy an analogue of this battery for 450 rubles, and after searching for a similar problem on the forums, it turned out that it was enough to peel off the sticker from the old battery and see its full characteristics and buy the right one.

We tear off the sticker and find there CSB 12v 7Ah

(The photo is not mine, but I had exactly the same battery)

In most stores, there is exactly the same “battery” available at a price of 600-900 rubles (depending on the greed of the seller), I also found it for 550 rubles. But I don't need it.

That's why:
There are 12v 9Ah batteries, which in most cases are identical in size to the "original" one that was in UPS.

Battery manufacturers should be divided by price / quality ratio:

Yuasa - seems to be the best manufacturers (did not check, but this statement can be found on the forums from many users)

CSB - manufacturer of quite good batteries, it is APC that resells it under its own brand

Delta -good batteries at a reasonable price.(One of my friends checked it - the battery worked for 5 years). I advise you to focus on him, because. The price corresponds to the quality by 100%.

So I did, I bought a Delta HR 12-34W 12v 9Ah for 630 rubles.

Also suitable: Yuasa NPW45-12 12V/9AH and CSB 12V/9Ah HR1234W

A small upgrade will not hurt and for this you will need:

crosshead screwdriver
Soldering iron and related kit
Hot glue gun
Wire 1m (I borrowed them from an old power supply)
Diode 12V
Drill with a drill
Anti-slip stickers for furniture 4 pcs

Small plastic clamps
And most importantly - Switch button

First, glue the rubber pads in the corners, after degreasing the surface.

I was always annoyed by the sound emitted by UPS, but it was not possible to turn it off or turn it down, so it was not uncommon to wake up in the middle of the night from his screams. It remains to correct this omission of the manufacturer:

Opening the case:

Unscrew the two screws, then lift the cover up, we put it on its side, and raise part of the case, so the board with all the giblets should remain in the lower part, and disconnect the top part along with the red and black cables. We take it aside.

We find the speaker and carefully remove it with a soldering iron and put a couple of pins in its place, for example, from one of the connectors of the old motherboard

We mark the back panel of the UPS with a marker for the appropriate size of the future switch and make a neat hole

We drill a hole suitable for the size of the diode in the protrusion of the front panel

We connect all parts of the circuit (switch, diode and speaker) with a wire according to a primitive scheme, assemble the wires with clamps and place all parts in free places in the case, fixing them with hot glue.

We assemble the body in the reverse order.

Outcome:
* Significantly reduced vibration
* The sound can now not only be completely turned off, but also replaced with a light indication
* Increased UPS capacity by 30%
* Significantly saved money, so that the toad has had enough and is no longer accepted to choke at the thought of buying a new UPS.

I tested the operation of a new battery, it gets infected and discharged as usual, but it works better than before. Lasted 43* minutes with wifi turned off (* 2009 aimag 24")

I hope my experience will be useful to someone and will save money, time and nature.

An uninterruptible power supply, or as it is commonly called UPS (BACK UPS), is essentially a boost converter and charger in one package. The device is very useful, especially for PC owners. The device can autonomously power the computer if, for some reason, the electricity is suddenly turned off. Unfortunately, the built-in battery does not allow you to power the computer for a long time, since its capacity is limited to 7 amperes (some powerful models have batteries up to 15-20A). Let's move on to the battery itself.

In uninterruptible voltage sources, a closed helium or acid battery is used. The built-in battery is usually designed for a capacity of 7 to 8 Amperes / hour, voltage - 12 volts. The battery is completely sealed, which allows you to use the device in any condition. In addition to the battery, inside you can see a huge transformer, in this case 400-500 watts. The transformer operates in two modes -

1) as a step-up transformer for a voltage converter.

2) as a step-down mains transformer for charging the built-in battery.

During normal operation, the load is powered by filtered mains voltage. Filters are used to suppress electromagnetic and interference in the input circuits. 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 to AC, the inverter powers the load from the batteries. Off-line BACK UPSs do not work economically in power grids with frequent and significant voltage deviations from the nominal value, since frequent switching to battery operation reduces the battery life. The power of Back-UPS manufactured by manufacturers is in the range of 250-1200 VA. uninterrupted voltage BACK UPS is quite complicated. you can download a large collection of circuit diagrams, and below are a few smaller copies - click to enlarge.

Here you can find a special controller that is responsible for the correct operation of the device. The controller activates the relay when there is no mains voltage and if the uninterruptible power supply is on, it will work as a voltage converter. If the mains voltage reappears, the controller turns off the converter and the device turns into a charger. The capacity of the built-in battery can last up to 10 - 30 minutes, if, of course, the device powers the computer. You can read more about the operation and purpose of uninterruptible power supply units in.

BACK UPS can be used as a backup power source, it is generally recommended that every home have an uninterruptible power supply. If an uninterruptible power supply is intended for domestic needs, then it is advisable to unsolder the signaling device from the board, it reminds that the device works as a converter, it makes a squeaking reminder every 5 seconds, and this is annoying. The output of the converter is pure 210-240 volts 50 hertz, but as for the shape of the pulses, there is clearly not a pure sine. BACK UPS can power any household appliances, including active ones, of course, if the power of the device allows it.

990-9231 5/03

Connect to device

Back-UPS equipment

The back panel of the Back-UPS contains
the following elements:

Battery back-up sockets
(qty: 3 pcs.). These outlets provide backup
battery powered, surge protection
and suppression of electromagnetic interference (EMI). At
loss of voltage in the network to these sockets
battery power is automatically supplied. If
back-ups off, supply to these sockets
(from the network and from the battery) is not supplied. Connect to
to these sockets a computer, monitor, external drive, or
CD-ROM drive.

Socket with surge protection only.
This socket is always included(if there is voltage in
network), and its state does not depend on the switch On/
Off In the event of a power failure in the power supply network,
this outlet is not supplied. Connect to this outlet
printer, fax or scanner.

Turn on the Back-UPS

Note: Before use, let the device
Back-UPS ability to charge within full
eight o'clock.

Press the button on the front of the Back-UPS.

Note that after you press and release the button,
the following should happen:

Green indicator mains supply starts flashing.

Yellow indicator battery power lights up
for the duration self-tests.

After successful completion self-tests remains
only green indicator on mains supply.

If the internal battery is not connected, the
green indicator mains supply and red indicator
battery replacement. The Back-UPS will also issue
high-pitched beep.

On the front panel of the Back-UPS are
four (light) status indicators (Powered by
Mains, Battery Power, Overload and Replace
battery).

Mains power (green)- lights up in all
cases when exits providing for
battery, voltage is supplied from the network.

Battery powered (yellow) –
lights up in all cases when
equipment connected to the outputs,
providing power supply from
backup battery, voltage is applied
from the Back-UPS battery.

Four beeps every 30
seconds– this alarm is given during
all cases. when the Back-UPS
battery operated. Think not
whether to save the current job.

Continuous buzzer- this
an alarm is given in all cases,
when the battery status approaches
discharged. Remaining time from
battery is very small. Fast
save all current work and exit
all running programs. Turn off
operating system, computer and
back-ups.

Overload (red)- lights up in all
cases where the electricity consumption
exceeds the capacity of the Back-UPS.

Continuous tone constant tone –
this alarm is given in all
cases where exits providing for
possibility of power supply from a backup
battery, overloaded.

Fuse- safety button,
located on the back of the device
Back-UPS, pops up from pressed
position, if the overload causes Back-
UPS disconnect from the network. If the button
jumped out of the pressed position, switch off
equipment, the operation of which is not so
important. Return the fuse to its original
position by pressing the button.

Replace battery (red)–
lights up in all cases when the time expires
battery operation, and if
battery not connected (see above).
A battery whose service life
expires, does not provide sufficient
operating time and needs to be replaced.

High tone for 1 minute
every 5 hours- this alarm
supplied in all cases when the battery is not
passes automatic diagnostic tests.

Placement/Connection

When placing the Back-UPS, avoid:

direct sunlight

Excessively high temperature

Excessively high humidity or contact with any
liquids

Plug the Back-UPS into an outlet as shown
on the picture.

Back-UPS internal battery
charges whenever the device is connected to
socket.

Protect your telephone line

from power surges

Phone ports provide surge protection
voltage caused by lightning strikes for any
devices connected to the telephone line
(computer, modem, fax, telephone). Telephone ports
meet the requirements of HPNA (Union
household telephone lines) and DSL (Digital Subscriber Lines)
lines), and also allow you to use modems with any
data transfer rate. Make the connection
as shown in the picture.

wall socket

Modem/Fax/Telephone

Turn the device on the side wall. Slide
battery compartment cover up and remove it from
UPS devices.

Pull out the battery so that you can access the
its terminals and connecting wires. Disconnect
wires from terminals.

Slide the new battery into the battery compartment.
Connect the wires to the battery terminals as
indicated below:
Black wire - to the ground terminal (-).
Red wire - to the positive terminal (+).

Align the battery cover with the grooves
UPS devices. Move the lid down until it
will not click.

Device

Management

user

Installation

Connect the USB cable and
install software
provision
(not required)

To replace the internal battery, follow the procedures below:

Note: Replacing the battery is not dangerous. However, during this process,
slight sparking is observed. This is normal.

Replace internal battery

APC, Back-UPS and PowerChute are registered trademarks of American Power Conversion. All
other trademarks are the property of their respective owners.

Your computer's power cable

instructions

will appear on

NOTE(for computer users
Macintosh): In order to maximize
take advantage of high speed
USB interface, you will need an operating system
Mac OS 10.1.5 and above.

If Autoplay is not enabled on the computer,
perform the following procedures:

On your computer desktop, double-click
mouse over the My Computer icon.

Double click on the driver icon
CD-ROM drive and follow the instructions
which will appear on the monitor.

Status indicators and alarms

Ordering a spare battery

Typical battery life is 3-6 years (depending on the number of discharge cycles and operating
temperatures). A spare battery can be ordered from APC.

Please specify battery cartridge when ordering RBC2.

Voltage and sensitivity adjustment (optional)

In cases where the Back-UPS or equipment connected to it exhibits increased
sensitivity to input voltage level, voltage adjustment may be required. It's simple
a procedure carried out using the button on the front panel. To adjust the voltage, do
following:
1. Plug the Back-UPS into a wall outlet. The Back-UPS will be in standby mode

(indicators are off).

2. Press the button on the front panel all the way and hold it for 10 seconds. All device indicators

The Back-UPS will flash to confirm that it has entered programming mode.

3. The Back-UPS will then display the current sensitivity level setting, according to the following

table.

4. To select a low sensitivity level, press the button until the

yellow indicator.

5. To select an average sensitivity level, press the button until the

yellow and red indicators (second and third from the top).

6. To select a high sensitivity level, press the button until the

yellow and both red indicators (lower three).

7. To exit this mode without changing the sensitivity level, press the button until