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Service Manual for the
American Power Conversion
Smart-UPS 450/ 700/ 1000/ 1400
Uninterruptible Power Supply
Document # 996-0237
AMERICAN POWER CONVERSION
American Power Conversion Corporation - 132 Fairgrounds Road, box 278
West Kingston, R.I. – 02893 – Phone (401) 789 - 5735
Document # 996-0237
American Power Conversion Corporation makes no warranty with regard to the
information in this manual. American Power Conversion Corporation assumes no
responsibility for any errors contained in this document. American Power Conversion
Corporation reserves the right to make changes to this document without notice.
No part of this document may be copied or reproduced in any form without prior written
consent of American Power Conversion Corporation.
Copyright (C) American Power Conversion Corporation 1991. All rights reserved.
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Revision Record
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•
Revision 1.0 Original document 09/07/94.
Revision 2.0 Upgrade manual to include procedure on how to test the float
voltage 03/13/95.
Revision 2.1. Upgrade manual to include a block diagram 02/27/96.
Revision 3.0 Troubleshooting section revised to include component level repair
03/27/00.
Revision 4.0 Original document transcribed to conform to FSE presentation
format. 7-20-00. JGuzman.
iii
Table of Contents
REVISION RECORD...........................................................................III
TABLE OF CONTENTS ......................................................................IV
1.0 INTRODUCTION.........................................................................1
2.0 SAFETY PRECAUTIONS............................................................2
3.0 TOOLS AND EQUIPMENT.........................................................3
4.0 PRINCIPLES OF OPERATION...................................................4
5.0 PROCEDURES FOR THE SMART-UPS 450/700........................7
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
5.23
5.24
5.25
5.26
5.27
5.28
6.0
Cover Removal: Smart-UPS 450 and Smart-UPS 700.------------------------------------------------- 7
Cover Installation: Smart -UPS 450 and Smart-UPS 700.---------------------------------------------- 8
Bezel Removal: Smart -UPS 450 and Smart -UPS 700. ------------------------------------------------- 8
Bezel Installation: Smart-UPS 450 and Smart-UPS 700. ---------------------------------------------- 9
Battery Removal: Smart-UPS 450 and Smart-UPS 700.----------------------------------------------- 9
Battery Installation: Smart-UPS 450 and Smart-UPS 700.-------------------------------------------10
PCB Removal: Smart-UPS 450 and Smart-UPS 700. -------------------------------------------------10
PCB Installation: Smart-UPS 450 and Smart-UPS 700.-----------------------------------------------13
Output Transformer Removal: Smart-UPS 450 and Smart-UPS 700. -----------------------------14
Output Transformer Installation: Smart-UPS 450 and Smart-UPS 700. --------------------------15
Rear Outlet Removal: Smart-UPS 450 and Smart-UPS 700. ----------------------------------------15
Rear Outlet Installation: Smart-UPS 450 and Smart-UPS 700. -------------------------------------17
Circuit Breaker Removal: Smart-UPS 450 and Smart-UPS 700. -----------------------------------17
Circuit Breaker Installation: Smart -UPS 450 and Smart-UPS 700. --------------------------------17
Cover Removal: Smart-UPS 1000 and Smart -UPS 1400. --------------------------------------------18
Cover Installation: Smart -UPS 1000 and Smart-UPS 1400. -----------------------------------------19
Bezel Removal: Smart -UPS 1000 and Smart-UPS 1400. ---------------------------------------------19
Bezel Installation: Smart-UPS 1000 and Smart-UPS 1400. ------------------------------------------20
Battery Removal: Smart-UPS 1000 and Smart-UPS 1400.-------------------------------------------20
Battery Installation: Smart-UPS 1000 and Smart-UPS 1400.----------------------------------------21
PCB Removal: Smart-UPS 1000 and Smart-UPS 1400. ----------------------------------------------23
PCB Installation: Smart-UPS 1000 and Smart-UPS 1400. -------------------------------------------25
Output Transformer Removal: Smart-UPS 1000 and Smart-UPS 1400.--------------------------26
Output Transformer Installation: Smart-UPS 1000 and Smart-UPS 1400.-----------------------27
Rear Outlet Removal: Smart-UPS 1000 and Smart-UPS 1400. -------------------------------------27
Rear Outlet Installation: Smart-UPS 1000 and Smart -UPS 1400. ----------------------------------28
Circuit Breaker Removal: Smart-UPS 1000 and Smart -UPS 1400. --------------------------------29
Circuit Breaker Installation: Smart -UPS 1000 and Smart-UPS 1400. -----------------------------29
FUNCTIONAL TEST PROCEDURES.......................................30
6.1
6.2
6.3
6.4
6.5
6.6
6.7
7.0
Site Wiring Fault Detector Test – 120VAC UPS’s only. ----------------------------------------------30
Output Voltage Test.---------------------------------------------------------------------------------------------30
Full Load Test On Battery.-------------------------------------------------------------------------------------31
Battery Reserve Time Test.------------------------------------------------------------------------------------32
Transfer Level Test. ---------------------------------------------------------------------------------------------33
Battery Charger Test.--------------------------------------------------------------------------------------------34
Computer Interface Port Test.---------------------------------------------------------------------------------34
TROUBLESHOOTING PROCEDURE......................................36
7.1
7.2
7.3
7.4
Troubleshooting Procedure. -----------------------------------------------------------------------------------36
Troubleshooting Procedure. -----------------------------------------------------------------------------------37
Troubleshooting Procedure. -----------------------------------------------------------------------------------38
Troubleshooting Procedure. -----------------------------------------------------------------------------------39
iv
v
1.0 Introduction
This manual provides information required for servicing American Power Conversion
Corporation Smart-UPS 450/ 700/ 1000/ and 1400. This guide is divided into the
following sections:
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Safety precautions - Lists recommended safety precautions to be followed when
servicing these products.
Tools & equipment - Lists all the necessary tools and equipment needed to
properly service these products.
Principles of operation - Provides a functional description of the UPS system
along with the major sections of the unit.
Parts replacement procedures - Lists steps to follow for removing and installing
the major assemblies of these products.
Functional test procedure - Lists steps to follow to qualify the system's
functionality.
Troubleshooting procedure - Lists the recommended procedure to follow when
servicing these products. The format of this section is as follows:
1.
2.
3.
Symptom.
Likely Cause.
Probable Solution.
1
2.0 Safety Precautions
CAUTION - UPS products contain voltages that are potentially hazardous. Personnel
trained in the service of electrical or electronic equipment should perform all service
procedures.
CAUTION - UPS products contain their own energy source allowing the output
receptacles and internal terminals to be energized when the UPS is not connected to an
external AC supply. Care should be used not to touch exposed metal surfaces and
terminals while the cover is off as the unit may have voltages present in the batteries and
printed circuit board (PCB).
CAUTION - Remove all jewelry (rings, hand bracelets, long necklaces) when servicing
these products to avoid accidentally short circuiting the battery or printed circuit board
(PCB) which could result in personal injury.
CAUTION - UPS systems contain components that may be damaged by Electrostatic
Discharge (ESD). For this reason, these units should only be serviced at static protected
workstations.
Note - Batteries should not be stored at temperatures above 77° F (25° C) for an extended
period of time. Do not store batteries longer than 6 months without recharge. Batteries
should only be recharged in an APC UPS system.
Batteries must be recycled. Deliver the battery to an appropriate recycling facility
or ship it to the supplier in the new battery’s packaging material.
USA laws prohibit the disposal of Lead Acid batteries with regular trash. These batteries
must be properly recycled.
Contact APC for information on proper disposal of batteries at:
USA/CANADA………………………………………..…...1-800-800-4272.
MEXICO………………………………………………..292-0253/292-0255.
BRAZIL……………………………………………………….0800-12-72-1.
WORLD WIDE……………………………………………..1-401-789-5735.
2
3.0 Tools and Equipment
The following is a list of the tools and equipment required for servicing American Power
Conversion UPS products:
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•
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•
•
20 MHz oscilloscope with a probe.
True RMS Digital multimeter (DMM). Note: Meters that are not true RMS may
give inaccurate readings. True RMS meters are usually marked "True RMS".
Clean and stable AC power source. For 100/120/230 Volt models, this source
must be able to generate 100/120/230 VAC at 50 or 60 HZ.
Variac: 0 to 280 Volts AC, (a variable adjust transformer).
Medium size flathead screwdriver.
#1 magnetized Phillips head screwdriver.
#2 X 4" magnetized Phillips head screwdriver.
#2 X 10" magnetized Phillips head screwdriver.
Flat head precision screwdriver.
Long nose pliers.
3/16" nut driver.
Load simulator: 450VA - 1400VA (280Watts - 950Watts, light bulbs, resistors).
Do not use a computer load, unless a true RMS Watt meter is available to
accurately determine the wattage. The wattage of a computer load cannot be
determined by simply multiplying Voltage times Amperage. The power factor of
the computer load needs to be known and multiplied in, as well. The typical
power factor for a computer load is .7.
Stop Watch: Used to time the UPS battery reserve time.
3
4.0 Principles of Operation
American Power Conversion Corporation (APC) models Smart-UPS 450/ 700/ 1000/ and
1400 supply 450VA to 1400VA (280Watts to 950 Watts) of dependable AC backup
power. These units are designed to protect the load from utility line disturbances.
These units have one printed circuit board that houses all of the electronic circuitry of the
UPS. On the following page is a block diagram of the different sections of the PCB
assembly. Below is a brief description of each section of the PCB assembly.
The AC Surge Suppressers & Filters - The UPS provides full-time protection against
surges, as well as RFI and EMI filtering through the use of surge suppressers and multistage filters.
Power inverter - A DC to AC inverter that converts the DC voltage supplied by the
battery into an AC voltage used by the loads that are plugged into the UPS. This inverter
also maintains phase synchronization with the commercial supply to ensure dependable
operation of the UPS.
Battery charger - The precision " Float" charger within the Smart-UPS ensures
maximum battery life by maintaining optimum battery float voltage whenever the UPS is
plugged in. The clean, low ripple voltage design of the Smart-UPS battery charger limits
continuous "exercising" of the battery. The low internal operating temperature of the
Smart-UPS ensures extended battery life in comparison to On-line and Ferro based UPS
designs.
Microprocessor controller - The brand that monitors the incoming AC line. When a
disturbance occurs, the sensor signals the transfer switch to open, allowing the inverter to
supply the output power. These sensors also send audible and remote signals to notify
the user of problems with the utility line.
Smart-UPS voltage correction features called SmartTrim and SmartBoost – Features
which allow the UPS to remain operating On-line during many high and low utility
voltage conditions. The SmartBoost feature compensates for the reduced line voltage by
boosting the On-line output voltage. By providing the computer load with power derived
from the utility, the UPS is capable of providing this protection even when the low utility
voltage condition is permanent. The UPS provides similar protection from high utility
voltage with the SmartTrim feature.
4
Computer interface port description – The Smart-UPS 450/ 700/ 1000/ and 1400 have
a communication’s port that may be connected to a host computer system using a special
optional interface kit. This port allows the computer to monitor the status of the UPS and
in some cases control the operation of the UPS. Below is a detailed description of each
of the serial port's pins:
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•
Pin 1 - Shutdown Input - The UPS will shut down when +5 VDC or a HI RS232 level, sustained for 4.5 seconds, is applied to pin 1. The UPS will respond to
the signal only when operating On-battery. If the UPS is shut down via this
utility, the UPS will turn On when the voltage is restored to within normal limits.
Pin 2 - Transfer To On Battery Signal Output - The UPS will generate a LO to
HI RS-232 level transition upon transfer from On-line to On-battery operation
(utility failure). The pin is normally at a LO RS-232 level. In the "smart"
signaling mode, this pin is the transmit data output line.
Pin 3 - Normally Open On Battery Signal - This pin is the open collector of a
transistor that turns On when the UPS transfer from On-line to On-battery
operation (utility failure). The transistor is capable of driving ground reference
TTL inputs or loads up to 50 ma at 40 VDC, non-inductive. If used to drive
relays, the relay coil must be clamped with a "catch" diode.
Pin 4 - Common - This pin is used as common for input and output signaling.
Pin 4 is separated from chassis ground with a 20 ohm resistor.
Pin 5 - Normally Open Low Battery Signal - This pin is the open collector of a
transistor that turns On when the UPS detects a low battery condition. The
transistor is capable of driving ground referenced TTL inputs or loads up to 50 ma
at 40 VDC, non-inductive. If used to drive relays, the relay coil must be clamped
with a "catch" diode.
Pin 6 - Normally Closed On Battery Signal - This pin is the open collector of a
transistor that turns Off when the UPS transfer from On-line to On-battery
operation (utility failure). The transistor is capable of driving ground reference
TTL inputs or loads of up to 25 ma at 40 VDC, non-inductive. If used to drive
relays the relay coil must be clamped with a "catch" diode.
Pin 7 –Remote Turn On/Off - The UPS will turn On and all loads connected at
its output will become powered when a HI RS-232 level, sustained for 1 second,
is applied to pin 7. This is true only when the UPS enable switch is in the 1
position. When pin 7 is grounded for 1 second, the UPS will shut down and all
connected loads will be turned Off.
Pin 8 – Unregulated +24 VDC - When the UPS enable switch is in the 1 position
an unregulated +24 VDC connected in series with a limiting resistor appears at
pin 8. A maximum of 40 maDC may be source from this output.
Pin 9 – Common - This pin is used as common for input and output signaling.
Pin 9 is separated from chassis ground with a 20 ohm resistor.
5
6
5.0 Procedures for the Smart-UPS 450/700.
Warning: Before disassembling and changing batteries, or servicing the Smart-UPS
make sure that mains supply and DC-supply have been switched Off. Make sure that
ALL power has been removed. Be aware that the capacitors in these units will store
energy well after all sources have been disconnected from the unit and remember to
follow ESD guidelines.
5.1 Cover Removal: Smart-UPS 450 and Smart-UPS 700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from
utility line.
2. Turn the unit on its side to allow access to the bottom screws and remove the
four (4) screws that secure the cover to the chassis (figure 5.1.1).
3. Turn the unit right side up and from the rear of the unit, grab the sides of the
cover and slide the cover back and away from the chassis. Keep the cover
horizontal at all times. (Fig 5.1.1).
7
5.2 Cover Installation: Smart-UPS 450 and Smart-UPS 700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Make sure that all wires are securely tucked inside the unit and from the rear
side of the unit, slide the cover forward onto the chassis. Keep the cover
horizontal at all times (Fig 5.1.1).
2. Turn the unit on its side to allow access to the bottom and replace the four (4)
screws that secure the cover to the chassis (figure 5.1.1).
5.3 Bezel Removal: Smart-UPS 450 and Smart-UPS 700.
Note: Make sure the LED display board does not make contact to chassis, as
there may be DC voltages present that will short to chassis. To prevent an
accidental shorting of the display PCB it is recommended that the batteries be
removed and the unit discharged per section 5.5.
1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from
utility line.
2. Unsnap the bezel from the chassis by applying a slight push at the top of the bezel
and away from the chassis (figure 5.3.1).
8
3. Unsnap the L.E.D. display PCB away from the bezel. The bezel is now free
from the chassis (figure 5.3.1).
5.4 Bezel Installation: Smart-UPS 450 and Smart-UPS 700.
Note: Make sure the LED display board does not make contact to chassis, as
there may be DC voltages present that will short to chassis. To prevent an
accidental shorting of the display PCB it is recommended that the batteries be
removed and the unit discharged per section 5.5.
1. Snap the L.E.D. display board into the bezel (figure 5.3.1).
2. Align the tabs of the bezel with the chassis battery door and snap the bezel in
place (figure 5.3.1).
5.5 Battery Removal: Smart-UPS 450 and Smart-UPS 700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from
utility line.
2. Unsnap the bezel away from the unit (figure 5.3.1).
3. Remove the two (2) screws from the battery door (figure 5.5.1).
9
4. Swing the battery door open (figure 5.5.1).
5. Gently slide the batteries out of the UPS.
6. Remove the UPS’s red battery wire from the positive tab of the battery and
remove the UPS’s black battery wire from the negative tab of the battery
(figure 5.5.1).
7. To discharge the unit, press the On button several times.
5.6 Battery Installation: Smart-UPS 450 and Smart-UPS 700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from
utility line.
2. Prepare the batteries as illustrated in figure 5.5.1.
3. Remove the two (2) screws from the battery door and swing the battery door
open (figure 5.5.1).
4. Disconnect and remove the old battery from the unit.
5. Connect the PCB’s red wire to the positive terminal of the battery and the
PCB’s black wire to the negative terminal of the battery (figure 5.5.1).
6. Gently slide the batteries into the battery compartment ensuring that the
battery wires are not jammed against the chassis edges.
7. Replace the two (2) screws that secure the battery door in place (figure 5.5.1).
8. Replace the bezel by snapping it in place (figure 5.3.1).
5.7 PCB Removal: Smart-UPS 450 and Smart-UPS 700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
Warning: The capacitors will store energy well after all sources have been
disconnected from the unit. Make sure the capacitors are discharged before
servicing the unit.
1. Remove the cover per section 5.1 and the battery per section 5.5.
2. Disconnect the PCB's black wires (W5&W6) from the output transformer's
primary side using a pair of needle nose pliers (figure 5.7.1).
10
3. Remove the PCB’s black wire from the circuit breaker.
4. Unsnap the LED display board from the front bezel (figure 5.3.1).
5. Remove the two (2) screws that secure the front of the PCB to the chassis
(figure 5.7.1).
6. Remove the center screw that secures the middle of the PCB to the chassis
(figure 5.7.1).
7. Remove the two (2) screws, one on the bottom rear left and the other on the
bottom rear right of the unit, that secure the rear panel to the chassis (figure
5.7.1).
8. Disconnect the SNMP adapter cable from the PCB’s tab J14 (figure 5.7.2).
9. Slide the PCB and the rear panel back and away from the rest of the chassis
(figure 5.7.1).
10. For Domestic units, disconnect the power cord’s white wire from the PCB’s
J4 tab and disconnect the power cord’s black wire from the PCB’s J3 tab.
For International units, disconnect the power inlet’s white wire from the
PCB’s J4 tab and the power inlet’s black wire from the PCB’s J3 tab (figure
5.7.2).
11
11. Disconnect the output transformer connector from the PCB’s J5.
12. Remove the two (2) screws that secure the rear of the PCB to the rear panel
(5.7.2).
13. Remove the hypot tap screw from the rear panel (figure 5.7.1).
14. Slide the PCB away from the rear panel.
15. Remove the power outlet’s white wire from the PCB’s J6 white out tab (figure
5.7.2).
16. Remove the power outlet’s black wire from the PCB’s J2 black out tab (figure
5.7.2).
17. The PCB is now free from the chassis.
12
5.8 PCB Installation: Smart-UPS 450 and Smart-UPS 700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Place the PCB on top of the rear panel (figure 5.7.2).
2. Slide the PCB into the rear panel using the rear panel guides (figure 5.7.2).
3. Replace the screws that secure the rear of the PCB to the rear panel (figure
5.7.2).
4. Replace the hypot tab screw to the rear panel (figure 5.7.1).
5. Connect the power outlet’s white wire to the PCB’s J6 tab (figure 5.7.2).
6. Connect the power outlet’s black wire to the PCB’s J2 tab (figure 5.7.2).
7. Reconnect the black wire from the PCB to the circuit breaker's tab (figure
5.7.2).
8. For Domestic units, reconnect the power cord's white wire to the PCB’s J4
tab and reconnect the power cord’s black wire to the PCB’s J3 tab.
For International units, reconnect the power inlet’s white wire to the PCB’s
J4 tab and reconnect the power inlet’s black wire to the PCB’s J3 tab (figure
5.7.2).
9. Place the PCB with the rear panel back onto the chassis. The lip at the bottom
of the rear panel should be underneath the bottom of the chassis.
10. Reconnect the output transformer's connector to the PCB tab labeled J5
(figure 5.7.1).
11. Insert the display PCB into the bezel and snap bezel back in place at the front
of the unit (figure 5.3.1).
12. Reconnect the SNMP adapter cable to the PCB’s J14 tab (figure 5.7.1).
13. Reconnect the PCB’s black wires to the output transformer’s primary side
(figure 5.7.1).
14. Replace the two (2) screws that secure the front of the PCB to the chassis
(figure 5.7.1).
15. Replace the two (2) screws that secure the rear panel to the bottom of the
chassis (figure 5.7.1).
16. Replace the battery per section 5.6 and replace the cover per section 5.2.
13
5.9 Output Transformer Removal: Smart-UPS 450 and SmartUPS 700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
Note: Although it is not a must to disconnect the batteries from the unit in order
to remove the output transformer, it is highly recommended and therefore listed as
a step to eliminate the potential of having power at the rear panel.
1. Remove the cover (section 5.1), the batteries (section 5.5), and the PCB
(section 5.7) before removing the output transformer.
2. Remove the four (4) screws that secure the transformer to the chassis (figure
5.9.1).
3. Remove the transformer.
14
5.10 Output Transformer Installation: Smart-UPS 450 and
Smart-UPS 700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Place the transformer inside the chassis. Make sure to orient the transformer
with its Black and White primary transformer wires toward the FET bank, that
is, to the left side of the UPS when viewing the UPS from the front (figure
5.9.1).
2. Replace the four (4) screws that secure the output transformer to the chassis
(figure 5.9.1).
3. Install the PCB per section 5.8.
5.11 Rear Outlet Removal: Smart-UPS 450 and Smart-UPS 700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
Note: Although it is not a must to disconnect the batteries from the unit in order
to remove the rear outlet, it is highly recommended and therefore listed as a step
to eliminate the potential of having power at the rear panel.
1. Remove the cover (section 5.1), the batteries (section 5.5.), and the PCB
(section 5.7) before removing the rear outlet.
2. For Domestic units, remove the two (2) screws that secure the outlets to the
rear panel and remove the outlets (figure 5.11.1).
For International units, remove the rear outlet’s green ground wire from the
chassis. Then, from the inside of the rear panel, press in the clips located on
each side of the outlet and push out until the outlets are free from the rear
panel (figure 5.11.2).
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3. Remove the outlet.
16
5.12 Rear Outlet Installation: Smart-UPS 450 and Smart-UPS
700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. For Domestic units, position the outlet in place and replace the two (2)
screws that secure the outlet to the chassis (figure 5.11.1).
For International units, position the outlet in place and push the outlet into
the rear panel until it snaps into place. Then, replace the screw that secures
the green ground wire to the chassis (figure 5.11.2).
2. Install the PCB per section 5.8.
5.13 Circuit Breaker Removal: Smart-UPS 450 and Smart-UPS
700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
Note: Although it is not a must to disconnect the batteries from the unit in order
to remove the circuit breaker, it is highly recommended and therefore listed as a
step to eliminate the potential of having power at the rear panel.
1. Remove the cover (section 5.1), the batteries (section 5.5.), and the PCB
(section 5.7) before removing the circuit breaker.
2. Disconnect the power inlet's black wire (international) or power cord's black
wire (domestic) from the circuit breaker (figure 5.11.2 and figure 5.11.1).
3. While holding in the clips at the sides of the circuit breaker, from the front of
the rear panel, push the circuit breaker out until it is free from the rear panel
(figure 5.11.1).
5.14 Circuit Breaker Installation: Smart-UPS 450 and SmartUPS 700.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. From the inside of the rear panel press in both clips on each side of the circuit
breaker and push in until it snaps into place (fig 5.11.1).
17
2. Connect the power inlet’s black wire (international) or power cord’s black
wire (domestic) to the circuit breaker (figure 5.11.1).
3. Install the PCB per section 5.8.
5.15 Cover Removal: Smart-UPS 1000 and Smart-UPS 1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from
utility line.
2. Turn the unit on its side to allow access to the bottom screws and remove the
six (6) screws that secure the cover to the chassis (figure 5.15.1).
3. Turn the unit right side up and from the rear of the unit, grab the sides of the
cover and slide the cover back and away from the chassis. Keep the cover
horizontal at all times. (Fig 5.15.1).
18
5.16 Cover Installation: Smart-UPS 1000 and Smart-UPS 1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Make sure that all wires are securely tucked inside the unit and from the rear
side of the unit, slide the cover forward onto the chassis. Keep the cover
horizontal at all times (Fig 5.15.1).
2. Turn the unit on its side to allow access to the bottom and replace the six (6)
screws that secure the cover to the chassis (figure 5.15.1).
5.17 Bezel Removal: Smart-UPS 1000 and Smart-UPS 1400.
Note: Make sure the LED display board does not make contact to chassis, as
there may be DC voltages present that will short to chassis. To prevent an
accidental shorting of the display PCB it is recommended that the batteries be
removed and the unit discharged per section 5.19.
1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from
utility line.
2. Unsnap the bezel from the chassis by applying a slight push at the top of the
bezel and away from the chassis (figure 5.17.1).
3. Unsnap the L.E.D. display PCB away from the bezel. The bezel is now free
from the chassis.
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5.18 Bezel Installation: Smart-UPS 1000 and Smart-UPS 1400.
Note: Make sure the LED display board does not make contact to chassis, as
there may be DC voltages present that will short to chassis. To prevent an
accidental shorting of the display PCB it is recommended that the batteries be
removed and the unit discharged per section 5.19.
1. Snap the L.E.D. into the bezel (figure 5.17.1).
2. Align the tabs of the bezel with the chassis battery door and snap the bezel in
place (figure 5.17.1).
5.19 Battery Removal: Smart-UPS 1000 and Smart-UPS 1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from
utility line.
2. Unsnap the bezel away from the unit (figure 5.17.1).
3. Remove the two (2) screws from the battery door (figure 5.19.1).
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4. Swing the battery door open (figure 5.19.2).
5. Gently slide the batteries out of the UPS.
6. For Smart-UPS 1000, remove the UPS’s red battery wire from the positive
tab of the battery and remove the UPS’s black battery wire from the negative
tab of the battery (figure 5.19.2).
For Smart-UPS 1400, disconnect the Anderson connector plug (figure
5.19.2).
7. To discharge the unit, press the On button several times.
5.20 Battery Installation: Smart-UPS 1000 and Smart-UPS 1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from
utility line.
2. For Smart-UPS 1400, prepare the batteries as described in figure 5.20.1.
For Smart-UPS 1000, prepare the batteries as described in figure 5.20.2.
21
22
3. Remove the two (2) screws from the battery door and swing the battery door
open (figure 5.19.1).
4. Remove the old batteries away form the chassis.
5. For the Smart-UPS1000, connect the PCB’s red wire to the positive terminal
of the battery and the PCB’s black wire to the negative terminal of the battery.
For the Smart-UPS1400, connect the battery’s Anderson connector plug to
the PCB’s Anderson connector plug.
6. Gently slide the batteries into the battery compartment ensuring that the
battery wires are not jammed against the chassis edges.
7. Replace the two (2) screws that secure the battery door in place.
8. Replace the bezel by snapping it in place (figure 5.17.1).
5.21 PCB Removal: Smart-UPS 1000 and Smart-UPS 1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
Warning: The capacitors will store energy well after all sources have been
disconnected from the unit. Make sure the capacitors are discharged before
servicing the unit.
1. Remove the cover per section 5.15 and the battery per section 5.19.
2. Press the On button on the front of the unit several times to discharge the unit.
3. Disconnect the black primary output transformer wire from heatsink #1
(figure 5.21.1).
23
4. Disconnect the white primary output transformer wire from heatsink #4
(figure 5.21.1).
5. Disconnect the PCB’s black wire from the circuit breaker tab (figure 5.21.1).
6. Remove the LED display PCB by unsnapping it out of the bezel (figure
5.17.1).
7. Remove the two (2) screws that secure the front of the PCB to the chassis
(figure 5.21.2).
8. Remove the center screw that secures the PCB to the chassis (figure 5.21.2).
9. Disconnect the SNMP adapter cable from the PCB’s J14 tab.
10. Slide both the PCB and rear panel back and away from the rest of the unit.
11. For Domestic units, disconnect the power cord’s white wire from the PCB’s
J4 tab and disconnect the power cord’s black wire from the PCB’s J3 tab.
For International units, disconnect the power inlet’s white wire from the
PCB’s J4 tab and the power inlet’s black wire from the PCB’s J3 tab.
12. Disconnect the Output transformer’s connector from the PCB’s J5 tab.
13. Remove the two (2) screws that secure the rear of the PCB to the rear panel
(figure 5.21.2).
14. Remove the two (2) screws that secure the rear panel to the base of the chassis
(figure 5.21.2).
24
15. Remove the hypot tab screw on the rear panel.
16. Slide the PCB away from the rear panel.
17. Remove the power outlet’s white wire from the PCB’s J6 tab
18. Remove the power outlet’s black wire from the PCB’s J2 tab.
19. For UPS’s with the rear panel quick-disconnect Anderson connector
plug, remove the two (2) screws that secure the connector to the rear panel
(figure 5.21.2).
20. The PCB is now free from the chassis.
5.22 PCB Installation: Smart-UPS 1000 and Smart-UPS 1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1.
2.
3.
4.
5.
6.
Place the PCB on top of the rear panel.
Slide the PCB into the rear panel using the rear panel guides (figure 5.21.1).
Replace the screws that secure the PCB to the rear panel (figure 5.21.1).
Connect the power outlet’s white wire to the PCB’s J6 tab.
Connect the power outlet’s black wire to the PCB’s J2 tab.
For Domestic units, reconnect the power cord's white wire to the PCB’s J4
tab and reconnect the power cord’s black wire to the PCB’s J3 tab.
For International units, reconnect the power inlet’s white wire to the PCB’s
J4 tab and reconnect the power inlet’s black wire to the PCB’s J3 tab.
7. Reconnect the black wire from the PCB to the circuit breaker's tab (figure
5.21.1).
8. Secure the hypot tap screw to the chassis.
9. Place the rear panel and PCB back onto the chassis. The lip at the bottom of
the rear panel should be underneath the bottom of the chassis.
10. Reconnect the output transformer's connector to the PCB tab labeled J5.
11. Reconnect the SNMP adapter cable from the PCB’s J14 tab.
12. Insert the display PCB into the bezel and snap the bezel back in place at the
front of the unit (figure 5.17.1).
13. Reconnect the black primary output transformer wire to heatsink #1 (figure
5.21.1).
14. Reconnect the white primary output transformer wire to heatsink #4 (figure
5.21.1).
15. Replace the two (2) screws that secure the front of the PCB to the chassis as
well as the center screw (figure 5.21.2).
16. Replace the two (2) screws that secure the rear panel to chassis (figure 5.21.2).
17. Replace the battery per section 5.20 and replace the cover per section 5.16.
25
5.23 Output Transformer Removal: Smart-UPS 1000 and SmartUPS 1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
Note: Although it is not a must to disconnect the batteries from the unit in order
to remove the output transformer, it is highly recommended and therefore listed as
a step to eliminate the potential of having power at the rear panel.
1. Remove the cover (section 5.15), the batteries (section 5.19.), and the PCB
(section 5.21) before removing the output transformer.
2. Remove the four (4) screws that secure the transformer to the chassis (figure
5.23.1).
3. Remove the transformer.
26
5.24 Output Transformer Installation: Smart-UPS 1000 and
Smart-UPS 1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. Place the transformer inside the chassis. Make sure to orient the transformer
with its Black and White primary transformer wires toward the FET bank, that
is, to the left side of the UPS when viewing the UPS from the front (figure
5.23.1).
2. Replace the four (4) screws that secure the output transformer to the chassis
(figure 5.23.1).
3. Install the PCB per section 5.22.
5.25 Rear Outlet Removal: Smart-UPS 1000 and Smart-UPS
1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
Note: Although it is not a must to disconnect the batteries from the unit in order
to remove the rear outlet, it is highly recommended and therefore listed as a step
to eliminate the potential of having power at the rear panel.
1. Remove the cover (section 5.15), the batteries (section 5.19.), and the PCB
(section 5.21) before removing the rear outlet.
2. For Domestic units, remove the two (2) screws that secure the outlets to the
rear panel and remove the outlets (figure 5.25.1).
For International units, remove the rear outlet’s green ground wire from the
chassis. Then, from the inside of the rear panel, press in the clips located on
each side of the outlet and push out until the outlets are free from the rear
panel (figure 5.25.1).
27
5.26 Rear Outlet Installation: Smart-UPS 1000 and Smart-UPS
1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. For Domestic units, position the outlet in place and replace the two (2)
screws that secure the outlet to the chassis (figure 5.25.1)
Note: The outlet’s ground screw must be on the opposite side of the circuit
breaker.
For International units, position the outlet in place and push the outlet into
the rear panel until it snaps into place. Then, replace the screw that secures
the green ground wire to the chassis (figure 5.25.1).
Note: The outlet’s ground screw must be facing downward.
2. Install the PCB per section 5.22.
28
5.27 Circuit Breaker Removal: Smart-UPS 1000 and Smart-UPS
1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
Note: Although it is not a must to disconnect the batteries from the unit in order
to remove the circuit breaker, it is highly recommended and therefore listed as a
step to eliminate the potential of having power at the rear panel.
1. Remove the cover (section 5.15), the batteries (section 5.19), and the PCB
(section 5.21) before removing the circuit breaker.
2. Disconnect the power inlet's black wire (international) or power cord's black
wire (domestic) from the circuit breaker (figure 5.25.1).
3. While holding in the clips at the sides of the circuit breaker, from the front of
the rear panel, push the circuit breaker out until it is free from the rear panel
(figure 5.25.1).
5.28 Circuit Breaker Installation: Smart-UPS 1000 and SmartUPS 1400.
Warning: The unit must be disconnected from facility power when removing or
replacing any assemblies.
1. From the inside of the rear panel press in both clips on each side of the circuit
breaker and push in until it snaps into place (fig 5.25.1).
2. Connect the power inlet’s black wire (international) or power cord’s black
wire (domestic) to the circuit breaker (figure 5.25.1).
3. Install the PCB per section 5.22.
29
6.0 Functional Test Procedures
This section outlines the steps to perform a functional test on the Smart-UPS 450/ 700/
1000/ and 1400. The functional test is broken down into the following sections; Site
wiring fault detector test, Output voltage test, Full load test On-battery, Battery reserve
time test, Transfer level test, Battery charger test, and the Computer interface port test.
6.1 Site Wiring Fault Detector Test – 120VAC UPS’s only.
The 120VAC 450-1400 Smart-UPS UPS has a site wiring fault detector that
warns the user of a potential wiring problem. The site wiring fault indicator is a
red LED on the rear panel. This LED will illuminate when the unit is plugged
into an improperly wired outlet. The LED will illuminate when any of the
following wiring faults are present:
1. An open or high resistance ground.
2. Reversed polarity of the hot and neutral lines.
3. An overloaded neutral circuit is present.
The site wiring fault circuit can be easily tested by plugging the UPS into an
ungrounded receptacle, or by reversing the polarity on the input (Hot-in & Neuin) although this is not recommended. A computer load should be present at the
time of testing. If the LED fails to illuminate, than the UPS should be serviced.
6.2 Output Voltage Test.
1. Plug the variac into the AC line and set the variac output for 120 VAC,
(100VAC) or (230 VAC}.
2. Plug the UPS into the variac and turn the UPS On. The UPS will perform a
self-test for approximately 8-10 seconds and return to the On-Line state.
3. Connect a true RMS voltmeter and an oscilloscope to the output of the UPS.
4. Turn Off the variac. The UPS should immediately transfer to backup power.
5. Using a voltmeter and oscilloscope, monitor the UPS's output voltage and
frequency.
6. The UPS should output a pure sine wave at approximately 117+5% VAC,
(100+5% VAC) or {225+5% VAC}
7. If the sine wave is heavily distorted or the output voltage is inaccurate, the
UPS should be serviced.
30
6.3 Full Load Test On Battery.
1. Prior to performing this test, the unit should be charged up. Time to charge
will vary depending on the current state of the batteries.
2. Plug the variac into the AC line and set the variac output for 120 VAC,
(100VAC) or {230 VAC}.
3. Plug the UPS into the variac and turn the UPS On. The UPS will perform a
self-test for approximately 8-10 seconds and return to the On-Line state.
4. Apply the correct size load to the UPS. Refer to table 6.3 for proper load size.
Model
SU450
SU700
SU1000
SU1400
Load (VA/Watt)
450VA/280W
700VA/450W
1000VA/670W
1400VA/950W
Table 6.3
5. Using a voltmeter, monitor the UPS’s output voltage. The UPS should remain
powered and it should output approximately 120+5% VAC, (100+5% VAC)
or {230+5% VAC}.
6. Remove the AC line input so that the UPS operates On Battery. The UPS
should remain powered and the output should remain the same as step 6
above. While the UPS is operating off of the utility voltage, increase the load
by approximately 75 Watts. Plugging a light bulb into the UPS can do this.
After 4 seconds, the overload light should come On and the unit should emit a
constant tone until the overload is removed.
7. If the UPS fails to support the load or recognize the overload, then it should be
serviced.
31
6.4 Battery Reserve Time Test.
1. Prior to performing this test, the unit should be charged up. Time to charge
will vary depending on the current state of the batteries.
2. Plug the variac into the AC line and set the variac output for 120 VAC,
(100VAC) or 230 VAC}.
3. Plug the UPS into the variac and turn the UPS On. The UPS will perform a
self-test for approximately 8-10 seconds and return to the On-Line state.
4. Connect a true RMS voltmeter to the output of the UPS.
5. Apply the correct size load to the UPS. Refer to table 6.3 for proper load size
or table 6.4 for variant load applications.
Typical Unit On-battery Runtimes Versus VA** Load, In Hours
Load
(VA)
50
75
100
150
200
250
300
350
400
450
500
550
600
700
800
900
1000
1200
1400
SU450
(min)
1.67
1.28
0.9
0.55
0.36
0.25
0.18
0.13
0.1
0.07
-
SU700
(min)
2.33
1.88
1.42
0.92
0.63
0.43
0.33
0.28
0.23
0.18
0.15
0.13
0.11
0.09
-
SU1000
(min)
2.5
2.08
1.67
1.25
0.97
0.73
0.6
0.47
0.4
0.33
0.3
0.25
0.22
0.18
0.14
0.12
0.11
-
SU1400
(min)
4.18
3.32
2.72
1.97
1.5
1.18
0.95
0.72
0.62
0.53
0.47
0.4
0.35
0.3
0.25
0.2
0.18
0.14
0.11
**Note: VA levels shown assume a 0.7 typical power factor
of the average non-PFC computer power supply
Table 6.4
32
6. Using a voltmeter, monitor the UPS’s output voltage. The UPS should remain
powered and it should output approximately 120+5% VAC, (100+5% VAC)
or {230+5% VAC}.
7. Remove the AC line input so that the UPS operates On Battery. The UPS
should remain powered and the output should remain the same as step 6
above.
8. Using a stopwatch, time how long the UPS maintains power to the load. The
UPS should beep every 30 seconds, and when only 2 or 3 minutes of runtime
remain, the UPS will beep every .5 seconds. Refer to table 6.4 for expected
runtimes. If the UPS fails to support the load for the expected runtime, the
batteries may need to be replaced. If the batteries are new and have drained
prematurely during normal operations it may be an indication that there may
be a problem with the charging circuit and the UPS should be serviced.
9. Plug the UPS into the wall and allow it to charge for at least 6 hours before
storing or using the UPS.
6.5 Transfer Level Test.
1. Plug the variac into the AC line and set the variac output for 120 VAC,
(100VAC) or {230 VAC}.
2. Plug the UPS into the variac and turn the UPS On. The UPS will perform a
self-test for approximately 8-10 seconds and return to the On-Line state.
3. Connect a true RMS voltmeter and an oscilloscope to the output of the UPS.
4. Slowly turn down the variac and monitor the UPS's input voltage. The UPS
should transfer to SmartBoost when the voltage drops to 103+5% VAC (90+
5% VAC) or {196+5% VAC}. Repeat this procedure several times to ensure
accurate results.
5. While the UPS is on SmartBoost, slowly turn the variac down until the UPS
transfers to battery. The UPS should transfer to battery at approximately
92+5% VAC (80+ 5%VAC) or {174+5% VAC}.
6. If the UPS does not transfer properly, then the calibration of the unit is
recommended. Otherwise, the UPS should be serviced.
7. Turn the variac back up so that the UPS goes back to On-Line operation.
8. Slowly turn up the variac and monitor the UPS’s input voltage. The UPS
should transfer to SmartTrim when the voltage increases to 132+5% VAC
(110+ 5% VAC) or {258+5% VAC}. Repeat this procedure several times to
ensure accurate results.
9. While the UPS is on SmartTrim, slowly turn the variac up until the UPS
transfers to battery. The UPS should transfer to battery at approximately
147+5% VAC (123+ 5%VAC) or {296+5% VAC}.
10. If the UPS does not transfer properly, then the calibration of the unit is
recommended. Otherwise, the UPS should be serviced.
33
6.6 Battery Charger Test.
1. Plug the variac into the AC line and set the variac output for 120 VAC,
(100VAC) or {230 VAC}.
2. Plug the UPS into the variac and turn the UPS On. The UPS will perform a
self-test for approximately 8-10 seconds and return to the On-Line state.
3. For the 450-700, remove the two (2) screws from the battery door (figure
5.5.1).
For the 1000-1400, remove the two (2) screws from the battery door (figure
5.19.1).
4. Swing the battery door open and gently slide the battery out of the UPS.
5. Remove the units black wire from the negative battery terminal and remove
the units red wire from the positive battery terminal.
Note: for the 1400, disconnect the battery’s Anderson connector plug.
6. Remove the battery.
7. Measure the DC battery charger voltage between the PCB's black battery wire
and the PCB's red battery wire.
8. The DC voltage should be at 26.7 - 28.5 VDC.
9. Should the battery charger voltage fail to meet the provided range, then the
unit should be serviced.
10. Connect the red wire from the unit to the positive battery terminal.
11. Connect the black wire from the unit to the negative battery terminal.
12. Gently slide battery into chassis.
13. Swing battery door closed and replace the two (2) screws that secure the
battery door to the chassis.
6.7 Computer Interface Port Test.
The Back-UPS is equipped with a rear panel interface port to allow for
communication between the UPS and a host computer. A detailed description of
the port can be found in section 4.0. The following steps should be performed to
ensure the interface port is working properly.
1. Plug the variac into the AC line and set the variac output for 120 VAC
(100VAC) or {230VAC}.
2. Plug the UPS into the variac and turn the UPS On. The UPS will perform a
self-test for approximately 8-10 seconds and return to the On-Line state.
34
3. Using a multimeter, measure the voltage between the interface port's pin 2 and
9. The voltage should be LO RS-232 signal (-8 to -12 VDC).
4. Unplug the UPS from the variac so that the UPS operates On battery. The DC
voltage between pins 2 and 9 should now be a HI RS-232 level (+8 - +12
VDC)
5. While the UPS is operating On battery, apply a HI RS-232 signal to pin 1.
Shorting pin 1 to pin 2 can do this. A metal paper clip can be used to short the
two pins. The UPS should go into sleep mode. The lights in front of the unit
will scroll.
6. Remove the short between pin 1 and pin 2. Plug the UPS back into the variac.
Now, the UPS should power back up.
7. Connect a 48 kΩ (± 5 kΩ) resistor between pins 3 and 8. Using a multimeter,
measure the DC voltage drop across pin 3 and ground. The DC voltage
should be greater than 19VDC.
8. The resistor should still be connected to pins 3 and 8. Unplug the UPS from
the utility line. Using a multimeter, measure the DC voltage between pin 3
and ground. The voltage should be less than 0.6 VDC.
9. Connect a 48 kΩ (± 5 kΩ) resistor between pins 5 and 8. Using a multimeter,
measure the DC voltage drop between pin 5 and ground. The voltage drop
should be greater than 19VDC.
10. The resistor should still be connected between pin 5 and 8. Unplug the UPS
from the utility line and allow it to run On battery until it reaches the low
battery state.
11. While the UPS is in low battery state, use a multimeter to measure the DC
voltage between pin 5 and ground. The voltage should be less than 0.6VDC.
12. Plug the UPS into the wall and allow it to charge for at least six (6) hours
before storing or using the UPS.
13. If the UPS fails any of the above tests, the PCB should be replaced.
35
7.0 Troubleshooting Procedure.
This section outlines the most common problems that may be encountered with a UPS.
The format of this section is as follows:
I.
II.
III.
Symptom - a brief description of a problem encountered.
Likely cause - the possible reasons that may have caused the problem to occur.
Probable solution - the probable solutions to each of the likely causes.
7.1 Troubleshooting Procedure.
Symptom:
Likely cause:
1. Will not
start:
Batteries not
connected.
Bad batteries.
2. Won’t go
On-line:
(continued on
next page).
Probable
solution:
Connect batteries.
Additional comments:
Replace batteries.
See comments at the bottom of the table
pertaining to batteries.
Typical failures when F3 is blown. a.
the UPS may turn on upon batt.
connection; Q5 and/or Q6 may be
shorted. b. F3 opens upon turn-on
attempt; 24v short present. See
comments at the bottom of the table
pertaining to bias voltages.
Internal fuse
blown.
Replace F3.
Transistor open.
Ribbon cable
cut.
Replace Q5.
Replace ribbon
cable and check
F3 and Q5.
Realign/ replace
sw2.
Push button
switch broken/
misaligned.
Program wrong
setting.
No input at
power cord.
Program wrong
setting.
Adjust (B) battery
setting.
Connect power
cord.
Display pcb ribbon cable may be cut,
shorting DC voltage to chassis blowing
F3 and shorting Q5.
Verify site power at receptacle. With
power removed, check the circuit
breaker with an ohm meter. A bad
circuit breaker will often show
resistance and must be replaced. Verify
continuity from power cord to hot-in tab
at pcb.
Adjust (L) line
setting.
36
7.2 Troubleshooting Procedure.
Symptom:
Likely cause:
2. Won’t go
On-line: (see
last page).
Component lead
out of pcb.
3. Flashing
LEDs:
4. Overload:
5. Won’t
charge:
(continued on
next page).
UPS sustained a
surge, MOV
blown.
Line sense
transformer
bad.
Large capacitor
fell off of the
pcb.
Capacitor leaks.
Relay welded.
Optocoupler
failed.
Leaky diode.
Load exceeds
UPS
parameters.
Output sense
transformer
open.
Current
transformer
failure.
IC failure.
Program wrong
setting.
Probable
solution:
Resolder lead to
pcb.
Additional comments:
Check components in AC-in path
ensuring leads are through the pcb.
L1,L2, and T1 are usually suspect.
Replace MOV.
Replace T1.
Other suspect components: D18, D19,
D20, C63, and IC10.
Resolder C17
onto the pcb.
Replace C44 or
C52.
Replace relay.
Replace IC3.
Replace D20.
Reduce load.
Replace T2.
Replace CT1.
A reading above 4 ohms across
transformer indicates it is faulty.
Replace IC15.
Overloads typically originate in the
inverter section – a complex circuit. –
8V should be verified first, then IC
replacement may be done as follows;
IC12, 8, 17, and 14. Drivers and fets as
well as the power transformer may be
bad also.
Check float voltage and verify battery
constants 4, 5, 6, and 0. The 0 constant
is critical for it will change per design
when the batteries are discharged.
Always check this constant after battery
replacement.
Adjust float
voltage (B)
setting.
37
7.3 Troubleshooting Procedure.
Symptom:
Likely cause:
5. Won’t
charge: (see
last page).
Bad charger
circuit.
6. UPS
clicking but
won’t start.:
7. L.E.D.
failure:
8. Will not
stay On-line:
Probable
solution:
Replace IC14.
Additional comments:
Bad battery.
Replace battery.
See comments at the bottom of the table
pertaining to batteries.
Bad
microprocessor.
Bad reset
circuit.
Replace IC12.
Bad L.E.D.
Replace faulty
L.E.D.
Replace Q56.
Bad turbo
circuit.
Replace C77.
IC14 pin 9 should be 8VDC,if not then
C88 or IC17 may be faulty.
The reset circuit is composed of several
components which could be the culprit
in a reset failure. Components should
be replaced in the following order: C77,
IC11, Q51, Q52, Q53, IC15, and R115.
Drivers may fail as well in display pcb Q57,Q58,Q59,andQ60
Q55, Q54, and IC12 could also trip the
turbo circuit. IC13 may be corrupted
and need replacing – if so, the UPS will
have to be fully reprogrammed.
Additional information pertinent to table above.
Caution: Batteries can leak or swell, exposing hazardous gases and acid, when exposed
to inadequate environments such as poor ventilated areas or excessively hot room
temperatures. The UPS should be kept in a well ventilated area where the ambient
temperature is within UPS operating temperature to avoid a reduced expected runtime or
a premature UPS failure. If new batteries drain prematurely it may be the effect of
another failure such as “will not go On-line”,“will not charge”,“clicking”, or “flashing
leds”. These failures can drain the batteries ultimately causing the UPS to fail for “won’t
start”. Ensure that the UPS is fully operational upon battery replacement to avoid
draining the new batteries.
Note: The UPS battery is really a battery pack composed of two or more batteries
depending on the model. If one of the battery cells is bad and the other one(s) is good
then the UPS may perform strangely, unexpectedly dropping the load or not fully
charging the battery. Each battery should be checked individually.
38
7.4 Troubleshooting Procedure.
Note: The UPS has several bias voltages that must be present for proper UPS operation.
Verification of Bias voltages for the Smart-UPS’s 450/700/1000/1400 may be conducted
as follows:
Using an Ohm meter and using chassis ground as a point of reference, verify
approximately 1Mohm at pin1 of IC4, 1Kohm at pin 1 of IC5, and 1Kohm at pin 3 of
IC5. These are 24VDC, 12VDC, and 5VDC reference respectively. Also, verify
approximately 15Kohm at pin 1 of IC17 for –8VDC reference. Listed below are the
typical components that fail when a reference voltage is missing.
•
24VDC
C41, C36, IC4, snmp and display pcb ribbon cable, Fan,C63.
•
12VDC
IC5, C8, D401, IC2, Power FET’s
•
5VDC
D402, IC12, IC13 (eeprom must be reprogrammed),IC5,IC10,C65.
•
-8VDC
C7, Q39, Q40, C54, C53, D28, D27, IC9, IC17.
39