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CyberPower 1500AVR - Repair

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    CyberPower 1500AVR - Repair

    My CyberPower 1500AVR endured after a long power instability in the past weeks, must have been on the way out. (about 7-9 years)The batteries no longer held a charge nor the UPS were charging them. Batteries are about a year old, but they are good and holding charge from an external SLA charger.

    I found thread 785895 and it helped determining what components were damaged.

    On this unit the charger circuit just got overheated to and extent I could not see was components where what.

    Like I wrote in that thread the traces are in good condition and the UPS was powering up and providing protection until the batteries no longer held a charge. Because this board is hard to get a replacement, I was thinking of repairing the section that got damaged by removing the components and filling with epoxy resin and re-drilling the holes. Also I have a stock of capacitors that if all works the ones on the board will be replaced.

    I like this unit better than the new model. I think it can be accomplished. Opinions Welcome.
    Attached Files
    A Picture of subject is always Welcome


    Things saved from the e-landfill:
    Vizio VA26LHDTV10T 26" - Bad EEPROM Cap
    Asus PTGD1-LA Full Recap - Cha1 DDR socket damage
    MSI PM8M3-V Unstable CPU Recap CPU VRM circuit
    ViewSonic VA712B - still working on it
    Kindle Fire USB Connector
    MSI G31M-F Full Recap - Record Breaker done in 3Hrs.
    MSI P67A-G43 BIOS chip Reprogram - Tested and Happy

    The list will go on thanks to the people of this forum and many hours of reading.

    #2
    Re: CyberPower 1350AVR - Repair

    Yeah try cleaning it with what's in english called a "white spirit" and see how it looks like beneath the condensed plastic
    Less jewellery, more gold into electrotech industry! Half of the computer problems is caused by bad contacts

    Exclusive caps, meters and more!
    Hardware Insights - power supply reviews and more!

    Comment


      #3
      Re: CyberPower 1500AVR - Repair

      Hello crash-cyberdrive,
      I have to say that you are brave in regards to taking this on.

      I would check the transformer to make sure that it hasn't gone open circuit before you start.
      You'll have to test quite a few components, both on the primary and secondary of the transformer.
      You MUST ensure that you remove ALL the carbon off the PCB, especially where the carbon is extending between two or more components.
      Please keep us updated on how you get on.
      Good Luck!!!
      Regards,
      Relayer

      Comment


        #4
        Re: CyberPower 1500AVR - Repair

        Yes good luck to you cleaning and repair this power supply keep us updated on how your coming along with it
        9 PC LCD Monitor
        6 LCD Flat Screen TV
        30 Desk Top Switching Power Supply
        10 Battery Charger Switching Power Supply for Power Tool
        6 18v Lithium Battery Power Boards for Tool Battery Packs
        1 XBox 360 Switching Power Supply and M Board
        25 Servo Drives 220/460 3 Phase
        6 De-soldering Station Switching Power Supply 1 Power Supply
        1 Dell Mother Board
        15 Computer Power Supply
        1 HP Printer Supply & Control Board * lighting finished it *


        These two repairs where found with a ESR meter...> Temp at 50*F then at 90*F the ESR reading more than 10%

        1 Over Head Crane Current Sensing Board ( VFD Failure Five Years Later )
        2 Hem Saw Computer Stack Board

        All of these had CAPs POOF
        All of the mosfet that are taken out by bad caps

        Comment


          #5
          Re: CyberPower 1350AVR - Repair

          Originally posted by Behemot View Post
          Yeah try cleaning it with what's in english called a "white spirit" and see how it looks like beneath the condensed plastic
          By looking at this PCB material, I don't think would be too good to use "white spirit" (aka Mineral Spirits"). I could try in a piece I have very similar to the one I working on.

          All related components where removed and tested a F4 fuse found blown, C1 a 22uF 50v capacitor is way out of specs it gave a reading of 2.5uF@120hz the cause of damage.
          The rest was reading good but the surrounding components will be replaced as they where too close to the damaged area and are inexpensive.
          There is one diode D3 that I cannot make the number it is because it was on top of the heat source partially charring it. the only digits I could make out is 24

          Any tips on testing the transformers?
          T2 has continuity and read 1.2ohms on legs 3-4 and .5 ohms on legs 1-2, to me something is off; could be a choke and not a transformer? Could be me During the writing of this post I found T2 is a common filter choke and .45uH @ 100kHz on 3-4 and .55uH @ 100kHz on 1-2 not far off.

          I will be testing more of the critical components.

          Will keep you posted.
          Attached Files
          A Picture of subject is always Welcome


          Things saved from the e-landfill:
          Vizio VA26LHDTV10T 26" - Bad EEPROM Cap
          Asus PTGD1-LA Full Recap - Cha1 DDR socket damage
          MSI PM8M3-V Unstable CPU Recap CPU VRM circuit
          ViewSonic VA712B - still working on it
          Kindle Fire USB Connector
          MSI G31M-F Full Recap - Record Breaker done in 3Hrs.
          MSI P67A-G43 BIOS chip Reprogram - Tested and Happy

          The list will go on thanks to the people of this forum and many hours of reading.

          Comment


            #6
            Re: CyberPower 1500AVR - Repair

            Are you able to read the P/N of that SMPS IC at all? Viper22?
            Last edited by budm; 11-26-2017, 10:36 PM.
            Never stop learning
            Basic LCD TV and Monitor troubleshooting guides.
            http://www.badcaps.net/forum/showthr...956#post305956

            Voltage Regulator (LDO) testing:
            http://www.badcaps.net/forum/showthr...999#post300999

            Inverter testing using old CFL:
            http://www.badcaps.net/forum/showthr...er+testing+cfl

            Tear down pictures : Hit the ">" Show Albums and stories" on the left side
            http://s807.photobucket.com/user/budm/library/

            TV Factory reset codes listing:
            http://www.badcaps.net/forum/showthread.php?t=24809

            Comment


              #7
              Re: CyberPower 1500AVR - Repair

              Originally posted by budm View Post
              Are you able to read the P/N of that SMPS IC at all? Viper22?
              Yes, luckily I was able to read "Viper22A". STMicro discontinued the one that has been removed but the substitute for is "Viper22A-E". I have been reading datasheets to try to determine what has been enhanced. But I think overall it will work with the circuit.
              A Picture of subject is always Welcome


              Things saved from the e-landfill:
              Vizio VA26LHDTV10T 26" - Bad EEPROM Cap
              Asus PTGD1-LA Full Recap - Cha1 DDR socket damage
              MSI PM8M3-V Unstable CPU Recap CPU VRM circuit
              ViewSonic VA712B - still working on it
              Kindle Fire USB Connector
              MSI G31M-F Full Recap - Record Breaker done in 3Hrs.
              MSI P67A-G43 BIOS chip Reprogram - Tested and Happy

              The list will go on thanks to the people of this forum and many hours of reading.

              Comment


                #8
                Re: CyberPower 1500AVR - Repair

                Today's update
                Started the PCB cleanup process with a small dremel drum sand paper to remove most of the carbon. Later finished using a very small tipped dremel tool to clean most of the carbon on one of the ic leg hole. It did exposed a little bit of the trace underneath but was not torn.
                Also was able to identify the diode that was "charred" it turn out to be a rl207 diode.
                About to make a digikey order for some parts finally.
                Keep you updated.
                Attached Files
                A Picture of subject is always Welcome


                Things saved from the e-landfill:
                Vizio VA26LHDTV10T 26" - Bad EEPROM Cap
                Asus PTGD1-LA Full Recap - Cha1 DDR socket damage
                MSI PM8M3-V Unstable CPU Recap CPU VRM circuit
                ViewSonic VA712B - still working on it
                Kindle Fire USB Connector
                MSI G31M-F Full Recap - Record Breaker done in 3Hrs.
                MSI P67A-G43 BIOS chip Reprogram - Tested and Happy

                The list will go on thanks to the people of this forum and many hours of reading.

                Comment


                  #9
                  Re: CyberPower 1500AVR - Repair

                  Hello crash-cyberdrive,
                  Could you please see your modified picture below:



                  You need to remove the glue that's shown by the red circles. Search the rest of the PCB, top and bottom for this glue and remove it ALL.
                  That garbage has been known to become conductive.
                  Companies that used that glue during assembly didn't do their research in regards to the long term effects it may cause over the years due to heat and age. They apparently couldn't care less.
                  By the way, did you check Q4 as shown by the green arrow?
                  You need to perform a thorough check for shorts, OC's and leakage.
                  I ask this due to the fact it doesn't seem that it's ever been removed from circuit.
                  Could you please look at the next picture:



                  Can you remove the burned glue shown in the red circle.
                  Also, it is vitally important that you remove ALL carbonization between component holes, as show by the green rectangle.

                  I have to admit you've done a great job so far.
                  Regards,
                  Relayer

                  Comment


                    #10
                    Re: CyberPower 1500AVR - Repair

                    the damage was caused by arcing under that dammed brown glue.
                    remove it ALL!

                    Comment


                      #11
                      Re: CyberPower 1500AVR - Repair

                      Not sure about arcing, it usuelly is not so conductive to transfer some signifficant amounts of power to blast anything directly.

                      I however thought about how it used to kill FETs especially in Enermax Liberty units and I think it acts as resistor divider, in time able to transfer voltage enough (with 380V input) onto the gate to keep the FET(s) open the whole time. Sometimes the controller manages to shut the unit down when it only takes longer to turn the FETs off but it is still not able to keep them on the whole time. After some time it will happen and the transistors explode as being both on at once, it is basically a short between primary high side and return.
                      Less jewellery, more gold into electrotech industry! Half of the computer problems is caused by bad contacts

                      Exclusive caps, meters and more!
                      Hardware Insights - power supply reviews and more!

                      Comment


                        #12
                        Re: CyberPower 1500AVR - Repair

                        Btw, those two rectifier diodes and the two filter caps is setup as Voltage doubler circuit to to run that SMPS IC. The diode right next to the transformer is part of RCD snubber network.
                        Last edited by budm; 12-02-2017, 11:55 AM.
                        Never stop learning
                        Basic LCD TV and Monitor troubleshooting guides.
                        http://www.badcaps.net/forum/showthr...956#post305956

                        Voltage Regulator (LDO) testing:
                        http://www.badcaps.net/forum/showthr...999#post300999

                        Inverter testing using old CFL:
                        http://www.badcaps.net/forum/showthr...er+testing+cfl

                        Tear down pictures : Hit the ">" Show Albums and stories" on the left side
                        http://s807.photobucket.com/user/budm/library/

                        TV Factory reset codes listing:
                        http://www.badcaps.net/forum/showthread.php?t=24809

                        Comment


                          #13
                          Re: CyberPower 1500AVR - Repair

                          i suggest you look at the carnage in samsung boards caused by arcs through glue.

                          Originally posted by Behemot View Post
                          Not sure about arcing, it usuelly is not so conductive to transfer some signifficant amounts of power to blast anything directly.

                          I however thought about how it used to kill FETs especially in Enermax Liberty units and I think it acts as resistor divider, in time able to transfer voltage enough (with 380V input) onto the gate to keep the FET(s) open the whole time. Sometimes the controller manages to shut the unit down when it only takes longer to turn the FETs off but it is still not able to keep them on the whole time. After some time it will happen and the transistors explode as being both on at once, it is basically a short between primary high side and return.

                          Comment


                            #14
                            Re: CyberPower 1500AVR - Repair

                            Like this?
                            https://www.badcaps.net/forum/showth...ight=bad+glues
                            Been there many many many times before.
                            Never stop learning
                            Basic LCD TV and Monitor troubleshooting guides.
                            http://www.badcaps.net/forum/showthr...956#post305956

                            Voltage Regulator (LDO) testing:
                            http://www.badcaps.net/forum/showthr...999#post300999

                            Inverter testing using old CFL:
                            http://www.badcaps.net/forum/showthr...er+testing+cfl

                            Tear down pictures : Hit the ">" Show Albums and stories" on the left side
                            http://s807.photobucket.com/user/budm/library/

                            TV Factory reset codes listing:
                            http://www.badcaps.net/forum/showthread.php?t=24809

                            Comment


                              #15
                              Re: CyberPower 1500AVR - Repair

                              Originally posted by budm View Post
                              Like this?
                              https://www.badcaps.net/forum/showth...ight=bad+glues
                              Been there many many many times before.
                              That post do contains valuable data, it's like that glue is timed failure in case the capacitors don't do just that. Another tip well learned, thanks.

                              Will continue the clean up and remove that Q4 and test it out, but there is a high chance it will be replaced too once off.
                              A Picture of subject is always Welcome


                              Things saved from the e-landfill:
                              Vizio VA26LHDTV10T 26" - Bad EEPROM Cap
                              Asus PTGD1-LA Full Recap - Cha1 DDR socket damage
                              MSI PM8M3-V Unstable CPU Recap CPU VRM circuit
                              ViewSonic VA712B - still working on it
                              Kindle Fire USB Connector
                              MSI G31M-F Full Recap - Record Breaker done in 3Hrs.
                              MSI P67A-G43 BIOS chip Reprogram - Tested and Happy

                              The list will go on thanks to the people of this forum and many hours of reading.

                              Comment


                                #16
                                Re: CyberPower 1500AVR - Repair

                                Originally posted by budm View Post
                                Like this?
                                https://www.badcaps.net/forum/showth...ight=bad+glues
                                Been there many many many times before.
                                When it's already degraded to almost plain carbon (never seen it so black myself though), than I guess yes, it conducts pretty much everything.

                                Otherwise it seems it always has resistance of at least few kiloohms, don't think it can arc with normal operating voltage (about 380 V DC with active PFC). Probably when there is some overvoltage spike which the varistor does not fully catch, than maybe a kilovolt could appear for an instance and than it could arc?
                                Less jewellery, more gold into electrotech industry! Half of the computer problems is caused by bad contacts

                                Exclusive caps, meters and more!
                                Hardware Insights - power supply reviews and more!

                                Comment


                                  #17
                                  Re: CyberPower 1500AVR - Repair

                                  It never turns to carbon by itslef. It turned to carbon after the arc and burnt occurs.
                                  Using Ohm meter to test the conductivity is not going to give you the real conduction test.
                                  Try 400V or more in real world where those glue are being used in.
                                  It is like testing 1000V rating diode with your meter that only puts out 3~6V (depend on batteries), it may show good but it fails when exposed to working Voltage.
                                  Been there done that many many many times before. I have dealt with these glue since the 70's, long enough to know better and see what it can destroy, I still get the request the Chinese OEM asking to use them in place of the more expensive Electronics grade Silicone RTV, I show them the pictures.
                                  Last edited by budm; 12-03-2017, 02:23 AM.
                                  Never stop learning
                                  Basic LCD TV and Monitor troubleshooting guides.
                                  http://www.badcaps.net/forum/showthr...956#post305956

                                  Voltage Regulator (LDO) testing:
                                  http://www.badcaps.net/forum/showthr...999#post300999

                                  Inverter testing using old CFL:
                                  http://www.badcaps.net/forum/showthr...er+testing+cfl

                                  Tear down pictures : Hit the ">" Show Albums and stories" on the left side
                                  http://s807.photobucket.com/user/budm/library/

                                  TV Factory reset codes listing:
                                  http://www.badcaps.net/forum/showthread.php?t=24809

                                  Comment


                                    #18
                                    Re: CyberPower 1500AVR - Repair

                                    You can use a Megger to test the glue.
                                    Not a multimeter as budm stated...
                                    In my picture below a multimeter shows no conductivity in the glue.
                                    But a Megger set to 1kV does, along with some buzzing.
                                    In this case it might not be a problem, as this is the PWM/PFC controller and thus sees low voltage.
                                    However the same glue is all over the PSU, this was just the area that was most blackened.
                                    And worse: if it where to become conductive even at low voltage here, due to for example increased moisture level.
                                    Then the whole PFC stage will go kaboom!
                                    Attached Files
                                    "The one who says it cannot be done should never interrupt the one who is doing it."

                                    Comment


                                      #19
                                      Re: CyberPower 1500AVR - Repair

                                      Guess it's even worse than I thought
                                      Less jewellery, more gold into electrotech industry! Half of the computer problems is caused by bad contacts

                                      Exclusive caps, meters and more!
                                      Hardware Insights - power supply reviews and more!

                                      Comment


                                        #20
                                        Re: CyberPower 1500AVR - Repair

                                        it develops a carbon track that rapidly grows and gets exponentially worse.
                                        pretty soon you have a big hole in the board or worse a fire.
                                        i bet if a major mfr gets sued and a huge judgement this shit will go away overnight.
                                        unfortunately that means folks die over this.
                                        Last edited by kc8adu; 12-03-2017, 01:34 PM.

                                        Comment

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