Cyberpower PR1500 won't charge battery

[budm]

Re: Cyberpower PR1500 won't charge battery

That carbonized section has to be removed so that is the problem, also there are SMD resistors in that burnt section.

[CapLeaker]

Re: Cyberpower PR1500 won't charge battery

I'd be doing that, if it is a worthy piece of electronics that's non available anymore / custom etc. But for that, the effort is more than what is it worth.
That's job is not for an inexperienced and you would have to have all the proper stuff for sure. The black stuff has to come out, all of it, as it is conductive.

[stj]

Re: Cyberpower PR1500 won't charge battery

that will look a lot better with a good clean.
biggest problem is getting a good pair of foto's of one that is not damaged.

[Agent24]

Re: Cyberpower PR1500 won't charge battery

That is the primary side driver circuit which is too far gone to be repaired, the component that burnt out are for the snubber circuit for that power MOSFET which drives the power transformer for charging circuit.

I reckon it's fixable... in theory... I saw the idea here: https://youtu.be/7o4ZWlG6mmo?t=16m12s

With another unit to compare with or a schematic I reckon I'd be able to do it, I'd probably etch my own replacement board piece though to put in the hole, rather than trying to stick traces onto a blank board.

I would agree it's not something for someone inexperienced though.

[budm]

Re: Cyberpower PR1500 won't charge battery

That is the primary side driver circuit which is too far gone to be repaired, the component that burnt out are for the snubber circuit for that power MOSFET which drives the power transformer for charging circuit.

[jcharing]

Re: Cyberpower PR1500 won't charge battery

Purchased PR2200 for my church in August of 2010. Batteries replaced in June of 2014 after being unable to power the unit up similar to other posters' experience. In early August we had a severe storm that did a lot of damage to sections of Long Island, and the church lost power for about 2.5 days. When power was restored, everything in the server closet came back up. My fault, I did not look at the battery state LED's on the front of the UPS.

About five days later I get a call from the office that they had a power blink and everything computer related was down. Went into the server closet and the UPS was dead. With one year old batteries, obviously something else was at work and I called CyberPower tech support. They gave me the same story that other posters got; basically if I replaced the batteries the unit may or may not work. They recommended getting a new UPS, which I did. Lugged the old one home and took a chance after finding I could get four replacement batteries for about $80. The unit powered up, but after a few days the batteries discharged. The board was putting out about 37.5 volts to the batteries. The batteries, fully charged, put out about 52 volts.

I found this post, and replaced capacitors 40, 44, 47 and 45. No joy. Here's where my situation is different. When I removed the board, I found scorching around twin capacitors C138 and the one next to it (scorching removed the number). Both are 100uF 250v. So I replaced them as well as 19 and 20 (1,000uf 63volts; no real reason other than that they were pretty big and since I was paying the minimum shipping from Mouser, why not?). Again, no joy.

Unless someone has another magic answer, the board appears to be toast. The scorching is not really noticeable on the top of the board unless you are looking right there, or the capacitors are removed. Much more noticeable on the bottom. There is a heat sink in the immediate area, which may or may not be related. I'm no electrical engineer. Two photos attached. So if you are having the same issue, I recommend you look closely for damage in that area of the board before investing your time and money on a board level fix. At least it was an educational experience and hopefully I'll be able to use the batteries in another UPS or alarm box.

[userdraco]

Re: Cyberpower PR1500 won't charge battery

back from a trip and replaced capacitor C40 of my faulty cyberpower pr2200, also the two big caps (which showed sign of leaking) for the rectifier. Now the charger is back to work outputting 54 V. Thanks a bunch budm for the solution!!!!

[userdraco]

Re: Cyberpower PR1500 won't charge battery

My CyberPower PR2200 has exactly the same changer problem. Searched internet for a week and finally found this thread. Will try to replace the caps and report back later.

Thanks a bunch for the thread.

[budm]

Re: Cyberpower PR1500 won't charge battery

Hi all, great thread but can anyone list part numbers for these? Thank you.

Cyberpower Manufacturer P/N for what? the caps? or the caps values?
See post 17.
As you can see, you just get the capacitance and Voltage value, the dimension of the caps then go to Digikey or Mouser and look for PANASONIC CAP FM/FR or FC series for the replacement.

[peterg]

Re: Cyberpower PR1500 won't charge battery

Hi all, great thread but can anyone list part numbers for these? Thank you.

[budm]

Re: Cyberpower PR1500 won't charge battery

Thanks for the good news, I fixed many of those boards with all the same failed cap (C40).

[elmo]

Re: Cyberpower PR1500 won't charge battery

Success! I installed the new batteries yesterday and everything is now working. Thanks to everyone for your help and especially to Budm for the accurate diagnosis that C40 was the cause of the malfunction. My total cost for parts and shipping was under $90.

[budm]

Re: Cyberpower PR1500 won't charge battery

Glad to hear the result, <$10 in repair + batteries.
Thanks for the follow-up.

[elmo]

Re: Cyberpower PR1500 won't charge battery

Good news. I got the replacement capacitors the other day and installed them yesterday. The charging circuit is now working well; charges up the battery whether the UPS is on or not. The batteries are not good any longer however. The deep discharge must have finished them off. I have ordered replacements.

[Agent24]

Re: Cyberpower PR1500 won't charge battery

What function does C40 have in the switching regulator? It must be critical for ESR to have that much effect.

Probably the supply smoothing capacitor for the switching controller, if the capacitor is bad the controller won't get steady power or enough voltage etc and it can't operate properly

[elmo]

Re: Cyberpower PR1500 won't charge battery

budm

Good news. You nailed it. Replacing C40 allowed the battery charging circuit to function again. I am now getting 55 Volts on the battery leads. It must have been ESR since the capacitance didn't seem that different from a new one. What function does C40 have in the switching regulator? It must be critical for ESR to have that much effect.

I am now replacing C44, C45,and C47. The bad news is that I ordered the wrong 100uF, 63V capacitors from Digi-key. They are too big to fit in the space provided. Neither Digi-key or Mouser has them in stock so I had to order them from Newark. I will have to wait another week before I can install them.

[budm]

Re: Cyberpower PR1500 won't charge battery

To remove the old caps you will use flux and ADD more solder to the joints using at least 40W iron with wide tip.

[elmo]

Re: Cyberpower PR1500 won't charge battery

budm

I have not replaced C40 yet. I wanted to make sure that that was still the right thing to do. I will go ahead and do that as well as C44, C45, and C47. This will take me a little time because the capacitors are hard to remove. I will get back to you as soon as I have replaced them and reinstalled the board in the UPS.

[budm]

Re: Cyberpower PR1500 won't charge battery

Capacitor cannot be check by Ohm meter since if it still have capacitance but not the correct capacitance, it will still show that it is charging up on the meter, you need capacitance meter and ESR meter to verify the cap.
For example, you can measure the 10uF and 47 uF, you will see both caps can be charged up by the meter so if the 47uF capacitance drop down to 10uF but the circuit requires 47uF to run, you meter will not show that. Then you have to verify the ESR of the cap also.
So are you getting the 55VDC at the black and red wires to the batteries, batteries are not needed to be connected?

[elmo]

Re: Cyberpower PR1500 won't charge battery

budm

I got the replacement capacitors for Digi-key yesterday and started replacing them today. I first removed C40. After removing it from the board I checked it with an ohmmeter. It seemed to check OK. The resistance first measured a short and then climbed toward infinity (>2Mohm). Could it still be bad or could something else be wrong?