Cyberpower PR1500 won't charge battery

[jiroy]

Re: Cyberpower PR1500 won't charge battery

Reading this thread from the start , while taking in consideration some of those cyberpower exceeded ten years of service , lead me to two options , the boards should be checked for weakening solder points , and then a full re-solder is a must , as well as checking the resistances over 1 watt . .

The other option is considering there is one faulty battery among the new ones ...

[budm]

Re: Cyberpower PR1500 won't charge battery

The batteries are new - and the voltage for the four batteries at the UPS is about 50V (with the UPS plugged in or not).

Is that the reading without load connected? You need to load the batteries to check the Voltage under load.

[CamilliLa]

Re: Cyberpower PR1500 won't charge battery

The batteries are new - and the voltage for the four batteries at the UPS is about 50V (with the UPS plugged in or not).

[kc8adu]

Re: Cyberpower PR1500 won't charge battery

are you sure the batteries are good?
i can show you 20 or so 17 ah ups batts on my recycling pile that are 12.9v but crash to 0 with a tink of the meter hitting the 0 stop of the meter on my cheap 50a cheese grater type tester.
the unit may be powering up fine but the battery voltage drops to nothing as soon as it tries to start the inverter for a power on test.

[CamilliLa]

Re: Cyberpower PR1500 won't charge battery - Still a potato

Still a potato (doorstop).

I replaced the capacitors (C40, C44, C45, and C47) and put in fresh batteries - in my PR2200.

When I turn it on, one beep, all lights except wiring fault come on, then blink off twice, on for a second or so, the fan comes on (and the lights flicker a bit). Then, they all go out, and the fan goes off. Repeats indefinitely. Unplugging it while it's doing this causes all of the lights to go out, but the fan to run steadily.

Haven't figured out if it's actually charging the batteries; I THINK the voltage at the batteries was higher when I turned it on. [It's near a range boundary of the meter I used, and the capacitor that seems to be across the batteries (for what purpose?) interferes, and, it seems like the self-test failure should be more informative - except that we don't seem to be able to find any documentation on what the beeps and blinking lights mean. The owner's manual says what the lights and beeps mean once it gets past self-test, but has nothing about self-test failure.

What I'd like to know: Is there a correct service manual? [For example, the part numbers in the manual that's posted in this forum have no relation to what's on the circuit board, at least for the charging circuit. -In the diagram, no C40, C44, etc... On the circuit board, the rectifier bridge near the little transformer in the upper left corner is D30. In the circuit diagram, that part seems to be D17.] And, the manual itself is internally inconsistent: On page 13, it has a table of parts/places to measure resistances, supposedly in the inverter section. But, those numbers correspond to parts in the charging section. (And the manual seems to be only for 230V versions.)

Anybody?

[CamilliLa]

Re: Cyberpower PR1500 won't charge battery

Somebody posted a request for (I assume) DigiKey/Mouser catalogue or Panasonic part numbers for the capacitors. Seems like a good idea, with lots of people with the same problem. It's been years since I've ordered a capacitor; took me quite a while to figure out which capacitors Panasonic FMs (and FC, etc.) are.

I have a PR2200 with the same problem. Called CyberPower; they said it's the batteries, so I bought new ones and then noticed no charging. (CyberPower also told me that there is no service manual; recent search found this site; wonderful!) I still haven't found C40 on the circuit diagram in the posted service manual. [But, I found it on the circuit board, which is what counts.]

The lead spacing for the C40 capacitor seems to be about 2.5mm. That means:
DigiKey P14413-ND / Panasonic EEU-FR1E101 or Mouser 667-EEU-FC1E101S / Panasonic EEU-FC1E101S.

For the others...
DigiKey P15403-ND / Panasonic EEU-FR1J101L
DigiKey P19659-ND / Panasonic EEU-FC1H470H

Is the 20% tolerance on the capacitance close enough?

[CamilliLa]

Re: Cyberpower PR1500 won't charge battery

Somebody posted a request for (I assume) DigiKey/Mouser catalogue or Panasonic part numbers for the capacitors. Seems like a good idea, with lots of people with the same problem. It's been years since I've ordered a capacitor; took me quite a while to figure out which capacitors Panasonic FMs (and FC, etc.) are.

I have a PR2200 with the same problem. Called CyberPower; they said it's the batteries, so I bought new ones and then noticed no charging. (CyberPower also told me that there is no service manual; recent search found this site; wonderful!) I still haven't found C40 on the circuit diagram in the posted service manual. [But, I found it on the circuit board, which is what counts.]

The lead spacing for the C40 capacitor seems to be about 2.5mm. That means:
DigiKey P14413-ND / Panasonic EEU-FR1E101 or Mouser 667-EEU-FC1E101S / Panasonic EEU-FC1E101S. No?

[8ternity]

Re: Cyberpower PR1500 won't charge battery

10 years? you'll be lucky if get 3~5 years.
What DC Voltage do you get at the wires (red and black) to the batteries without batteries connected, around 55VDC?

Agreed. battery life is about 3-5 years. Lucky if you get 6 or 7 years.

[jcharing]

Re: Cyberpower PR1500 won't charge battery

Voltage from (and to) the battery pack is fine. The unit does power up. It's throwing the error tones and no output to the rear outlets.

[LetsGo]

Re: Cyberpower PR1500 won't charge battery

I moved this board into my original pr2200 (that one had a board fried beyond repair) in the hope that the issue was a transformer or other part of this "new" pr2200 that was off the main board. Got the same behavior and error tones. So the issue does appear to be somewhere on the main board itself. So the charging circuit is fixed but there is a second issue causing the unit not to power up.

If the battery voltage is too low, the unit doesn't power up for me. The battery pack should supply 48V. I had two wires reversed on one of the batteries, so I was supplying 24V, and my PR1500 would not power up. Fixed the bad connection and it's back to normal. What is the voltage on your battery pack?

[LetsGo]

Re: Cyberpower PR1500 won't charge battery

I also replaced caps C40, C44, C45, and C47 in my PR1500 with the FR and FC series Panasonic caps from DigiKey as budm had mentioned previously. The unit is now charging the batteries again, and so far appears to be working properly. Strangely, the PowerPanel status shows the battery fluctuating between 89 and 91% charged after charging overnight, but all four battery level LEDs on the front panel are lit. The battery voltage reads 55.2V. All four batteries are brand new 8 Ah units.

Before I changed out the caps, the UPS was not only not charging the batteries, but it was discharging them slowly. By the time I found this happening, the battery voltage was in the low 40's (maybe 42v?), and I immediately shut it down and charged each battery individually with a BatteryMINDer charger until they reached the float charge stage. Maybe the discharge level damaged the new batteries such that they are no longer capable of maintaining full voltage? Any opinions on that?

My thanks again to budm for his expert guidance. I was not looking forward to spending another $400 on a new UPS, especially after having just invested $50 in new batteries for this one. A couple bucks to DigiKey and four cap replacements later, I'm back in business.

[LetsGo]

Re: Cyberpower PR1500 won't charge battery

Batteries fully charged

1. depress power button; single beep
2. all three columns of leds light except wiring fault led at top of column three
3. column three goes out; columns one & two on with top load light yellow
4. at same time as #3, 1 short and four long beeps
5. all lights out; several second pause
6. all lights on briefly, then right bank off
7. one short & four long beeps
repeat #5 to #7 indefinitely

Could this be worn out MOVs from a frequent surge environment? The long beeps seem to indicate an overload condition.

[jcharing]

Re: Cyberpower PR1500 won't charge battery

I moved this board into my original pr2200 (that one had a board fried beyond repair) in the hope that the issue was a transformer or other part of this "new" pr2200 that was off the main board. Got the same behavior and error tones. So the issue does appear to be somewhere on the main board itself. So the charging circuit is fixed but there is a second issue causing the unit not to power up.

[jcharing]

Re: Cyberpower PR1500 won't charge battery

Batteries fully charged

1. depress power button; single beep
2. all three columns of leds light except wiring fault led at top of column three
3. column three goes out; columns one & two on with top load light yellow
4. at same time as #3, 1 short and four long beeps
5. all lights out; several second pause
6. all lights on briefly, then right bank off
7. one short & four long beeps
repeat #5 to #7 indefinitely

[budm]

Re: Cyberpower PR1500 won't charge battery



How about the LED indicators? What do they show? Batteries are fully charged?

[jcharing]

Re: Cyberpower PR1500 won't charge battery

Purchased another used PR2200 "parts only" UPS. It was putting out only 34 volts to the batteries, and replacing C40 and the other caps in the charging circuit brought that up to 54 volts. But the unit still is not operating (new batteries installed). On startup I get one short and 4 long beeps, and this repeats at intervals. Can't find diagnostic tone table in the service manual or on line. Suggestions?

Unit puts out the 54 volts to the batteries when plugged in, whether or not switched on. No AC voltage at the rear outlets. No signs of physical damage or scorching on the main board. All connections triple checked. All solder spots rechecked.

[LetsGo]

Re: Cyberpower PR1500 won't charge battery

So glad I found this thread, and thanks to budm and everyone who replied with results. I am going to attempt the same repair of replacing C40 on my PR1500 and will report back. Hope my ham-handed soldering is up to the task!

[jcharing]

Re: Cyberpower PR1500 won't charge battery

Thanks, will do. Becoming an expert on maneuvering the board out and back in.

[budm]

Re: Cyberpower PR1500 won't charge battery

"Budm: how important is it to also replace 44, 45 & 47? " These caps are on the secondary side of the charging circuit, C40 is in the primary side of the charging circuit. The caps can look normal but they can dry out and lose its capacitance, ESR goes up, lytics cap does have shelf life (see SU-SCON SK spec sheet), heat is also the problem. Chance of those caps to go bad is very high. Recap the whole board is good idea, but you can at least do that in the charging circuit otherwise you may have to spend money on batteries when the batteries go bad due to not being charged.
You should also exercise (kill the AC to the UPS) the UPS once a month to make sure that it still have enough run time on the batteries.
Another thing you can try is to disconnect the batteries once the UPS is powered up and finish the self test to see if it smarts enough to detect open batteries circuit.

[jcharing]

Re: Cyberpower PR1500 won't charge battery

Since this type of repair is beyond what I want to attempt, I took a look on eBay. A fair number of the PR2200 units are there, several "as is" "parts only" as the units won't power up. Clearly most owners don't know this is "normal" for this unit if the batteries are discharged. Picked one up for 99 cents as the only bidder--plus a hefty but fair shipping charge.

Upon arrival, I put in fresh batteries and the beast powered right up. Bad news: the board is putting out 34 volts to the battery pack. But no sign of any scorching or physical damage. I had ordered one extra 100uF 25v capacitor when I did this on the original board, so put that in to replace C40. Voltage now up to 54 and seems to otherwise working well.

Budm: how important is it to also replace 44, 45 & 47? I'm generally an "if it ain't broke, don't fix it" person. The spade connectors on this board are also very tight and I pulled two of the male ends out of the board when I removed the wiring (no such issues with my original board), so I'm hesitant to keep taking the unit apart unless it's needed. The cost of the parts is less than the shipping, so cost is not the factor. Just don't want to risk breaking what is now working, unless chances are good that those other caps are going to fail.

Thanks for all the help on this matter.