Cyberpower PR1500 won't charge battery

[ikalafat]

Guys, I need your help, I was changing the capacitors on the board of my PR2200 and did not see that a piece of the cut-off pin got on the pins of the P7NK80ZFP transistor. The first turn on of UPS was bright😁
Of course, this transistor died immediately. Zener diode D103 and the nearby resistor R135 are also dead.

In my opinion, the UC3845B PWM controller has also failed; there is a trace on its body as if from an electric shock. The resistor R101 next to it also looks bad.
I have several questions for selecting replacements for failed components, I would be grateful if you can help:
1. Values and sizes of resistors R135, R101 and R143
2. Voltage of zener diode D103
3. Is there any way to check the functionality of the UC3845B? If I buy a new one, do I need to program it?
4. Are there any other electronic components that I need to pay attention to or replace with new ones?

Thank you in advance

1. attached images of the board with visible values of R135, R101 and R143
2. unfortunately, I don't have schematic nor I have reliable way to determine value of zener diode, so can't help here.
3. it is easiest to replace it than to fiddle with oscilloscopes. programming is not needed, just replace it


I've fixed 5 of 6 PR1500ELCDRT2U (230V/European, rack version) by replacing many capacitors on the board, one on hot side, other on cold.

6th UPS that I have has an additional problem, with output voltage (BAT+/BAT-) being too high (58.5V), while others have output voltage significantly lower, around 54-54.5V.

I don't have scope, so I can't check the waveforms, but I was considering replacing optocouplers in feedback circuit, and possibly UC3845.
Has anyone had similar issue?

[Alc0pone]

Guys, I need your help, I was changing the capacitors on the board of my PR2200 and did not see that a piece of the cut-off pin got on the pins of the P7NK80ZFP transistor. The first turn on of UPS was bright😁
Of course, this transistor died immediately. Zener diode D103 and the nearby resistor R135 are also dead.

In my opinion, the UC3845B PWM controller has also failed; there is a trace on its body as if from an electric shock. The resistor R101 next to it also looks bad.
I have several questions for selecting replacements for failed components, I would be grateful if you can help:
1. Values and sizes of resistors R135, R101 and R143
2. Voltage of zener diode D103
3. Is there any way to check the functionality of the UC3845B? If I buy a new one, do I need to program it?
4. Are there any other electronic components that I need to pay attention to or replace with new ones?

Thank you in advance

[sam_sam_sam]

Re: Cyberpower PR1500 won't charge battery

One thing about changing the VIPer22A ic chip replace the capacitor next to it as well for good measure
You might want to check the optic sensor right next to the capacitor that I also talk about earlier

If you replace the diode next to the ic chip that you are replacing when installing the new leave a small space between the board and the bottom of the diode when replacing it

Also check an make sure that you do have a short on the wires going to the battery if not then see if you have voltage on the wires to the battery with out the battery connected

[gquiring]

Re: Cyberpower PR1500 won't charge battery

I got a better photo of the chip - VIPer22A for the 1350 UPS. Any ideas on that diode next to it? I am not sure what I should replace.

[gquiring]

CyberPower 1350AVR won't charge

I have a 1350AVR that works except for charging. I replaced the batteries, pulled the power to drain them, restored the power and they are not charging.

There is burnt area on the board, pictures are enclosed. The area in question is near the U3 chip and diode.

[CamilliLa]

Re: Cyberpower PR1500 won't charge battery

Problem solved. I had four PR2000s (two new; two "refurbished" - new batteries; untested; neither charging the batteries). In one, I replaced the capacitor-most-likely-to fail and got a second three years out of it. On the others, I changed the five caps identified here. Most never revived; all were dead by about six years. Changing those capacitors didn't help.

After speaking with the guy with the server farm in his house and many APC UPSes (the oldest of which is 21 years old), I bought a refurbished APC commercial model (not for consumer use, which seems to mean not FCC-compliant for interference). In addition to the UPS, I bought an external battery pack to extend battery time. The external pack actually contains two of the packs like what's in the base, so I've now got three hours of battery time for my AlphaServer. [I can attach 10 external packs for a LOT of battery time.] I have it set to run self-test once a week, so when the batteries fail, I'll know - before there's a power failure. [Hot-swap OK.] Presumably, if the charging circuit fails, I'll know. It can run in pass-through mode - in which the charger charges the batteries as the batteries feed an inverter to supply power or I can run it in standby mode (like those Cyberpowers), which is a little more efficient.

It cost about what the new Cyberpowers cost - and has a better warranty. And, I could have paid more for a warranty that's the same as the actual lifetime I got from the longest-lived Cyberpower UPSes.

I still have some smaller Cyberpower UPSes around the house. One, less than a year old, has an intermittently-blinking power-on light. [I found a YouTube video that claims that the glue that Cyberpower used on some components becomes conductive with age, which causes more failures within the UPS.]

The PR2200s were a huge waste of time and money. [I recycled what I could.] Never again.

By the way, the AlphaServer has two power supplies, so I was a able to move it from an outlet to the "new" UPS without stopping it. Next step is to duplicate the APC UPS so I can have each power supply plugged into its own UPS, with each UPS on a separate line (on alternate sides of the 240/120 split) - for even more reliability.

[sam_sam_sam]

Re: Cyberpower PR1500 won't charge battery

I just changed out C42 on my OR1500LCDRTXL2U that would not power up without batteries. Now it does power up without batteries, and its charging them fine.

I would go headed and replace all the capacitors on this board that are around the area where you replace the capacitor because those capacitors might be questionable also and for good measure

[rotohammer]

Re: Cyberpower PR1500 won't charge battery

I just changed out C42 on my OR1500LCDRTXL2U that would not power up without batteries. Now it does power up without batteries, and its charging them fine.

[CamilliLa]

Re: Cyberpower PR1500 won't charge battery

So, what, exactly, is the purpose of a UPS? People use them to provide reliable power to things like computers that have uptimes of 25 years. If your electronic device has a very short life because of internal heat, maybe it needs better cooling. If it's designed with a critical component that will fail so quickly that the device won't outlast its batteries, maybe the component should be in a socket so it's easy to replace. [Or, maybe it should be like a "Flashcube" that rotates as each flashbulb is used up, sliding the next one into place.]

The person I compared notes with said that his oldest APC UPS is 21 years old. He's replaced the batteries multiple times on multiple units. Apparently, it is possible to design a UPS that'll outlast its batteries.

As far as I can tell, Cyberpower contracted out to some company in China to design and manufacture these things. They made no provision for ECOs as they learned how they fail. They made no provision for repairs. [They refuse to provide any service information to customers. There are service manuals circulating on what seems pretty much like a black market - and the manuals are inaccurate.]

I'd settle for them being honest and admitting that these things aren't designed to last more than five years, so potential customers can decide if they want to go another way.

Of course, eventually, their reputation would make it impossible for them to continue in this business, and they'd have to branch out, perhaps making PCs or something (which involves nothing but assembling commodity componets and slapping a brand name on the outside). -Wait a minute...

People have criticized Keurig for all of the trash that their coffee makers generate. But, how many of these unreliable UPS units are in landfills or sitting in corners, unused?

[redwire]

Re: Cyberpower PR1500 won't charge battery

I don't know what value or function C40 is. What make of capacitor did you use a replacements?
The power supply runs 24/7 which is 8,640hrs per year, if you're using say 3,000hr parts well 5 years life is fine. The temperature is up there too in the 30's, worse if there is a shorted cell and it's stuck in high-rate charging.

[CamilliLa]

Re: Cyberpower PR1500 won't charge battery

Another update. I last posted in 2016 about reviving my second PR2200 by replacing C40. [Replacing the five "usual-suspect" capacitors in my first PR2200 didn't fix it.] {I picked up two supposedly refurbished PR2200s on eBay; both defective, but with new batteries. Got a refund.} My second PR2200 failed again a few months ago. I dug out the extra capacitors that I bought in 2016; if it doesn't work, these things deserve to be recycled. These things should NOT have to be repaired every five years. The charging circuit doesn't last as long as the batteries do. [Reliable power would be nice, but that's not going to happen...]

[SamNorbin]

Re: Cyberpower PR1500 won't charge battery

If someone has a schematic for a PR2200LCDRT2U, please share it. I tried using the PR1500E/2200E/3000E service manual schematic (from page 1 of this discussion) but my unit's circuitry is significantly different. The PCB silkscreen says it's for the "PRII 1000/1500/2200". Various components have 2008 date codes.

[budm]

Re: Cyberpower PR1500 won't charge battery

BTW, you should also make new thread since your model is not the same as OP.

[budm]

Re: Cyberpower PR1500 won't charge battery

Can we see good clear pictures of the whole top and bottom side of the board?

[sam_sam_sam]

Re: Cyberpower PR1500 won't charge battery

Check and make sure that you do not have a short some where in battery charging circuit or circuits that might why you are seeing the charging current going up and down might be the reason that the Viper 22A is running hot or it could a bad chip however if change it and still run hot I would looking for something low ohm short

[electronicsuk]

Re: Cyberpower PR1500 won't charge battery

Sometimes chips will go faulty and overheat by themselves.

Indeed, although probably not this time. I forgot to mention on my first post thay I also replaced the optocoupler on the SMPS. I've just checked back at some photos I took of the PCB before I started, and it looks like the opto should be a Cosmo K1010C. I've fitted a K1010B. The datasheet shows the 1010B has about 50% of the current transfer ratio of the 1010C, so I suspect it's an issue with incorrect feedback to the Viper.

I suppose this is karma for my lazy repair technique - if I'd spent more time fault finding than replacing lots of components that *might* be the problem, I probably would never have replaced the opto in the first place!

Sadly I can't easily get a 1010C in the UK so I've had to order some from China. I'll report back with how I get on. Will probably replace the Viper as well, just in case the thermal overload has caused any damage.

[Agent24]

Re: Cyberpower PR1500 won't charge battery

Sometimes chips will go faulty and overheat by themselves.

[electronicsuk]

Re: Cyberpower PR1500 won't charge battery

Hey guys. I've had a similar issue with my CyberPower OR1000ELCD not charging the batteries, ultimately discharging them to the point thay the UPS wouldn't even power on with mains present. I was almost going to ditch it after already having wasted money changing the batteries, but finding this thread gave me some hope.

As removing the PCB was a bit of a pain and not something I wanted to do twice, I ended up replacing almost all of tjr through hole caps on the board, along with the Viper 22A, TIP42C and the two LM series voltage regulators.

Good news is that the UPS powers on now and I have 27V open circuit at the battery terminals. However, with the batteries connected and an ammeter in series, I can see that the charging current climbs to about 600mA for a couple of seconds, drops off for a few seconds, and repeats ad infinitum.

I know that the batteries are good, having charged them fully from a bench PSU and then running them down while load testing the UPS. I've noticed the Viper 22A runs extremely hot. I've also noticed that after leaving the UPS off for a minute or two, I get continuous charging current for about 10 seconds before the stop/start cycle begins. This all leads me to suspect the Viper 22A is going into thermal shutdown.

As it sounds like the PR1500 and OR1000 share a common charger design, have any PR1500 owners measured the charging current of their UPS into a discharged battery? Assuming the US and EU models are common, the Viper will be set up for wide input voltage range. According to the datasheet, the DIP8 model is only rated for 12W in wide range application. I'm seeing 600mA at 25V, which is 15W - this could explain the Viper going into thermal shutdown. I'd like to know if this is "normal" behaviour (i.e. the charging system is just badly designed), or if I have another fault to find.

I suspect eventually the batteries will charge up, the charge current will decrease and the Viper will come back into limits. That being the case, the UPS might have worked this way from new - I've never had cause to measure the charging current until now and I only own one UPS so can't compare to another working one!

[kitts]

Re: Cyberpower PR1500 won't charge battery

OK, replace C40 (100uF 25V) startup cap, you should also replace the output filter caps C44, C47 (100uF 63V), C45 (47uf 50V) at the same time.
Replace C40 will make the charger circuit work again.
Use good caps such as Panasonic FM/FC/FR series from Mouser or Digikey.

Thank you. Followed this and replaced all 4 caps and now my PR2200 is fully functional!

[budm]

Re: Cyberpower PR1500 won't charge battery

hello, my name is Frank, BUDM can you help me please... I have right now the same problem. The UPS won't charge the battery... I have a UPS Cyberpower model CP1500AVR... The Battery are New......Dou you have the service manual for this equipment ? Thanks very much for all.

Is your board the same as in my post #17? If it is then read post #17 and later to know which caps to replace.