Download the back ups cs 500 diagram. Design and repair of uninterruptible power supplies from ARS. PC connection
This source model uninterruptible power supply is also frequent guest on the desks of service engineers. The APC RS 500, as a rule, works properly for two years, after which a defect appears in almost every source.
Repair of uninterruptible power supply APC-500:
The first sign of a malfunction is darkening of the upper part of the case due to overheating of the elements. The UPS does not charge the battery to the nominal level; the charging voltage is often no higher than 5 - 8 volts. In this case, the battery fails and the UPS simply does not turn on.
Such a malfunction often leads an inexperienced repairman to make a common mistake. The technician changes the battery uninterruptible power supply It turns on and seems to work properly.
But this continues until the battery is completely discharged, which then has to be replaced with a new one due to a noticeable loss of capacity. Therefore, it is important to check the charge voltage when replacing the battery. When measuring, the source must be connected to the network, and one of the battery contacts must be disconnected.
The source does not turn on or the low battery indicator lights up
APC Back UPS RS 500 is a stand-by type source, the battery is charged from a converter assembled on a UC3843 PWM controller chip.
The circuit starts when the voltage on capacitor C7 reaches 7.8-9.0 volts. This voltage is obtained at the divider R28, R139. After startup, the PWM controller is powered from the transformer via the diode circuit D7, R50. Due to the leakage of this same capacitor C7 (22 μF x 16 V), resistor R28 begins to heat up, the output voltage of the source decreases, as well as the battery charge.
It is better to install a capacitor with a higher operating voltage and an operating temperature of 105 degrees. If, after replacing C7, resistor R28 does not stop heating, you need to check capacitor C43 or replace the PWM controller chip.
High charge voltage, noise during operation
Another malfunction UPS, this is an increased charge voltage to 18 volts. The cause of the defect must be sought in the output voltage stabilization circuit (highlighted in the diagram above). Most often, optocoupler U2 or stabilizer chip IC6 fails.
Also, the stabilization circuit is disabled if the signal CHARGER_EN has a potential above 0.8 volts. In this case, optocoupler U3 should turn on and bypass capacitor C44, which leads to stopping the generator of the PWM chip and turning off the converter.
If U3 is faulty, the converter will not turn off, and the output voltage will rise to 18 - 22 volts. Also, if the output voltage is too high, you need to check the serviceability of Q34, C61, C41.
If one of the elements listed above is faulty, after the battery is fully charged, the uninterruptible power supply begins to make quite a loud noise. UPSs of earlier releases are also noisy due to capacitor C22 with a nominal value of 0.1 µF x 400V; later it was replaced by 10 µF x 400V (see photo above).
Burnt resistors
In almost every source, you can find burnt 10 ohm resistors. These are R150 and R151. They are connected in RC spark extinguishing circuits on the contacts of relay RY3.
Any noticeable effect on UPS operation burnt resistors do not have any effect, but in order to avoid the need to replace the relay later, the elements must be replaced.
Replacing the APC-500 UPS battery:
Hello all readers! Got me in hands ups APC Back-UPS CS 500VA BK500-RS. It has been working for a long time, I don’t remember since when. Planned repairs in the form of battery replacement. Otherwise the electronics are fine. There seems to be plenty of material on this UPS on the Internet, but I’ll still make my own article for the story) Let’s start with the characteristics:
Exit
Output power: 300W / 500VA
Maximum set power (W): 300W / 500VA
Rated output voltage: 230V
Topology: Standby
Voltage waveform type: Step sine wave approximation
Maximum output force current: 7
Output Connectors: (2) IEC Jumpers (Battery Backup); (1) IEC 320 C13 (selector_surgetitle); (3) IEC 320 C13 (Battery backup)
Switching time: 4 ms typical: 8 ms maximum
Input
Rated input voltage: 230V
Input frequency: 47 – 63 Hz
Input connection type: IEC-320-C14 inlet
Input voltage range when operating from the network: 180 - 260V
Variable (settable) input voltage range: 160 - 282V
Number of power cords: 1
The case of this UPS is plastic, it was once white. Over the course of its use, it turned into a dirty white color, and plus everything, we had this UPS in the server room, where it was repaired. In general, now he is such a handsome speckled man. On the front panel there is a power button for the UPS, and four LEDs that notify us of what is happening with the UPS. There are ventilation holes on the sides at the very bottom. Exactly the same ones are available on the top of the source. Serves for natural cooling.
On the rear panel there is an input connector, a block of output connectors, three connectors operate from the battery in the event of a power failure, and one, marked in gray, is connected to the input connector, but only through circuit breaker, you will see it below. There is no protection for the telephone line or Ethernet. At the bottom of the UPS there is a battery compartment cover, which is a full-fledged box, and is separated from the electronics board and transformer. I've always liked this about APC. This kind of feature doesn't come across often.
To get to the electronics, we need to unscrew two screws on the back panel, remove it (which is very easy), and then remove one of the halves. Next, to free the board, you need to disconnect the wires. This is where I had to puff. All wires suitable for the power connectors of the rear panel are terminated by soldering. And here is that same WY63 7.0 A circuit breaker. It is installed based on how much the input wire can withstand.
Front panel board. There is nothing special about it: a microphone and four LEDs. But here there is an interesting point. The board is connected with a flat cable, which is not soldered into the board, but is first crimped at the ends, and only then sealed into the board with such tips. A very interesting solution.
All electronics are made on one board. The installation is of high quality, there are no complaints. The board is double-sided, assembly is done automatically. The only thing is that the board is cut a little poorly from the overall blank. So hairy. The main thing is that it’s not like in the riddle: “It’s standing in the corner and it’s hairy.”
The board contains full-fledged interference filters. In addition to the fact that there is a filter at the input, there are a lot of noise-suppression capacitors installed at the output. A little more detail: choke 420-0053-Z-001, varistor, many JNC X1/Y1 ceramic capacitors.
The power supply is assembled according to pulse circuit using a PWM controller from Power Integrations. The capacitors in the power supply are installed by Jamicon.
There is only one relay installed on the board. It is made of white plastic. DC12V model from OEN India Limited.
Let's move on to the inverter. It is assembled on two transistors from STMicroelectronics, which are installed on two radiators for cooling.
Next to it there are two transistors from the same STMicroelectronics. One is connected to the winding of the transformer, but I didn’t look where the other is connected, and I didn’t particularly wonder what they were used for.
As I said earlier, APC loves to make complex devices, stuffed with a bunch of protections. From here, a huge number of components and chips immediately grows, which varies from one device to another. On this board were found: two op-amps from ON Semiconductor, a shift register and an oscillator
My UPS has failed.
My UPS is APC Back-UPS CS 500, this also applies to slightly younger and older models that have successfully served their service life of 3-4 years (they don’t last longer - it’s all about the battery).
As a good citizen, I decided to replace the used battery with an original one, which is recommended by the manufacturer. This model retails from 1,500 to 1,800 rubles, while I managed to find a new Back-UPS CS 500 for 2,000 rubles. There is no particular point in buying a battery separately.
The store advised me to buy an analogue of this battery for 450 rubles, and after searching for a similar problem on the forums, it turned out that it was enough to peel off the sticker from the old battery and look at it full specifications and buy the right one.
We peel off the sticker and find there CSB 12v 7Ah
(Photo not mine, but I had exactly the same battery)
Most stores have exactly the same “battery” in stock at a price of 600-900 rubles (depending on the greed of the seller), I also found it for 550 rubles. But I don't need it.
Here's why:
There are 12v 9Ah batteries, which in most cases are identical in size to the “original” one that was in UPS.
Battery manufacturers should be divided according to price/quality ratio:
Yuasa - seems like the most best manufacturers(not tested, but this statement can be found on forums from many users)
C.S.B. - a manufacturer of pretty good batteries, which is what APC resells under its own brand
Delta - good batteries at an adequate price.(One of my friends checked it - the battery lasted 5 years). I advise you to focus on him, because... the price corresponds to the quality 100%.
That’s what I did and bought a Delta HR 12-34W 12v 9Ah for 630 rubles.
Also suitable: Yuasa NPW45-12 12V/9AH and C.S.B. 12V/9Ah HR1234W
A small upgrade won't hurt and for this you will need:
Phillips screwdriver
Soldering iron and accompanying kit
Hot glue gun
1m wire (I borrowed them from an old power supply)
Diode 12 V
Drill with drill
Anti-slip stickers for furniture 4 pcs
Small plastic clamps
And most importantly - Switch button
First, glue the rubber pads to the corners, having previously degreased the surface.
I was always annoyed by the sound made by the UPS, but it was not possible to turn it off or turn it down, so I often had to wake up in the middle of the night from its screams. It remains to correct this omission of the manufacturer:
Opening the case:
Unscrew the two screws, then lift the cover up, put it on its side and lift part of the case, so the board with all the giblets should remain in the lower part, and disconnect the upper part along with the red and black cables. We put it aside.
We find the speaker and carefully remove it with a soldering iron and place a couple of pins in its place, for example from one of the connectors of the old motherboard
We mark the back panel of the UPS with a marker for the appropriate size of the future switch and make a neat hole
Drill a hole suitable for the size of the diode in the protrusion of the front panel
We connect all parts of the circuit (switch, diode and speaker) using a wire according to a primitive circuit, assemble the wires with clamps and place all parts on free seats in the case, fixing with hot glue.
Reassemble the body in reverse order.
Result:
* Vibration has been significantly reduced
* The sound can now not only be turned off completely, but also replaced with a light indication
* UPS capacity increased by 30%
* Significant savings have been made so that the toad has had his fill and no longer begins to choke at the thought of buying a new UPS.
I tested the new battery, it gets charged and discharges as usual, but it works better than before. Lasted 43* minutes with wifi turned off (* aimak 2009 24")
I hope my experience will be useful to someone and will save money, time and nature.
This model of uninterruptible power supply is also a frequent guest on the desks of service engineers. The APC RS 500, as a rule, works properly for two years, after which a defect appears in almost every source. The first sign of a malfunction is darkening of the upper part of the case due to overheating of the elements. The UPS does not charge the battery to the nominal level; the charging voltage is often no higher than 5 - 8 volts. In this case, the battery fails and the UPS simply does not turn on.
Such a malfunction often leads an inexperienced repairman to make a common mistake. The technician changes the battery uninterruptible power supply It turns on and seems to work properly. But this continues until the battery is completely discharged, which then has to be replaced with a new one due to a noticeable loss of capacity. Therefore, it is important to check the charge voltage when replacing the battery. When measuring, the source must be connected to the network, and one of the battery contacts must be disconnected.
The source does not turn on or the low battery indicator lights up
APC Back UPS RS 500 is a stand-by type source, the battery is charged from a converter assembled on a UC3843 PWM controller chip.
It is better to install a capacitor with a higher operating voltage and an operating temperature of 105 degrees. If, after replacing C7, resistor R28 does not stop heating, you need to check capacitor C43 or replace the PWM controller chip.
High charge voltage, noise during operation
Another malfunction UPS, this is an increased charge voltage to 18 volts. The cause of the defect must be sought in the output voltage stabilization circuit (highlighted in the diagram above). Most often, optocoupler U2 or stabilizer chip IC6 fails.
Also, the stabilization circuit is disabled if the signal CHARGER_EN has a potential above 0.8 volts. In this case, optocoupler U3 should turn on and bypass capacitor C44, which leads to stopping the generator of the PWM chip and turning off the converter. If U3 is faulty, the converter will not turn off, and the output voltage will rise to 18 - 22 volts. Also, if the output voltage is too high, you need to check the serviceability of Q34, C61, C41.
If one of the elements listed above is faulty, after the battery is fully charged, the uninterruptible power supply begins to make quite a loud noise. UPSs of earlier releases are also noisy due to capacitor C22 with a nominal value of 0.1 µF x 400V; later it was replaced by 10 µF x 400V (see photo above).
Burnt resistors
In almost every source, you can find burnt 10 ohm resistors. These are R150 and R151. They are connected in RC spark extinguishing circuits on the contacts of relay RY3.
Burnt resistors do not have any noticeable effect on the operation of the UPS, but in order to avoid the need to replace the relay later, the elements must be replaced.
Download the diagram You cannot download files from our server
Uninterruptible power supplies (UPS) Back-UPS CS 350 and Back-UPS CS 500 are designed for desktop PCs. Back-UPS CS 350 and 500 VA provide reliable power supply, equipped with three connectors with power surge filtering and battery backup capability and one connector only for surge protection, indicators, and protection for fax modem and DSL lines. The main characteristics of the sources are given in Table 1.
Table 1.
Parameter | Description |
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Manufacturer code | |||||
Main Features |
|||||
Standby UPS/ for home and office (Stand-by UPS) |
|||||
Input voltage range AC, V | |||||
Power | 210 W/ 350 VA | ||||
Input voltage | 230 V (AC) V (AC) single phase 230 V, 50 or 60 Hz ± 3% (auto-sensing) |
||||
Input frequency range | |||||
Jump energy | |||||
Output voltage | Stepped sine wave approximation, voltage 230 V ± 8% (with auto detection) |
||||
Control Panel | LED display with load and battery charge scales, as well as On Line (mains operation): On Battery (battery operation): Replace Battery (battery replacement): and Overload (overload) indicators |
||||
Special Features | Autotest with battery status recording, network protection, network filtering, automatic self-test every 14 days, manual self-test |
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Additional Features |
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1 internal acid-lead (lead-acid), operating time 22.2 min. at 50% load, typical battery charging time (up to 90%-95% capacity) - 6 hours |
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Interfaces and connectors | DB-9 for R.S.-232 ,USB 3 IEC-320 C13 power outputs |
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Physical characteristics |
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Dimensions (WWG), Weight | 16.5 cm x 28.5 cm x 9.1 cm, weight 6.3 kg |
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Minimum charging current value, [mA] | |||||
Nominal value of charging current, [mA] | |||||
Maximum charging current value, [mA] |
Microcircuit IC4 (TNY255) is a PWM controller that provides switching of the internal FET transistor with a frequency of 130 kHz, while stabilization of the output voltages is carried out by changing the open time of the internal transistor.
Signature: Fig. 3 The FET transistor current is limited at each clock cycle, i.e., when the amount of current flowing through the FET reaches the value set inside the microcircuit, the FET transistor turns off. If the voltage at the output of the pulse converter has a nominal value, the TNY255 microcircuit “skips” several generation cycles, i.e., at this time its operation is prohibited. This prohibition is carried out by introducing a signal feedback, acting on the ENABLE input.
The feedback circuit of D2 (16V), resistor R62 and microcircuit IC6 is designed to stabilize the output voltage of the pulse converter at 17V. Stabilization is carried out by opening the zener diode D2 and passing current through the LED of the optocoupler IC6. Resistor R62 ensures that the maximum current flowing through D2 and the LED of optocoupler IC6 is limited to 130mA. As a result, the phototransistor of the optocoupler opens and shunts the collector-emitter pin 4 (ENABLE) of the TNY25S microcircuit to ground with its junction. The microcircuit is blocked, and therefore the pulse converter is turned off. The voltage on capacitor C45 begins to drop until the zener diode D2 closes, which in turn prevents the flow of current through the LED of the optocoupler IC6. The phototransistor of the optocoupler closes, and the TNY255 microcircuit begins to generate again, which leads to an increase in the voltage at C45. Thus, the pulse converter operates in intermittent mode, maintaining the specified voltage on C45.
The voltage from capacitor C45 is then supplied to chip IC3, which is a 13.7 V linear stabilizer. In addition to stabilizing the voltage for charging the batteries, it limits the battery leakage current to no more than 90 mA during periods when the charging circuit is not working. The stabilizer has built-in current and thermal protection. If the current or thermal protection is triggered, the stabilizer chip turns off, but after this emergency event ends, the stabilizer should automatically restart. To monitor the correct operation of the battery charging circuits, the CHARGER_ON signal is generated for the UPS microprocessor using the diode assembly D38 and resistor R9. This signal generates +12V and +5V voltages for the microprocessor and other circuits on the main control board.
PC connection
The UPS is connected to the PC via a specialized 10-pin connector. On the UPS side, the connector has 10 pins, and on the PC side, the cable connects to a USB connector or one of the computer’s serial interfaces. To transmit signals via the USB interface, the UPS uses the pins of connector J1. The purpose of which is given in Table 5 below.
Table 5
Conn. number | Purpose |
USB power(VCC) |
|
USB signal D- |
|
USB signal D+ |
|
Shielding |
If there is a connection via USB, then the interface controller is powered by voltage from the PC (+5V) and signals the connection to the UPS microprocessor, then data and signals will be exchanged via this interface. The J1 connector for the PC software receives signals that “inform” it about the state of the UPS; this exchange mode is called “Simple Signaling”. TTL level signals are received at connector pins 3, 8, 2, 4, 7. The purpose and functions of the signals are given in Table 6. To work with the UPS using of this cable, APC PowerChute Plus software is used.
Table 6
Conclusion | Name | Purpose |
Inverter Shutdown (INVSD) | UPS shutdown input signal. To turn off the UPS, a high level TTL signal (+5V) must be established on this contact. Setting a high level signal on pin 8 of J1 leads to the opening of transistor Q9, therefore, 10 and 11 will be present at the microprocessor inputs (U1) low level signal, it is read and the UPS shutdown procedure is initiated. Also, shutdown can be done from controller U2 via the USB interface by controlling transistors Q14, Q16. |
|
Transfer On Battery Signal | Output signal indicating that the UPS has switched to battery power. The moment the UPS switches to battery power, this signal changes from low to high (+12V). |
|
Low Battery Signal | Output signal indicating that batteries discharged. This contact is an open collector output. The signal on the contact is set to a low level if the voltage on the batteries falls below the corresponding threshold (11V), i.e. the batteries are discharged. This signal informs the user to shut down and save data. |
|
General. This pin is used as a common pin for the input and output signals of the interface. |
Inverter
The inverter - one of the main modules of the power source - consists of four powerful field effect transistor(Q70, Q8, Q6, Q15), controlling the current in the primary winding of the transformer. Transistors, switching in the sequence specified by the processor, create an output power transformer step voltage. They are controlled by a microprocessor (pin 20,21) through a specialized microcircuit IC8. The power stage of the inverter is made according to a push-pull circuit, so it is necessary to control the upper and lower shoulders of the cascade.
Control signals for transistors are generated at pins 12 and 14 of the IC8 chip. The condition for issuing pulses is the presence of control signals from the microprocessor at inputs 10 and 11. The combination of TTL input signals is presented in Table 7.
Table 7
Signals from the CPU | Signals from IC8 |
|
Inverter control signals |
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No signals |
||
Also, the IC 8 microcircuit is assigned the functions of protection against excess current flowing through the inverter transistors. The control circuit is implemented on resistors and diodes R98, R5, D32, and D34, as well as transistors Q26 and Q17, the signal from this circuit is sent to pin 7 of IC8, from which the protection is carried out. Additional function The microcircuit is the formation of an OSC signal at pin 16, which is used to generate a -8V voltage using circuits C28, D48 and C43, as well as to control sound in the user notification circuit (Q29, BZ1).
Table. Brands of elements depending on the UPS model
R E F D E S | BK350 | V K 5 0 0 | V K 3 5 0 I | V K 5 0 0 I |
C6, C7, C4, C27 | ||||