UNINTERRUPTIBLE POWER SYSTEMS

SERVICE MANUAL

PR1500E / 2200E / 3000E

Date Version. Remark

2005/08/23 00 ISSUE

6F., NO. 32, Sec. 1,Chenggong Rd, Taipei, Taiwan 115, Website:www.cyberpowersystems.com TEL: 886-2-26518699 FAX:886-2-26516821
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 Table of Contents
1. Product Feature ----------------------------------------------------------------- 03

2. Components Location --------------------------------------------------------- 04

3. Principle Of Operation --------------------------------------------------------- 06

3.1 System Function Block --------------------------------------------------- 06
3.2 Normal Mode Sub-system ----------------------------------------------- 06
3.3 Boost Mode Sub-system ------------------------------------------------- 07
3.4 UPS Buck Mode Sub-system ------------------------------------------- 08
3.5 UPS Battery Mode Sub-system ---------------------------------------- 08

4. Repair Procedure --------------------------------------------------------------- 09

4.1 Test Procedure -------------------------------------------------------------- 09
4.2 Test Equipment ------------------------------------------------------------- 10
4.3 Repair Steps ----------------------------------------------------------------- 11
4.4 Turn on the unit ------------------------------------------------------------- 14
4.5 Connect the UPS to AC Input ------------------------------------------- 14
4.6 Charging Circuitry ---------------------------------------------------------- 14
4.7 Get Load Connected ------------------------------------------------------ 15
4.8 Customer Service ---------------------------------------------------------- 15

5. Schematic ------------------------------------------------------------------------ 16
5.1 CHGR Parts ----------------------------------------------------------------- 16
5.2 COM & CPU Parts --------------------------------------------------------- 16
5.3 AVR Parts -------------------------------------------------------------------- 17
5.4 INVERTER Parts ----------------------------------------------------------- 18

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Product Features:

Pure Sine Wave Output

Multiple output for multiple servers

Multiple communication interface

Automatic voltage regulator (AVR)

Power Management software included

User-Replaceable batteries

Programmable brownout and over voltage protection

Microprocessor based full digital control

EMI, RFI Noise Suppression

Protection from lighting induced surges and spikes

Phone / Fax / Modem and DSL / Network protection

Scheduled shutdown and restart

Auto-Restart / Auto-Charge

Free USB Cable included

SNMP / HTTP card (optional)

2U Rack Space

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2.Components Location
PR1500E / PR2200E / PR3000E Front Panel (Fig2-1)

○ 1 ○○○ ○ ○ ○
2 3 4 5 6 7 ○8

PR1500E/2200E/3000E
No. Description Q’TY Remark
○ Power Switch
1 1
○2 Test Switch 1
○ Battery Level Indicators
3 4 25%,50%,75%,100%
○4 Load Level Indicators 4 25%,50%,75%,100%
○ Using Battery Indicator
5 1 Yellow LED
○6 AVR Indicator (Boost & Trim) 1 Green LED
○ Power On Indicator
7 1 Green LED
○8 Battery Cover 1

PR3000E Rear Panel (Fig2-2)

○ 3 ○○
3 2 ○ 1 ○8 ○○ ○ ○ ○
4 9 5 6 7 ○8

No. Description Q’TY Remark

○1 Battery Backup and Surge Protection Outlets 2
○2 Output Circuit Breaker 1
○3 Backup Power for Critical Loads 2
○4 Primary Serial Port 1 DB9
○5 Secondary Serial Port 1 DB9
○6 RJ11 / RJ45 Socket 1 1 in / 1 out
○7 Input Circuit Breaker 1
○8 Cooling Fan 2
○9 Battery Socket 1 Extend Battery Bank

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PR1500E/2200E Rear Panel (Fig2-2)

○
1 ○○
2 3 ○
3 ○ 3 ○4 ○5 ○ ○
6 7 ○8

PR1500E / 2200E (IEC) Rear Panel (Fig2-3)

○ ○
1 2 ○
1 ○2 ○ ○ ○
1 2 7 ○4 ○ ○ 5 6 ○
8

No. Description Q’TY Remark

3 Fig2-2
○
1 Battery Backup and Surge Protection Outlets
4 Fig2-3
1 Fig2-2
○
2 Output Circuit Breaker
3 Fig2-3
○
3 Backup Power for Critical Loads 2
○
4 Primary Serial Port 1 DB9
○
5 Secondary Serial Port 1 DB9
○
6 RJ11 / RJ45 Socket 1 1 in / 1 out
○
7 Input Circuit Breaker 1
○
8 Cooling Fan 1

6F., NO. 32, Sec. 1,Chenggong Rd, Taipei, Taiwan 115, Website:www.cyberpowersystems.com TEL: 886-2-26518699 FAX:886-2-26516821
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3.Principle Of Operation
3.1.System Functional Block Diagram

System Functional Block Diagram

3.2.UPS Normal Mode

When AC utility power is normal, it will go through the UPS to provide power (Bypass), at
the same time it will charge battery through AC/DC circuit (UPS Normal Mode).

UPS Normal Mode

3.3.UPS Boost Mode
Boost Mode:
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When the voltage of AC utility power is lower than normal, Boost Relay will activate and
AVR transformer will boost the voltage up to normal mode (Boost Mode), at the same time
utility power keeps charging battery via AC/DC circuit (UPS Boost Mode).

UPS Boost Mode

Double Boost Mode:

When the voltage of AC utility power is lower than normal, Boost & Buck Relay will activate
and AVR transformer will boost the voltage up to normal mode (Double Boost Mode), at the
same time utility power keeps charging battery via AC/DC circuit (UPS Double Boost
Mode)..
Leakage Buck
Inductance Relay

DC Fuse

AC Cap.
48V Batt.
DC Cap.
OUTPUT

Boost
Relay
Transfer
Relay

INPUT
AC Fuse

UPS Double Boost Mode

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3.4.UPS Buck Mode
When the voltage of AC utility power is higher than normal, Buck Relay will activate and
AVR transformer will buck the voltage down to normal mode (Buck Mode), at the same
time utility power keeps charging battery via AC/DC circuit (UPS Buck Mode).

U
PS Buck Mode

3.5.UPS Battery Mode

When AC utility power is abnormal, battery will provide power via DC/AC circuit to output
socket.

UPS Battery Mode

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4.Repair Procedure
4.1 Test Procedure

※For PR1500E/2200E

Item Test point Test Procedure Expected result

D11+(+) 1.Connect power cord to AC 220V/230V
D11-(-) then start UPS
+300V 300V±25V
2.Connect DVM(DC) to test points.
D40 N(+) 1. .Connect power cord to AC
C47 cathode(-) 220V/230V then start UPS.
Battery Charger 54.0-55.2V
2.Connect DVM(DC) to test points.
D45 N(+) 1.Start UPS at Line mode or Battery
ZD3 P(-) mode
+24V 24V±0.5V
2.Connect DVM(DC) to test points.
U8 p1(+) 1. Start UPS at Line mode or Battery
U8 p2(-) mode
+12V 12V±0.5V
2.Connect DVM(DC) to test points.
U8 p3(+) 1. Start UPS at Line mode or Battery
U3 p2(-) mode
+5V 5V±0.1V
2.Connect DVM(DC) to test points.
U5 P42(+) 1. Start UPS at Line mode or Battery
ZD1 P(-) mode
RESET+5V 5V±0.1V
2.Connect DVM(DC) to test points.
U5 p44(+) 1. Start UPS at Line mode or Battery
U5 p45(+) mode
OSC waveform 16M Hz
ZD1 P(-)
2.Connect DSO to test points
1. Start UPS at Line mode or Battery
mode
230V Output 230V±5%
2.Connect DVM(AC) to test points.

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※For PR3000E

Item Test point Test Procedure Expected result

D30+(+)
1.Connect power cord to AC 220V/230V
+300V D30-(-)
then start UPS.
2.Connect DVM(DC) to test points. 300V±25V
D40 N(+) 1. Connect power cord to AC
Battery Charger C47 cathode(-) 220V/230V then start UPS. 54.0-55.2V
2.Connect DVM(DC) to test points.
D45 N(+) 1. Start UPS at Line mode or Battery
+24V ZD3 P(-) mode 24V±0.5V
2.Connect DVM(DC) to test points.
U8 p1(+) 1. Start UPS at Line mode or Battery
+12V U8 p2(-) mode) 12V±0.5V
2.Connect DVM(DC) to test points.
U8 p3(+) 1. Start UPS at Line mode or Battery
+5V U3 p2(-) mode 5V±0.1V
2.Connect DVM(DC) to test points.
U5 P42(+) 1. Start UPS at Line mode or Battery
RESET+5V ZD1 P(-) mode 5V±0.1V
2.Connect DVM(DC) to test points.
U5 p44(+) 1. Start UPS at Line mode or Battery
OSC waveform U5 p45(+) mode 16M Hz
ZD1 P(-) 2.Connect DSO to test points
1. Start UPS at Line mode or Battery
230V Output mode 230V±5%
2.Connect DVM(AC) to test points.

4.2 Test Equipment

• Digital Multi-Meter (DMM) with true RMS measurement
• DC power supply 60V 20A
• Digital Storage Oscilloscope (DSO)
• Energy discharge resistor with the resistance 100 ohm and 50-100W
• Load: 100~200W/230V milky light bulb.

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4.3 Repair Steps
Please follow the repair procedures step by step.
• Check the outlook of the unit to see if there is any damage on the surface.

4.3.1 Preparation
• Remove the cover.

• Disconnect the battery wires.

• Measure the battery voltage by DC voltage meter, the normal voltage should be within the
range of 40V~54.0V
• Discharge the capacitor by connecting the resistor between the anode and cathode of
C19/C20/C82 (for PR3000E).

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4.3.2 Check the voltage of MOSFET and BJT of the Inverter circuit of PCB

• Remove the PCB from the metal case.

• Select the “ ”function on DMM then use DMM check the voltage of the MOSFET and
BJT as described below.
• Read the figure of voltage difference between S-D (“Source” and “Drain”) and the S-G
(“Source” and “Gate”) of the MOSFET. The reading should be within the range of
0.45-0.65V.
• Read the figure of voltage difference between B-E (“Base” and “Emitter”) or B-C (“Base”
and “Collector”) of the BJT. The reading should be within the range of 0.45-0.65V.
• If the figures are out of normal range, the components shown in the table might be
damaged.

※PR1500E/2200E
Part Measured Expected Reading Possible damaged component
reference location
Q10 S-G/S-D 0.45-0.65V Q10,D66
Q11 S-G/S-D 0.45-0.65V Q11,D16
Q12 S-G/S-D 0.45-0.65V Q12,D65
Q13 S-G/S-D 0.45-0.65V Q13,D24
Q14 S-G/S-D 0.45-0.65V Q14,D64
Q15 S-G/S-D 0.45-0.65V Q15,D67
Q18 S-G/S-D 0.45-0.65V Q18,D70
Q19 S-G/S-D 0.45-0.65V Q19,D73
Q20 S-G/S-D 0.45-0.65V Q20,D69
Q21 S-G/S-D 0.45-0.65V Q21,D72
Q22 S-G/S-D 0.45-0.65V Q22,D68
Q23 S-G/S-D 0.45-0.65V Q23,D71
Q8 B-E/B-C 0.45-0.65V Q8
Q9 B-E/B-C 0.45-0.65V Q9
Q26 B-E/B-C 0.45-0.65V Q26
Q27 B-E/B-C 0.45-0.65V Q27

※PR3000E
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Part reference Measured Expected Reading Possible damaged component
location
Q10 S-G/S-D 0.45-0.65V Q10,D66
Q11 S-G/S-D 0.45-0.65V Q11,D16
Q12 S-G/S-D 0.45-0.65V Q12,D65
Q13 S-G/S-D 0.45-0.65V Q13,D24
Q14 S-G/S-D 0.45-0.65V Q14,D64
Q15 S-G/S-D 0.45-0.65V Q15,D67
Q45 S-G/S-D 0.45-0.65V Q45,D32
Q46 S-G/S-D 0.45-0.65V Q46,D33
Q47 S-G/S-D 0.45-0.65V Q47,D39
Q48 S-G/S-D 0.45-0.65V Q48,D75
Q18 S-G/S-D 0.45-0.65V Q18,D70
Q19 S-G/S-D 0.45-0.65V Q19,D73
Q20 S-G/S-D 0.45-0.65V Q20,D69
Q21 S-G/S-D 0.45-0.65V Q21,D72
Q22 S-G/S-D 0.45-0.65V Q22,D68
Q23 S-G/S-D 0.45-0.65V Q23,D71
Q24 S-G/S-D 0.45-0.65V Q24,D5
Q25 S-G/S-D 0.45-0.65V Q25,D13
Q17 S-G/S-D 0.45-0.65V Q17,D11
Q44 S-G/S-D 0.45-0.65V Q44,D31
Q8 B-E/B-C 0.45-0.65V Q8
Q9 B-E/B-C 0.45-0.65V Q9
Q26 B-E/B-C 0.45-0.65V Q26
Q27 B-E/B-C 0.45-0.65V Q27

4.3.3 Check the resistance of RESISTOR of the Inverter circuit of the PCB
※PR1500E/2200E
Part reference Measured location Expected Reading Possible damaged component
R49,R50,R53,R54,R57, 39 Ohm R49,R50,R53,R54,R57,R58R70,
R58,R70,R73,R75,R76, R73,R75,R76,R80,R81
R80,R81
R47,R48, 22 Ohm R47,R48,R88,R89
R88,R89

※PR3000E
Part reference Measured location Expected Reading Possible damaged component
R49,R50,R53,R5,R57, 39 Ohm R49,R50,R53,R54,R57,R58,R70,
R58,R70,R73,R75,R76, R73,R75,R76,R80,R81,R85,R86,
R80,R81,R85,R86,R87, R87, R113, R74,R82,R83,R84
R113,R74,R82,R83,R84,
R47,R48, 22 Ohm R47,R48,R88,R89
R88,R89

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4.4 Turn on the unit with DC power supply
• Setup the instrument: adjust the output voltage of DC power supply to 54V with current limit
set at 5Adc.
• Connect the positive output of the DC power supply (Red wire) to the BAT(+)(Red wire) of
the PCB and the negative output (Black wire) to the BAT(-)(Black wire) of the PCB.
• Turn on the UPS then press the “Test” button on the front panel for at least 5 seconds.
• Check the reading of output current from the power supply, it should be between1~1.5A (or
1.7-2.1A for PR3000E).
• Check the output voltage of UPS. The reading should be within 225~240Vac.
• Check the waveform of UPS output, it should be sine wave.
If there is no output voltage, then the PCB needs to be checked by a higher level service
center.

4.5 Connect the UPS to AC Input

• Connect UPS to the utility power, the UPS should transfer to AC mode at this moment.

• If the transfer fails, check if input circuit breaker is tripped or fuse is blown. When this
occurs, reset the circuit breaker or replace the fuse.

• If the UPS can not transfer to AC mode even with normal fuse and circuit breaker, then
check the waveform at C16.

O.K

N.G.

• If the waveform measured is N.G., please change C16 104Z (SMT package)

4.6 Charging Circuitry

• In AC mode: Check the charging voltage by measuring the voltage between BAT(+) and
BAT(-) (Note: the battery wires are not connected to battery nor to the DC power supply at
this moment). VBat=54.0~55Vdc.
• Turn off the UPS then connect the battery wires back to the batteries and make PCB and
other cables properly assembled inside the UPS. Then start the UPS in AC mode.

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4.7 Get Load Connected
• Connect load to the outlet of the UPS.
• Disconnect the AC input. The UPS should supply power to the load.
• Connect a computer to the UPS. Recover the AC input to UPS then disconnect the AC
utility power again.
• The computer should work properly without reboot OS when the UPS transfers between AC
mode and Battery mode.

4.8 Customer Service

Question for the customer when they call or return the unit back to the distributor:
• Date of purchase, from what distributor or store ?
• Serial number
• Description of the problem
• Check if the input fuse is normal and if the input power cord is properly connected.
• Disconnect all the loads that are connected to the UPS and turn on the unit again.

• Confirm how many loads connected to the UPS while malfunction occurred
• When does the malfunction occur?
1. When the unit just first turned on.
2. When power failure occurs.
3. When the UPS return to AC mode.
4. When the UPS is in battery mode.

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5. Schematic
5.1 CHGR Parts
※PR1500E/PR220E/PR3000E

5.2 Communication & CPU Parts

※PR1500E/PR2200E/PR3000E

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5.3 AVR Parts
※PR1500E/PR2200E

※PR3000E

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5.4 INVERTER Parts
※PR1500E/PR2200E

※PR3000E

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