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    APC BR550GI Pro UPS not charging battery

    I have an APC BR550GI Pro UPS
    https://www.se.com/il/en/product/BR5...ckups-pro-550/

    The motherboard model I have in the UPS is the 640-1172A-Z_REV05

    The problem I have is that my UPS does not seem to charge the battery when ON.
    After charging the battery with an external battery charger and installing into the UPS (updating change date) the battery drains slowly ~7% every 12 hours with no load connected (the PowerChute SW show decrease in jumps of ~7% not 1% decrements).

    I think it does charge the battery when OFF because I measure ~0.3-0.4A on the wires to the battery. and when connecting external battery charger it does say battery is at 100%.

    The UPS does switch from Mains to battery and back when it should.

    I see no physical damage to the board.

    The 2 fuses F4 and F5 are OK.

    Does anyone have the schematics of this board or can help point me in the right direction for troubleshooting and finding the bad component/connection.

    Thank you
    Attached Files

    #2
    Re: APC BR550GI Pro UPS not charging battery

    What is going on with the device that is on the heat sink it is looking odd it near T1 and I think is also near IC2 can you please post the part number for IC2
    Last edited by sam_sam_sam; 03-14-2022, 06:28 AM.
    9 PC LCD Monitor
    6 LCD Flat Screen TV
    30 Desk Top Switching Power Supply
    10 Battery Charger Switching Power Supply for Power Tool
    6 18v Lithium Battery Power Boards for Tool Battery Packs
    1 XBox 360 Switching Power Supply and M Board
    25 Servo Drives 220/460 3 Phase
    6 De-soldering Station Switching Power Supply 1 Power Supply
    1 Dell Mother Board
    15 Computer Power Supply
    1 HP Printer Supply & Control Board * lighting finished it *


    These two repairs where found with a ESR meter...> Temp at 50*F then at 90*F the ESR reading more than 10%

    1 Over Head Crane Current Sensing Board ( VFD Failure Five Years Later )
    2 Hem Saw Computer Stack Board

    All of these had CAPs POOF
    All of the mosfet that are taken out by bad caps

    Comment


      #3
      Re: APC BR550GI Pro UPS not charging battery

      Originally posted by sam_sam_sam View Post
      What is going on with the device that is on the heat sink it is looking odd it near T1 and I think is also near IC2 can you please post the part number for IC2
      IC2 is TNY278PN (I am waiting for order for replacement - maybe it will help)

      What device looks odd? The silver one I marked PINK In attached picture? I don't know what it is? Why do you think it odd?
      Attached Files

      Comment


        #4
        Re: APC BR550GI Pro UPS not charging battery

        Is there an ic chip that is mounted to it or something else that is mounted to it
        9 PC LCD Monitor
        6 LCD Flat Screen TV
        30 Desk Top Switching Power Supply
        10 Battery Charger Switching Power Supply for Power Tool
        6 18v Lithium Battery Power Boards for Tool Battery Packs
        1 XBox 360 Switching Power Supply and M Board
        25 Servo Drives 220/460 3 Phase
        6 De-soldering Station Switching Power Supply 1 Power Supply
        1 Dell Mother Board
        15 Computer Power Supply
        1 HP Printer Supply & Control Board * lighting finished it *


        These two repairs where found with a ESR meter...> Temp at 50*F then at 90*F the ESR reading more than 10%

        1 Over Head Crane Current Sensing Board ( VFD Failure Five Years Later )
        2 Hem Saw Computer Stack Board

        All of these had CAPs POOF
        All of the mosfet that are taken out by bad caps

        Comment


          #5
          Re: APC BR550GI Pro UPS not charging battery

          Originally posted by sam_sam_sam View Post
          Is there an ic chip that is mounted to it or something else that is mounted to it
          I have no idea what it is. There are no markings.
          Attached Files

          Comment


            #6
            Re: APC BR550GI Pro UPS not charging battery

            Originally posted by theone111 View Post
            I have no idea what it is. There are no markings.
            This is simply heatsink for TNY278PN.

            I have the same symptoms. I've changed TNY278PN chip, but there is no changes. Problem exists.
            battery will not charge!
            If I switch UPS on, it makes it internal tests, shows that battery is empty, but no error message.
            If I disconnect the battery and measure voltage on battery pins, it's about 9V -- this is the reason why the battery does not charge.

            Has anyone Idea why it could happen? Why it does not charge the battery?

            Best regards,
            Q

            Comment


              #7
              Re: APC BR550GI Pro UPS not charging battery

              There are two capacitors on th board -- C18 and C32

              Please take a look at the capacitor C18. It is 330mkf
              I've measured it with multimeter and it was about 250mkf...
              I've changed it to something I've found (470mkf 50v) and UPS is working again. Charge voltage about 13v!
              Hope this helps you.

              Solution - change capacitor C18.

              Best regards,
              Q

              Comment


                #8
                Re: APC BR550GI Pro UPS not charging battery

                Originally posted by benq32 View Post
                There are two capacitors on th board -- C18 and C32

                Please take a look at the capacitor C18. It is 330mkf
                I've measured it with multimeter and it was about 250mkf...
                I've changed it to something I've found (470mkf 50v) and UPS is working again. Charge voltage about 13v!
                Hope this helps you.

                Solution - change capacitor C18.

                Best regards,
                Q
                Did you measure them (C18, C32) out of the board (removed from board)?

                I meausred them on the board (they seem to be connected in parallel and got ~600uF (they are each marked as 330uF 35v). I will try and remove them and measure outside the board.

                When I power up the UPS with no battery connected I get ~5.4v and a buzzing sound (see attached zipped video)
                Attached Files
                Last edited by theone111; 03-20-2022, 09:35 AM.

                Comment


                  #9
                  Re: APC BR550GI Pro UPS not charging battery

                  Yes, I've measured them by removing from board. If I measured them on the board, it was more or less normal, but it was not so.
                  I've orderen another elkos 330mkf 63v from Panasonic.
                  now all is working fine!
                  Change your capacitors and have a look what happens.

                  Comment


                    #10
                    Re: APC BR550GI Pro UPS not charging battery

                    I had exactly the same problem. My capacitors looked fine, but tried to replace them with 330uf 35V Panasonic and that helped. Thanks a lot for the tip!

                    Comment


                      #11
                      Re: APC BR550GI Pro UPS not charging battery

                      So I replaced c18 and c32 (i measured them after removal and they were about 300uf instead of 330uf).

                      Now I get 14.1v when no battery connected and get charging current (measured on the battery wires) of about 0.5A and battery voltage increasing slowly.

                      Is this charging current OK?

                      Comment


                        #12
                        Re: APC BR550GI Pro UPS not charging battery

                        Originally posted by benq32 View Post
                        Yes, I've measured them by removing from board. If I measured them on the board, it was more or less normal, but it was not so.
                        I've orderen another elkos 330mkf 63v from Panasonic.
                        now all is working fine!
                        Change your capacitors and have a look what happens.
                        So I have tested the UPS after the capacitors replacement and it seems to work.

                        Thank you @benq32

                        Comment


                          #13
                          Re: APC BR550GI Pro UPS not charging battery

                          Originally posted by benq32 View Post
                          There are two capacitors on th board -- C18 and C32

                          Please take a look at the capacitor C18. It is 330mkf
                          I've measured it with multimeter and it was about 250mkf...
                          I've changed it to something I've found (470mkf 50v) and UPS is working again. Charge voltage about 13v!
                          Hope this helps you.

                          Solution - change capacitor C18.

                          Best regards,
                          Q
                          I had the same problem as you, battery was not charging at all. After removing and measuring the C18 and C32, I found they had much lower capacity (not any visual damage). After soldering new ones, UPS works fine. Thanks for your efforts !

                          Comment


                            #14
                            Re: APC BR550GI Pro UPS not charging battery

                            More items not ending up in a landfill good work to both of you
                            9 PC LCD Monitor
                            6 LCD Flat Screen TV
                            30 Desk Top Switching Power Supply
                            10 Battery Charger Switching Power Supply for Power Tool
                            6 18v Lithium Battery Power Boards for Tool Battery Packs
                            1 XBox 360 Switching Power Supply and M Board
                            25 Servo Drives 220/460 3 Phase
                            6 De-soldering Station Switching Power Supply 1 Power Supply
                            1 Dell Mother Board
                            15 Computer Power Supply
                            1 HP Printer Supply & Control Board * lighting finished it *


                            These two repairs where found with a ESR meter...> Temp at 50*F then at 90*F the ESR reading more than 10%

                            1 Over Head Crane Current Sensing Board ( VFD Failure Five Years Later )
                            2 Hem Saw Computer Stack Board

                            All of these had CAPs POOF
                            All of the mosfet that are taken out by bad caps

                            Comment


                              #15
                              Re: APC BR550GI Pro UPS not charging battery

                              Thank you all for help my BR550GI is up and running again now! An interesting fact is that one of the capacitors was of absolutely normal capacity (C18 - 331mkf), and the second was only 10% less than the nominal (C32 - 298mkf). Wierd though...

                              Comment


                                #16
                                Re: APC BR550GI Pro UPS not charging battery

                                Originally posted by lego1234567 View Post
                                I had the same problem as you, battery was not charging at all. After removing and measuring the C18 and C32, I found they had much lower capacity (not any visual damage). After soldering new ones, UPS works fine. Thanks for your efforts !
                                Dear All,

                                My UPC is a APC Back-UPS Pro 550 BR550GI to 640-1172A-Z_REV05. Same problem, no charging. I replaced the following: IC2 - TNY278PN, 22 uF/400V on the raised board 2 x 330μF /35V and it still doesn't work. Is there anything else related to the charging circuit breaking down?

                                Thank you

                                Comment

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