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    #21
    Re: Cyberpower PR1500 won't charge battery

    To remove the old caps you will use flux and ADD more solder to the joints using at least 40W iron with wide tip.
    Never stop learning
    Basic LCD TV and Monitor troubleshooting guides.
    http://www.badcaps.net/forum/showthr...956#post305956

    Voltage Regulator (LDO) testing:
    http://www.badcaps.net/forum/showthr...999#post300999

    Inverter testing using old CFL:
    http://www.badcaps.net/forum/showthr...er+testing+cfl

    Tear down pictures : Hit the ">" Show Albums and stories" on the left side
    http://s807.photobucket.com/user/budm/library/

    TV Factory reset codes listing:
    http://www.badcaps.net/forum/showthread.php?t=24809

    Comment


      #22
      Re: Cyberpower PR1500 won't charge battery

      budm

      Good news. You nailed it. Replacing C40 allowed the battery charging circuit to function again. I am now getting 55 Volts on the battery leads. It must have been ESR since the capacitance didn't seem that different from a new one. What function does C40 have in the switching regulator? It must be critical for ESR to have that much effect.

      I am now replacing C44, C45,and C47. The bad news is that I ordered the wrong 100uF, 63V capacitors from Digi-key. They are too big to fit in the space provided. Neither Digi-key or Mouser has them in stock so I had to order them from Newark. I will have to wait another week before I can install them.

      Comment


        #23
        Re: Cyberpower PR1500 won't charge battery

        Originally posted by elmo View Post
        What function does C40 have in the switching regulator? It must be critical for ESR to have that much effect.
        Probably the supply smoothing capacitor for the switching controller, if the capacitor is bad the controller won't get steady power or enough voltage etc and it can't operate properly
        "Tantalum for the brave, Solid Aluminium for the wise, Wet Electrolytic for the adventurous"
        -David VanHorn

        Comment


          #24
          Re: Cyberpower PR1500 won't charge battery

          Good news. I got the replacement capacitors the other day and installed them yesterday. The charging circuit is now working well; charges up the battery whether the UPS is on or not. The batteries are not good any longer however. The deep discharge must have finished them off. I have ordered replacements.

          Comment


            #25
            Re: Cyberpower PR1500 won't charge battery

            Glad to hear the result, <$10 in repair + batteries.
            Thanks for the follow-up.
            Never stop learning
            Basic LCD TV and Monitor troubleshooting guides.
            http://www.badcaps.net/forum/showthr...956#post305956

            Voltage Regulator (LDO) testing:
            http://www.badcaps.net/forum/showthr...999#post300999

            Inverter testing using old CFL:
            http://www.badcaps.net/forum/showthr...er+testing+cfl

            Tear down pictures : Hit the ">" Show Albums and stories" on the left side
            http://s807.photobucket.com/user/budm/library/

            TV Factory reset codes listing:
            http://www.badcaps.net/forum/showthread.php?t=24809

            Comment


              #26
              Re: Cyberpower PR1500 won't charge battery

              Success! I installed the new batteries yesterday and everything is now working. Thanks to everyone for your help and especially to Budm for the accurate diagnosis that C40 was the cause of the malfunction. My total cost for parts and shipping was under $90.

              Comment


                #27
                Re: Cyberpower PR1500 won't charge battery

                Thanks for the good news, I fixed many of those boards with all the same failed cap (C40).
                Never stop learning
                Basic LCD TV and Monitor troubleshooting guides.
                http://www.badcaps.net/forum/showthr...956#post305956

                Voltage Regulator (LDO) testing:
                http://www.badcaps.net/forum/showthr...999#post300999

                Inverter testing using old CFL:
                http://www.badcaps.net/forum/showthr...er+testing+cfl

                Tear down pictures : Hit the ">" Show Albums and stories" on the left side
                http://s807.photobucket.com/user/budm/library/

                TV Factory reset codes listing:
                http://www.badcaps.net/forum/showthread.php?t=24809

                Comment


                  #28
                  Re: Cyberpower PR1500 won't charge battery

                  Hi all, great thread but can anyone list part numbers for these? Thank you.

                  Comment


                    #29
                    Re: Cyberpower PR1500 won't charge battery

                    Originally posted by peterg View Post
                    Hi all, great thread but can anyone list part numbers for these? Thank you.
                    Cyberpower Manufacturer P/N for what? the caps? or the caps values?
                    See post 17.
                    As you can see, you just get the capacitance and Voltage value, the dimension of the caps then go to Digikey or Mouser and look for PANASONIC CAP FM/FR or FC series for the replacement.
                    Last edited by budm; 07-27-2015, 07:17 PM.
                    Never stop learning
                    Basic LCD TV and Monitor troubleshooting guides.
                    http://www.badcaps.net/forum/showthr...956#post305956

                    Voltage Regulator (LDO) testing:
                    http://www.badcaps.net/forum/showthr...999#post300999

                    Inverter testing using old CFL:
                    http://www.badcaps.net/forum/showthr...er+testing+cfl

                    Tear down pictures : Hit the ">" Show Albums and stories" on the left side
                    http://s807.photobucket.com/user/budm/library/

                    TV Factory reset codes listing:
                    http://www.badcaps.net/forum/showthread.php?t=24809

                    Comment


                      #30
                      Re: Cyberpower PR1500 won't charge battery

                      My CyberPower PR2200 has exactly the same changer problem. Searched internet for a week and finally found this thread. Will try to replace the caps and report back later.

                      Thanks a bunch for the thread.

                      Comment


                        #31
                        Re: Cyberpower PR1500 won't charge battery

                        back from a trip and replaced capacitor C40 of my faulty cyberpower pr2200, also the two big caps (which showed sign of leaking) for the rectifier. Now the charger is back to work outputting 54 V. Thanks a bunch budm for the solution!!!!

                        Comment


                          #32
                          Re: Cyberpower PR1500 won't charge battery

                          Purchased PR2200 for my church in August of 2010. Batteries replaced in June of 2014 after being unable to power the unit up similar to other posters' experience. In early August we had a severe storm that did a lot of damage to sections of Long Island, and the church lost power for about 2.5 days. When power was restored, everything in the server closet came back up. My fault, I did not look at the battery state LED's on the front of the UPS.

                          About five days later I get a call from the office that they had a power blink and everything computer related was down. Went into the server closet and the UPS was dead. With one year old batteries, obviously something else was at work and I called CyberPower tech support. They gave me the same story that other posters got; basically if I replaced the batteries the unit may or may not work. They recommended getting a new UPS, which I did. Lugged the old one home and took a chance after finding I could get four replacement batteries for about $80. The unit powered up, but after a few days the batteries discharged. The board was putting out about 37.5 volts to the batteries. The batteries, fully charged, put out about 52 volts.

                          I found this post, and replaced capacitors 40, 44, 47 and 45. No joy. Here's where my situation is different. When I removed the board, I found scorching around twin capacitors C138 and the one next to it (scorching removed the number). Both are 100uF 250v. So I replaced them as well as 19 and 20 (1,000uf 63volts; no real reason other than that they were pretty big and since I was paying the minimum shipping from Mouser, why not?). Again, no joy.

                          Unless someone has another magic answer, the board appears to be toast. The scorching is not really noticeable on the top of the board unless you are looking right there, or the capacitors are removed. Much more noticeable on the bottom. There is a heat sink in the immediate area, which may or may not be related. I'm no electrical engineer. Two photos attached. So if you are having the same issue, I recommend you look closely for damage in that area of the board before investing your time and money on a board level fix. At least it was an educational experience and hopefully I'll be able to use the batteries in another UPS or alarm box.
                          Attached Files

                          Comment


                            #33
                            Re: Cyberpower PR1500 won't charge battery

                            That is the primary side driver circuit which is too far gone to be repaired, the component that burnt out are for the snubber circuit for that power MOSFET which drives the power transformer for charging circuit.
                            Never stop learning
                            Basic LCD TV and Monitor troubleshooting guides.
                            http://www.badcaps.net/forum/showthr...956#post305956

                            Voltage Regulator (LDO) testing:
                            http://www.badcaps.net/forum/showthr...999#post300999

                            Inverter testing using old CFL:
                            http://www.badcaps.net/forum/showthr...er+testing+cfl

                            Tear down pictures : Hit the ">" Show Albums and stories" on the left side
                            http://s807.photobucket.com/user/budm/library/

                            TV Factory reset codes listing:
                            http://www.badcaps.net/forum/showthread.php?t=24809

                            Comment


                              #34
                              Re: Cyberpower PR1500 won't charge battery

                              Originally posted by budm View Post
                              That is the primary side driver circuit which is too far gone to be repaired, the component that burnt out are for the snubber circuit for that power MOSFET which drives the power transformer for charging circuit.
                              I reckon it's fixable... in theory... I saw the idea here: https://youtu.be/7o4ZWlG6mmo?t=16m12s

                              With another unit to compare with or a schematic I reckon I'd be able to do it, I'd probably etch my own replacement board piece though to put in the hole, rather than trying to stick traces onto a blank board.

                              I would agree it's not something for someone inexperienced though.
                              "Tantalum for the brave, Solid Aluminium for the wise, Wet Electrolytic for the adventurous"
                              -David VanHorn

                              Comment


                                #35
                                Re: Cyberpower PR1500 won't charge battery

                                that will look a lot better with a good clean.
                                biggest problem is getting a good pair of foto's of one that is not damaged.

                                Comment


                                  #36
                                  Re: Cyberpower PR1500 won't charge battery

                                  I'd be doing that, if it is a worthy piece of electronics that's non available anymore / custom etc. But for that, the effort is more than what is it worth.
                                  That's job is not for an inexperienced and you would have to have all the proper stuff for sure. The black stuff has to come out, all of it, as it is conductive.

                                  Comment


                                    #37
                                    Re: Cyberpower PR1500 won't charge battery

                                    That carbonized section has to be removed so that is the problem, also there are SMD resistors in that burnt section.
                                    Attached Files
                                    Last edited by budm; 10-01-2015, 08:46 AM.
                                    Never stop learning
                                    Basic LCD TV and Monitor troubleshooting guides.
                                    http://www.badcaps.net/forum/showthr...956#post305956

                                    Voltage Regulator (LDO) testing:
                                    http://www.badcaps.net/forum/showthr...999#post300999

                                    Inverter testing using old CFL:
                                    http://www.badcaps.net/forum/showthr...er+testing+cfl

                                    Tear down pictures : Hit the ">" Show Albums and stories" on the left side
                                    http://s807.photobucket.com/user/budm/library/

                                    TV Factory reset codes listing:
                                    http://www.badcaps.net/forum/showthread.php?t=24809

                                    Comment


                                      #38
                                      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.

                                      Comment


                                        #39
                                        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.
                                        Attached Files
                                        Last edited by budm; 10-09-2015, 08:47 AM.
                                        Never stop learning
                                        Basic LCD TV and Monitor troubleshooting guides.
                                        http://www.badcaps.net/forum/showthr...956#post305956

                                        Voltage Regulator (LDO) testing:
                                        http://www.badcaps.net/forum/showthr...999#post300999

                                        Inverter testing using old CFL:
                                        http://www.badcaps.net/forum/showthr...er+testing+cfl

                                        Tear down pictures : Hit the ">" Show Albums and stories" on the left side
                                        http://s807.photobucket.com/user/budm/library/

                                        TV Factory reset codes listing:
                                        http://www.badcaps.net/forum/showthread.php?t=24809

                                        Comment


                                          #40
                                          Re: Cyberpower PR1500 won't charge battery

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

                                          Comment

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