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Document # 996-0237
Copyright (C) American Power Conversion Corporation 1991. All rights reserved.
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Revision Record
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Table of Contents
REVISION RECORD...........................................................................III
TABLE OF CONTENTS ......................................................................IV
1.0 INTRODUCTION.........................................................................1
2.0 SAFETY PRECAUTIONS............................................................2
3.0 TOOLS AND EQUIPMENT.........................................................3
4.0 PRINCIPLES OF OPERATION...................................................4
5.0 PROCEDURES FOR THE SMART-UPS 450/700........................7
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
5.17
5.18
5.19
5.20
5.21
5.22
5.23
5.24
5.25
5.26
5.27
5.28
6.0
7.0
TROUBLESHOOTING PROCEDURE......................................36
7.1
7.2
7.3
7.4
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1.0 Introduction
This manual provides information required for servicing American Power Conversion
Corporation Smart-UPS 450/ 700/ 1000/ and 1400. This guide is divided into the
following sections:
Symptom.
Likely Cause.
Probable Solution.
USA/CANADA.....1-800-800-4272.
MEXICO..292-0253/292-0255.
BRAZIL.0800-12-72-1.
WORLD WIDE..1-401-789-5735.
Computer interface port description The Smart-UPS 450/ 700/ 1000/ and 1400 have
a communications port that may be connected to a host computer system using a special
optional interface kit. This port allows the computer to monitor the status of the UPS and
in some cases control the operation of the UPS. Below is a detailed description of each
of the serial port's pins:
Pin 1 - Shutdown Input - The UPS will shut down when +5 VDC or a HI RS232 level, sustained for 4.5 seconds, is applied to pin 1. The UPS will respond to
the signal only when operating On-battery. If the UPS is shut down via this
utility, the UPS will turn On when the voltage is restored to within normal limits.
Pin 2 - Transfer To On Battery Signal Output - The UPS will generate a LO to
HI RS-232 level transition upon transfer from On-line to On-battery operation
(utility failure). The pin is normally at a LO RS-232 level. In the "smart"
signaling mode, this pin is the transmit data output line.
Pin 3 - Normally Open On Battery Signal - This pin is the open collector of a
transistor that turns On when the UPS transfer from On-line to On-battery
operation (utility failure). The transistor is capable of driving ground reference
TTL inputs or loads up to 50 ma at 40 VDC, non-inductive. If used to drive
relays, the relay coil must be clamped with a "catch" diode.
Pin 4 - Common - This pin is used as common for input and output signaling.
Pin 4 is separated from chassis ground with a 20 ohm resistor.
Pin 5 - Normally Open Low Battery Signal - This pin is the open collector of a
transistor that turns On when the UPS detects a low battery condition. The
transistor is capable of driving ground referenced TTL inputs or loads up to 50 ma
at 40 VDC, non-inductive. If used to drive relays, the relay coil must be clamped
with a "catch" diode.
Pin 6 - Normally Closed On Battery Signal - This pin is the open collector of a
transistor that turns Off when the UPS transfer from On-line to On-battery
operation (utility failure). The transistor is capable of driving ground reference
TTL inputs or loads of up to 25 ma at 40 VDC, non-inductive. If used to drive
relays the relay coil must be clamped with a "catch" diode.
Pin 7 Remote Turn On/Off - The UPS will turn On and all loads connected at
its output will become powered when a HI RS-232 level, sustained for 1 second,
is applied to pin 7. This is true only when the UPS enable switch is in the 1
position. When pin 7 is grounded for 1 second, the UPS will shut down and all
connected loads will be turned Off.
Pin 8 Unregulated +24 VDC - When the UPS enable switch is in the 1 position
an unregulated +24 VDC connected in series with a limiting resistor appears at
pin 8. A maximum of 40 maDC may be source from this output.
Pin 9 Common - This pin is used as common for input and output signaling.
Pin 9 is separated from chassis ground with a 20 ohm resistor.
3. Turn the unit right side up and from the rear of the unit, grab the sides of the
cover and slide the cover back and away from the chassis. Keep the cover
horizontal at all times. (Fig 5.1.1).
1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from
utility line.
2. Unsnap the bezel from the chassis by applying a slight push at the top of the bezel
and away from the chassis (figure 5.3.1).
3. Unsnap the L.E.D. display PCB away from the bezel. The bezel is now free
from the chassis (figure 5.3.1).
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11. Disconnect the output transformer connector from the PCBs J5.
12. Remove the two (2) screws that secure the rear of the PCB to the rear panel
(5.7.2).
13. Remove the hypot tap screw from the rear panel (figure 5.7.1).
14. Slide the PCB away from the rear panel.
15. Remove the power outlets white wire from the PCBs J6 white out tab (figure
5.7.2).
16. Remove the power outlets black wire from the PCBs J2 black out tab (figure
5.7.2).
17. The PCB is now free from the chassis.
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13
14
15
16
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2. Connect the power inlets black wire (international) or power cords black
wire (domestic) to the circuit breaker (figure 5.11.1).
3. Install the PCB per section 5.8.
3. Turn the unit right side up and from the rear of the unit, grab the sides of the
cover and slide the cover back and away from the chassis. Keep the cover
horizontal at all times. (Fig 5.15.1).
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3. Unsnap the L.E.D. display PCB away from the bezel. The bezel is now free
from the chassis.
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20
21
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3. Remove the two (2) screws from the battery door and swing the battery door
open (figure 5.19.1).
4. Remove the old batteries away form the chassis.
5. For the Smart-UPS1000, connect the PCBs red wire to the positive terminal
of the battery and the PCBs black wire to the negative terminal of the battery.
For the Smart-UPS1400, connect the batterys Anderson connector plug to
the PCBs Anderson connector plug.
6. Gently slide the batteries into the battery compartment ensuring that the
battery wires are not jammed against the chassis edges.
7. Replace the two (2) screws that secure the battery door in place.
8. Replace the bezel by snapping it in place (figure 5.17.1).
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8. Remove the center screw that secures the PCB to the chassis (figure 5.21.2).
9. Disconnect the SNMP adapter cable from the PCBs J14 tab.
10. Slide both the PCB and rear panel back and away from the rest of the unit.
11. For Domestic units, disconnect the power cords white wire from the PCBs
J4 tab and disconnect the power cords black wire from the PCBs J3 tab.
For International units, disconnect the power inlets white wire from the
PCBs J4 tab and the power inlets black wire from the PCBs J3 tab.
12. Disconnect the Output transformers connector from the PCBs J5 tab.
13. Remove the two (2) screws that secure the rear of the PCB to the rear panel
(figure 5.21.2).
14. Remove the two (2) screws that secure the rear panel to the base of the chassis
(figure 5.21.2).
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26
27
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Model
SU450
SU700
SU1000
SU1400
Load (VA/Watt)
450VA/280W
700VA/450W
1000VA/670W
1400VA/950W
Table 6.3
5. Using a voltmeter, monitor the UPSs output voltage. The UPS should remain
powered and it should output approximately 120+5% VAC, (100+5% VAC)
or {230+5% VAC}.
6. Remove the AC line input so that the UPS operates On Battery. The UPS
should remain powered and the output should remain the same as step 6
above. While the UPS is operating off of the utility voltage, increase the load
by approximately 75 Watts. Plugging a light bulb into the UPS can do this.
After 4 seconds, the overload light should come On and the unit should emit a
constant tone until the overload is removed.
7. If the UPS fails to support the load or recognize the overload, then it should be
serviced.
31
SU450
(min)
1.67
1.28
0.9
0.55
0.36
0.25
0.18
0.13
0.1
0.07
-
SU700
(min)
2.33
1.88
1.42
0.92
0.63
0.43
0.33
0.28
0.23
0.18
0.15
0.13
0.11
0.09
-
SU1000
(min)
2.5
2.08
1.67
1.25
0.97
0.73
0.6
0.47
0.4
0.33
0.3
0.25
0.22
0.18
0.14
0.12
0.11
-
SU1400
(min)
4.18
3.32
2.72
1.97
1.5
1.18
0.95
0.72
0.62
0.53
0.47
0.4
0.35
0.3
0.25
0.2
0.18
0.14
0.11
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6. Using a voltmeter, monitor the UPSs output voltage. The UPS should remain
powered and it should output approximately 120+5% VAC, (100+5% VAC)
or {230+5% VAC}.
7. Remove the AC line input so that the UPS operates On Battery. The UPS
should remain powered and the output should remain the same as step 6
above.
8. Using a stopwatch, time how long the UPS maintains power to the load. The
UPS should beep every 30 seconds, and when only 2 or 3 minutes of runtime
remain, the UPS will beep every .5 seconds. Refer to table 6.4 for expected
runtimes. If the UPS fails to support the load for the expected runtime, the
batteries may need to be replaced. If the batteries are new and have drained
prematurely during normal operations it may be an indication that there may
be a problem with the charging circuit and the UPS should be serviced.
9. Plug the UPS into the wall and allow it to charge for at least 6 hours before
storing or using the UPS.
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3. Using a multimeter, measure the voltage between the interface port's pin 2 and
9. The voltage should be LO RS-232 signal (-8 to -12 VDC).
4. Unplug the UPS from the variac so that the UPS operates On battery. The DC
voltage between pins 2 and 9 should now be a HI RS-232 level (+8 - +12
VDC)
5. While the UPS is operating On battery, apply a HI RS-232 signal to pin 1.
Shorting pin 1 to pin 2 can do this. A metal paper clip can be used to short the
two pins. The UPS should go into sleep mode. The lights in front of the unit
will scroll.
6. Remove the short between pin 1 and pin 2. Plug the UPS back into the variac.
Now, the UPS should power back up.
7. Connect a 48 k ( 5 k) resistor between pins 3 and 8. Using a multimeter,
measure the DC voltage drop across pin 3 and ground. The DC voltage
should be greater than 19VDC.
8. The resistor should still be connected to pins 3 and 8. Unplug the UPS from
the utility line. Using a multimeter, measure the DC voltage between pin 3
and ground. The voltage should be less than 0.6 VDC.
9. Connect a 48 k ( 5 k) resistor between pins 5 and 8. Using a multimeter,
measure the DC voltage drop between pin 5 and ground. The voltage drop
should be greater than 19VDC.
10. The resistor should still be connected between pin 5 and 8. Unplug the UPS
from the utility line and allow it to run On battery until it reaches the low
battery state.
11. While the UPS is in low battery state, use a multimeter to measure the DC
voltage between pin 5 and ground. The voltage should be less than 0.6VDC.
12. Plug the UPS into the wall and allow it to charge for at least six (6) hours
before storing or using the UPS.
13. If the UPS fails any of the above tests, the PCB should be replaced.
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Likely cause:
1. Will not
start:
Batteries not
connected.
Bad batteries.
2. Wont go
On-line:
(continued on
next page).
Probable
solution:
Connect batteries.
Additional comments:
Replace batteries.
Internal fuse
blown.
Replace F3.
Transistor open.
Ribbon cable
cut.
Replace Q5.
Replace ribbon
cable and check
F3 and Q5.
Realign/ replace
sw2.
Push button
switch broken/
misaligned.
Program wrong
setting.
No input at
power cord.
Program wrong
setting.
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Likely cause:
2. Wont go
On-line: (see
last page).
Component lead
out of pcb.
3. Flashing
LEDs:
4. Overload:
5. Wont
charge:
(continued on
next page).
UPS sustained a
surge, MOV
blown.
Line sense
transformer
bad.
Large capacitor
fell off of the
pcb.
Capacitor leaks.
Relay welded.
Optocoupler
failed.
Leaky diode.
Load exceeds
UPS
parameters.
Output sense
transformer
open.
Current
transformer
failure.
IC failure.
Program wrong
setting.
Probable
solution:
Resolder lead to
pcb.
Additional comments:
Check components in AC-in path
ensuring leads are through the pcb.
L1,L2, and T1 are usually suspect.
Replace MOV.
Replace T1.
Resolder C17
onto the pcb.
Replace C44 or
C52.
Replace relay.
Replace IC3.
Replace D20.
Reduce load.
Replace T2.
Replace CT1.
Replace IC15.
Adjust float
voltage (B)
setting.
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Likely cause:
5. Wont
charge: (see
last page).
Bad charger
circuit.
6. UPS
clicking but
wont start.:
7. L.E.D.
failure:
8. Will not
stay On-line:
Probable
solution:
Replace IC14.
Additional comments:
Bad battery.
Replace battery.
Bad
microprocessor.
Bad reset
circuit.
Replace IC12.
Bad L.E.D.
Replace faulty
L.E.D.
Replace Q56.
Bad turbo
circuit.
Replace C77.
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24VDC
C41, C36, IC4, snmp and display pcb ribbon cable, Fan,C63.
12VDC
5VDC
-8VDC
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