Service Manual for the APC Smart_UPS 450_700_1000_1400 UPS

Service Manual for the American Power Conversion Smart-UPS 450/ 700/ 1000/ 1400 Uninterruptible Power Supply Document # 996-0237

AMERICAN POWER CONVERSION American Power Conversion Corporation - 132 Fairgrounds Road, box 278 West Kingston, R.I. – 02893 – Phone (401) 789 - 5735

Document # 996-0237

American Power Conversion Corporation makes no warranty with regard to the information in this manual. American Power Conversion Corporation assumes no responsibility for any errors contained in this document. American Power Conversion Corporation reserves the right to make changes to this document without notice. No part of this document may be copied or reproduced in any form without prior written consent of American Power Conversion Corporation.

Copyright (C) American Power Conversion Corporation 1991. All rights reserved.

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Revision Record • • • • •

Revision 1.0 Original document 09/07/94. Revision 2.0 Upgrade manual to include procedure on how to test the float voltage 03/13/95. Revision 2.1. Upgrade manual to include a block diagram 02/27/96. Revision 3.0 Troubleshooting section revised to include component level repair 03/27/00. Revision 4.0 Original document transcribed to conform to FSE presentation format. 7-20-00. JGuzman.

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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

Cover Removal: Smart-UPS 450 and Smart-UPS 700.------------------------------------------------- 7 Cover Installation: Smart -UPS 450 and Smart-UPS 700.---------------------------------------------- 8 Bezel Removal: Smart -UPS 450 and Smart -UPS 700. ------------------------------------------------- 8 Bezel Installation: Smart-UPS 450 and Smart-UPS 700. ---------------------------------------------- 9 Battery Removal: Smart-UPS 450 and Smart-UPS 700.----------------------------------------------- 9 Battery Installation: Smart-UPS 450 and Smart-UPS 700.-------------------------------------------10 PCB Removal: Smart-UPS 450 and Smart-UPS 700. -------------------------------------------------10 PCB Installation: Smart-UPS 450 and Smart-UPS 700.-----------------------------------------------13 Output Transformer Removal: Smart-UPS 450 and Smart-UPS 700. -----------------------------14 Output Transformer Installation: Smart-UPS 450 and Smart-UPS 700. --------------------------15 Rear Outlet Removal: Smart-UPS 450 and Smart-UPS 700. ----------------------------------------15 Rear Outlet Installation: Smart-UPS 450 and Smart-UPS 700. -------------------------------------17 Circuit Breaker Removal: Smart-UPS 450 and Smart-UPS 700. -----------------------------------17 Circuit Breaker Installation: Smart -UPS 450 and Smart-UPS 700. --------------------------------17 Cover Removal: Smart-UPS 1000 and Smart -UPS 1400. --------------------------------------------18 Cover Installation: Smart -UPS 1000 and Smart-UPS 1400. -----------------------------------------19 Bezel Removal: Smart -UPS 1000 and Smart-UPS 1400. ---------------------------------------------19 Bezel Installation: Smart-UPS 1000 and Smart-UPS 1400. ------------------------------------------20 Battery Removal: Smart-UPS 1000 and Smart-UPS 1400.-------------------------------------------20 Battery Installation: Smart-UPS 1000 and Smart-UPS 1400.----------------------------------------21 PCB Removal: Smart-UPS 1000 and Smart-UPS 1400. ----------------------------------------------23 PCB Installation: Smart-UPS 1000 and Smart-UPS 1400. -------------------------------------------25 Output Transformer Removal: Smart-UPS 1000 and Smart-UPS 1400.--------------------------26 Output Transformer Installation: Smart-UPS 1000 and Smart-UPS 1400.-----------------------27 Rear Outlet Removal: Smart-UPS 1000 and Smart-UPS 1400. -------------------------------------27 Rear Outlet Installation: Smart-UPS 1000 and Smart -UPS 1400. ----------------------------------28 Circuit Breaker Removal: Smart-UPS 1000 and Smart -UPS 1400. --------------------------------29 Circuit Breaker Installation: Smart -UPS 1000 and Smart-UPS 1400. -----------------------------29

FUNCTIONAL TEST PROCEDURES.......................................30 6.1 6.2 6.3 6.4 6.5 6.6 6.7

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Site Wiring Fault Detector Test – 120VAC UPS’s only. ----------------------------------------------30 Output Voltage Test.---------------------------------------------------------------------------------------------30 Full Load Test On Battery.-------------------------------------------------------------------------------------31 Battery Reserve Time Test.------------------------------------------------------------------------------------32 Transfer Level Test. ---------------------------------------------------------------------------------------------33 Battery Charger Test.--------------------------------------------------------------------------------------------34 Computer Interface Port Test.---------------------------------------------------------------------------------34

TROUBLESHOOTING PROCEDURE......................................36 7.1 7.2 7.3 7.4

Troubleshooting Procedure. -----------------------------------------------------------------------------------36 Troubleshooting Procedure. -----------------------------------------------------------------------------------37 Troubleshooting Procedure. -----------------------------------------------------------------------------------38 Troubleshooting Procedure. -----------------------------------------------------------------------------------39

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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: • • • • • •

Safety precautions - Lists recommended safety precautions to be followed when servicing these products. Tools & equipment - Lists all the necessary tools and equipment needed to properly service these products. Principles of operation - Provides a functional description of the UPS system along with the major sections of the unit. Parts replacement procedures - Lists steps to follow for removing and installing the major assemblies of these products. Functional test procedure - Lists steps to follow to qualify the system's functionality. Troubleshooting procedure - Lists the recommended procedure to follow when servicing these products. The format of this section is as follows: 1. 2. 3.

Symptom. Likely Cause. Probable Solution.

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2.0 Safety Precautions CAUTION - UPS products contain voltages that are potentially hazardous. Personnel trained in the service of electrical or electronic equipment should perform all service procedures. CAUTION - UPS products contain their own energy source allowing the output receptacles and internal terminals to be energized when the UPS is not connected to an external AC supply. Care should be used not to touch exposed metal surfaces and terminals while the cover is off as the unit may have voltages present in the batteries and printed circuit board (PCB). CAUTION - Remove all jewelry (rings, hand bracelets, long necklaces) when servicing these products to avoid accidentally short circuiting the battery or printed circuit board (PCB) which could result in personal injury. CAUTION - UPS systems contain components that may be damaged by Electrostatic Discharge (ESD). For this reason, these units should only be serviced at static protected workstations. Note - Batteries should not be stored at temperatures above 77° F (25° C) for an extended period of time. Do not store batteries longer than 6 months without recharge. Batteries should only be recharged in an APC UPS system.

Batteries must be recycled. Deliver the battery to an appropriate recycling facility or ship it to the supplier in the new battery’s packaging material. USA laws prohibit the disposal of Lead Acid batteries with regular trash. These batteries must be properly recycled. Contact APC for information on proper disposal of batteries at:

USA/CANADA………………………………………..…...1-800-800-4272. MEXICO………………………………………………..292-0253/292-0255. BRAZIL……………………………………………………….0800-12-72-1. WORLD WIDE……………………………………………..1-401-789-5735.

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3.0 Tools and Equipment The following is a list of the tools and equipment required for servicing American Power Conversion UPS products: • • • • • • • • • • • •

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20 MHz oscilloscope with a probe. True RMS Digital multimeter (DMM). Note: Meters that are not true RMS may give inaccurate readings. True RMS meters are usually marked "True RMS". Clean and stable AC power source. For 100/120/230 Volt models, this source must be able to generate 100/120/230 VAC at 50 or 60 HZ. Variac: 0 to 280 Volts AC, (a variable adjust transformer). Medium size flathead screwdriver. #1 magnetized Phillips head screwdriver. #2 X 4" magnetized Phillips head screwdriver. #2 X 10" magnetized Phillips head screwdriver. Flat head precision screwdriver. Long nose pliers. 3/16" nut driver. Load simulator: 450VA - 1400VA (280Watts - 950Watts, light bulbs, resistors). Do not use a computer load, unless a true RMS Watt meter is available to accurately determine the wattage. The wattage of a computer load cannot be determined by simply multiplying Voltage times Amperage. The power factor of the computer load needs to be known and multiplied in, as well. The typical power factor for a computer load is .7. Stop Watch: Used to time the UPS battery reserve time.

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4.0 Principles of Operation American Power Conversion Corporation (APC) models Smart-UPS 450/ 700/ 1000/ and 1400 supply 450VA to 1400VA (280Watts to 950 Watts) of dependable AC backup power. These units are designed to protect the load from utility line disturbances. These units have one printed circuit board that houses all of the electronic circuitry of the UPS. On the following page is a block diagram of the different sections of the PCB assembly. Below is a brief description of each section of the PCB assembly. The AC Surge Suppressers & Filters - The UPS provides full-time protection against surges, as well as RFI and EMI filtering through the use of surge suppressers and multistage filters. Power inverter - A DC to AC inverter that converts the DC voltage supplied by the battery into an AC voltage used by the loads that are plugged into the UPS. This inverter also maintains phase synchronization with the commercial supply to ensure dependable operation of the UPS. Battery charger - The precision " Float" charger within the Smart-UPS ensures maximum battery life by maintaining optimum battery float voltage whenever the UPS is plugged in. The clean, low ripple voltage design of the Smart-UPS battery charger limits continuous "exercising" of the battery. The low internal operating temperature of the Smart-UPS ensures extended battery life in comparison to On-line and Ferro based UPS designs. Microprocessor controller - The brand that monitors the incoming AC line. When a disturbance occurs, the sensor signals the transfer switch to open, allowing the inverter to supply the output power. These sensors also send audible and remote signals to notify the user of problems with the utility line. Smart-UPS voltage correction features called SmartTrim and SmartBoost – Features which allow the UPS to remain operating On-line during many high and low utility voltage conditions. The SmartBoost feature compensates for the reduced line voltage by boosting the On-line output voltage. By providing the computer load with power derived from the utility, the UPS is capable of providing this protection even when the low utility voltage condition is permanent. The UPS provides similar protection from high utility voltage with the SmartTrim feature.

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Computer interface port description – The Smart-UPS 450/ 700/ 1000/ and 1400 have a communication’s 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: •

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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.

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5.0 Procedures for the Smart-UPS 450/700. Warning: Before disassembling and changing batteries, or servicing the Smart-UPS make sure that mains supply and DC-supply have been switched Off. Make sure that ALL power has been removed. Be aware that the capacitors in these units will store energy well after all sources have been disconnected from the unit and remember to follow ESD guidelines.

5.1 Cover Removal: Smart-UPS 450 and Smart-UPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from utility line. 2. Turn the unit on its side to allow access to the bottom screws and remove the four (4) screws that secure the cover to the chassis (figure 5.1.1).

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).

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5.2 Cover Installation: Smart-UPS 450 and Smart-UPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Make sure that all wires are securely tucked inside the unit and from the rear side of the unit, slide the cover forward onto the chassis. Keep the cover horizontal at all times (Fig 5.1.1). 2. Turn the unit on its side to allow access to the bottom and replace the four (4) screws that secure the cover to the chassis (figure 5.1.1).

5.3 Bezel Removal: Smart-UPS 450 and Smart-UPS 700. Note: Make sure the LED display board does not make contact to chassis, as there may be DC voltages present that will short to chassis. To prevent an accidental shorting of the display PCB it is recommended that the batteries be removed and the unit discharged per section 5.5.

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).

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3. Unsnap the L.E.D. display PCB away from the bezel. The bezel is now free from the chassis (figure 5.3.1).

5.4 Bezel Installation: Smart-UPS 450 and Smart-UPS 700. Note: Make sure the LED display board does not make contact to chassis, as there may be DC voltages present that will short to chassis. To prevent an accidental shorting of the display PCB it is recommended that the batteries be removed and the unit discharged per section 5.5. 1. Snap the L.E.D. display board into the bezel (figure 5.3.1). 2. Align the tabs of the bezel with the chassis battery door and snap the bezel in place (figure 5.3.1).

5.5 Battery Removal: Smart-UPS 450 and Smart-UPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from utility line. 2. Unsnap the bezel away from the unit (figure 5.3.1). 3. Remove the two (2) screws from the battery door (figure 5.5.1).

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4. Swing the battery door open (figure 5.5.1). 5. Gently slide the batteries out of the UPS. 6. Remove the UPS’s red battery wire from the positive tab of the battery and remove the UPS’s black battery wire from the negative tab of the battery (figure 5.5.1). 7. To discharge the unit, press the On button several times.

5.6 Battery Installation: Smart-UPS 450 and Smart-UPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from utility line. 2. Prepare the batteries as illustrated in figure 5.5.1. 3. Remove the two (2) screws from the battery door and swing the battery door open (figure 5.5.1). 4. Disconnect and remove the old battery from the unit. 5. Connect the PCB’s red wire to the positive terminal of the battery and the PCB’s black wire to the negative terminal of the battery (figure 5.5.1). 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 (figure 5.5.1). 8. Replace the bezel by snapping it in place (figure 5.3.1).

5.7 PCB Removal: Smart-UPS 450 and Smart-UPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. Warning: The capacitors will store energy well after all sources have been disconnected from the unit. Make sure the capacitors are discharged before servicing the unit. 1. Remove the cover per section 5.1 and the battery per section 5.5. 2. Disconnect the PCB's black wires (W5&W6) from the output transformer's primary side using a pair of needle nose pliers (figure 5.7.1).

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3. Remove the PCB’s black wire from the circuit breaker. 4. Unsnap the LED display board from the front bezel (figure 5.3.1). 5. Remove the two (2) screws that secure the front of the PCB to the chassis (figure 5.7.1). 6. Remove the center screw that secures the middle of the PCB to the chassis (figure 5.7.1). 7. Remove the two (2) screws, one on the bottom rear left and the other on the bottom rear right of the unit, that secure the rear panel to the chassis (figure 5.7.1). 8. Disconnect the SNMP adapter cable from the PCB’s tab J14 (figure 5.7.2). 9. Slide the PCB and the rear panel back and away from the rest of the chassis (figure 5.7.1). 10. For Domestic units, disconnect the power cord’s white wire from the PCB’s J4 tab and disconnect the power cord’s black wire from the PCB’s J3 tab. For International units, disconnect the power inlet’s white wire from the PCB’s J4 tab and the power inlet’s black wire from the PCB’s J3 tab (figure 5.7.2).

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11. Disconnect the output transformer connector from the PCB’s 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 outlet’s white wire from the PCB’s J6 white out tab (figure 5.7.2). 16. Remove the power outlet’s black wire from the PCB’s J2 black out tab (figure 5.7.2). 17. The PCB is now free from the chassis.

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5.8 PCB Installation: Smart-UPS 450 and Smart-UPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Place the PCB on top of the rear panel (figure 5.7.2). 2. Slide the PCB into the rear panel using the rear panel guides (figure 5.7.2). 3. Replace the screws that secure the rear of the PCB to the rear panel (figure 5.7.2). 4. Replace the hypot tab screw to the rear panel (figure 5.7.1). 5. Connect the power outlet’s white wire to the PCB’s J6 tab (figure 5.7.2). 6. Connect the power outlet’s black wire to the PCB’s J2 tab (figure 5.7.2). 7. Reconnect the black wire from the PCB to the circuit breaker's tab (figure 5.7.2). 8. For Domestic units, reconnect the power cord's white wire to the PCB’s J4 tab and reconnect the power cord’s black wire to the PCB’s J3 tab. For International units, reconnect the power inlet’s white wire to the PCB’s J4 tab and reconnect the power inlet’s black wire to the PCB’s J3 tab (figure 5.7.2). 9. Place the PCB with the rear panel back onto the chassis. The lip at the bottom of the rear panel should be underneath the bottom of the chassis. 10. Reconnect the output transformer's connector to the PCB tab labeled J5 (figure 5.7.1). 11. Insert the display PCB into the bezel and snap bezel back in place at the front of the unit (figure 5.3.1). 12. Reconnect the SNMP adapter cable to the PCB’s J14 tab (figure 5.7.1). 13. Reconnect the PCB’s black wires to the output transformer’s primary side (figure 5.7.1). 14. Replace the two (2) screws that secure the front of the PCB to the chassis (figure 5.7.1). 15. Replace the two (2) screws that secure the rear panel to the bottom of the chassis (figure 5.7.1). 16. Replace the battery per section 5.6 and replace the cover per section 5.2.

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5.9 Output Transformer Removal: Smart-UPS 450 and SmartUPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. Note: Although it is not a must to disconnect the batteries from the unit in order to remove the output transformer, it is highly recommended and therefore listed as a step to eliminate the potential of having power at the rear panel. 1. Remove the cover (section 5.1), the batteries (section 5.5), and the PCB (section 5.7) before removing the output transformer. 2. Remove the four (4) screws that secure the transformer to the chassis (figure 5.9.1).

3. Remove the transformer.

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5.10 Output Transformer Installation: Smart-UPS 450 and Smart-UPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Place the transformer inside the chassis. Make sure to orient the transformer with its Black and White primary transformer wires toward the FET bank, that is, to the left side of the UPS when viewing the UPS from the front (figure 5.9.1). 2. Replace the four (4) screws that secure the output transformer to the chassis (figure 5.9.1). 3. Install the PCB per section 5.8.

5.11 Rear Outlet Removal: Smart-UPS 450 and Smart-UPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. Note: Although it is not a must to disconnect the batteries from the unit in order to remove the rear outlet, it is highly recommended and therefore listed as a step to eliminate the potential of having power at the rear panel. 1. Remove the cover (section 5.1), the batteries (section 5.5.), and the PCB (section 5.7) before removing the rear outlet. 2. For Domestic units, remove the two (2) screws that secure the outlets to the rear panel and remove the outlets (figure 5.11.1). For International units, remove the rear outlet’s green ground wire from the chassis. Then, from the inside of the rear panel, press in the clips located on each side of the outlet and push out until the outlets are free from the rear panel (figure 5.11.2).

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3. Remove the outlet.

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5.12 Rear Outlet Installation: Smart-UPS 450 and Smart-UPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. For Domestic units, position the outlet in place and replace the two (2) screws that secure the outlet to the chassis (figure 5.11.1). For International units, position the outlet in place and push the outlet into the rear panel until it snaps into place. Then, replace the screw that secures the green ground wire to the chassis (figure 5.11.2). 2. Install the PCB per section 5.8.

5.13 Circuit Breaker Removal: Smart-UPS 450 and Smart-UPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. Note: Although it is not a must to disconnect the batteries from the unit in order to remove the circuit breaker, it is highly recommended and therefore listed as a step to eliminate the potential of having power at the rear panel. 1. Remove the cover (section 5.1), the batteries (section 5.5.), and the PCB (section 5.7) before removing the circuit breaker. 2. Disconnect the power inlet's black wire (international) or power cord's black wire (domestic) from the circuit breaker (figure 5.11.2 and figure 5.11.1). 3. While holding in the clips at the sides of the circuit breaker, from the front of the rear panel, push the circuit breaker out until it is free from the rear panel (figure 5.11.1).

5.14 Circuit Breaker Installation: Smart-UPS 450 and SmartUPS 700. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. From the inside of the rear panel press in both clips on each side of the circuit breaker and push in until it snaps into place (fig 5.11.1).

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2. Connect the power inlet’s black wire (international) or power cord’s black wire (domestic) to the circuit breaker (figure 5.11.1). 3. Install the PCB per section 5.8.

5.15 Cover Removal: Smart-UPS 1000 and Smart-UPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from utility line. 2. Turn the unit on its side to allow access to the bottom screws and remove the six (6) screws that secure the cover to the chassis (figure 5.15.1).

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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5.16 Cover Installation: Smart-UPS 1000 and Smart-UPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Make sure that all wires are securely tucked inside the unit and from the rear side of the unit, slide the cover forward onto the chassis. Keep the cover horizontal at all times (Fig 5.15.1). 2. Turn the unit on its side to allow access to the bottom and replace the six (6) screws that secure the cover to the chassis (figure 5.15.1).

5.17 Bezel Removal: Smart-UPS 1000 and Smart-UPS 1400. Note: Make sure the LED display board does not make contact to chassis, as there may be DC voltages present that will short to chassis. To prevent an accidental shorting of the display PCB it is recommended that the batteries be removed and the unit discharged per section 5.19. 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 5.17.1).

3. Unsnap the L.E.D. display PCB away from the bezel. The bezel is now free from the chassis.

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5.18 Bezel Installation: Smart-UPS 1000 and Smart-UPS 1400. Note: Make sure the LED display board does not make contact to chassis, as there may be DC voltages present that will short to chassis. To prevent an accidental shorting of the display PCB it is recommended that the batteries be removed and the unit discharged per section 5.19. 1. Snap the L.E.D. into the bezel (figure 5.17.1). 2. Align the tabs of the bezel with the chassis battery door and snap the bezel in place (figure 5.17.1).

5.19 Battery Removal: Smart-UPS 1000 and Smart-UPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from utility line. 2. Unsnap the bezel away from the unit (figure 5.17.1). 3. Remove the two (2) screws from the battery door (figure 5.19.1).

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4. Swing the battery door open (figure 5.19.2).

5. Gently slide the batteries out of the UPS. 6. For Smart-UPS 1000, remove the UPS’s red battery wire from the positive tab of the battery and remove the UPS’s black battery wire from the negative tab of the battery (figure 5.19.2). For Smart-UPS 1400, disconnect the Anderson connector plug (figure 5.19.2). 7. To discharge the unit, press the On button several times.

5.20 Battery Installation: Smart-UPS 1000 and Smart-UPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from utility line. 2. For Smart-UPS 1400, prepare the batteries as described in figure 5.20.1. For Smart-UPS 1000, prepare the batteries as described in figure 5.20.2.

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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 PCB’s red wire to the positive terminal of the battery and the PCB’s black wire to the negative terminal of the battery. For the Smart-UPS1400, connect the battery’s Anderson connector plug to the PCB’s 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).

5.21 PCB Removal: Smart-UPS 1000 and Smart-UPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. Warning: The capacitors will store energy well after all sources have been disconnected from the unit. Make sure the capacitors are discharged before servicing the unit. 1. Remove the cover per section 5.15 and the battery per section 5.19. 2. Press the On button on the front of the unit several times to discharge the unit. 3. Disconnect the black primary output transformer wire from heatsink #1 (figure 5.21.1).

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4. Disconnect the white primary output transformer wire from heatsink #4 (figure 5.21.1). 5. Disconnect the PCB’s black wire from the circuit breaker tab (figure 5.21.1). 6. Remove the LED display PCB by unsnapping it out of the bezel (figure 5.17.1). 7. Remove the two (2) screws that secure the front of the PCB to the chassis (figure 5.21.2).

8. Remove the center screw that secures the PCB to the chassis (figure 5.21.2). 9. Disconnect the SNMP adapter cable from the PCB’s 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 cord’s white wire from the PCB’s J4 tab and disconnect the power cord’s black wire from the PCB’s J3 tab. For International units, disconnect the power inlet’s white wire from the PCB’s J4 tab and the power inlet’s black wire from the PCB’s J3 tab. 12. Disconnect the Output transformer’s connector from the PCB’s 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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15. Remove the hypot tab screw on the rear panel. 16. Slide the PCB away from the rear panel. 17. Remove the power outlet’s white wire from the PCB’s J6 tab 18. Remove the power outlet’s black wire from the PCB’s J2 tab. 19. For UPS’s with the rear panel quick-disconnect Anderson connector plug, remove the two (2) screws that secure the connector to the rear panel (figure 5.21.2). 20. The PCB is now free from the chassis.

5.22 PCB Installation: Smart-UPS 1000 and Smart-UPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. 2. 3. 4. 5. 6.

Place the PCB on top of the rear panel. Slide the PCB into the rear panel using the rear panel guides (figure 5.21.1). Replace the screws that secure the PCB to the rear panel (figure 5.21.1). Connect the power outlet’s white wire to the PCB’s J6 tab. Connect the power outlet’s black wire to the PCB’s J2 tab. For Domestic units, reconnect the power cord's white wire to the PCB’s J4 tab and reconnect the power cord’s black wire to the PCB’s J3 tab. For International units, reconnect the power inlet’s white wire to the PCB’s J4 tab and reconnect the power inlet’s black wire to the PCB’s J3 tab. 7. Reconnect the black wire from the PCB to the circuit breaker's tab (figure 5.21.1). 8. Secure the hypot tap screw to the chassis. 9. Place the rear panel and PCB back onto the chassis. The lip at the bottom of the rear panel should be underneath the bottom of the chassis. 10. Reconnect the output transformer's connector to the PCB tab labeled J5. 11. Reconnect the SNMP adapter cable from the PCB’s J14 tab. 12. Insert the display PCB into the bezel and snap the bezel back in place at the front of the unit (figure 5.17.1). 13. Reconnect the black primary output transformer wire to heatsink #1 (figure 5.21.1). 14. Reconnect the white primary output transformer wire to heatsink #4 (figure 5.21.1). 15. Replace the two (2) screws that secure the front of the PCB to the chassis as well as the center screw (figure 5.21.2). 16. Replace the two (2) screws that secure the rear panel to chassis (figure 5.21.2). 17. Replace the battery per section 5.20 and replace the cover per section 5.16.

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5.23 Output Transformer Removal: Smart-UPS 1000 and SmartUPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. Note: Although it is not a must to disconnect the batteries from the unit in order to remove the output transformer, it is highly recommended and therefore listed as a step to eliminate the potential of having power at the rear panel. 1. Remove the cover (section 5.15), the batteries (section 5.19.), and the PCB (section 5.21) before removing the output transformer. 2. Remove the four (4) screws that secure the transformer to the chassis (figure 5.23.1).

3. Remove the transformer.

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5.24 Output Transformer Installation: Smart-UPS 1000 and Smart-UPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. Place the transformer inside the chassis. Make sure to orient the transformer with its Black and White primary transformer wires toward the FET bank, that is, to the left side of the UPS when viewing the UPS from the front (figure 5.23.1). 2. Replace the four (4) screws that secure the output transformer to the chassis (figure 5.23.1). 3. Install the PCB per section 5.22.

5.25 Rear Outlet Removal: Smart-UPS 1000 and Smart-UPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. Note: Although it is not a must to disconnect the batteries from the unit in order to remove the rear outlet, it is highly recommended and therefore listed as a step to eliminate the potential of having power at the rear panel. 1. Remove the cover (section 5.15), the batteries (section 5.19.), and the PCB (section 5.21) before removing the rear outlet. 2. For Domestic units, remove the two (2) screws that secure the outlets to the rear panel and remove the outlets (figure 5.25.1). For International units, remove the rear outlet’s green ground wire from the chassis. Then, from the inside of the rear panel, press in the clips located on each side of the outlet and push out until the outlets are free from the rear panel (figure 5.25.1).

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5.26 Rear Outlet Installation: Smart-UPS 1000 and Smart-UPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. For Domestic units, position the outlet in place and replace the two (2) screws that secure the outlet to the chassis (figure 5.25.1) Note: The outlet’s ground screw must be on the opposite side of the circuit breaker. For International units, position the outlet in place and push the outlet into the rear panel until it snaps into place. Then, replace the screw that secures the green ground wire to the chassis (figure 5.25.1). Note: The outlet’s ground screw must be facing downward. 2. Install the PCB per section 5.22.

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5.27 Circuit Breaker Removal: Smart-UPS 1000 and Smart-UPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. Note: Although it is not a must to disconnect the batteries from the unit in order to remove the circuit breaker, it is highly recommended and therefore listed as a step to eliminate the potential of having power at the rear panel. 1. Remove the cover (section 5.15), the batteries (section 5.19), and the PCB (section 5.21) before removing the circuit breaker. 2. Disconnect the power inlet's black wire (international) or power cord's black wire (domestic) from the circuit breaker (figure 5.25.1). 3. While holding in the clips at the sides of the circuit breaker, from the front of the rear panel, push the circuit breaker out until it is free from the rear panel (figure 5.25.1).

5.28 Circuit Breaker Installation: Smart-UPS 1000 and SmartUPS 1400. Warning: The unit must be disconnected from facility power when removing or replacing any assemblies. 1. From the inside of the rear panel press in both clips on each side of the circuit breaker and push in until it snaps into place (fig 5.25.1). 2. Connect the power inlet’s black wire (international) or power cord’s black wire (domestic) to the circuit breaker (figure 5.25.1). 3. Install the PCB per section 5.22.

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6.0 Functional Test Procedures This section outlines the steps to perform a functional test on the Smart-UPS 450/ 700/ 1000/ and 1400. The functional test is broken down into the following sections; Site wiring fault detector test, Output voltage test, Full load test On-battery, Battery reserve time test, Transfer level test, Battery charger test, and the Computer interface port test.

6.1 Site Wiring Fault Detector Test – 120VAC UPS’s only. The 120VAC 450-1400 Smart-UPS UPS has a site wiring fault detector that warns the user of a potential wiring problem. The site wiring fault indicator is a red LED on the rear panel. This LED will illuminate when the unit is plugged into an improperly wired outlet. The LED will illuminate when any of the following wiring faults are present: 1. An open or high resistance ground. 2. Reversed polarity of the hot and neutral lines. 3. An overloaded neutral circuit is present. The site wiring fault circuit can be easily tested by plugging the UPS into an ungrounded receptacle, or by reversing the polarity on the input (Hot-in & Neuin) although this is not recommended. A computer load should be present at the time of testing. If the LED fails to illuminate, than the UPS should be serviced.

6.2 Output Voltage Test. 1. Plug the variac into the AC line and set the variac output for 120 VAC, (100VAC) or (230 VAC}. 2. Plug the UPS into the variac and turn the UPS On. The UPS will perform a self-test for approximately 8-10 seconds and return to the On-Line state. 3. Connect a true RMS voltmeter and an oscilloscope to the output of the UPS. 4. Turn Off the variac. The UPS should immediately transfer to backup power. 5. Using a voltmeter and oscilloscope, monitor the UPS's output voltage and frequency. 6. The UPS should output a pure sine wave at approximately 117+5% VAC, (100+5% VAC) or {225+5% VAC} 7. If the sine wave is heavily distorted or the output voltage is inaccurate, the UPS should be serviced.

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6.3 Full Load Test On Battery. 1. Prior to performing this test, the unit should be charged up. Time to charge will vary depending on the current state of the batteries. 2. Plug the variac into the AC line and set the variac output for 120 VAC, (100VAC) or {230 VAC}. 3. Plug the UPS into the variac and turn the UPS On. The UPS will perform a self-test for approximately 8-10 seconds and return to the On-Line state. 4. Apply the correct size load to the UPS. Refer to table 6.3 for proper load size.

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 UPS’s 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.

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6.4 Battery Reserve Time Test. 1. Prior to performing this test, the unit should be charged up. Time to charge will vary depending on the current state of the batteries. 2. Plug the variac into the AC line and set the variac output for 120 VAC, (100VAC) or 230 VAC}. 3. Plug the UPS into the variac and turn the UPS On. The UPS will perform a self-test for approximately 8-10 seconds and return to the On-Line state. 4. Connect a true RMS voltmeter to the output of the UPS. 5. Apply the correct size load to the UPS. Refer to table 6.3 for proper load size or table 6.4 for variant load applications. Typical Unit On-battery Runtimes Versus VA** Load, In Hours Load (VA) 50 75 100 150 200 250 300 350 400 450 500 550 600 700 800 900 1000 1200 1400

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

**Note: VA levels shown assume a 0.7 typical power factor of the average non-PFC computer power supply Table 6.4

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6. Using a voltmeter, monitor the UPS’s 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.

6.5 Transfer Level Test. 1. Plug the variac into the AC line and set the variac output for 120 VAC, (100VAC) or {230 VAC}. 2. Plug the UPS into the variac and turn the UPS On. The UPS will perform a self-test for approximately 8-10 seconds and return to the On-Line state. 3. Connect a true RMS voltmeter and an oscilloscope to the output of the UPS. 4. Slowly turn down the variac and monitor the UPS's input voltage. The UPS should transfer to SmartBoost when the voltage drops to 103+5% VAC (90+ 5% VAC) or {196+5% VAC}. Repeat this procedure several times to ensure accurate results. 5. While the UPS is on SmartBoost, slowly turn the variac down until the UPS transfers to battery. The UPS should transfer to battery at approximately 92+5% VAC (80+ 5%VAC) or {174+5% VAC}. 6. If the UPS does not transfer properly, then the calibration of the unit is recommended. Otherwise, the UPS should be serviced. 7. Turn the variac back up so that the UPS goes back to On-Line operation. 8. Slowly turn up the variac and monitor the UPS’s input voltage. The UPS should transfer to SmartTrim when the voltage increases to 132+5% VAC (110+ 5% VAC) or {258+5% VAC}. Repeat this procedure several times to ensure accurate results. 9. While the UPS is on SmartTrim, slowly turn the variac up until the UPS transfers to battery. The UPS should transfer to battery at approximately 147+5% VAC (123+ 5%VAC) or {296+5% VAC}. 10. If the UPS does not transfer properly, then the calibration of the unit is recommended. Otherwise, the UPS should be serviced.

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6.6 Battery Charger Test. 1. Plug the variac into the AC line and set the variac output for 120 VAC, (100VAC) or {230 VAC}. 2. Plug the UPS into the variac and turn the UPS On. The UPS will perform a self-test for approximately 8-10 seconds and return to the On-Line state. 3. For the 450-700, remove the two (2) screws from the battery door (figure 5.5.1). For the 1000-1400, remove the two (2) screws from the battery door (figure 5.19.1). 4. Swing the battery door open and gently slide the battery out of the UPS. 5. Remove the units black wire from the negative battery terminal and remove the units red wire from the positive battery terminal. Note: for the 1400, disconnect the battery’s Anderson connector plug. 6. Remove the battery. 7. Measure the DC battery charger voltage between the PCB's black battery wire and the PCB's red battery wire. 8. The DC voltage should be at 26.7 - 28.5 VDC. 9. Should the battery charger voltage fail to meet the provided range, then the unit should be serviced. 10. Connect the red wire from the unit to the positive battery terminal. 11. Connect the black wire from the unit to the negative battery terminal. 12. Gently slide battery into chassis. 13. Swing battery door closed and replace the two (2) screws that secure the battery door to the chassis.

6.7 Computer Interface Port Test. The Back-UPS is equipped with a rear panel interface port to allow for communication between the UPS and a host computer. A detailed description of the port can be found in section 4.0. The following steps should be performed to ensure the interface port is working properly. 1. Plug the variac into the AC line and set the variac output for 120 VAC (100VAC) or {230VAC}. 2. Plug the UPS into the variac and turn the UPS On. The UPS will perform a self-test for approximately 8-10 seconds and return to the On-Line state.

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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 kΩ (± 5 kΩ) 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 kΩ (± 5 kΩ) 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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7.0 Troubleshooting Procedure. This section outlines the most common problems that may be encountered with a UPS. The format of this section is as follows: I. II. III.

Symptom - a brief description of a problem encountered. Likely cause - the possible reasons that may have caused the problem to occur. Probable solution - the probable solutions to each of the likely causes.

7.1 Troubleshooting Procedure. Symptom:

Likely cause:

1. Will not start:

Batteries not connected. Bad batteries.

2. Won’t go On-line: (continued on next page).

Probable solution: Connect batteries.

Additional comments:

Replace batteries.

See comments at the bottom of the table pertaining to batteries. Typical failures when F3 is blown. a. the UPS may turn on upon batt. connection; Q5 and/or Q6 may be shorted. b. F3 opens upon turn-on attempt; 24v short present. See comments at the bottom of the table pertaining to bias voltages.

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.

Adjust (B) battery setting. Connect power cord.

Display pcb ribbon cable may be cut, shorting DC voltage to chassis blowing F3 and shorting Q5.

Verify site power at receptacle. With power removed, check the circuit breaker with an ohm meter. A bad circuit breaker will often show resistance and must be replaced. Verify continuity from power cord to hot-in tab at pcb.

Adjust (L) line setting.

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7.2 Troubleshooting Procedure. Symptom:

Likely cause:

2. Won’t go On-line: (see last page).

Component lead out of pcb.

3. Flashing LEDs:

4. Overload:

5. Won’t 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.

Other suspect components: D18, D19, D20, C63, and IC10.

Resolder C17 onto the pcb. Replace C44 or C52. Replace relay. Replace IC3. Replace D20. Reduce load.

Replace T2.

Replace CT1.

A reading above 4 ohms across transformer indicates it is faulty.

Replace IC15.

Overloads typically originate in the inverter section – a complex circuit. – 8V should be verified first, then IC replacement may be done as follows; IC12, 8, 17, and 14. Drivers and fets as well as the power transformer may be bad also. Check float voltage and verify battery constants 4, 5, 6, and 0. The 0 constant is critical for it will change per design when the batteries are discharged. Always check this constant after battery replacement.

Adjust float voltage (B) setting.

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7.3 Troubleshooting Procedure. Symptom:

Likely cause:

5. Won’t charge: (see last page).

Bad charger circuit.

6. UPS clicking but won’t start.:

7. L.E.D. failure: 8. Will not stay On-line:

Probable solution: Replace IC14.

Additional comments:

Bad battery.

Replace battery.

See comments at the bottom of the table pertaining to batteries.

Bad microprocessor. Bad reset circuit.

Replace IC12.

Bad L.E.D.

Replace faulty L.E.D. Replace Q56.

Bad turbo circuit.

Replace C77.

IC14 pin 9 should be 8VDC,if not then C88 or IC17 may be faulty.

The reset circuit is composed of several components which could be the culprit in a reset failure. Components should be replaced in the following order: C77, IC11, Q51, Q52, Q53, IC15, and R115. Drivers may fail as well in display pcb Q57,Q58,Q59,andQ60 Q55, Q54, and IC12 could also trip the turbo circuit. IC13 may be corrupted and need replacing – if so, the UPS will have to be fully reprogrammed.

Additional information pertinent to table above. Caution: Batteries can leak or swell, exposing hazardous gases and acid, when exposed to inadequate environments such as poor ventilated areas or excessively hot room temperatures. The UPS should be kept in a well ventilated area where the ambient temperature is within UPS operating temperature to avoid a reduced expected runtime or a premature UPS failure. If new batteries drain prematurely it may be the effect of another failure such as “will not go On-line”,“will not charge”,“clicking”, or “flashing leds”. These failures can drain the batteries ultimately causing the UPS to fail for “won’t start”. Ensure that the UPS is fully operational upon battery replacement to avoid draining the new batteries. Note: The UPS battery is really a battery pack composed of two or more batteries depending on the model. If one of the battery cells is bad and the other one(s) is good then the UPS may perform strangely, unexpectedly dropping the load or not fully charging the battery. Each battery should be checked individually.

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7.4 Troubleshooting Procedure. Note: The UPS has several bias voltages that must be present for proper UPS operation. Verification of Bias voltages for the Smart-UPS’s 450/700/1000/1400 may be conducted as follows: Using an Ohm meter and using chassis ground as a point of reference, verify approximately 1Mohm at pin1 of IC4, 1Kohm at pin 1 of IC5, and 1Kohm at pin 3 of IC5. These are 24VDC, 12VDC, and 5VDC reference respectively. Also, verify approximately 15Kohm at pin 1 of IC17 for –8VDC reference. Listed below are the typical components that fail when a reference voltage is missing. •

24VDC

C41, C36, IC4, snmp and display pcb ribbon cable, Fan,C63.

•

12VDC

IC5, C8, D401, IC2, Power FET’s

•

5VDC

D402, IC12, IC13 (eeprom must be reprogrammed),IC5,IC10,C65.

•

-8VDC

C7, Q39, Q40, C54, C53, D28, D27, IC9, IC17.

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