Service Manual for the

American Power Conversion

Back-UPS Pro
280S/ 420S/ 650S Duet
Smart-UPS
420/ 620 NET
Uninterruptible Power Supply
Document # 996-0356

AMERICAN POWER CONVERSION

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

Document # 996-0356

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.

ii

Revision Record

Revision 1.0. Original document. 4/30/96.

Revision 1.1. Original document added 280SI to the manual. 9/9/98.
Revision 2.0. Original document addressed Back-UPS Pro & VS - Original
document transcribed to conform to FSE presentation format and to address the
Back-UPS Pro Duet and Net models only. 9-01-00. JGuzman.

iii

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 OPERATIONS -------------------------------------------------------- 4
5.0
PROCEDURES FOR THE BACK-UPS PRO 280S/ 420S/ 650S DUET &
SMART-UPS 420/ 620 NET -------------------------------------------------------------------------- 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

6.0

Cover Removal. ---------------------------------------------------------------------------------------------------- 7

Cover Installation.------------------------------------------------------------------------------------------------- 8
Bezel Removal. ---------------------------------------------------------------------------------------------------- 8
Bezel Installation. ------------------------------------------------------------------------------------------------- 9
Battery Removal. -------------------------------------------------------------------------------------------------- 9
Battery Installation. ----------------------------------------------------------------------------------------------10
PCB Removal.-----------------------------------------------------------------------------------------------------10
PCB Installation.--------------------------------------------------------------------------------------------------12
Output Transformer Removal. --------------------------------------------------------------------------------13
Output Transformer Installation. -----------------------------------------------------------------------------14
Rear Outlet Removal. -------------------------------------------------------------------------------------------14
Rear Outlet Installation. ----------------------------------------------------------------------------------------15
Circuit Breaker Removal. --------------------------------------------------------------------------------------16
Circuit Breaker Installation. -----------------------------------------------------------------------------------16

FUNCTIONAL TEST PROCEDURES ------------------------------------------------17

6.1
6.2
6.3
6.4
6.5
6.6
6.7

Phase Synchronization Test.-----------------------------------------------------------------------------------17

Output Voltage Test.---------------------------------------------------------------------------------------------17
Full Load Test On-Battery. ------------------------------------------------------------------------------------18
Battery Reserve Time Test.------------------------------------------------------------------------------------19
Transfer Level Test. ---------------------------------------------------------------------------------------------19
Battery Charger Test.--------------------------------------------------------------------------------------------20
Computer Interface Port Test.---------------------------------------------------------------------------------21

7.0 TROUBLESHOOTING PROCUDURE ---------------------------------------------------22

7.1
7.2
7.3

Troubleshooting Procedure. -----------------------------------------------------------------------------------22

Troubleshooting Procedure. -----------------------------------------------------------------------------------23
Troubleshooting Procedure. -----------------------------------------------------------------------------------24

iv

1.0 Introduction
This manual provides information required for servicing American Power Conversion
Corporation Back-UPS Pro 280S/ 420S/ 650S Duet and Smart-UPS 420/620 Net. 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. Symptom.
2. Likely Cause.
3. Probable Solution.

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) that 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 batterys 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.

3.0 Tools and Equipment

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

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 120/230 Volt models, this source must be
able to generate 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: 280VA - 650VA (180+2 Watts, - 410+2 Watts, 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: to time the UPS battery reserve time.

4.0 Principles of Operations

American Power Conversion Corporation models Back-UPS PRO 280S/ 420S/ 650S and
Smart-UPS 420/ 620 supply 280VA up to 650VA (180 Watts to 410 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 multi-stage
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 Back-Ups Pro Duet and
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 Back-Ups
Pro Duet and Smart-UPS battery charger limits continuous "exercising" of the battery.
The low internal operating temperature of the Back-Ups Pro Duet and 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.
The Back-Ups Pro Duet and Smart-UPS provide voltage correction features, called
SmartTrim and SmartBoost (and DoubleBoost), which allow the UPS to remain operating
On-Line during many high and low utility voltage conditions. The SmartBoost
(DoubleBoost) 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.

Computer interface port description The Back-UPS Pro 280S/ 420S/ 650S and
Smart-UPS 420/ 620 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.
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 25 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 Turn On/ Low turn Off.
Pin 8 This pin has no connection.
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.

BACK-UPS PRO 280S/ 420S/ 650S DUET

SMART-UPS 420/ 620
BLOCK DIAGRAM
DOMESTIC

BACK-UPS 280S/ 420S/ 650S DUET

SMART-UPS 420/ 620
BLOCK DIAGRAM
INTERNATIONAL

5.0 Procedures for the Back-UPS Pro 280S/ 420S/ 650S Duet
& Smart-UPS 420/ 620 Net
Warning: Before disassembling and changing batteries, or servicing the Back-UPS Pro
Duet and 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.

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 5.3.
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).

5.2 Cover Installation.

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.

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. Remove the four (4) screws that secure the cover to the chassis and remove
the cover (Fig 5.1.1).
3. Slide the bezel in an upward motion and then pull out on the bezel (figure
5.3.1).

4. Remove the LED display PCB from the bezel being careful not to allow the
exposed display PCB to short out any of its contacts to the chassis. The bezel
is now free from the unit.

5.4 Bezel Installation.

1. Replace the LED display PCB into the bezel. Be sure to guide the display
PCB ribbon cable inside the chassis to avoid damaging it (figure 5.3.1).
2. Position bezel into proper slots and slide the bezel in a downward motion until
it seats flush and even on the chassis (figure 5.3.1).
3. Replace the cover onto the chassis and replace the four (4) screws that secure
the cover to the chassis.

5.5 Battery Removal.

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. Place the unit on its side and remove the two (2) screws that secure the battery
door to the chassis at the bottom of the unit (figure 5.5.1).

3. Swing the battery door open and gently slide the battery out of the UPS. The
white battery label can be used to pull the batteries out (Fig 5.5.1).
4. Remove the units black wire from the negative battery terminal (figure 5.5.1).
5. Remove the units red wire from the positive battery terminal (figure 5.5.1).
6. To discharge the unit, press the On button several times.
7. The battery is now free from the unit.

5.6 Battery Installation.

1. Connect the red wire from the unit to the positive battery terminal (figure
5.5.1).
2. Connect the black wire from the unit to the negative battery terminal (figure
5.5.1).
3. Gently slide battery into chassis.
4. Swing battery door closed and replace the two (2) screws that secure the
battery door to the chassis (figure 5.5.1).

5.7 PCB Removal.

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. Press the On button on the front of the unit several times to discharge the unit.
3. Remove the Output transformer wires as follows (figure 5.7.1):
Note: The primary side of the transformer consists of a white, orange, brown and
black wire. The secondary side consists of a white wire, a yellow wire and one
(1) or two (2) violet wires, a brown (1) and a blue (1) wire.
Disconnect:
a. Disconnect the primary side four (4) wire Mate-N-Lock connector
from the PCBs J17 connector.
b. Disconnect the secondary side yellow wire from the PCBs J11 tab.
c. Disconnect the secondary side white wire from the PCBs J8 tab.

10

d. Disconnect the secondary side violet wire from the PCBs J10 tab.
e. Disconnect the secondary side brown wire from the PCBs J5 tab.
f. Disconnect the secondary side blue wire from the PCBs J4 tab.

4. Remove the two (2) screws that connect the front of the PCB to the bezel side
of the chassis (figure 5.7.1).
5. Remove the PCBs black wire from the circuit breaker.
6. Remove the inlets white wire (power cords white wire for domestic unit)
from the PCBs tab J13 (Wht In).
7. Remove the power outlets white wire from the PCBs tab J16 (Wht Out).
8. Remove the power outlets black wire from the PCBs tab J15 (Blk Out).
9. Remove the Red battery wire from the PCBs tab J6 (Positive batt. wire).
10. Remove the Black battery wire from the PCBs tab J7 (Negative batt. wire).
11. Remove the four (4) screws that secure the rear of the PCB to the rear panel.
12. Remove the screw on the rear panel that holds the PCB to chassis (hypot
screw).
13. Lift the PCB up and away from the chassis.
14. Remove the display PCB from the bezel and now the PCB is free from its
chassis.

11

5.8 PCB Installation.

1. Place the PCB back onto the chassis. Guide the DB9 port through rear panel
opening and use chassis guide screw to ensure PCB is seating correctly.
2. Replace the LED display PCB into the bezel. Be sure to guide the display
PCB ribbon cable inside the chassis to avoid damaging it (figure 5.3.1).
3. Position bezel into proper slots and slide the bezel in a downward motion until
it sits flush and even on the chassis (figure 5.3.1).
4. Replace the two (2) screws that connect the front of the PCB to the bezel side
of the chassis (figure 5.7.1).
5. Replace the PCBs black wire to the circuit breaker.
6. Replace the inlets white wire (power cords white wire for domestic unit) to
the PCBs tab J13 (Wht In).
7. Replace the power outlets white wire to the PCBs tab J16 (Wht Out).
8. Replace the power outlets black wire to the PCBs tab J15 (Blk Out).
9. Replace the Red battery wire to the PCBs tab J6 (Positive batt. wire).
Warning: Do not connect the red wire to the battery at this point.
10. Replace the Black battery wire to the PCBs tab J7 (Negative batt. wire).
11. Replace the four (4) screws that secure the rear of the PCB to the rear panel.
12. Replace the Output transformer wires as follows (figure 5.7.1):
Reconnect:
a. Reconnect the primary side four (4) wire Mate-N-Lock connector to
the PCBs J17 connector.
b. Reconnect the secondary side yellow wire to the PCBs J11 tab.
c. Reconnect the secondary side white wire to the PCBs J8 tab.
d. Reconnect the secondary side violet wire to the PCBs J10 tab.
e. Reconnect the secondary side brown wire to the PCBs J5 tab.
f. Reconnect the secondary side blue wire to the PCBs J4 tab.
13. Replace the battery per section 5.6 and replace the cover per section 5.2.
14. After the Hypot test, replace the Hypot screw (figure 5.7.1).

12

5.9 Output Transformer Removal.

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 panel, it is highly recommended and therefore listed as a step
to eliminate the potential of having power at the rear panel.
1. Remove any load from the UPS and turn the UPS Off. Then, unplug it from
utility line.
2. Remove the cover (section 5.1), the batteries (section 5.5.), and the PCB
(section 5.7) before removing the output transformer.
3. Remove the four (4) screws that secure the transformer to the chassis (figure
5.9.1).

13

Note: Although the rear panel does not need to be removed during the Output
Transformer removal, it is recommended to ease access to the transformer.
4. Remove rear panel by removing the two screws on each side that secure the
rear panel to the bottom of the chassis (figure 5.9.1).
5. Remove the transformer from the chassis.

5.10 Output Transformer Installation.

1. Place the transformer inside the chassis and make sure to orient the
transformer with its four (4) pin Mate-N-Lock connector toward the left side
of the unit (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.

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. Remove the rear panel to allow easy access to the outlets by removing the two
(2) screws that secure the rear panel to the bottom of the chassis (figure 5.9.1).
3. For Domestic units, remove the two (2) screws that secure the outlet to the
rear panel and remove the outlet (figure 5.11.1).
For International units, remove the rear outlets 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 5.11.1).

14

4. Remove the wires connected to the outlet and remove the outlet.

5.12 Rear Outlet Installation.

1. Replace the jumper wires connected to the outlets ensuring proper polarity
and place the outlets in place to be secured to the rear panel.
2. For Domestic units, ensure that the outlets ground screws are on the same
side as the circuit breaker and replace the screws that secure each set of outlets
to the chassis (figure 5.11.1).
For International units, align the outlets onto the rear panel, snap them in,
and replace the screw that secures the outlets green ground wire to the chassis
(figure 5.11.1).
3. Replace the batteries per section 5.8.

15

5.13 Circuit Breaker Removal.

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. Remove the rear panel to allow easy access to the circuit breaker by removing
the two (2) screws that secure the rear panel to the bottom of the chassis
(figure 5.9.1).
3. Disconnect the power inlet's black wires (international) or power cord's black
wires (domestic) from the circuit breaker (figure 5.11.1).
4. 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.

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).
2. Connect the power inlets black wires (international) or power cords black
wires (domestic) to the circuit breaker (figure 5.11.1).
3. Install the PCB per section 5.8.

16

6.0 Functional Test Procedures

This section outlines the steps to perform a functional test on the Back-UPS Pro 280S/
420S/ 650S Duet and Smart-UPS 420/620 Net. The functional test is broken down into
the following sections: Phase synchronization test, Transfer level test, Short circuit test,
Back up capacity test, Battery reserve time test, Computer interface port test, and the
Battery charger test. For International units, the applicable voltages will be included in
brackets [].

6.1

Phase Synchronization Test.

1. Plug the variac into the AC line and set the variac output for 120 VAC [230
VAC].
2. Plug the UPS into the variac and turn the UPS On.
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
(while On-Battery the UPS's output is a stepped approximation to a sine wave
with the correct peak and rms values).
5. Using a voltmeter and oscilloscope, monitor the UPS's output voltage and
frequency.
6. Turn on the variac and observe the transfer from power inverter (stepped
wave) to utility line (sine wave) on the scope. The stepped wave should lock
into the sine wave and maintain phase synchronization. Repeat this test a few
times to clearly observe the phase lock in action.
7. If phase lock does not occur, the PCB should be replaced.

6.2

Output Voltage Test.

1. Plug the variac into the AC line and set the variac output for 120 VAC [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
(while On-Battery the UPS's output is a stepped approximation to a sine wave
with the correct peak and rms values).

17

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
[225+5% VAC].
7. If the sine wave is heavily distorted or the output voltage is inaccurate, the
UPS should be serviced.

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 [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
BP280S
BP420S
BP650S
SmartUPS420
SmartUPS620

Load (VA/Watt)
280VA/180W
420VA/260W
650VA/410W
420VA/260W
620VA/390W
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 [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.

18

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 [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.
6. Using a voltmeter, monitor the UPSs output voltage. The UPS should remain
powered and it should output approximately 120+5% VAC [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. 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 [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
[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 [174+5% VAC].

19

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 UPSs input voltage. The UPS
should transfer to SmartTrim when the voltage increases to 132+5% VAC
[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 [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.

6.6

Battery Charger Test.

1. Plug the variac into the AC line and set the variac output for 120 VAC [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. Place the unit on its side and remove the two (2) screws that secure the battery
door to the chassis at the bottom of the unit (figure 5.5.1).
4. Swing the battery door open and gently slide the battery out of the UPS. The
white battery label can be used to pull the batteries out (Fig 5.5.1).
5. Remove the units black wire from the negative battery terminal (figure 5.5.1).
6. Remove the units red wire from the positive battery terminal (figure 5.5.1).
7. Remove the battery.
8. Measure the DC battery charger voltage between the PCB's black battery wire
and the PCB's red battery wire.
9. The DC voltage should be at 13.6VDC+/- 3%.
10. Should the battery charger voltage fail to meet the provided range then the
unit should be serviced.
11. Connect the red wire from the unit to the positive battery terminal (figure
5.5.1).
12. Connect the black wire from the unit to the negative battery terminal (figure
5.5.1).
13. Gently slide battery into chassis.
14. Swing battery door closed and replace the two (2) screws that secure the
battery door to the chassis (figure 5.5.1).

20

6.7

Computer Interface Port Test.

The Duet and the Smart-UPS are 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
[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.
3. Using a multimeter, measure the voltage between the interface port's pin 2 and
9. The voltage should be LO RS-232 signal (-3 to -15 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 (+3 - +15
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 emit a tone and then shutdown.
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 10 k ( 0.5 k) resistor between a 5 volt DC source and the
UPS's pin 3. Using a multimeter, measure the DC voltage drop across the
resistor. The voltage drop should be greater than 3.5 VDC.
8. The resistor should still be connected between a 5 volt DC source and the
UPS's pin 3. Unplug the UPS from the utility line. Using a multimeter,
measure the DC voltage drop across the resistor. The voltage should be less
than 0.6 VDC.
9. Connect a 10 k ( 0.5 k) resistor between a 5 volt DC source and the
UPS's pin 6. Using a multimeter, measure the DC voltage drop across the
resistor. The voltage drop should be less than 0.6 VDC.
10. The resistor should still be connected between a 5 volt DC source and the
UPS's pin 6. Unplug the UPS from the utility line. Using a multimeter,
measure the DC voltage drop across the resistor. The voltage should be
greater than 3.5 VDC.
11. If the UPS fails any of the above tests, the PCB should be replaced.

21

7.0 Troubleshooting Procudure

This section outlines the most common problems that may be encountered with a
BP280S/ BP420S/ BP650S/ SU420/ and SU620. The format of this section is as follows:
I.
II.
III.

Symptom - a brief description of the problem or problems encountered.

Likely cause - the possible reasons that may have caused the recorded symptom to
occur. A trained service technician should verify all of the likely causes.
Probable solution - the recommended solutions to each of the likely causes.

7.1 Troubleshooting Procedure.

Symptom:
Will not
start:

Likely caus e:
Batteries not
connected.
Bad batteries.

Probable solution:
Connect batteries.

Additional comments:

Replace batteries.

See comments at the bottom of the

table pertaining to batteries.

Internal fuse blown.

Replace F1, F2, F3,

and/or F4
Replace U6 and/or U1.
Replace Q2, Q7, and/or
Q6.
Connect power cord.

Faulty I.C.
Transistor failure.
Will not go
On-Line:

Flashing
LEDs:
(continued
on next
page).

No input at power
cord.
Program wrong
setting.
MOV blown.
Bad IC

Check circuit breaker.

Adjust line setting.

Replace MOV.
Replace U6

Over clenching.

Replace PCB.

Burned trace.
Bad IC.

Repair trace from C28

to R84.
Replace U7.

Bad relay.

Replace relay.

R27, R28,R31, and R32 should be

checked as well as U7.
Over clenching occurs when
components are inserted onto the
PCB with excessive pressure. The
UPS wont operate properly, often
failing for flashing LEDS. PCB
replacement may be inevitable.
Damage may be beyond repair.
Other suspect ICs are U6, U9, U1,
and U3. C70 may be bad also.
Check relay drivers Q23, Q24,
Q25, Q26, and Q27.

22

7.2 Troubleshooting Procedure.

Symptom:
Flashing
LEDs (see
last page).

Overload:

Likely cause:
Circuit breaker bad.

Probable solution:
Replace circuit breaker.

Resistor out of
tolerance.

Check R27, R28, R31,

R32, R53, R54, R50
and R51.
Reduce the load.

Overload condition
present.
Clamp fets or
Power fets blown.

Tel./Net.
Jack fail:
Clicking
sound:
Battery
LED On:

Bad transistor.

Will not
charge:

Bad crystal.

Replace Phq1 and/or

Phq3.
Replace Y1.

Bad capacitor.

Replace C60.

Bad I.C.

Replace U8.

Bad Fets.

Check Q12 and /or

Q13.
Check D19 and/or
D20.
Replace L.E.D.

Bad diode.
L.E.D.
failure:
Power
calibration
failed:

Replace clamp fets Q12

and Q13.

Bad L.E.D.
Bad diode.

Check D30 D31, D32,

and/or D33.

Additional comments:

The clamp fets turn On during the

Off time of the inverter fets
(Q14,15,16,17 and Q18,19,20,and
21). If these fets are turned On
during the On-Line state they will
fail (blow up) and typically will
severely damage adjacent
components; It may be inevitable
to replace the PCB. 2 capacitors
that may cause an overload also
are C1 and C12.
Located on separate PCB where
phone jack hooks up.

The batteries could indeed be bad.

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

Other suspect components are C1,

C2, C3, and C4.
Q28 and the microprocessor are
possible culprits as well.

23

7.3 Troubleshooting Procedure.

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
wont start. Ensure that the UPS is fully operational upon battery replacement to avoid
draining the new batteries.

24