Automatic 12V Lead Acid Battery Charger Home > Circuits > Power Supply > Automatic 12V

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This charger will charge any 12V lead acid battery including flooded, gel and AGM. It is fully automatic and will charge at a rate up to about 4A until the battery voltage reaches a preset point at which it will switch to a very low current float charge. If the battery voltage drops again the charger will begin charging until the voltage once again reaches the cut off point. In this way it can be left connected to a battery indefinitely to maintain full charge without causing damage. An LED indicates when the battery is fully charged. Schematic

Parts Part R1, R3 R2 R4, R5, R7, R8 R6 R9 C1 D1 Total Description Qty. 2 330 Ohm 1/4W Resistor 1 100 Ohm 1/4W Pot 4 1 1 1 1 82 Ohm 2W Resistor 100 Ohm 1/4W Resistor 1K 1/4W Resistor 220uF 25V Electrolytic Capacitor P600 Diode Substitutions

Any 50V 5A or

D2 D3 D4 Q1 Q2 T1 F1 S1 MISC

1 1 1 1 1 1 1 1 1

1N4004 Diode 5.6V Zener Diode LED (Red, Green or Yellow) BT136 TRIAC BRX49 SCR 12V 4A Transformer See Notes 3A Fuse SPST Switch, 120VAC 5A Wire, Board, Heatsink For U1, Case, Binding Posts or Alligator Clips For Output, Fuse Holder Notes

greater rectifier diode 1N4002, 1N4007

1. R2 will have to be adjusted to set the proper finish charge voltage. Flooded and gel batteries are generally charged to 13.8V. If you are cycling the battery (AGM or gel) then 14.5V to 14.9V is generally recommended by battery manufacturers. To set up the charger, set the pot to midway, turn on the charger and then connect a battery to it's output. Monitor the charge with a voltmeter until the battery reaches the proper end voltage and then adjust the pot until the LED glows steadily. The charger has now been set. To charge multiple battery types you can mount the pot on the front of the case and have each position marked for the appropriate voltage. 2. Q1 will need a heatsink. If the circuit is mounted in a case then a small fan might be necessary and can generally be powered right off the output of D1. 3. T1 is a transformer with a primary voltage appropriate to your location (120V, 220V, etc.) and a secondary around 12V. Using a higher voltage secondary (16V-18V) will allow you to charge 16V batteries sometimes used in racing applications. 4. If the circuit is powered off, the battery should be disconnected from it's output otherwise the circuit will drain the battery slowly. Related Circuits 6V to 12V Converter, Portable CD Player Adapter For Car, Car Battery Charger, Automatic 12V Lead Acid Battery Charger, Solid State Tesla Coil/High Voltage Generator, 12VDC To 120VAC Inverter, LASER Power Supply, Power Supply, High Current Power Supply, Dual Polarity Power Supply, High Voltage High Current Power Supply, Transformerless Power Supply, Fixed Voltage Power Supply, Voltage Inverter, Voltage Inverter II, Automatic Load Sensing Power Switch, 12V To 24V DC-DC Converter, Solid State Tesla Coil Comments

Add A Comment Automatic 12V Lead Acid emmanuel Friday, May 18, 2012 4:26:23 AM Battery Charger Dr. thanks for the good work, Please how long will it take to charge 12V 200AH battery and how will i change the design to charge the battery within 5hrs Please send me the reply if possible with the circuit diagram to my email Automatic 12V Lead Acid Tuesday, May 08, 2012 5:45:05 tjolle62 Battery Charger PM Hello, I'm going to build this nice gel charger and i womder what values and components do i need to change for a 24V feed ? Automatic 12V Lead Acid Saturday, April 28, 2012 4:48:55 wempire Battery Charger AM third class circuit dont try to assemble otherwise you will loos your mony and time Automatic 12V Lead Acid Wednesday, March 21, 2012 anonymous Battery Charger 12:32:03 PM Does this circuit really works? What is the charging time for a fully discharged battery? What will be the approximate cost(in Indian rupees) of building this? Automatic 12V Lead Acid Thursday, March 08, 2012 E.L. Gabriel Battery Charger 11:42:49 AM Hello, and thanks for a good circuit, it is easy to build and to modify' I've made two of these and two of my friends are very happy. For starters, I substituted the 4x2 watt resistors,for 5watt ceramic type, added adjustable fan cooling using separate power supply. Next time I make another I'll add volt and amp gauges. Thanks once again Automatic 12V Lead Acid Tuesday, March 06, 2012 Ryn Battery Charger 11:44:16 AM can i know , how the triac in this circuit operate? And the overall operation for the circuit ? TQ Automatic 6V Lead Acid Thursday, February 02, 2012 mj Battery Charger 4:23:05 AM hi sir Can this circuit be modified using 6V battery? Automatic 12V Lead Acid Wednesday, January 25, 2012 Jimmie Battery Charger 11:44:22 AM How long does it take,n how much in $ Automatic 12V Lead Acid Sunday, January 22, 2012 ATH Battery Charger 4:47:07 PM Can I use BT138 or BT137 instead of BT136 ?, (75 ohm 4w) instead of (82 ohm 4w) resistors ?, are there any equivalents to brx49 ? Automatic 12V Lead Acid Monday, January 16, 2012 alby Battery Charger 9:50:23 AM Would like to have a go at this one & was wondering if anyone has the layout for the PC board The last 10 comments are currently shown. Show All Add A Comments. Comment

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Privacy Policy Unlike many units, this battery charger continuously charges at maximum current, tapering off only near full battery voltage. In this unit, the full load current of the supply transformer/rectifier section was 4.4A. It tapers off to 4A at 13.5V, 3A at 14.0V, 2A at 14.5V and 0A at 15.0V.

Circuit operation: Transistor Q1, diodes D1-D3 and resistor R1 form a simple constant current source. R1 effectively sets the current through Q1 - the voltage across this resistor plus Q1's emitter-base voltage is equal to the voltage across D1-D3. Assuming 0.7V across each diode and across Q1's baseemitter junction, the current through R1 is approximately 1.4/0.34 = 4.1A. IC ensures that Q1 (and thus the constant current source) is turned on. When the battery has fully charged, the current through IC drops to a very low value and so Q1 turns off (since there is no longer any baseemitter current). R2 limits the current through IC. It allows enough current to flow through the regulator so that Q1 is fully on for battery voltages up to about 13.5V. Decreasing the value of R2 effectively increases the final battery voltage by raising the current cutoff point. Conversely, a diode in series with one of the battery leads will reduce the fully-charged voltage by about 0.7V.

Circuit diagram:

12 Volt Car Battery Charger Circuit Diagram Parts: Resistors R1 = 0.32R R2 = 8.2R Capacitors C1 = 10,000uF - 63V Semiconductors D1 = 1N4004 D2 = 1N4004 D3 = 1N4004 Q1 = MJ1504 IC = 7815 REG BR1 = 1N4004x4 Miscellaneous B1 = 12 Volt Battery

Notes:

Charger's input voltages are 20 volt AC R1 and R2 are high wattage resistor like 2W, 3W, 5W and could be above. Select wattage on your choice. Q1 and IC requires a good heatsink. If they are mounted on the same heatsink and will throttle the circuit back if Q1 gets too hot.

12v DC to 12v DC Battery Charger Circuit You cannot charge a 12v battery from a 12v battery. The battery being charged creates a "floating charge" or "floating voltage" that is higher than the charging voltage and the charging stops. The following circuit produces a voltage higher than 12v via a CHARGE PUMP arrangement in which the energy in an electrolytic is fed to a battery to charge it. The circuit produces about 900mA "charge current" and the diodes and transistors must be fitted with heat sinks. The LEDs are designed to prevent the two output transistors turning ON at the same time. The lower output transistor does not start to turn on until the voltage is above 5v and the top transistor does not turn on until the voltage drops 4v from the positive rail. This means both transistors will be turned on when the voltage passes a mid-point-gap of 4v. The transition is so fast that no wasted current (short-circuit current) flows via the two output transistors (as per our test). Circuit diagram:

12v DC to 12v DC Battery Charger Circuit diagram The electrolytic charges to about 10v via the lower transistor and top diode. The top BD679 then pulls the negative of the 2200u electrolytic towards the 12v6 rail and the positive is higher than 12v6 by a theoretical 10v, however we talk about the energy in the electrolytic and in our circuit it is capable of delivering a current flow of about 900mA. This energy is passed to the battery via the lower diode. Most batteries should not be charged faster than the "14-hour-rate." This basically means a flat battery will be charged in 14 hours. To do this, divide the AHr capacity by 14 to get the charge-rate. For example, a 17AHr battery should be charged at 1.2A or less. For lower-capacity batteries, the 2200u can be reduced to 1,000u. Charging is about 80% efficient. In other words, delivering 120% of the AHr capacity of a battery will fully charge it.

UPS Battery Charger Options

ypically, the UPS contains the battery charger, battery and inverter inside of an enclosure. The battery life is shortened at increased temperature, so its important to keep the temperature inside the enclosure as low as practically possible. Also the charging voltage has to be adjusted as a function of the battery temperature. Finally, the battery charger has to function under a wide range of input voltages and protect itself during overvoltage or voltage-surge conditions. The battery charger keeps the UPS battery fully charged during normal input-voltage range. When the alternate current (ac) power line voltage goes out of normal range (geographical area defined), the power turns off and the battery supplies the power to the load. When the line voltage returns within the normal range, the battery is recharged.

Linear Power Supply

The linear power supply (continuous energy flow) is most commonly used due to low cost, but is has low efficiency, is bulky and is limited to single-voltage input. It uses a line-powered 50Hz/60Hz, iron-core, step-down transformer that is energized and dissipates heat all the time.

T
This, added to the low efficiency of the linear regulator, translates into a higher temperature inside the enclosure (shared with the battery). The immediate lower cost benefit of this solution hides the higher long-term cost, due to a shorter

battery lifetime and an increased maintenance time. The weight and volume make the mechanical design of the UPS more difficult.

Discrete Ringing Choke Circuit

The ringing choke circuit is another continuous energy flow power supply, limited like the linear to single-voltage input, but using higher frequency to pass the energy to the load, reducing the transformer size. The efficiency is also improved, but the circuit is highly dependent on the components tolerance and it is difficult to design and manufacture.

Switch-Mode Power Supply

The switch-mode power supply (SMPS) transfers the energy to the load discontinuously. The SMPS offers a lower cost of ownership solution because it: extends the battery life by maintaining a lower battery temperature, and reduces the maintenance due to better reliability. These benefits derive from the higher efficiency of the SMPS (cooler operation). The SMPS is also powered from the line, but it stores energy in an input capacitor and transfers it to the load as needed, in high-frequency increments, by switching on and off. A solid-state switch, controlled by a pulse-width modulation (PWM) controller, accomplishes the switching. Figure 1. IC (U1 in Figure 3) functional block diagram. Figure 2. SMPS schematic.
CY1 2.2nF

BT1

+ -

F1 3.15A/250V + C1 33uF/450V R8 4.7 1/8W 4

10

Q1 2N3904 3 + C4 560uF/35V R9 11.5K 1% 4 3 RTN

85-265 VAC
D7 UF5402 CX1 0.1uF/X2 D1 VR1

P6KE150 D4 1N4007 J2-3 + C6 4.7uF/35V D6 BAV20 R5 1 1/2W

RT1
THERMISTOR (NTC)

D5 UF1005 1 D2 LED1 1 2

29

R10 11.5K 1% R11 47.5K 1%

*
TP2 1 C3 0.1uF/50V R6 47, 1/8W L2 3.3uH, 2.65A J2-1 R12 6.8k

D3 J1-2 R1 1M 1/4W 1 R7 470, 1/8W

EF-20 917uH

R3 6.8, 1/8W L1 J2-2 10mH/0.3A TP1 U2 PC817A 5 R4 1 1/2W C7 0.1uF/50V 2 + C2 47uF/10V J1-1

F D S C M

CONTROL

U1 TOP233Y
C8 + 0.1uF/50V C5 220uF/35V 3

OPTIONAL
2 R2 910k 1/4W +14VDC

T1

U3 TL431CLP 23 1

The transformer has a ferrite core that is a much smaller and lighter than the linears iron-core counterpart, making the UPS design easier. Also, a SMPS can be used worldwide because it accepts universal input voltages.

SMPS with Integrated Switcher/Controller IC

The integrated switcher/controller IC functional block diagram is shown in Figure 1. The power supply schematic is shown

in Figure 2, and the power supplys infrared and visible pictures are shown in Figure 3. This solution brings the following benefits, when compared with the discrete SMPS: Figure 3. SMPS infrared and visible pictures. Output Shunt Resistors, 64C. TOP233Y , 60C. Lower total solution cost is the result of fewer components, tighter IC tolerances, and built-in features that eliminate or reduce the cost of external components. Tighter temperature and absolute IC tolerances afford a more accurate design. The added tolerances of the numerous parts in a discrete design lead to oversizing the SMPS to meet the powe r requirements. Built-in features save the cost of components necessary to implement the various functions. The undervoltage/ over-voltage thresholds and maximum duty cycle reduction are implemented with one resistor. The overtemperature shutdown simplifies the thermal protection. The fully integrated soft-start (10ms) saves the cost of components needed for the soft-start and allows use of cheaper RCD clamps and more efficient Schottky output diodes. Cycle skipping at low/no load eliminates the dummy load resistor. The remote ON/OFF synchronization reduces the system interfaces implementation cost. The increased maximum duty cycle (78 percent) allows a smaller/cheaper input capacitor and a more efficient Schottky output rectifier to be used. The increased PWM gain (-22 percent/mA) reduces line frequency output ripple. The nominal switching frequency of 132kHz reduces transformer size with no EMI penalty. The frequency jitter allows a smaller/cheaper EMI filter to be used. Shorter design cycle is facilitated by readily available reference designs; by

faster agencies approvals, as the SMPS is

Benefits Features Lower Total Solution Cost Fewer components, improved tolerances, built-in features: Under-voltage/over-voltage (UV/OV) thresholds and maximum duty cycle (DCmax) reduction, overtemperature shutdown, fully integrated soft-start, cycle skipping, remote ON/OFF synchronization, increased maximum duty cycle and PWM gain, 132kHz switching frequency, and frequency jitter. Shorter Design Cycle Reference design, easier agencies approvals (EMI and safety: creepage, isolation), and software tools. Simplified Design Fewer components, smaller PCB area, simpler thermal design, auto-restart, and built-in protection. Higher Reliability Fewer components, wide creepage, built-in protection: UV/OV, current limit, over-temperature shutdown, and fully integrated soft-start. Energy-Saving High efficiency and cycle skipping (stand-by mode). Reduced Radiated EMI Frequency jitter and smaller PCB area. Versatility Programmable under-voltage/over-voltage, output-current limit, output-voltage, and output-voltage temperatu re compensation.

designed to meet EMI and safety standards; and by readily available power supply design tools. Simplified design refers to both SMPS (fewer components, simpler system interface, simpler thermal design, and built-in protection) and the UPS (smaller SMPS and reduced heat generation). Higher reliability results from fewer components, wide creepage distance between D and S pins, and the IC built-in protection features. Fewer components is achieved by integrating the MOSFET switch, the controller and the ancillary circuitry into one monolithic (one die) IC. Figure 1 shows the functional block diagram of the IC (U1 in Figure 2). The IC operates in PWM with a current limit mode, thus controlling the output short-circuit current, and has overtemperature shutdown, protecting the supply in case of excessive ambient temperature. A wide creepage distance between the D and S pins gives the IC a higher immunity to arcing and eliminates the requirement to short adjacent pins during

safety-agency approval testing. Built-in protection features contribute to the higher reliability of the integrated SMPS. Line under-voltage detection prevents turn-off glitches and line over-voltage shutdown extends the line-surge limit (the DC rail is allowed to rise up to 700Vdc without device damage). The power supply passed the surge test defined by IEC/UL 1000-4-5 Class 3 and was designed to meet the safety requirements of IEC950/UL1950. The hysteretic thermal shutdown allows automatic recovery when the ambient temperature returns within the operating range. Large thermal hysteresis prevents PC board overheating. The soft-start reduces component stress and outputvoltage overshoot. Energy saving takes place at full load due to high efficiency (>75 percent), and at light or no-load due to cycle skipping. Reduced Radiated EMI. The power supply passed the conducted EMI test (CISPR22B) using a low-cost filter (made possible by the 4kHz frequency jitter) and a PCB with small area and proper layout.
0 2 4 6 8 10 12 14 16

0.00 0.50 1.00 1.50 2.00 2.50

Iout(A) Vout(Vdc) 85Vac, 60Hz 265Vac, 60Hz

Figure 4. SMPS Vout vs Iout. Versatility refers to the application of the circuit for different input-voltage ranges with different under-voltage/over-voltage thresholds and various output-current/ voltage requirements (Figure 4). It also refers to the output-voltage compensation based on battery temperature (Figure 5).

Low-Power UPS Topologies

The external UPS (outside the PC) is the dominant solution for PC backup power.

The built-in UPS is restricted to an insignificant volume of applications and will not be discussed. Of the external UPSs, the Passive for the low-end and the Active Standby for mid-range technology are the most frequently used with a power level of <2kVA and a transfer time of about 4msec.

The Passive-Standby UPS

This is the most common UPS type used for protecting PCs in environments with infrequent power failures. There is no power conversion and no monitoring of the ac power line (passive) during normal operation, and the transfer switch connects the filtered ac power line as the primary power source. In case of power failure (voltage out of range), the transfer switch switches over to the backup power source (battery and inverter). The inverter only starts when the power fails, hence the name "standby".

The Active-Standby UPS

This is the most common UPS used for small business, Internet and departmental servers. In this design, the ac line is continuously monitored (active). The inverter also provides regulation, operating to correct brownout conditions, which would otherwise force the UPS to switch to battery operation. This allows the UPS to operate at sites with very poor power. The transfer switch disconnects the primary power and connects the backup power (battery and inverter) only when the power line fails. Figure 5. SMPS battery-charging voltage temperature compensation.
13.0 13.1 13.2 13.3 13.4 13.5 13.6 13.7 13.8 13.9 14.0 14.1 14.2 14.3 14.4 14.5 14.6 14.7 -10-50510152025303540455055 Temp(C)

Vout(Vdc)

High limit Low limit Calculated value Measured value

Conclusion
Higher levels of IC integration lead to lower system cost and lower cost of ownership. The ease of designing and qualifying a power supply using these ICs dramatically reduces the time to market. The value of the presented solution, in both lower cost and shorter time to market, should be compelling benefits to consider it for existing or new designs. D GDG
Copyright 2001 Power Pulse is a registered trademark of, and published by, Darnell.Com Inc. Materials may not be reproduced or republished without written permission from Darnell.Com Inc. Darnell.Com Inc. shall not be responsible for any representations, statements of fact, or individual opinions made by advertisers or authors in Power Pulse . The views expressed here are those of the author(s) and do not necessarily reflect the opinion or agreement of Darnell.Com Inc. Inquiries should be addressed to Darnell.Com Inc., 1159-B Pomona Road, Corona, California 92882.
LINE LOAD BATTERY Surge Protection Filter Transfer Switch

~==~
Battery Charger DC to AC Convert.

Passive standby UPS operating diagram.

LINE LOAD BATTERY Surge Protection Filter Transfer Switch

~ ~ =
Battery Charger DC to AC Convert.

Active standby UPS operating diagram.

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Heime > Posts > Repair instructions for APC Back-UPS RS 500

27.12.2006 Repair instructions for APC Back-UPS RS 500 I have two of these units with the same fault and I have also read about this problem on usenet problem is that the Back-UPS RS 500 stop charging the battery. For me it was easy and not ex to repair them. If you have some experience with soldering it should be easy for you too to do repair work.

Before you start, remove mains power and the battery. This unit is generating high voltage from 12 volts battery and a battery like this contain a lot of energy. Please take notice of any safety precautions.

Here is the front panel with model name. I suppose yours are similar.

Remove the two screws on the back panel

Lift the panel out at the bottom. It snaps in position at the top and you maybe have to use some to take it off completely.

Lift out the side panel and disconnect the red and black battery wire. Make sure you know whe reconnect those wires when assembling the unit.

Take a sheet of paper and make a drawing of the circuit board and all the wires to the transform back panel. Disconnect all the wires and remove both the transformer and back panel.

Remove the circuit board on the front panel.

Remove the main board. It is fastened with two clips on the back side.

Main board with the faulty capacitor.

Charging unit and the faulty capacitor.

Make sure you take notice of the polarity of this capacitor.

Replace the capacitor with a new one with similar or better specification. I bought mine from h Elfa

After the unit is assembled, connect it to the mains and measure the voltage at the battery term without a battery connected. It should be approx. 13.6 Volts.

Disconnect from the mains and mount and connect the battery. You probably have to buy a ne battery if the old one has been completely discharged and been like that for several weeks. Bat are easily damaged if discharged over a long time. Connect it to the mains and measure that it charging the battery. The voltage should be rising slowly up to 13.6 Volts. Posted at 18:36 by Stig Vidar Hovland | Category: General | Permalink | Email this Post | Comments (101) Comments It works! Thank you for this very detailed fixit. My RS500 failed a few days ago with this problem and replacing the capacitor (with a 33uF 35v component) does seem to have fixed it. I'm watching

battery charge back up again as I type this.

I wonder what causes this capacitor to fail? According to my meter it is open circuit and exhib capacitance at all and that is a very unusual failure mode!

Anyway, thank you again for a very timely posting - you've saved me from spending some mo a new unit. The power of the Internet!

John L (G3WGV), England. at 30.12.2006 11:27 Fabulous Thanks, fabulous tip, I above thank for you and the people like You Ricardo at 09.01.2007 16:27 Just as you wrote It worked like a charm i replaced it with a 22uF x 25V 85C Capacitor it works!! Now i have t check if the battery is dead... Thank you a lot at 25.01.2007 03:42 thanks thanks, my RS 500 again live. Mirob, Slovakia at 05.02.2007 21:42 Thanks!! Same problem here!!! Thanks for the tip, I'll fetch the soldering iron ASAP 8-) at 28.04.2007 20:29 Thanks so much APC said my battery had died, but I tried this and my UPS is as good as new! Unusual that thi happening on a large number of devices, and disappointing that APC gave me the wrong "solu when I even linked them to this page to see if they would admit the capacitor was at fault. How as an electrical engineering student, this was very fun too! Thanks so much for your advice. at 11.05.2007 17:19 GONZALO muy buena solucion hace meses que buscaba la solucion. Gracias ( thanks you) at 12.06.2007 17:09 APC USED WRONG CAP Replace with a 105c cap not a 85c that was in it. A 85c cap works good with 60hz, A switchin power supply has a much higher freq and a 85c cap with over heat and develop high ESR, due drying out. Clarence Southwest Monitors & Printers POS SWMP@VERIZON.NET at 27.08.2007 01:14 THX U SO MUCH I LEAVE IN INDONESIA, I HAVE SOME TROUBLE WITH MY RS500, NOW WITH YO

BLOG, MY RS500 WA COME BACK AGAIN.... I REPLACE WITH SAME CAPASITOR 22uf 16v 85c. MAY BE, I WANT TO RE-REPLACE WITH 105c CAPACITOR FOR LONG LIFE COMPONENT. THX FOR U ALL. at 21.09.2007 22:54 PERMIT FOR RE-VIEW IN INDONESIAN LANGUAGE I WANT TO RE-VIEW OR TRANSLATE TO INDONESIAN LANGUAGE WITH COMPL U'R PHOTO IN MY BLOG, I WILL PUT YOUR LINK, FOR ORIGINALITY SOURCE. TH

SVH: That is OK. It would be fine if you give me a link to your translation. at 21.09.2007 22:57 Thanks Cured mine fine, I think I may replace the other caps as several are reading a bit high with my meter, the faulty one would not give any reading. now all I need is some non corrosive silicone to dampen the buzz from the inductors. Ben. NB I used a 105c 35V 22UF low esr capacitor. Thanks for saving me the time of finding the fault. at 25.10.2007 16:19 Mi agradecimiento a esta solucion !!!!!!!!! Desde Buenos Aires Argentina, agradezco sinceramente de corazon, la solucion brindada por e tutorial.- Ya daba por perdida mi confiable APC RS 500, cuando descubri esta solucion, por la decima parte de un dolar , volvio a tener vida la tan valiosa ups.- Recomendare este link en los de electronica sin duda.-Gracias a su autor.-

Thanks !!!!!!!! at 04.03.2008 22:42 Mi agradecimiento a esta solucion !!!!!!!!! Desde Buenos Aires Argentina, agradezco sinceramente de corazon, la solucion brindada por e tutorial.- Ya daba por perdida mi confiable APC RS 500, cuando descubri esta solucion, por la decima parte de un dolar , volvio a tener vida la tan valiosa ups.- Recomendare este link en los de electronica sin duda.-Gracias a su autor.-

Thanks !!!!!!!! at 04.03.2008 22:43 APC upgraded the cap for the new builds The C7 had used a 50V 22uF 105c with unknown manufacturer. Other caps are gold color Jamicon. at 07.03.2008 08:40 EXCELENTE!! Muchas gracias Este tutorial es excelente, le cambi a 4 UPSs el condensador y estn cargando perfectamente. Gracias de nuevo. at 17.03.2008 16:00

UPS APC BR 1500 Hello My name is Willan Can you help me? I have have a UPS APC BR1500, and in this moment it is on OVERLOAD state, I repleced th and it dont operate, so I see all the electronical elements and I did not found nothing Please, if you have any idea you can help me? PD I am sorry my english is very very bad

I from Ecuador at 19.03.2008 21:51 works ! Hi folks, it worked for my APC. It was 1 year broken and now it is charging a new battery. Thanks U an web. Sleyo at 29.03.2008 16:07 RS 500 Alive again!! Excellent fix!! I was just about to buy a replacement UPS. Many thanks. Neville UK at 03.05.2008 19:37 APC Backup 500UPS Do you have anything on fixing power relay? My unit charges the battery but when unpluged external power it fails to transfer load to battery supply. Harry at 11.05.2008 21:27 APC BE500-AS Using another apc product. Everything is fine except circuit not charging the battery. How to identify the batery charging capacitor? How do you check faulty capacitors? at 25.07.2008 16:33 Excellent job Indeed works.

Thanks at 26.07.2008 18:21 Anyone seen an overheating problem? Congratulations on the capacitor replacement instructions -- but I have a different problem wit RS500 (BR500I, 240 V version).

It's a new unit, and as soon as I plugged it in it started to give off a scorching smell that has no away after 24 hours. The hot spot seems to be near the top vent, on the left-hand side as you lo the front of the unit.

This is a replacement for an RS500 that failed with overheating around R28 on the main board suspected the K2608 MOSFET nearby but am not enough of an electronics person to be confid diagnosing a fault. Does anyone else have experience of overheating with these units? at 21.08.2008 18:15 Working Thanks from Finland friends. at 08.10.2008 23:30 many thanks to u... I have one exactly the same problem and the capacitor replacement indeed fix the problem.

regards, john_t Subic Bay, Philippines. at 20.11.2008 09:15 R28 overheat as well BCB was burned around R28 of my APC, even plastic case was bit melted at 09.12.2008 13:37 RS 500 discharging battery My UPS disarching battery, what problem? at 18.12.2008 19:26 Resisters prob hi in my unit the large resisters have been damaged (burnt out) can you please post or email m codes or values thanks par_0020 <at> hotmail.com at 05.05.2009 12:22 BackUPS500 Where can I find repair solutions like this for my APC BackUPS 500?

It is operational with power coming from the battery but when AC power returns, nothing happ operates as if there is no AC power at the input.

This is a very good repair guide here. at 02.06.2009 15:56 R28 overheating? Hello, I have same issue with overheating, I have two RS500 with smoked top and PCB, one o was deformed by high temp just above R28 and R29. I also hear some stertorous noise when m power cord is plugged into UPS. How to fix that?

Thanks. at 26.06.2009 16:29 RS500s overheating I forgot to mention, there are different dates on PCBs, older one is APC C2001 08/03/2002 64 0259_REV05 and second one is APC C2004 640-0259A_REV06, both have same issue and n one overheated more. at 26.06.2009 16:35 Overheating problems Sorry, but I can't help you here. I have a few RS500, but all of them are working and in contin use. It isn't easy for anyone to tell what is wrong with your units, but if someone has experienc this spesific problem, please send me some text and photos and I could add them to the blog. Stig Vidar Hovland at 26.06.2009 22:54 Inductor buzz driving me nuts I bought one of these last week and i already want to throw it away. The buzz is killing me any sugestions? Would realy apreciate it. Thanks at 18.07.2009 05:53 same problem but no power indicator on i have the same problem, but i have bought a new one, prolink ups. when i read your post, i tri fix the problem. first thing that i do is plug the power cable and turn on the power. but no sign power on (no lights on). do you think that if i replace the capacitor, ill fix all the problem?? ple reply, i really need your help. thanks at 30.08.2009 20:24 back ups ra500 up side very hot one of place]

how i repaire at 06.09.2009 08:56 Thank you very much i've repaired 2 unit (same symtom) and it work like a new one, by replaced all cap (85->105c) i hope it won't need any cap replacement again for 2-3 years :D at 12.09.2009 09:39 Similar to .... CS 650 APC noisy resistor buzz I wish I had the same fault..... Got a new CS 650 that is driving me crazy with the charger control circuit with audible noise. You wouldn't believe it but the noise is comming from a RESISTOR # R3 on this rev6 board. (March 2008) I've never heard of a resistor making this much noise. Has any tech experienced this - however works yet it produces high frequency noise. Weird. Capacitors - chokes are fine. at 04.10.2009 11:38

More radical modification Well, designers of this circuits were (censored)

I have had the same problem, analyzed the switching power supply and found the same proble Consulting the data sheet of UC3842B, the 22F capacitor seems to be underestimated.

At least in RS500 230V version REV05 one of resistor around eats permanently about 2 Watts generates a lot of heat. That is why I decided to do a more radical change: Replace the capacitor with much larger one: 220F. Remove the parallel 3.3k resistor R139 without any replacement.

Replace large hot 50k resistor R28 by 220k of the same size (probably even more is possib

It decreases power current by 2 Watts and temperature there by 40C at cost of 1 second delay connecting the power plug. Purpose of such modification:

Original design used a very hard divisor that divides the plug voltage to supply ~10mA. It is n enough for running the oscillator, so 22F was (nearly) enough.

But the divisor should be used just to start oscillation. Once the oscillator runs, it is powered fr transformer and the divisor is not needed. You can verify this fact by disconnecting the large d resistor, touch, and remove. Oscillator runs. The datasheet says, that when there is no power to run oscillator, the IC eats less than 0.5mA. It means, that the divisor could be designed to provide only 0.5mA, not 10mA.

In this case, capacitor must be larger (e. g. 220F), because the complete start of the oscillator powered nearly exclusively from it. It must have enough juice to keep voltage above the minim voltage until the transformer start to give power. Happy hacking Stanislav, http://www.penguin.cz/~utx/ at 08.11.2009 01:13 A zillion thanks!! Following an overnight power surge I noticed in the morning the three lower leds flashing continuously and no backup power. So I soldered off of an old pentiumII motherboard a 16V 105C capacitor and replaced the one shown in this tutorial. I plugged in and for a few seconds

three lower leds flashed till the power on (green) led lit (I guess meaning that the battery was completely uncharged and now it is charging). Many thanks again at 08.11.2009 12:36 More radical modification documented Hallo. I just documented my more radical modification described above: http://www.penguin.cz/~utx/apc-ups/

Apropos, if anybody is able to read values on R138 and R150, please let me know. My UPS ha damaged so it was imposible to measure them or read the value. They are replaced by 10R on images, but I am not sure, whether it is correct. Thanks, Stanislav at 09.11.2009 00:28 RS 500 is in the second life! Hallo,

Thanks a lot for this repair instruction - the best I've ever seen! My RS 500 is now working again, I used a capacitor with 47uF/16V because it was sunday and there was no original capacitor in my box. RS500 runs very well wi 47uF! best regards, Bill from Germany at 13.11.2009 22:25 Lot of thanks We have the same problem ,it was not charging the battery so i have seen your procedure for repairing and now it is up to the mark Another thing plz tell us the specification of Resistor R28 in circuit boared of UPS .

Junaid at 23.12.2009 06:36 Thank you twice.. I had two apc 500 units with this problem, both of them are fine thanks to you! So thank you tw Alkis from Athens, Greece at 22.01.2010 14:59 Thanks and thanks.

Newer version of RS 500 unit with 50V 22uF capacitor fixed with replacement from an old Ba network card. at 30.01.2010 11:57 Thanks !! 100uF/35V 105C Works :-)

Matony at 11.02.2010 07:23 suwat Thanks a lot. My APC BR500i work again. at 25.03.2010 14:38 lost battery backup output Last month, during a power failure I plugged my APC BE500U-CN into a120V generator that ground potential of 40V and now it started beeping, and does not offer any battery backup pow The battery measures 13Volts AND THE units battery charging leads show 13.5V with battery removed. any ideas how to fix? at 30.04.2010 15:56 rs 500 alarm Could somebody tell how to disable the alarm in this model... apc rs 500... take in account tha an engineer....thanks

dapal55@yahoo.es at 12.05.2010 14:48 Hello Following an overnight power surge I noticed in the morning the three lower leds flashing continuously and no backup power. So I soldered off of an old pentiumII motherboard a 16V 105C capacitor and replaced the one shown in this tutorial ( I plugged in and for a few seconds three lower leds flashed till the power on (green) led lit (I guess meaning that the battery was completely uncharged and now it is charging). at 14.05.2010 12:11 resistance value Kindly tell the value of resistance R28. at 12.06.2010 12:30 resistor value R28 = 56K at 15.06.2010 03:17 RESISTOR KINDLY THE VALUE OF R26 at 22.06.2010 12:25 resistor resistance value R29 email at peweelocsin@yahoo.com at 22.06.2010 13:35 APS CS 500, always "On Battery", can't turn off

It is a very nice tutorial. I found it when i did a research about repairing my CS 500.

When the unit is connected on power source there is a yellow light "On battery", even when th no battery inside. The unit won't turn off. Do u have any idea what i should do?

Thanks in advance. at 03.08.2010 12:38 Resistor values apc RS 500 Thanks for the nice tutorial and great solution to my problematic rs 500. I would like to help s other users and publish values of resistors that may be erased because of overheating. R28 = 5 5%, R29=3,3K 2W, R75=2,2R 2W, R157=20R 1/4W. at 17.09.2010 12:02 Thanks my friend!! I just replasced the capasitor and the r28 resistor and it works! at 02.10.2010 14:44 Graciassss Excelente tutorial, recupere 2 UPS. at 04.10.2010 19:06 overload Hi, I have have a UPS APC CS500, and in this moment it is on OVERLOAD state. at 19.10.2010 20:16 thanks! I have just repaired my ups using your instructions. at 20.10.2010 18:45 UPS APC RS1500 Overload Hi, I have have a UPS APC RS1500, and in this moment it is on OVERLOAD state. how i repaire at 06.12.2010 17:20 A zillion thanks AGAIN!! Almost one year following heimes' instructions, [comment 8.11.2009: A zillion thanks!! Follo an overnight power surge I noticed......uncharged and now it is charging). Many thanks again], rs500 died again!!! I followed the more radical modification http://www.penguin.cz/~utx/hardware/APC_UPS_ 500/ and guess what: It's ALIVE again (cost <1euro) Many thanks to all the electronics gurus at 12.01.2011 18:13 CS 500 This text help me solve similar problem. On CS500 from AC input it goes to fuse(SMD) then gretz(4 diode) and to charger. After gretz it has similar capacitor(10uF 450V 85C) which was

and made short circuit dameging PCB(+&- undernith capacitor are VERY close), blowing fuse stop charging battery(and not doing self-test). After replaceing capatitor, fuse and repairing PC everything OK! Thanks at 16.01.2011 18:22 radical modification on CS500 rev06? can anyone confirm the "radical modification" (http://www.penguin.cz/~utx/hardware/APC_UPS_RS-500/) works also on cs 500 rev06? thanks marco at 07.02.2011 21:56 elektroniko Muy bueno el articulo si no es mucha moelstia podrian ayudarme a buscar el diagrama del APC UPS RS-800 el problema es que se apaga por ratos Gracias at 26.02.2011 12:17 want ups diagram i am manjula i want 600VA ups circuit diagram my mail id-sntmanjula@yahoo.com at 07.03.2011 11:19 Great work Thank you very much for that great tutorial! Greetings from Patagonia Seb at 20.04.2011 14:07 Thanks Worked perfect for me although I did not see any damage on capacitor on my RS 500. Greetin from Switzerland at 28.05.2011 09:25 R138 and R150 Looking at the pcb, I founded these two resistors, C65 and C66, are snubbers that protect the c for two of the tree existing relays; there are places not populated for the third relay (C67 and R I think that two relays are used for the regulation of the AC incoming from the wall, and the th for transfer the supply from AC to inverter during the outages. Perhaps the best decision is to replace the resistors for other of 10 ohm, but made from metalf with 1 watt or more. I replaced C7 and the unit satrted to work fine again, but it is very noisy now, at least it seems with the whole circuit of the original case; is the any clue for the reason of this?. Excuse me by my basic english, is not my native language; tahnks!. Hernn at 29.05.2011 17:25 Cool!!!!!!!

It's working!!! I'll write a dissertation about this)))!!)!)!)! at 08.06.2011 09:56 work thanks, my RS 500 again live. mclareniak, Slovakia at 24.06.2011 08:24 Thx Work!!! thank for the tip! cmo descubrio la solucion? at 30.06.2011 23:08 Thx Sorry.... Brain bug: P how discovered the solution? at 30.06.2011 23:09 contribution i thing this is the diagram of the circuit http://www.eserviceinfo.com/downloadsm/3842/APC_UPS%20500.html

thanks for the post VNC at 12.07.2011 16:16 what is r28 where can i buy the r28 resistor or what ever its called from ? mine has burnt out and make the turn yellow i found the capacitor in the 1st post on ebay but dont know any thing about r28 so info would be good.

thanx at 29.07.2011 02:47 Worked well on REV08 I have replaced C7 Capacitor and my UPS started to charge the battery again. Thanks for the a at 03.08.2011 15:56 arora 1000va black at 12.08.2011 08:23 It works! Thank you very much! It was the same problem for me, but how you've understand that proble this capacitor? In my case bad capacitor was 12uF --- it's not very bad. Original value was 22u More over, may be you know, Is is a capacitor problem or bad circuit design? at 23.08.2011 23:21 Not worked on battery My UPS RS 1000 is not holding on battery supply for more thant 30 second.. Pls advice me. at 26.08.2011 09:21 Thanks

Now it works ,Faults was in power storage!It fail to store power for along time. at 13.09.2011 07:09 RS800 - Bypass Hi,

i am planning to use RS800 as inverter , off-grid power do you know who to bypass / reset the relay to switch to battery mode without prior ac input at 19.10.2011 02:50 Great! My Back-UPS RS 500 rev 06 is back in duty with new 22uF/50V/105c for nearly no cost ;) Th at 21.10.2011 01:42 Overload Hi, I have have a APC BACKUP-UPS 800, and in this moment it is on OVERLOAD state. When checked the out put connections with line tester it shows both wire live ( Phase & neutral ). Please let me know the problem. Thanks in advance. bk35@hotmail.com at 04.11.2011 10:12 RS 1000 not working anybody here knows how the RS 1000 works or have circuit diagram here at 20.11.2011 13:58 Great !!! Thank you man. Very useful guide. Thank you again :) at 05.12.2011 09:27 How to Modify what should i change or modify if APC Back-UPS RS 500 use with large battery.. at 12.12.2011 17:12 UPS Manufactureing / Assembling Helo, Thanks for your advise regarding RS-500 Repairing , it really works,. I am planning to have manufacturing UPS, Assembling UPS, so can you provide me detailed information to how to assembling/manufactre UPS. Email : gisplindia@gmail.com Contact : +91-9428222374 Thanks dear , From : Dhaval Chauhan, India. at 05.01.2012 10:13 Still Works Thanks very much. Changed the cap and all is well. at 09.01.2012 09:34

solved!!!! thank master..solved my problem at 12.01.2012 18:20 Indian Model is different My UPS mother board is completely different, and i could not figured out which capacitor was mine is Indian version, can somebody help me?? baba dot maal gmail.com Thanks at 13.01.2012 14:15 Charging again! Thank you!

A-P,Finland at 10.02.2012 22:48 Spot on Fix! Thank you so much for posting this. At C7 I used a 47uF 35v 105C cap I had hanging around seems to be fine. Nice one. Thank you. Jon (Australia) at 11.02.2012 09:41 Thank you I just made Stanislav's modification on a REV06, it works nice now. So after some years you still deserve a thank you everybody :D ! at 19.02.2012 12:52 br500 can my br500 replace the battre with 12v 50ah? at 09.03.2012 12:17 how to repair.. how about the socomec sicon ups net0600-pe how to repair .. the ups is not charging, what should i do to repair ..., anybody there can help.. thks cris (philippines) at 18.03.2012 04:49 thanks a lot thank lot for share i can fix the problem on my UPS RS500 just change another one cap 22 mF with a new one thnks so much

at 06.05.2012 22:07 how to repair CS 500 ? I have a Ups APC CS 500 I changed all transistors and few capacitors. Ups shows me is overload and off. What are the possible faults on Ups, some of your suggestion ? Help me, thank you, Best regards, Nikica Subat (from Croatia). at 13.05.2012 12:27 It was unused for 1 year Thank you very much for the information. I searched in google for the same fault that I have w model RS 800 and suddenly I found information for model RS 500. 1 year it was unused into m storehouse with the same fault. I changed the capacitor, which seemed to be okay with a new a repaired the damage. Thanks again for your help for a component with the least of cost repair my ups. If anyone know what is the corresponding capacitor for model RS 800 with the same fault plea report it here. at 07.06.2012 07:45 overload Hi all! I've an apc rs800 Ups shows me is overload. I'm changed the battery's. The 12V and the IC11( KA7812 ) good! Another apc rs800 Ups is switching between inverter and AC mode.

What are the possible faults on Ups, some of your suggestion ? Help me, thank you, Best regards, Frank webmaster100@freemail.hu at 28.06.2012 13:33 yellow on battery led blinking Hi to every body, i have the same problem, but i've got another motherboard, exactly 6400287c_rev08 , and I can't find the capacity mentioned before. Is there anybody with same prob and same mb, that have solved ? at 06.07.2012 13:26 yellow on battery led blinking #2 thank you

flavio (Italy) at 06.07.2012 13:28 apc sc 620 if power on ups continious ly buzzer i have apc sc 620 if power on ups continious ly buzzer and red light on and no 220 volts out pu at 19.07.2012 14:32

UPS faults My UPS indicates the beep tone as A\C not connected, but power cable had been connected to main line (fuse and power wire also good). whats wrong with it? (inverter works well) at 28.07.2012 15:24 Add Comment Title * Body * Attachments

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