CyberPower BRICs Series User manual

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
1
Uninterruptible Power Systems
BRICs Series
BR 450E/650E/850E
Service Manual
Date Version Remark
2008/6/10 1.0 English Version

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
2
Table of Contents
1 INTRODUCTION................................................................................................................................5
1.1 Features ...........................................................................................................................................5
1.2 Applications.....................................................................................................................................5
2 PRODUCT OUTLOOK ......................................................................................................................6
3 PRINCIPLES OF OPERATION........................................................................................................8
3.1 System Block Diagram....................................................................................................................8
3.2 Normal Mode ..................................................................................................................................8
3.3 Boost Mode .....................................................................................................................................9
3.4 Battery Mode...................................................................................................................................9
4 REPAIR ..............................................................................................................................................10
4.1 Test Equipment..............................................................................................................................10
4.2 Repair Procedure ...........................................................................................................................10
4.2.1 Equipment Preparation ...........................................................................................................10
4.2.2 Check MOSFET, Transistor, and Diode ................................................................................12
4.2.3 Check Resister ........................................................................................................................12
4.2.4 Turn on the unit with DC Power Supply ................................................................................13
4.2.5 Signal Measurement ...............................................................................................................13
4.2.6 Output Voltage Measurement.................................................................................................13
4.2.7 Connect UPS to Utility Power................................................................................................14
4.2.8 Charging Voltage Measurement.............................................................................................14
4.2.9 Boost Test...............................................................................................................................14
5 SCHEMATIC.....................................................................................................................................15
5.1 Charger Circuit ..............................................................................................................................15
5.2 Transformer Flux Continue Circuit...............................................................................................16
5.3 Buzzer Circuit................................................................................................................................16
5.4 Inverter Circuit ..............................................................................................................................17
5.5 USB Sensing Circuit .....................................................................................................................17

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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5.6 Starting & System Power Circuit ..................................................................................................18
5.7 Utility Power Sensing Circuit........................................................................................................19
5.8 USB Communication Circuit ........................................................................................................19
5.9 Overload Protection Sensing Circuit.............................................................................................20
5.10 MCU Circuit................................................................................................................................20
5.11 LCD Circuit.................................................................................................................................21
5.12 Output Voltage Sensing Circuit ..................................................................................................21
5.13 AC Input / Output Main Circuit ..................................................................................................22

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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Figures
Figure 1: Product Outlook ........................................................................................................................6
Figure 2: Product Outlook ........................................................................................................................7
Figure 3: System Block Diagram..............................................................................................................8
Figure 4: Normal Mode.............................................................................................................................8
Figure 5: Boost Mode ...............................................................................................................................9
Figure 6: Battery Mode .............................................................................................................................9
Figure 7: Square Wave............................................................................................................................13
Figure 8: Sine Wave................................................................................................................................14
Figure 9: Charger Circuit ........................................................................................................................15
Figure 10: Transformer Flux Continue Circuit.......................................................................................16
Figure 11: Buzzer Circuit........................................................................................................................16
Figure 12: Inverter Circuit ......................................................................................................................17
Figure 13: USB Circuit ...........................................................................................................................17
Figure 14: Starting & System Power Circuit ..........................................................................................18
Figure 15: Utility Sensing Circuit...........................................................................................................19
Figure 16: USB Communication Circuit ................................................................................................19
Figure 17: Overload Protection Sensing Circuit.....................................................................................20
Figure 18: MCU Circuit..........................................................................................................................20
Figure 19: MCU Circuit..........................................................................................................................21
Figure 20: Output Sensing Circuit ..........................................................................................................21
Figure 21: AC Input / Output Main Circuit ............................................................................................22

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
5
1INTRODUCTION
The BRICs Series UPS can supply clean and stable power to protect your equipment. The included
PowerPanel® Personal Edition management software showcases the feature rich abilities of this UPS
such as input/output power voltage readings, self-diagnostics, scheduled shutdown, and approximate
battery back-up time readings. These UPS units can be placed in either a horizontal or wall-mount
position to mark the most of your space. With Energy-Saving Technology, BRICs Series UPS can save
up to 75% of electricity and save your electricity bill.
1.1 Features:
Energy-Saving UPS
Microprocessor-based full digital control
Automatic Voltage Regulator (AVR)
EMI, RFI, surge and lighting spike protection
Power Management software included
Scheduled Shutdown
Auto Restart / Auto Charge
Horizontal / Wall-mount Use
USB Connectivity Port
Compact design with highest power output
Green Power Technology
Save up to 75% of electricity
Cable collector included
1.2 Applications:
Home and Home Office
Small Office
This manual introduces basic functions and troubleshooting methods of the UPS unit.

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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2PRODUCT OUTLOOK
Figure 1: Product Outlook
No. Function Description
1 Power ON/OFF Switch Press the power switch to turn the UPS ON or OFF.
2 LCD Display The LCD will display the UPS status including input voltage, output
voltage, runtime, percentage of load and battery, etc.
3 LCD Function Selection
Switch Press the LCD function selected switch to know the UPS status.
4 Surge Protection
Outlets Provides three surge protected outlets for connected equipment.
5
Battery Backup and
Surge Protection
Outlets
Provides three battery powered and surge protected outlets for
connected equipment to insure temporary uninterrupted operation
during a power failure.
6 Input Power Cord Connect to utility.
7 Input Circuit Breaker The Circuit Breaker provides optimal overload protection.
8 USB Port to PC This port allows connection and communication from the USB port on the
computer to the UPS unit.

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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Figure 2: Product Outlook
No. Function Description
9 Cable Collector Collect the cables connected from the AC outlets in
the cable collector.
10 Communication Protection Ports (RJ45) 2 ports (one in, one out)
11 Battery Charger Port (USB 5V) Charge external AA/AAA battery via battery
charger port with the battery charger.
12 Battery Charger Fixture For placing battery charger
13 Battery Charger
Put external AA/AAA batteries into the battery
charger for charge. (AA/AAA Batteries NOT
included)

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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3PRINCIPLES OF OPERATION
3.1 System Block Diagram
Figure 3: System Block Diagram
3.2 Normal Mode
When AC utility power is normal, it will go through the UPS to provide power (Bypass). At the same
time, it will charge battery through AC/DC circuit (UPS Normal Mode).
Extemal
Battery
Charger
5Vdc/1A Output
(USB Port)
Surge
Supperessor Charger
O/P C
AC
Fuse
X-Cap Y-Cap
Push Pull
Power Stage
K2
I/P RLY
K4
BUCK
K3
AVR RLY
K1
Boost
DC
Fuse
Battery
Figure 4: Normal Mode
EMI Filter
Surge
Suppressor
AVR
Charger
AC/DC
Battery
Inverter
Input Output
Normal Mode
Battery Mode

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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3.3 Boost Mode
When AC utility power is low, it will go through boost circuit of the UPS to provide power, and
correct it back to normal. At the same time, it will charge battery through AC/DC circuit (UPS
Boost Mode).
Extemal
Battery
Charger
5Vdc/1A Output
(USB Port)
Surge
Supperessor Charger
O/P C
AC
Fuse
X-Cap Y-Cap
Push Pull
Power Stage
K2
I/P RLY
K4
BUCK
K3
AVR RLY
K1
Boost
DC
Fuse
Battery
Figure 5: Boost Mode
3.4 Battery Mode
When AC utility power is abnormal, battery will provide power via DC/AC circuit (push-pull
power stage) to output socket.
Extemal
Battery
Charger
5Vdc/1A Output
(USB Port)
Surge
Supperessor Charger
O/P C
AC
Fuse
X-Cap Y-Cap
Push Pull
Power Stage
K2
I/P RLY
K4
BUCK
K3
AVR RLY
K1
Boost
DC
Fuse
Battery
Figure 6: Battery Mode (INV)

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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4REPAIR
4.1 Test Equipment
Digital Multi-Meter (DMM) with true RMS measurement
DC power supply 15V 5A
Digital Storage Oscilloscope (DSO)
Load: 100~200W/230V milky light bulb.
4.2 Repair Procedure
4.2.1 Equipment Preparation
•Remove the screws and open the cover
•Disconnect battery red and black wires. Turn the power on to discharge remaining electricity. Turn
the power off.
Remove battery wires
Remove screws

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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* Measure the battery voltage with DC power meter. Normal voltage should be within the range of
10.8V~13.8V.
•Remove the screws and bottom case to repair.
•PCB main board as shown below
Remove screws

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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4.2.2 Check MOSFET, Transistor, and Diode
•Remove the PCB from the cover
•Select the “ ” function on DMM then use DMM to check the voltage of the MOSFET and BJT
as described below.
•Read the figure of voltage difference between S-G (“Source” and “Drain”) and the S-D (“Source”
and “Gate”) of the MOSFET. The reading should be within the range of 1.3-2.5V / 0.45-0.65V.
•Read the figure of voltage difference between B-E (“Base” and “Emitter”) or B-C (“Base” and
“Collector”) of the BJT. The reading should be within the range of 0.45-0.65V.
•Read the figure of voltage difference between A-K (“Anode” and “Cathode”) of the diode. The
reading should be within the range of 0.45-0.65V
Part
Reference
Measured
Location Expected Reading Part Outline and Foot
Q1 S-G / S-D 1.3-1.5V / 0.45-0.65V
Q2 S-G / S-D 1.5-2.5V / 0.45-0.65V
Q3 S-G / S-D 1.5-2.5V / 0.45-0.65V
Q4 S-G / S-D 1.5-2.5V / 0.45-0.65V
Q5 S-G / S-D 1.5-2.5V / 0.45-0.65V
Q20,Q10,
Q7,Q9,Q15,Q
16,Q18,Q19,Q
21,Q22,Q23,Q
24,
Q6,Q13,Q14
B-E / B-C 0.45-0.65V/ 0.45-0.65V
D11-D14 P-N 0.45-0.65V
4.2.3 Check Resister
•Set the DMM to “ Ω” function and measure the resistance value of Inverter Circuit as the
following table.
Part Reference Measured Location Expected Reading Remark
R8,R9,R11,R14
R7,R10,R12,R13
2KOhm
R8,R9,R11,R14for BR 450E
R8,R9,R11,R14,
R7,R10,R12,R13
for BR 650E/850E
G
D
S
B
E
C
A
K

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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4.2.4 Turn on the unit with DC power supply
•Setup the instrument: adjust the output voltage of DC power supply to 13V with current limit set at
5~6Adc.
•Connect the positive output of the DC power supply to the BAT(+)(Red wire) of the transformer
and the negative output to the BAT(-)(Black wire) of the PCB.
•Turn on the UPS.
•Check the reading of output current from the power supply; it should be between 0.6-0.9A.
4.2.5 Signal Measurement
Please follow the table below.
Item Test Point Test Procedure Expected Result
+12V power C18 TO GRND
1. Start UPS at battery mode.
2. Connect DVM (DC) to test points. 12V±0.5V
+5V power C12 TO GRND
1. Start UPS at battery mode.
2. Connect DVM (DC) to test points. 5V±0.1V
CPU RESET
signal
U7_PIN 8 TO
GRND
1. Start UPS at battery mode.
2. Connect DVM (DC) to test points. 5V±0.1V
CPU oscillation
wave
U7_PIN 2 3 TO
GRND
1. Start UPS at battery mode.
2. Connect DSO to test points. 24M Hz
4.2.6 Output Voltage Measurement
•Check the output voltage of UPS. The reading should be within 225~240Vac.
•Check the waveform of UPS output. It should be square wave.
Figure 7: Square Wave

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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4.2.7 Connect UPS to Utility Power
•Connect UPS to utility power. The UPS should transfer to AC mode at this moment.
•If the transfer fails, check if input fuse is blown. When this occurs, replace the fuse.
•Check the output voltage of UPS. The reading should be within 220~240Vac, same as utility voltage.
•Check the waveform of UPS output. It should be sine wave.
Figure 8: Sine Wave
4.2.8 Charging Voltage Measurement
•In utility mode, charging voltage is higher than original DC voltage output (13Vdc). The value is
displayed on DC power supply. Check the value 13.8±0.2V. You can also remove (+)(-) wires of DC
power supply and measure the charging voltage of (+)(-) battery wires with DMM.
•Turn off the UPS unit and turn off utility power (or remove the UPS input power core from AC
outlet). Remove (+)(-) wires of DC power supply, then connect the battery.
4.2.9 Boost Test
•Connect light bulb to UPS output outlet.
•Turn on the unit in battery mode. The UPS should supply power to light bulb normally. If UPS fails
to supply power, it could be the problems of battery shortage or damage. Please charge the
battery for hours or change a new battery before conducting the test again.
•Change the light bulb to computer and connect it to UPS output outlet. Connect the UPS power core
to AC power and turn on the computer.
•Disconnect utility power. After UPS switch to battery mode, connect utility power back to utility
mode. Check if the computer restarts due to the shift between battery and utility mode.
•Test completed. UPS can function normally.

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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5SCHEMATIC
5.1 Charger Circuit
Figure 9: Charger Circuit

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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5.2 Transformer Flux Continue Circuit
Figure 10: Transformer Flux Continue Circuit
5.3 Buzzer Circuit
Figure 11: Buzzer Circuit

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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5.4 Inverter Circuit
Figure 12: Inverter Circuit
5.5 USB Sensing Circuit
Figure 13: USB Sensing Circuit

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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5.6 Starting & System Power Circuit
Figure 14: Starting & System Power Circuit

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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5.7 Utility Power Sensing Circuit
Figure 15: Utility Sensing Circuit
5.8 USB Communication Circuit
Figure 16: USB Communication Circuit

BRICs Series
6F, NO. 32, Sec. 1, Chenggong Rd, Taipei, Taiwan 115, Website: www.cyberpowersystems.com TEL: [phone] FAX: [phone]
Copyright ©2006 CyberPower Systems, Inc. All rights reserved.
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5.9 Overload Protection Sensing Circuit
Figure 17: Overload Protection Sensing Circuit
5.10 MCU Circuit
Figure 18: MCU Circuit