102609844 12v Battery Chargers

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Automatic 12V Lead Acid Battery Charger

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

Schematic

Parts

PartTotalQty.

Description Substitutions

R1, R3 2 330 Ohm 1/4W Resistor R2 1 100 Ohm 1/4W Pot

R4, R5,R7, R8

4 82 Ohm 2W Resistor

R6 1 100 Ohm 1/4W Resistor

R9 1 1K 1/4W Resistor

C1 1 220uF 25V Electrolytic Capacitor

D1 1 P600 Diode Any 50V 5A or
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greater rectifierdiode

D2 1 1N4004 Diode 1N4002, 1N4007

D3 1 5.6V Zener Diode

D4 1 LED (Red, Green or Yellow)

Q1 1 BT136 TRIACQ2 1 BRX49 SCR

T1 1 12V 4A Transformer See Notes

F1 1 3A Fuse

S1 1 SPST Switch, 120VAC 5A

MISC 1Wire, Board, Heatsink For U1, Case,Binding Posts or Alligator Clips ForOutput, Fuse Holder

Notes

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 arecycling the battery (AGM or gel) then 14.5V to 14.9V is generallyrecommended by battery manufacturers. To set up the charger, set thepot to midway, turn on the charger and then connect a battery to it'soutput. Monitor the charge with a voltmeter until the battery reaches theproper end voltage and then adjust the pot until the LED glows steadily.The charger has now been set. To charge multiple battery types you canmount the pot on the front of the case and have each position marked forthe 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 ofD1.

3. T1 is a transformer with a primary voltage appropriate to your location(120V, 220V, etc.) and a secondary around 12V. Using a higher voltagesecondary (16V-18V) will allow you to charge 16V batteries sometimesused in racing applications.

4. If the circuit is powered off, the battery should be disconnected from it'soutput otherwise the circuit will drain the battery slowly.

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Supply, High Voltage High Current Power Supply, Transformerless PowerSupply, Fixed Voltage Power Supply, Voltage Inverter, Voltage Inverter II,

Automatic Load Sensing Power Switch, 12V To 24V DC-DC Converter, SolidState Tesla Coil

Comments
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Add A Comment

emmanuelAutomatic 12V Lead Acid

Battery ChargerFriday, May 18, 2012 4:26:23 AM

Dr. thanks for the good work, Please how long will it take to charge 12V 200AHbattery 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

tjolle62Automatic 12V Lead Acid

Battery ChargerTuesday, May 08, 2012 5:45:05

PM

Hello, I'm going to build this nice gel charger and i womder what values andcomponents do i need to change for a 24V feed ?

wempireAutomatic 12V Lead Acid

Battery ChargerSaturday, April 28, 2012 4:48:55

AM

third class circuit dont try to assemble otherwise you will loos your mony and time

anonymousAutomatic 12V Lead Acid

Battery ChargerWednesday, March 21, 2012

12:32:03 PM

Does this circuit really works? What is the charging time for a fully dischargedbattery? What will be the approximate cost(in Indian rupees) of building this?

E.L. GabrielAutomatic 12V Lead Acid

Battery ChargerThursday, March 08, 2012

11:42:49 AM

Hello, and thanks for a good circuit, it is easy to build and to modify' I've made twoof these and two of my friends are very happy. For starters, I substituted the 4x2watt resistors,for 5watt ceramic type, added adjustable fan cooling using separatepower supply. Next time I make another I'll add volt and amp gauges. Thanksonce again

RynAutomatic 12V Lead Acid

Battery ChargerTuesday, March 06, 2012

11:44:16 AM

can i know , how the triac in this circuit operate? And the overall operation for thecircuit ? TQ

mjAutomatic 6V Lead Acid

Battery ChargerThursday, February 02, 2012

4:23:05 AM

hi sir Can this circuit be modified using 6V battery?

JimmieAutomatic 12V Lead Acid

Battery ChargerWednesday, January 25, 2012

11:44:22 AM

How long does it take,n how much in $

ATHAutomatic 12V Lead Acid

Battery ChargerSunday, January 22, 2012

4:47:07 PM

Can I use BT138 or BT137 instead of BT136 ?, (75 ohm 4w) instead of (82 ohm4w) resistors ?, are there any equivalents to brx49 ?

albyAutomatic 12V Lead Acid

Battery ChargerMonday, January 16, 2012

9:50:23 AM

Would like to have a go at this one & was wondering if anyone has the layout forthe PC board

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Unlike many units, this battery charger continuously charges atmaximum 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 constantcurrent source. R1 effectively sets the current through Q1 - the voltage

across this resistor plus Q1's emitter-base voltage is equal to the voltageacross D1-D3. Assuming 0.7V across each diode and across Q1's base-emitter junction, the current through R1 is approximately 1.4/0.34 =4.1A. IC ensures that Q1 (and thus the constant current source) isturned on.

When the battery has fully charged, the current through IC drops to avery low value and so Q1 turns off (since there is no longer any base-emitter current). R2 limits the current through IC. It allows enoughcurrent to flow through the regulator so that Q1 is fully on for batteryvoltages 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 reducethe fully-charged voltage by about 0.7V.

Circuit diagram:
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12 Volt Car Battery Charger Circuit Diagram

Parts:

ResistorsR1 = 0.32R

R2 = 8.2R

CapacitorsC1 = 10,000uF - 63V

SemiconductorsD1 = 1N4004D2 = 1N4004D3 = 1N4004Q1 = MJ1504IC = 7815 REG

BR1 = 1N4004x4

MiscellaneousB1 = 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.
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12v DC to 12v DC Battery Charger Circuit

You cannot charge a 12v battery from a 12v battery. The battery being chargedcreates a "floating charge" or "floating voltage" that is higher than the chargingvoltage and the charging stops.

The following circuit produces a voltage higher than 12v via a CHARGE PUMParrangement 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 andtransistors must be fitted with heat sinks. The LEDs are designed to prevent thetwo output transistors turning ON at the same time. The lower output transistordoes not start to turn on until the voltage is above 5v and the top transistor doesnot turn on until the voltage drops 4v from the positive rail. This means bothtransistors will be turned on when the voltage passes a mid-point-gap of 4v. Thetransition is so fast that no wasted current (short-circuit current) flows via the twooutput transistors (as per our test).

Circuit diagram:

12v DC to 12vDC Battery Charger Circuit diagram

The electrolytic charges to about 10v via the lower transistor and top diode. Thetop BD679 then pulls the negative of the 2200u electrolytic towards the 12v6 railand 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 currentflow 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." Thisbasically 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 shouldbe charged at 1.2A or less. For lower-capacity batteries, the 2200u can bereduced to 1,000u. Charging is about 80% efficient. In other words, delivering120% of the AHr capacity of a battery will fully charge it.
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UPS Battery Charger

Optionsypically, the UPS contains the batterycharger, battery and inverter

inside of an enclosure. The battery

life is shortened at increased temperature,

so its important to keep the temperatureinside 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 chargerhas to function under a wide range of input

voltages and protect itself during overvoltageor voltage-surge conditions. The

battery charger keeps the UPS battery

fully charged during normal input-voltagerange. When the alternate current (ac)

power line voltage goes out of normal

range (geographical area defined), the

power turns off and the battery suppliesthe power to the load. When the line voltage

returns within the normal range, the

battery is recharged.

Linear Power SupplyThe linear power supply (continuous energy

flow) is most commonly used due tolow 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.

TThis, added to the low efficiency ofthe linear regulator, translates into a

higher temperature inside the enclosure

(shared with the battery). The immediatelower cost benefit of this solution hides

the higher long-term cost, due to a shorter


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battery lifetime and an increased maintenance

time. The weight and volume make

the mechanical design of the UPS moredifficult.

Discrete Ringing Choke Circuit

The ringing choke circuit is another continuousenergy flow power supply, limited

like the linear to single-voltage input, but

using higher frequency to pass the energyto the load, reducing the transformer size.

The efficiency is also improved, but the

circuit is highly dependent on the componentstolerance and it is difficult to design

and manufacture.

Switch-Mode Power SupplyThe 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 betterreliability.

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, inhigh-frequency increments, by switchingon and off. A solid-state switch, controlled

by a pulse-width modulation

(PWM) controller, accomplishes theswitching.

Figure 1. IC (U1 in Figure 3) functional block diagram.

Figure 2. SMPS schematic.CY12.2nF

*

BT1

+-F1 3.15A/250V+

C1 33uF/450VR84.7 1/8W4

10Q12N39043

+ C4 560uF/35VR911.5K 1%4

3

RTN

85-265 VACD7 UF5402CX10.1uF/X2D1VR1


9/45

P6KE150D4 1N4007J2-3+

C6 4.7uF/35VD6 BAV20R5 1 1/2W

*

RT1THERMISTOR (NTC)

ND5UF10051

D2

LED112

2 9R1011.5K 1%R1147.5K 1%

5*

TP21

C30.1uF/50VR647, 1/8WL23.3uH, 2.65A

J2-1R126.8k

LD3

J1-2R1

1M 1/4W 1R7470, 1/8W

EF-20917uHR36.8, 1/8WL1J2-210mH/0.3ATP1U2PC817A5

R4 1 1/2WC70.1uF/50V 2+

C247uF/10V

J1-1

FDSCMCONTROL

U1TOP233YC8+ 0.1uF/50V C5

220uF/35V3

OPTIONAL

2

R2910k 1/4W+14VDC

T1U3

TL431CLP2 31

4

The transformer has a ferrite core thatis a much smaller and lighter than the linears

iron-core counterpart, making the

UPS design easier. Also, a SMPS can beused worldwide because it accepts universal

input voltages.SMPS with Integrated

Switcher/Controller ICThe integrated switcher/controller IC

functional block diagram is shown inFigure 1.

The power supply schematic is shown


10/45

in Figure 2, and the power supplys infrared

and visible pictures are shown in Figure

3. This solution brings the followingbenefits, when compared with the discrete

SMPS:

Figure 3. SMPS infrared and visible pictures.Output ShuntResistors, 64C.TOP233Y , 60C.Lower total solution cost is the result offewer 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 numerousparts in a discrete design lead to oversizing

the SMPS to meet the powe r

requirements.

Built-in features save the cost ofcomponents necessary to implement the

various functions. The undervoltage/

over-voltage thresholds andmaximum duty cycle reduction are implemented

with one resistor. The overtemperature

shutdown simplifies thethermal 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 efficientSchottky output diodes. Cycle

skipping at low/no load eliminates the

dummy load resistor. The remoteON/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 increasedPWM gain (-22 percent/mA) reduces line

frequency output ripple. The nominal

switching frequency of 132kHz reduces

transformer size with no EMI penalty. Thefrequency jitter allows a smaller/cheaper

EMI filter to be used.

Shorter design cycle is facilitated byreadily available reference designs; by


11/45

faster agencies approvals, as the SMPS isBenefits 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, increasedmaximum 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-currentlimit, 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 fewercomponents, wide creepage distance between

D and S pins, and the IC built-inprotection features.

Fewer components is achieved by

integrating the MOSFET switch, the controller

and the ancillary circuitry into onemonolithic (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 outputshort-circuit current, and has overtemperatureshutdown, protecting the supply

in case of excessive ambient temperature.

A wide creepage distance betweenthe D and S pins gives the IC a higher

immunity to arcing and eliminates the requirement

to short adjacent pins during


12/45

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 (theDC rail is allowed to rise up to 700Vdc

without device damage). The power supply

passed the surge test defined byIEC/UL 1000-4-5 Class 3 and was designed

to meet the safety requirements of

IEC950/UL1950.

The hysteretic thermal shutdown allowsautomatic recovery when the ambient

temperature returns within the operating

range. Large thermal hysteresis prevents

PC board overheating. The soft-startreduces 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) anda PCB with small area and proper layout.0

2468101214160.00 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 thecircuit for different input-voltage ranges

with different under-voltage/over-voltagethresholds 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 TopologiesThe external UPS (outside the PC) is the

dominant solution for PC backup power.


13/45

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 apower level of


14/45

Vout(Vdc)

High limitLow limitCalculated valueMeasured value

ConclusionHigher 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 dramaticallyreduces 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 GDGCopyright 2001 Power Pulse is a registeredtrademark 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 anyrepresentations, statements of fact, or individualopinions made by advertisers or authors inPower Pulse . The views expressed here arethose of the author(s) and do not necessarily reflectthe opinion or agreement of Darnell.Com Inc.Inquiries should be addressed to Darnell.ComInc., 1159-B Pomona Road, Corona, California92882.LINELOADBATTERYSurge

Protection FilterTransferSwitch

~ = = ~BatteryChargerDC to ACConvert.

Passive standby UPS operating diagram.LINELOADBATTERYSurgeProtection FilterTransfer

Switch~

~

=

Battery =ChargerDC to ACConvert.


15/45

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 o

problem is that the Back-UPS RS 500 stop charging the battery. For me it was easy anto repair them. If you have some experience with soldering it should be easy for you torepair work.

Before you start, remove mains power and the battery. This unit is generating high vol12 volts battery and a battery like this contain a lot of energy. Please take notice of any

precautions.
http://www.heime.org/Lists/Categories/Category.aspx?Name=Photohttp://www.heime.org/Lists/Categories/Category.aspx?Name=Photos%20shown%20in%20Sandnes%20Fotoklubbhttp://www.heime.org/Lists/Categories/Category.aspx?Name=Photos%20shown%20in%20Sandnes%20Fotoklubbhttp://www.heime.org/Lists/Categories/Category.aspx?Name=Photos%20shown%20in%20Sandnes%20Fotoklubbhttp://www.heime.org/Lists/Categories/Category.aspx?Name=Photos%20shown%20in%20Sandnes%20Fotoklubbhttp://www.heime.org/Lists/Categories/Category.aspx?Name=Generalhttp://www.heime.org/Lists/Categories/Category.aspx?Name=Portugalhttp://theonlinephotographer.typepad.com/the_online_photographer/blog_index.htmlhttp://theonlinephotographer.typepad.com/the_online_photographer/blog_index.htmlhttps://mail.heime.org/owahttp://server.heime.org/epost/timelimitedaddress/http://server.heime.org/epost/timelimitedaddress/http://download.heime.org/upload/Default.aspxhttp://download.heime.org/upload/Default.aspxhttp://www.heime.org/Diverse/Weather.aspxhttp://www.heime.org/Diverse/MRTG.aspxhttp://www.pentaxphotogallery.com/http://www.pentaxphotogallery.com/http://www.pentaxphotogallery.com/http://album.heime.org/http://album.heime.org/https://mail.heime.org/owa/omahttps://mail.heime.org/owa/omahttp://www.heime.org/http://www.heime.org/Lists/Posts/AllPosts.aspxhttp://www.heime.org/Lists/Posts/Post.aspx?ID=17http://www.heime.org/Lists/Categories/Category.aspx?Name=Photohttp://www.heime.org/Lists/Categories/Category.aspx?Name=Photos%20shown%20in%20Sandnes%20Fotoklubbhttp://www.heime.org/Lists/Categories/Category.aspx?Name=Photos%20shown%20in%20Sandnes%20Fotoklubbhttp://www.heime.org/Lists/Categories/Category.aspx?Name=Photos%20shown%20in%20Sandnes%20Fotoklubbhttp://www.heime.org/Lists/Categories/Category.aspx?Name=Generalhttp://www.heime.org/Lists/Categories/Category.aspx?Name=Portugalhttp://theonlinephotographer.typepad.com/the_online_photographer/blog_index.htmlhttp://theonlinephotographer.typepad.com/the_online_photographer/blog_index.htmlhttps://mail.heime.org/owahttp://server.heime.org/epost/timelimitedaddress/http://server.heime.org/epost/timelimitedaddress/http://download.heime.org/upload/Default.aspxhttp://download.heime.org/upload/Default.aspxhttp://www.heime.org/Diverse/Weather.aspxhttp://www.heime.org/Diverse/MRTG.aspxhttp://www.pentaxphotogallery.com/http://www.pentaxphotogallery.com/http://www.pentaxphotogallery.com/http://album.heime.org/http://album.heime.org/https://mail.heime.org/owa/omahttps://mail.heime.org/owa/omahttp://www.heime.org/http://www.heime.org/Lists/Posts/AllPosts.aspxhttp://www.heime.org/Lists/Posts/Post.aspx?ID=17


17/45

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


18/45

Remove the two screws on the back panel


19/45

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


20/45

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


21/45

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


22/45

Remove the circuit board on the front panel.


23/45

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


24/45

Main board with the faulty capacitor.


25/45

Charging unit and the faulty capacitor.


26/45

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


27/45

Replace the capacitor with a new one with similar or better specification. I bought min

Elfa
http://www.elfa.se/elfa-bin/dyndok.pl?lang=en&vat=0&dok=2012719.htmhttp://www.elfa.se/elfa-bin/dyndok.pl?lang=en&vat=0&dok=2012719.htmhttp://www.elfa.se/elfa-bin/dyndok.pl?lang=en&vat=0&dok=2012719.htm


28/45

After the unit is assembled, connect it to the mains and measure the voltage at the battwithout a battery connected. It should be approx. 13.6 Volts.


29/45

Disconnect from the mains and mount and connect the battery. You probably have to b

battery if the old one has been completely discharged and been like that for several we

are easily damaged if discharged over a long time. Connect it to the mains and measur

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 Comments (101)

Comments

It works!

Thank you for this very detailed fixit. My RS500 failed a few days ago with this problreplacing the capacitor (with a 33uF 35v component) does seem to have fixed it. I'm w
http://www.heime.org/Lists/Categories/Category.aspx?Name=Generalhttp://www.heime.org/Lists/Posts/Post.aspx?ID=17http://navigatemailtolink%28%27mailto/?body=http%5Cu00253a%5Cu00252f%5Cu00252fwww%5Cu00252eheime%5Cu00252eorg%5Cu00252FLists%5Cu00252FPosts%5Cu00252FPost.aspx?ID%5Cu00253D17%27)http://www.heime.org/Lists/Posts/Post.aspx?ID=17#Commentshttp://www.heime.org/Lists/Categories/Category.aspx?Name=Generalhttp://www.heime.org/Lists/Posts/Post.aspx?ID=17http://navigatemailtolink%28%27mailto/?body=http%5Cu00253a%5Cu00252f%5Cu00252fwww%5Cu00252eheime%5Cu00252eorg%5Cu00252FLists%5Cu00252FPosts%5Cu00252FPost.aspx?ID%5Cu00253D17%27)http://www.heime.org/Lists/Posts/Post.aspx?ID=17#Comments


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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 ancapacitance 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 sa 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 Ricardoat 09.01.2007 16:27

Just as you wroteIt worked like a charm i replaced it with a 22uF x 25V 85C Capacitor it works!! Now

check if the battery is dead... Thank you a lot

at 25.01.2007 03:42

thanks

thanks, my RS 500 again live.

Mirob, Slovakiaat 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! Unusua

happening on a large number of devices, and disappointing that APC gave me the wrowhen I even linked them to this page to see if they would admit the capacitor was at fa

as an electrical engineering student, this was very fun too! Thanks so much for your ad

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 CAPReplace with a 105c cap not a 85c that was in it. A 85c cap works good with 60hz, A s

power supply has a much higher freq and a 85c cap with over heat and develop high E

drying out.Clarence

Southwest Monitors & Printers POS

[email protected]

at 27.08.2007 01:14

THX U SO MUCH

I LEAVE IN INDONESIA, I HAVE SOME TROUBLE WITH MY RS500, NOW W
mailto:[email protected]:[email protected]


31/45

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 LIFECOMPONENT. 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 C

U'R PHOTO IN MY BLOG, I WILL PUT YOUR LINK, FOR ORIGINALITY SOUR

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 wmeter, 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 brind

tutorial.- Ya daba por perdida mi confiable APC RS 500, cuando descubri esta soluciodecima parte de un dolar , volvio a tener vida la tan valiosa ups.- Recomendare este lin

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 brind

tutorial.- Ya daba por perdida mi confiable APC RS 500, cuando descubri esta solucio

decima parte de un dolar , volvio a tener vida la tan valiosa ups.- Recomendare este linde electronica sin duda.-Gracias a su autor.-

Thanks !!!!!!!!at 04.03.2008 22:43

APC upgraded the cap for the new buildsThe 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 perfect

Gracias de nuevo.

at 17.03.2008 16:00


32/45

UPS APC BR 1500

HelloMy name is Willan

Can you help me?

I have have a UPS APC BR1500, and in this moment it is on OVERLOAD state, I repand 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 Ecuadorat 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. Tha

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 u

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 prob

RS500 (BR500I, 240 V version).


33/45

It's a new unit, and as soon as I plugged it in it started to give off a scorching smell tha

away after 24 hours. The hot spot seems to be near the top vent, on the left-hand side athe front of the unit.

This is a replacement for an RS500 that failed with overheating around R28 on the masuspected the K2608 MOSFET nearby but am not enough of an electronics person to b

diagnosing a fault.

Does anyone else have experience of overheating with these units?at 21.08.2008 18:15

WorkingThanks 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 prob

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 meltedat 09.12.2008 13:37

RS 500 discharging batteryMy 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

codes or values thanks

par_0020 hotmail.comat 05.05.2009 12:22

BackUPS500Where 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, nothoperates 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 PCwas deformed by high temp just above R28 and R29. I also hear some stertorous noise

power cord is plugged into UPS. How to fix that?


34/45

Thanks.

at 26.06.2009 16:29

RS500s overheating

I forgot to mention, there are different dates on PCBs, older one is APC C2001 08/03/0259_REV05 and second one is APC C2004 640-0259A_REV06, both have same issu

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

use. It isn't easy for anyone to tell what is wrong with your units, but if someone has ethis spesific problem, please send me some text and photos and I could add them to th

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

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 p

fix the problem. first thing that i do is plug the power cable and turn on the power. butpower on (no lights on). do you think that if i replace the capacitor, ill fix all the probl

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 at 12.09.2009 09:39

Similar to .... CS 650 APC noisy resistor buzzI wish I had the same fault.....

Got a new CS 650 that is driving me crazy with the charger control circuit with audib

You wouldn't believe it but the noise is comming from a RESISTOR # R3 on this rev(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. W

Capacitors - chokes are fine.

at 04.10.2009 11:38


35/45

More radical modification

Well, designers of this circuits were (censored)

I have had the same problem, analyzed the switching power supply and found the sam

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

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

It decreases power current by 2 Watts and temperature there by 40C at cost of 1 seconconnecting the power plug.

Purpose of such modification:

Original design used a very hard divisor that divides the plug voltage to supply ~10mA

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 po

transformer and the divisor is not needed. You can verify this fact by disconnecting th

resistor, touch, and remove. Oscillator runs.

The datasheet says, that when there is no power to run oscillator, the IC eats less than

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 o

powered nearly exclusively from it. It must have enough juice to keep voltage above tvoltage 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 flash

continuously and no backup power. So I soldered off of an old pentiumII motherboar105C capacitor and replaced the one shown in this tutorial. I plugged in and for a few
http://www.penguin.cz/~utx/http://www.penguin.cz/~utx/http://www.penguin.cz/~utx/


36/45

three lower leds flashed till the power on (green) led lit (I guess meaning that the batte

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

damaged so it was imposible to measure them or read the value. They are replaced by

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 very47uF!

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 proced

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 than

Alkis from Athens, Greece

at 22.01.2010 14:59

Thanks and thanks.
http://www.penguin.cz/~utx/apc-ups/http://www.penguin.cz/~utx/apc-ups/


37/45

Newer version of RS 500 unit with 50V 22uF capacitor fixed with replacement from a

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 generground potential of 40V and now it started beeping, and does not offer any battery bac

The battery measures 13Volts AND THE units battery charging leads show 13.5V wit

removed.any ideas how to fix?

at 30.04.2010 15:56

rs 500 alarmCould somebody tell how to disable the alarm in this model... apc rs 500... take in acc

an engineer....thanks

[email protected]

at 12.05.2010 14:48

Hello

Following an overnight power surge I noticed in the morning the three lower leds flash

continuously and no backup power. So I soldered off of an old pentiumII motherboar105C capacitor and replaced the one shown in this tutorial ( I plugged in and for a few

three lower leds flashed till the power on (green) led lit (I guess meaning that the batte

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 valueR28 = 56K

at 15.06.2010 03:17

RESISTORKINDLY THE VALUE OF R26

at 22.06.2010 12:25

resistor

resistance value R29 email at [email protected]

at 22.06.2010 13:35

APS CS 500, always "On Battery", can't turn off
mailto:[email protected]:[email protected]:[email protected]:[email protected]


38/45

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 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 500Thanks for the nice tutorial and great solution to my problematic rs 500. I would like

other users and publish values of resistors that may be erased because of overheating.

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

GraciassssExcelente tutorial, recupere 2 UPS.

at 04.10.2010 19:06

overloadHi,

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 thanksan overnight power surge I noticed......uncharged and now it is charging). Many thank

rs500 died again!!!

I followed the more radical modification http://www.penguin.cz/~utx/hardware/APC

500/ and guess what:

It's ALIVE again (cost


39/45

and made short circuit dameging PCB(+&- undernith capacitor are VERY close), blow

stop charging battery(and not doing self-test). After replaceing capatitor, fuse and repa

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 thanks marco

at 07.02.2011 21:56

elektronikoMuy 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 ratosGracias

at 26.02.2011 12:17

want ups diagram

i am manjula i want 600VA ups circuit diagram my [email protected] 07.03.2011 11:19

Great work

Thank you very much for that great tutorial!

Greetings from PatagoniaSeb

at 20.04.2011 14:07

Thanks

Worked perfect for me although I did not see any damage on capacitor on my RS 500.

from Switzerlandat 28.05.2011 09:25

R138 and R150

Looking at the pcb, I founded these two resistors, C65 and C66, are snubbers that protfor two of the tree existing relays; there are places not populated for the third relay (C

I think that two relays are used for the regulation of the AC incoming from the wall, an

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

with 1 watt or more.

I replaced C7 and the unit satrted to work fine again, but it is very noisy now, at least i

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!!!!!!!
http://www.penguin.cz/~utx/hardware/APC_UPS_RS-500/mailto:[email protected]:[email protected]://www.penguin.cz/~utx/hardware/APC_UPS_RS-500/mailto:[email protected]


40/45

It's working!!! I'll write a dissertation about this)))!!)!)!)!

at 08.06.2011 09:56

work

thanks, my RS 500 again live.

mclareniak, Slovakiaat 24.06.2011 08:24

ThxWork!!! 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

contributioni 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 mturn yellow i found the capacitor in the 1st post on ebay but dont know any thing abo

info would be good.

thanx

at 29.07.2011 02:47

Worked well on REV08I have replaced C7 Capacitor and my UPS started to charge the battery again. Thanks

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 tha

this capacitor? In my case bad capacitor was 12uF --- it's not very bad. Original value 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 advic

at 26.08.2011 09:21

Thanks
http://www.eserviceinfo.com/downloadsm/3842/APC_UPS%20500.htmlhttp://www.eserviceinfo.com/downloadsm/3842/APC_UPS%20500.html


41/45

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

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 c

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

checked the out put connections with line tester it shows both wire live ( Phase & neut

Please let me know the problem.Thanks in advance.

[email protected]

at 04.11.2011 10:12

RS 1000 not working

anybody here knows how the RS 1000 works or have circuit diagram hereat 20.11.2011 13:58

Great !!!Thank you man. Very useful guide. Thank you again :)

at 05.12.2011 09:27

How to Modifywhat 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 d

information to how to assembling/manufactre UPS.

Email :[email protected] 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
mailto:[email protected]:[email protected]:[email protected]:[email protected]:[email protected]


42/45

solved!!!!

thank master..solved my problemat 12.01.2012 18:20

Indian Model is different

My UPS mother board is completely different, and i could not figured out which capacmine 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

seems to be fine.

Nice one. Thank you.

Jon (Australia)at 11.02.2012 09:41

Thank youI 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-pehow 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 RS500just change another one cap 22 mF with a new one

thnks so much


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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 model RS 800 and suddenly I found information for model RS 500. 1 year it was unus

storehouse with the same fault. I changed the capacitor, which seemed to be okay with

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 f

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 th

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

[email protected]

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 6

0287c_rev08 , and I can't find the capacity mentioned before. Is there anybody with sand 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 buzzeri have apc sc 620 if power on ups continious ly buzzer and red light on and no 220 vol

at 19.07.2012 14:32
mailto:[email protected]:[email protected]


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UPS faults

My UPS indicates the beep tone as A\C not connected, but power cable had been connmain line (fuse and power wire also good). whats wrong with it? (inverter works well)

at 28.07.2012 15:24

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102609844 12v Battery Chargers