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Technical CapabilitiesREVERSEENGINEERINGSCHEMATICSBOARD LEVEL REPAIRSTEST RIGS & QUALITY TESTINGTECH TRAINING& FIELD GUIDESTOOLS& TECHTRICKSRobert Furmanak,Lead Engineer
REVERSE ENGINEERING: As a reseller of refurbished equipment, it is essential that we have the ability to service what we sell. Without access to information from the manufacturers, our only option is to reverse engineer the equipment and teach ourselves how to repair them. We have reverse engineered several popular models from APC, Liebert, Tripp Lite, Eaton, Toshiba and others. The reverse engineering efforts also includes analyzing software and firmware. We have detailed error codes for models such as the APC VT and SymmetraBOARD REPAIRS We analyze equipment failures to find the root cause. In some cases, a shortcoming in the original design is found, and we modify the equipment for improved reliability. We have the ability to reprogram SYBT5 battery packs with fresh serial numbers and dates. We can also reprogram APC SURT control boards to use in different models. We can convert a 7.5kva brain to a 10kva brain, for example.TEST TOOLS & RIGS: To make the troubleshooting and repairs more efficient, we developed various aids like specialized test rigs and tools. Some equipment cannot be serviced without special tools, and modular equipment requires a means to operate it outside of its cabinet or rack.INFORMATION SHARING: By creating a network of people interested in repairs, we have expanded our knowledge base tremendously through information exchanges. Every failed unit yields new information, and combining our information with other companies experiences has reduced the time needed to locate a problem to the point that where we often know what is wrong without even opening up the unit. The following pages provide specific examples.
Sample Failure: APC Smart UPS RT 7500vaThe Smart Online UPS unit from APC is a well-designed system, but even minor failures can cause “Inverter” faults and subsequent disposal.When we looked into these faults, we found that the LV supply has the potential for catastrophic failures that cause extensive damage to the main board. Our reverse engineering drawings helped us understand the components and the failure process.Reverse EngineeringBoard levels repairs start with knowing the design. Our reverse engineering efforts start with drawings but also includes analyzing software. We have detailed resources for models such as the APC RT, VT and Symmetra.One of our drawings
(APC Smart Online Problem continued)The LV supply is causing many of these types of faults, because of APC’s decision to use a thin circuit board trace in place of a real fuse for F701. There is 400 volts present when this fuse blows, and there is no arc suppression. In our example, the trace fuse vaporized the copper and wreaked havoc on the rest of the circuit. The main board is damaged as a result.We analyzed the entire UPS to determine the full extent to the damage.Board Level RepairsOnce you identify the problem, you need be able to understand why it failed, often tracing back through the circuit.F701
(APC Smart Online Problem continued)In this example, the fuse did not completely burn up. It is only open at the right solder pad. However, much of the right pad is gone. It appears that the arc bypassed the fuse, for the opposite pad is eroded. C774 and D718 arced to the transformer. An arc jumped from TH701 to the heat sink for IC702 and then from there to ground. This indicates that the logic ground trace was blown, and the heat sink rose to over 200VDC relative to ground. The current on the trace connected to the -200v battery bus was so great that the green coating was blown off. Board Level Repairs
Our Repair:We cut away the PCB fuse completely and solder a new 450VDC, 2.5A SMD fuse in its place.The negative trace is cut on the rear of the board and a second fuse is added there. There is ample clearance on the rear of the board for the fuse. Other parts are changed, with the original problem identified and repaired.Board Repaired:Once you understand the problem you find a fix that will last.Board Level Repairs: SolutionThis is just one example of a board repair. We have similar stories for Symmetra, Smart UPS VT, Eaton 9155 and other models….
Tools & Tech TricksSometimes you need to make the tool, to make the repair.The challenge: RemoveThe heat sink to work on transistors.Tool compresses the spring holding the transistors, releasing them from the heat sink. Heat Sink Remover Transistor Screwdriver
BREAK OUT BOX: This device inserts into a 10kva power module slot and provides the ability to operate power modules and static switches externally for easier diagnosis and repair. Custom connectors were designed and fabricated to make the external operation of the modules easy and safe.Test RigsOur lab is filled with Symmetra PX, LX, RM, VT, 9x55 core systems that we can use to test and repair modules with.
Field GuidesOn Left: Top and bottom views of an APC inverter board. The purpose is to make it easy for the technician to find a particular component on the board, and to assist in visualizing the power flow.On Right: High level schematic of the board.Our philosophy is that for information to be useful, it needs to be in a format that is easily transferred to others. We create easy to read illustrations and schematics.
Tech TrainingWe use our repair facility to teach troubleshootingskills. The more the field techs understand the foundations of the UPS’s workings the better.This circuit is from an Avaya UPS, and is a good example of how simple a UPS can be inside, and the variations that exist in UPS design. This one is useful for illustrating how a UPS can create both a positive and negative 200 volts from 120VAC while using only a single transistor.
• AboutGreenLightUPS started as an offshoot of Wesworth Electric formed in 1981. Wes Shreve and Bob Durham started servicing UPS systems in 2005. By 2010, UPS sales surpassed our electrical sales. In 2014 we spun off our electrical business and renamed ourselves GreenLightUPS, Inc.Today we offer new and & refurbished UPS systems, UPS service, and depot repairs.Our core focus is from 1 to 100kva systems from APC, Eaton, Liebert and Toshiba.• Address:800 NE 42nd Street, Pompano Beach FL 33064• Phone:954-366-3070• Website:www.greenlightups.com• Technical Team:Robert Furmanak Robert@greenlightups.com• Business Development:Bob Durham Bob@greenlightups.comGreenLightUPS