DX Series

Uninterruptible Power Systems

DX400E/DX600E/DX800E

Service Manual

Date Version. Remark

2009/08/16 1.0

6F., NO. 32, Sec. 1,Chenggong Rd, Taipei, Taiwan 115, Website:www.cyberpowersystems.com TEL: 886-2-26518699 FAX:886-2-26516821
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 DX Series
Table of Contents

1 SPECIFICATIONS ......................................................................................................................... 5

2 COMPONENTS LOCATION ........................................................................................................ 6

3 PRINCIPLES OF OPERATION.................................................................................................... 8

3.1 System Block Diagram ............................................................................................................... 8

3.2 UPS Normal Mode ..................................................................................................................... 8

3.3 UPS 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 Component Test ................................................................................................................. 11

4.2.3 Function Test ..................................................................................................................... 11

5 SCHEMATIC ................................................................................................................................ 14

5.1 Charger & Output Test.............................................................................................................. 14

5.2 System Power ........................................................................................................................... 15

5.3 Inverter Circuit ......................................................................................................................... 15

5.4 Main Circuit ............................................................................................................................. 16

5.5 Input Test ................................................................................................................................. 16

5.6 CPU & Communication ............................................................................................................ 17

6F., NO. 32, Sec. 1,Chenggong Rd, Taipei, Taiwan 115, Website:www.cyberpowersystems.com TEL: 886-2-26518699 FAX:886-2-26516821
Copyright ©2006 CyberPower Systems, Inc. All rights reserved
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 DX Series
1 SPECIFICATIONS

Model DX400E DX600E DX800E

Capacity (VA) 400VA 600VA 800VA
Capacity (Watts) 240W 360W 480W
Input
192-263Vac
Transfer Point: Recovery Point:
Input Voltage Range
VL=192±10Vac VL+2V~+12V
VH=263±10Vac VH-2V~VH-12V
Frequency Range 47Hz To 63Hz
Nominal RMS Current
1.74 A 2.61A 3.48A
(VA/120)
Max. RMS Current 5A 5A 8A
Output
On Battery Output Voltage Simulated Sine Wave at 230±7%
On Battery Output Frequency 50/60 Hz +/-1%
Surge Protection
Lightning / Surge Protection 405Joules(L-N)
Battery
Sealed Maintenance Free Lead
12Vdc / 4.5Ah 12Vdc / 4Ah 12Vdc / 8.5Ah
Acid Battery
Protection DC fuse 40A/32V x1 DC fuse 30A/32V x2 DC fuse 40A/32V x2

Battery Low 11Vdc+/-0.3Vdc

Battery Shutdown 10Vdc+/-0.3Vdc
User Replaceable Yes
Charger
Charge Voltage 13.3Vdc-13.8Vdc
Charge Current 1.0Amax
Typical Recharge Time 8 Hours(Recovery to 90% capacity)
Charging Over Volt 15Vdc±0.3Vdc
Transfer Time
Typical ≤10ms
Overload Protection
Overload Protection-Output
Circuit breaker: 5A Circuit breaker: 5A Circuit breaker: 8A
Short(Line mode)

Overload Protection-Output - Load ≥ 120%: Buzzer long beep, shutdown in 3 secs.

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 DX Series
Short(Batt mode) - 120% ≥ Load ≥ 110%: Buzzer long beep, shutdown in 60 secs.
- Load ≤ 90%: Stop warning & stop over load shut down procedure.
Indicators
Orange LED Illuminate when main switch is on and the UPS is working.
LCD: Battery Capacity Show 5 level
LCD: Load Capacity Show 5 level
LCD: Estimated run time Show run time in minutes
LCD: Input voltage Show input voltage in 1 volt resolution
LCD: Output voltage Show output voltage in 1 volt resolution
LCD: AVR Show AVR status
LCD: normal/battery Show normal/battery status
LCD: overloaded Show overloaded status
LCD sleep LCD mask will be turn off after 1 minute if the “display” switch was
not pressed in 1 minute. The back light led will be turn off after 2
minutes if the “display” switch was not pressed in 2 minutes.
LCD wake up LCD will be waked up after 2 seconds if the “display” switch is
pressed.
Audible Alarms
Battery Discharge 2 beeps in 30 seconds
Battery Low Sounding every 1 second
Overload Continuously sounding
Physical
Total # of UPS Receptacles French/Schuko *3
Maximum Dimensions 235x90x190mm
Weight (Kg) 2.7Kg 3.4Kg 3.9Kg

Environmental
Operating Temperature +32°F to 95°F ( 0°C to 35°C )
Operating Relative Humidity 0 to 95% NON-CONDENSING
Noise Level Less than 40dB
Communication
PowerPanel Business Edition
Windows 98/ME/2000/NT/XP
(for USB Port)
PowerPanel Business Edition
(for Serial Port 1)
Windows 98/ME/2000/NT/XP
PowerPanel® Software
(for Serial Port 2)
Management
Self-Test Manual Self-Test

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 DX Series
Auto-Charger Yes
Auto-Restart Yes
USB Interface USB1.1

2 COMPONENTS LOCATION

1. Power Switch
Press the power switch to turn the UPS ON or OFF.
2. LCD Function Selected Switch
The switch can be used to select the LCD display contents Including input/output voltage and
estimated run time, etc.

1. AC Inlet
Connect to utility power through the input power cord
2. Input Circuit Breaker
The circuit breaker provides optimal overload protection.
3. AC outlet
The UPS provides 6 outlets for connected equipment to insure temporary uninterrupted operation
6F., NO. 32, Sec. 1,Chenggong Rd, Taipei, Taiwan 115, Website:www.cyberpowersystems.com TEL: 886-2-26518699 FAX:886-2-26516821
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 DX Series
during a power failure and against surges and spikes.
4. Serial Port to PC
This port allows connection and communicates from the DB-9 serial on the computer to the UPS unit.
5. USB Port to PC
This port allows connection and communication from the USB port on the computer to the UPS unit.
6. Communication Protection Ports RJ11/RJ45
Communication protection ports will protect any standard modem, fax, telephone line, or network
cable.

3 PRINCIPLES OF OPERATION

3.1 System Block Diagram

Output
Output

DC Push-Pull
Circuit X Power Stage

Breaker Backup Output

Surge

Input

Relay
Output
Surge Protection Output
Battery

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).
Output
Output

DC Push-Pull
Circuit X Power Stage

Breaker Backup Output

Surge

Input

Relay
Surge Protection Output
Battery

UPS Normal Mode

6F., NO. 32, Sec. 1,Chenggong Rd, Taipei, Taiwan 115, Website:www.cyberpowersystems.com TEL: 886-2-26518699 FAX:886-2-26516821
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 DX Series
3.3 Battery Mode

When AC utility power is abnormal, battery will provide power via DC/AC circuit to output socket.

Output
Output

DC Push-Pull
Circuit X Power Stage

Breaker Backup Output

Surge

Input

Relay
Surge Protection Output
Battery

UPS Battery Mode

4 REPAIR

4.1 Test Equipment

• Digital Multi-Meter (DMM) with true RMS measurement

• DC power supply 30V 6A
• Digital Storage Oscilloscope (DSO)
• AC power supply
• Power Meter
• Load: 100~200W/230V milky light bulb
• PC

4.2 Repair Procedure

4.2.1 Equipment Preparation
• Adjust the DC power supply to 12V
• Adjust the AC power supply to 230Vac
• Prepare 100W/480W light bulb load
• Install UPS communication software and prepare USB cable
• Check the waveform of UPS output
• Observe the output voltage, frequency, and power with Power Meter.

4.2.2 Check Components

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• Please check if there is any object that may cause a short circuit on the surface of circuit board or
electronic components. (Please remove it if any.)
• Please check if there is any tin stick on the surface of circuit board or electronic components.
(Please remove it if any.)
• Measure the components with Digital Multi-Meter.

1. Set DMM to function and measure Transistor and Diode voltage, as described below.
• Read the figure of voltage difference between A-K (“Anode” and “Cathode”) of the diode
(including Zener diode). The reading should be within the range of 0.4-0.65V.
• 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 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.

• If the measured reading is over normal value, the component might be broken.

Part Reference Approval Sheet Measured Reading

D11,D12,D13,D14,D15,D16,D1
BAS32L(Diode) 0.4V~0.65V
7,D18,D29
Z1 30V/0.5W(Zener Diode) 0.4V~0.65V
Z2 12V/0.5W(Zener Diode) 0.4V~0.65V
D23 BAV70LT1(Diode) 0.4V~0.65V
D21,D22,D23 1N5404(Diode) 0.4V~0.6V
D10 HER108(Diode) 0.4V~0.6V
D3,D4,D9,D10,D26,D28 1N4007(Diode) 0.4V~0.6V
D5,D6,D7,D8 MUR460(Diode) 0.4V~0.6V
Q11,Q12,Q13,Q14,Q15,Q16,Q1
7,Q18,Q19,Q21,Q22,Q25,Q26,Q PN2222A(BJT NPN) 0.5V~0.75V
27
Q20,Q24 MPSA42(BJT NPN) 0.5V~0.75V
Q23 PN2907(BJT PNP) 0.5V~0.75V
Q3,Q4,Q5,Q8 CEP83A3 (N MOS) 0.4V~0.6V
Q6,Q7,Q9,Q10 IRF840( N MOS) 0.4V~0.6V

2. Set DMM to” Ω” function and measure the resistor and fuse and see if they are normal.

6F., NO. 32, Sec. 1,Chenggong Rd, Taipei, Taiwan 115, Website:www.cyberpowersystems.com TEL: 886-2-26518699 FAX:886-2-26516821
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 DX Series

4.2.3 Check Functions

• Connect the transformer, wires, and power cord to the main board. Use DC power supply (set 24V)
to replace the battery. Follow the steps below to measure.

Step Test Point Test Steps Solutions

Charger Test 1. Input AC 230V when • If there is no output, check charger
power is off. circuit.
2. Observe if battery side (DC 1. Check if there is input. The fuse or
charger header) become copper foil might be broken if there is no
13.3-13.8V from DC 12V. input. (Change or touch up the broken
1
3. Remove AC 230V. parts.)
2. Check if there is broken semi-conductor.
(Change the broken parts.)
3. Check if there is broken resistor. (Change
the broken parts.)
Boot Test 1. Supply DC 12V with DC • If fail to boot (no power condition),
power supply. please check the system power circuit.
System Power 2. Observe if the output 1. Check if DC fuse or copper foil are
Test voltage, frequency, and broken. (Change or touch up the broken
waveform are correct. parts.)
Battery Mode 3. Observe if the LCD header 2. Check if the tin of switch board is broken.
Test is correct. (Touch up the broken parts.)
4. Press the LCD function 3. Measure if BJT is damaged. (Change the
switch to see if the function broken parts.)
selection is normal. 4. Measure if 7805 output to ground is
5. Check if the voltage 24V, short. (If short, please check if there is tin
15V, -15V, 5V are correct stick of 5V to gound. If there is no tin
with DMM. stick, CPU might be broken. Change the
broken parts.)

• If fail to boot (there is a little power and

2
then shut down), please check system
power circuit.
1. Check if there is ON signal sent out. (If
no, the CPU ON foot might have problem
or the CPU is broken. Please make sure
the CPU is with program.)
2. If ON signal is sent out, please check if
the path (R45、D16、R18) from ON to
BJT is broken. (Change the broken parts.)

• If fail to boot (there is power but inverter

does not work), please check is input
battery voltage is too low. (Battery voltage
must be higher than 12V.)

• If fail to boot (buzzer long beep without

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 DX Series
output), please check inverter circuit.
1. Please check if output is short. (Remove
the short part.)
2. Please check if inverter circuit MOSFET
D-S side is short and if copper foil is
broken. (Change or touch up the broken
parts.)
3. Please check if resistors of inverter circuit
are normal. (Change the damaged parts.)

• If UPS can boot but the output waveform

is not normal, please check interver
circuit.
1. Check if Q3,Q4,Q5,Q8 are installed
backwards. (Correct the installation.)
2. Check if Q3,Q4,Q5,Q8 driver circuit
Q22Q21Q18Q17 are broken. (Change the
broken parts.)
3. Check if the value of resistor is wrong or
damaged. (Change the broken parts.)
• If LCD cannot display normally, please
check Panel circuit.
1. Please check if there is broken tin or
wires fall off on LCD board. (Touch up
the broken parts.)
2. Check if the Panel circuit is normal.
(Change the broken parts.)
3. Check if RB, BL, WB, DAT signals are
sent out. (If not, the CPU feet of RB, BL,
WB, DAT might have problem or the
CPU is damaged. Please make sure the
CPU is with program.)
• If LCD cannot switch normally, please
check panel circuit.

1. Please check if there is broken tin or

wires fall off on LCD board. (Touch up
the broken parts.)
2. Please check if there is broken tin or
wires fall off on Switch board. Please
check if the switch is normal. (Touch up
the broken parts.)
3. Please check if Panel BDT+ circuit is
normal. (Change the broken parts.)
4. Check if BDT+signal is sent into CPU.
(If yes but no reaction, the CPU BDT+
foot might have problem or the CPU is
damaged. Please make sure the CPU is
with program.)

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Line Mode Test 1. Followed by step 2, turn on • If fail to switch to Line Mode, please
the UPS in battery mode check input detection circuit and main
and then add AC 230V circuit Relay and Relay control.
(using AC power supply). 1. Please make sure AC input is rated
2. Observe if it switches to frequency. (If not, adjust the AC power
Line Mode. supply.)
3. Adjust the utility power to 2. Please check input detection circuit and if
AC 192V to see if it the resistor or copper foil is broken.
switches to battery mode. (Change or touch up the broken parts.)
4. Adjust the utility power 3. Observe if the SYNC and LINEV
back to AC 263V to see if it waveforms are normal with DSO. (If not,
switches to battery mode. check if the detection circuit elements are
5. Adjust the utility power broken.)
back to AC 230V. 4. Check if SYNC (50Hz square wave) and
3 LINEV (50Hz full-wave rectifier) signals
are sent into CPU. (If not, the CPU
SYNC or LINEV feet might have
problem or the CPU is damaged. Please
make sure the CPU is with program.)
5. Check if Relay (K1, K2) and control
circuit are normal. (Change or touch up
the broken parts.)

• If the above is all normal but over

voltage and low voltage cannot switch to
battery mode, please check if the
program version is correct. (If not, please
burn correct program.)
Load/Overload 1. Followed by step 3, add If USB fails to communicate, check the
Test 100W load. USB related CPU circuit.
2. Check if the LCD display is 1. Check if USB to CPU components and
USB correct. circuit are normal. (Pay attention to stick
Communication 3. Check if the USB software tin or broken tin. Change the broken
Test (PPPE) display (firmware parts.)
version) is correct. 2. Make sure the CPU program version is
Dry Contact 4. Power Panel Personel correct. (If not, burn the correct program.)
Test Edition。Disconnect utility If dry contact fails to communicate, check
power to switch to battery the dry contect related CPU circuit.
4 mode and check the USB 3. Check if dry contact to CPU components
software display using and circuit are normal. (Pay attention to
PPPE. stick tin or broken tin. Change the broken
5. Restore utility power and parts.)
add rated load and check if 4. Make sure the CPU program version is
display and software are correct. (If not, burn the correct program.)
correct and goes to
overload constant tone.
6. Remove load and run self • If it fails to display correct percentage
test with software. (wattage) or no overload warning, check if
the program version is correct. (If not, burn
the correct program.)

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 DX Series

• If the program is correct but percentage

(wattage) display is wrong or no overload
warning, check if main circuit current
detection components are normal.
1. Check if CT is correct and surrounding
components are normal. (Change the
broken parts.)
2. Check if LOAD signal is sent into CPU.
(If yes but no action. The CPU LOAD
feet might have problem or the CPU is
damaged.)

• If cannot run self test, please check if the

program version is correct. (If not, burn
the correct version.)

5 SCHEMATIC

5.1 Charger & Output Detection

5.2 System Power

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 DX Series

5.3 Inverter Circuit

5.4 Main Circuit

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 DX Series

6F., NO. 32, Sec. 1,Chenggong Rd, Taipei, Taiwan 115, Website:www.cyberpowersystems.com TEL: 886-2-26518699 FAX:886-2-26516821
Copyright ©2006 CyberPower Systems, Inc. All rights reserved
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 DX Series
5.6 Input Detection

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 DX Series
5.7 CPU & Communication

6F., NO. 32, Sec. 1,Chenggong Rd, Taipei, Taiwan 115, Website:www.cyberpowersystems.com TEL: 886-2-26518699 FAX:886-2-26516821
Copyright ©2006 CyberPower Systems, Inc. All rights reserved
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