APC Smart-UPS SMT3000i 3kVA Repair - Power Plant, Raichur
Fault Analysis
The Problem
Inverter output breaker trips at no-load (200W), every 15-20 minutes
DC bus voltage oscillates unstably between 245-255V with 8V peak-to-peak ripple
Main filter capacitor (2200µF/400V) visibly bulged with brown electrolyte seepage
ESR (Equivalent Series Resistance) measured 2.8 ohms vs. specification 0.12 ohms
Thermal imaging detected 62°C hot-spot at capacitor location; thermal runaway risk
Money Saved
Cost Savings Breakdown
What this customer saved by repairing instead of buying new
* Govt. taxes extra as applicable · Shipping charges extra as applicable on the repair quote.
This Repair's Journey
From Inquiry to Delivery
Completed in 117 hours
Inquiry Received
Equipment details logged, initial assessment scheduled
Diagnosis & Evaluation
Component-level fault analysis with detailed report
Repair Work
Expert component-level repair using OEM-grade parts
Testing & QC
Full-load testing under operating conditions, QA sign-off
Delivery & Warranty
Dispatched with test report and 6-month warranty
Inquiry Received
Equipment details logged, initial assessment scheduled
Diagnosis & Evaluation
Component-level fault analysis with detailed report
Repair Work
Expert component-level repair using OEM-grade parts
Testing & QC
Full-load testing under operating conditions, QA sign-off
Delivery & Warranty
Dispatched with test report and 6-month warranty
Technical Details
Our Repair Approach
Visual and Thermal Inspection
Identified main filter capacitor bulging with electrolyte staining and confirmed 62°C thermal anomaly via infrared camera survey of power stage.
ESR and Dielectric Testing
Measured capacitor ESR at 2.8 ohms using Fluke ESR-60 meter and performed high-potential (HiPot) testing to confirm internal dielectric degradation and breakdown risk.
Capacitor Bank Replacement
Desoldered and removed primary 2200µF/400V filter capacitor plus two companion 470µF/400V snubber capacitors; installed upgraded Vishay MKP 2200µF/450V and Nichicon GXE 470µF/400V units using precision wave-soldering.
DC Bus Reference Calibration
Recalibrated the DC bus voltage reference circuit using a precision decade box and adjusted Infineon gate driver IC bias supply to restore PWM stability and eliminate over-voltage latch-off events.
Full-Load Stability Testing
Performed 4-hour continuous testing at 100%, 75%, and 50% load levels with oscilloscope capture confirming DC bus stability at 250V ±1.2V and ripple <2V peak-to-peak.
Static Transfer and Battery Discharge Validation
Executed battery discharge simulation and bypass static transfer switch testing to verify breaker remained stable across all inverter-to-bypass and battery-to-inverter transitions.
Mission Accomplished
The Result
The repaired APC Smart-UPS SMT3000i restored uninterrupted backup power to the control room SCADA system, eliminating costly 72-hour downtime cycles and protecting mission-critical instrumentation. Synchronics' repair solution delivered Rs 35,000 in cost savings (74% reduction vs. OEM replacement price) with a 117-hour turnaround time, enabling the power plant to meet its critical availability targets without extended equipment swap logistics.
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