UPS repair and overhauling
Component-level diagnosis, not board swapping. On site where we can, at the works where the job needs a bench and a load bank.
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- Steps in the process
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- Equipment types covered
- Any make
- Not only ours
- Same day
- Pune & PCMC response
What this covers, and why it is done this way
Most UPS "failures" come down to a handful of causes: dried electrolytic capacitors on the DC bus, a failed cooling fan that let the heatsink run hot, a dry solder joint on a driver board, or a battery bank that lost capacity while the display kept saying it was fine.
We repair at component level. That means diagnosing which device failed and why, replacing it, and identifying the upstream cause — because a shorted power device usually has a reason, and replacing it without finding the reason gets you a second call in a month.
Overhauling is the scheduled version of the same work, and it is worth considering on any machine past six or seven years: full strip-down, all electrolytics replaced regardless of test result, fans replaced, contactors and terminations checked, cabinet cleaned, then a full load-bank verification before it goes back. It typically buys another four to five years for a fraction of replacement cost.
Step by step
- 1
Fault report
Symptoms, alarm codes, recent history and load conditions taken over the phone. Many faults are identified before anyone travels.
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On-site diagnosis
Measurement of input, DC bus, output and battery, alarm log download, thermal inspection of the power stage.
- 3
Repair decision
A written repair-or-replace recommendation with costs both ways. If the machine is not worth repairing we say so.
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Component-level repair
Board-level rework, power device replacement, capacitor bank renewal, fan and filter replacement. Complex jobs come back to the works.
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Load-bank verification
Repaired units run at rated load before recommissioning. No unit is handed back on the basis that it powered up.
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Root-cause note
Written statement of what failed and why, so the same fault is not repeated.
UPS Repair & Overhauling — questions we get asked
Anything not covered here, call us — most of it is faster to answer on the phone.
Is it worth repairing a ten-year-old UPS?
Often, yes, and the honest test is whether replacement parts are still available and whether the repair costs less than about 40% of replacement. A ten-year-old machine with an available capacitor kit and fans is usually a good repair. One with an obsolete control board and no spares is a replacement, and we will tell you that instead of taking the repair order.
Do you repair UPS from other manufacturers?
Yes. Most of our repair work is other makes. Give us the make, model and the fault code and we will tell you on the phone whether spares are realistically available before anyone travels.
How long does a repair take?
On-site repairs of common faults — fans, capacitors, a battery string — are usually same day if the part is in stock. Board-level work at the works typically runs three to seven working days depending on component lead time. We can supply a rental unit to cover the gap on critical loads.
What does UPS overhauling involve?
Full strip-down, replacement of all electrolytic capacitors and fans regardless of test result, contactor and termination inspection, cabinet clean-down, firmware update where available, and a full load-bank verification. It is planned work on a healthy machine, done to prevent a failure rather than after one.
Where we attend
Everything is built at our Pune works and delivered, installed and commissioned across the city and the industrial belt around it.
Outside these areas we contract individually against distance, and we will tell you honestly if the response time you need is not one we can hold to. All areas served
Other services
UPS Annual Maintenance Contract
Quarterly preventive visits, an annual battery load test rather than a voltage check, and a breakdown line that answers. Any make — not only ours.
UPS Installation & Commissioning
From the site survey and cable schedule through battery rack assembly to a witnessed load-bank test and a signed commissioning certificate.
UPS Upgradation & Retrofit
A machine that no longer suits the load is not always a machine that needs replacing. Any make — we assess what the existing unit can still carry and upgrade what actually limits it.
Talk to someone who has done this before
Tell us the make, rating and age of the equipment and we will tell you what is realistic — including when the honest answer is that it is not worth doing.