UPS Battery Mod - Mini Worklog

MorTus · 25th June 2009, 5:53 PM

My friend works in IT and replaced an IBM 1000THV UPS (APC Smart UPS 1000VA rebadged) for a client. The only thing wrong with it was the batteries were stuffed, however, replacement batteries from APC are about the same cost as a new UPS and the UPS comes with a new 1 year warrenty so clients just opt for the new item.

So, more to the point, I received this poor unloved UPS. Now, the APC Smart UPS 1000 and 1500 use the same chassis and as far as I can tell use the same electronics. The only difference are the batteries, so instead of replacing the RBC6 battery pack with generics, I will be replacing it with RBC7 generics.

APC Smart UPS 1000Va Specs
APC Smart UPS 1500Va Specs

The RBC6 battery pack is made up of 2x 12V 12Ah batteries, these are the Jaycar generics: Jaycar SB2489

The RBC7 battery pack is made up of 2x 12V 18Ah batteries, these are the Jaycar generics: Jaycar SB2490

Now notice that the connectors for the RBC6 and RBC7 are different. So I will be replacing the standard connectors. Also note that the APC batteries are linked with a fuse, I will be using the fuse from my old battery pack.

MorTus · 25th June 2009, 6:03 PM

So without further delay here is my mini worklog.

Materials:
IBM UPS 1000THV (Rebadged APC Smart UPS 1000) - Free
New 12V 18Ah batteries - $149.90
1m each of 12AWG red and black wire - $4.40
A pack of ring crips - $2.75
2 way auto connector - $3.95

Total Cost: $161.00

Tools:
Multimeter
Crimping Tool
Screw Driver
OCAU mug with fresh brew of coffee

Menthu_Rae · 25th June 2009, 6:12 PM

Quote:

Originally Posted by MorTus

So without further delay here is my mini worklog.

Materials:
IBM UPS 1000THV (Rebadged APC Smart UPS 1000)
New 12V 18Ah batteries
1m each of 12AWG red and blue wire
A pack of ring crips
2 way auto connector

Tools:
Multimeter
Crimping Tool
Screw Driver
OCAU mug with fresh brew of coffee

Sweet, looks the goods! Will keep an eye on this because I'm going to have to replace my Powerware 5110 UPS batteries sometime in the next 18-24 months or so.

MorTus · 25th June 2009, 6:33 PM

I nearly forgot ...

GENERAL DISCLAIMER: Follow this guide at your own risk, I don't accept any liability for you blowing up your UPS, frying your computer or burning down your house.

High Voltage Warning: A UPS has components inside that run at 240V and certain items such as capacitors can hold their charge even once mains power is removed. The device should be left for at least 1 hr before dismantling to allow capacitors to discharge

Now that we got that over and done with...

Carefully pop off the front panel.

Unscrew the battery panel.

Slide out the old batteries.

Here you can see the difference is battery size. These new batteries should give me 50% more run time that the old ones.

MorTus · 25th June 2009, 6:37 PM

The next step is to remove the small battery runners as these will prevent the larger batteries sliding in.

Remove the 6 screws at the bottom to remove the main cover. Note: At this point you may be exposing yourself to high voltages.

Unscrew and remove the runners.

Here you can see the extra space and the clear path for the larger batteries which now takes up the full height of the UPS.

MorTus · 25th June 2009, 6:47 PM

Now we need to build a new battery pack by linking the two batteries in series, this will give 24V and 18Ah.

Remove the fuse unit from the old battery pack.

Strip and crimp round connectors on the ends.

The batteries need to face each other to allow them to be easily wired in series. The fuse unit is installed between the +pos terminal on one battery and the -neg terminal on the other battery.

MorTus · 25th June 2009, 6:59 PM

Now to replace connector on the UPS, simply cut back the wires and crimp on the new 2-way automotive connector. Remember this needs to be the male connector.

I then installed the batteries for a test fit and to measure up the final connecting lead.

I made up a lead using the 12AWG wire, the female 2-way automotive connector and the round crimp connectors. Note, that I have left plenty of length to allow for easy installation and removal of the battery pack.

And here is the battery pack all ready to go. I have also added some additional electrical tape on the terminals to pervent any accidental short circuits.

The battery pack is now ready to be installed. Again, note the length of cable allows for easy install.

The battery pack fits in nicely with enough room on top for the fuse unit and excess cable.

Then simply replace the main cover, battery cover and front face plate.

MorTus · 25th June 2009, 7:05 PM

The UPS all running again. Its running around 50% load.

And on battery (orange light). I ran a full drain test (battery down to 15%) and it lasted 31mins 35secs. Not too bad for a computer running an Intel Core Dual 3Ghz, AMD 4870, 10 Hard Drives and a 24" monitor.

qwertylesh · 25th June 2009, 7:48 PM

I especially like the part about the coffee, yum.

cvidler · 25th June 2009, 8:25 PM

I wish my UPSs had room inside for bigger batteries.

Got two MGE PulsarEX 1500VA units. each has 7x 12V 7AH SLAs in series for 84V.

DJ_Hippster · 25th June 2009, 10:00 PM

hahahahaha.

You know, I just purchased 4x 18aH batteries just like that, to put into my APC SC1000 and SUA1000, same chassis and situation you have done.

Very easy mod this one, and gives great results!

Renza · 26th June 2009, 12:27 AM

is it possible to have larger batteries and have them externally mounted?

also, what about multiple smaller batteries mounted in series externally?

the Fan-Man · 26th June 2009, 3:01 AM

i did that with a 1500VA APC unit...

the only problem is, that it didnt like being run for over 20 mins. so the extra battery didnt really do much in terms of extra power. the voltage fluctuated and cut off with 2 short beeps at a time (overheat) - mind you my load is only about 4A (250v). (2 of 5 load LEDs on the front panel)

keep in mind that UPSs are designed to give backup power in case of failure, enough that there is time to safely shutdown a unit or wave a cycle of power. they arent designed for continuous supply of power

Quote:

Originally Posted by Renza

is it possible to have larger batteries and have them externally mounted?

also, what about multiple smaller batteries mounted in series externally?

>> thats the mod i did, ill post pics when i can pull the unit out of the rack.

DJ_Hippster · 26th June 2009, 6:43 AM

Quote:

Originally Posted by Renza

is it possible to have larger batteries and have them externally mounted?

also, what about multiple smaller batteries mounted in series externally?

Yeah a friend has 4x 40aH batteries sitting in his cupboard below his APC SC1500, all it means is you get longer run time on existing loads. You cannot increase the load beyond the original specs of the UPS as the circuitry is not designed for more, but you can certainly increase run time

cvidler · 26th June 2009, 4:39 PM

Quote:

Originally Posted by Renza

is it possible to have larger batteries and have them externally mounted?

also, what about multiple smaller batteries mounted in series externally?

You certainly can, it's advisable to increase the size of the wire, as the long run will have increased resistance (thicker wire has less).

A long run of thin wire, may in extreme circumstances be a fire hazard.

25th June 2009, 5:53 PM	#1
MorTus Member Join Date: Jun 2001 Location: Perth Posts: 752	UPS Battery Mod - Mini Worklog My friend works in IT and replaced an IBM 1000THV UPS (APC Smart UPS 1000VA rebadged) for a client. The only thing wrong with it was the batteries were stuffed, however, replacement batteries from APC are about the same cost as a new UPS and the UPS comes with a new 1 year warrenty so clients just opt for the new item. So, more to the point, I received this poor unloved UPS. Now, the APC Smart UPS 1000 and 1500 use the same chassis and as far as I can tell use the same electronics. The only difference are the batteries, so instead of replacing the RBC6 battery pack with generics, I will be replacing it with RBC7 generics. APC Smart UPS 1000Va Specs APC Smart UPS 1500Va Specs The RBC6 battery pack is made up of 2x 12V 12Ah batteries, these are the Jaycar generics: Jaycar SB2489 The RBC7 battery pack is made up of 2x 12V 18Ah batteries, these are the Jaycar generics: Jaycar SB2490 Now notice that the connectors for the RBC6 and RBC7 are different. So I will be replacing the standard connectors. Also note that the APC batteries are linked with a fuse, I will be using the fuse from my old battery pack. Last edited by MorTus; 25th June 2009 at 6:13 PM.

25th June 2009, 6:03 PM	#2
MorTus Member Join Date: Jun 2001 Location: Perth Posts: 752	UPS Mod Continued... So without further delay here is my mini worklog. Materials: IBM UPS 1000THV (Rebadged APC Smart UPS 1000) - Free New 12V 18Ah batteries - $149.90 1m each of 12AWG red and black wire - $4.40 A pack of ring crips - $2.75 2 way auto connector - $3.95 Total Cost: $161.00 Tools: Multimeter Crimping Tool Screw Driver OCAU mug with fresh brew of coffee Last edited by MorTus; 25th June 2009 at 7:06 PM.

25th June 2009, 7:05 PM	#8
MorTus Member Join Date: Jun 2001 Location: Perth Posts: 752	The UPS all running again. Its running around 50% load. And on battery (orange light). I ran a full drain test (battery down to 15%) and it lasted 31mins 35secs. Not too bad for a computer running an Intel Core Dual 3Ghz, AMD 4870, 10 Hard Drives and a 24" monitor. Last edited by MorTus; 25th June 2009 at 7:07 PM.

25th June 2009, 8:25 PM	#10
cvidler Member Join Date: Jun 2001 Location: Canberra Posts: 7,149	I wish my UPSs had room inside for bigger batteries. Got two MGE PulsarEX 1500VA units. each has 7x 12V 7AH SLAs in series for 84V. __________________ We might eviscerate your arguments, but we won't hurt you. Honest! - Lucifers Mentor ⠠⠵ [#]

25th June 2009, 10:00 PM	#11
DJ_Hippster Member Join Date: May 2003 Location: NE Adelaide, Australia Posts: 497	hahahahaha. You know, I just purchased 4x 18aH batteries just like that, to put into my APC SC1000 and SUA1000, same chassis and situation you have done. Very easy mod this one, and gives great results! __________________ Air-Stream Community Wireless Network Desktop: i7-3770, Intel DB75EN, 16GB DDR3, Samsung 840Pro 256GB, Lian-Li PC-A17 \| Server: i7-3770S, Intel DQ77MK, 32GB DDR3, 3x 3TB WD RED, Kingston 120GB V300 SSD, Antec NSK2480B NO CLICKY CLICKY

25th June 2009, 6:33 PM	#4
MorTus Member Join Date: Jun 2001 Location: Perth Posts: 752	I nearly forgot ... GENERAL DISCLAIMER: Follow this guide at your own risk, I don't accept any liability for you blowing up your UPS, frying your computer or burning down your house. High Voltage Warning: A UPS has components inside that run at 240V and certain items such as capacitors can hold their charge even once mains power is removed. The device should be left for at least 1 hr before dismantling to allow capacitors to discharge Now that we got that over and done with... Carefully pop off the front panel. Unscrew the battery panel. Slide out the old batteries. Here you can see the difference is battery size. These new batteries should give me 50% more run time that the old ones.

25th June 2009, 6:37 PM	#5
MorTus Member Join Date: Jun 2001 Location: Perth Posts: 752	The next step is to remove the small battery runners as these will prevent the larger batteries sliding in. Remove the 6 screws at the bottom to remove the main cover. Note: At this point you may be exposing yourself to high voltages. Unscrew and remove the runners. Here you can see the extra space and the clear path for the larger batteries which now takes up the full height of the UPS.

25th June 2009, 6:47 PM	#6
MorTus Member Join Date: Jun 2001 Location: Perth Posts: 752	Now we need to build a new battery pack by linking the two batteries in series, this will give 24V and 18Ah. Remove the fuse unit from the old battery pack. Strip and crimp round connectors on the ends. The batteries need to face each other to allow them to be easily wired in series. The fuse unit is installed between the +pos terminal on one battery and the -neg terminal on the other battery.

25th June 2009, 6:59 PM	#7
MorTus Member Join Date: Jun 2001 Location: Perth Posts: 752	Now to replace connector on the UPS, simply cut back the wires and crimp on the new 2-way automotive connector. Remember this needs to be the male connector. I then installed the batteries for a test fit and to measure up the final connecting lead. I made up a lead using the 12AWG wire, the female 2-way automotive connector and the round crimp connectors. Note, that I have left plenty of length to allow for easy installation and removal of the battery pack. And here is the battery pack all ready to go. I have also added some additional electrical tape on the terminals to pervent any accidental short circuits. The battery pack is now ready to be installed. Again, note the length of cable allows for easy install. The battery pack fits in nicely with enough room on top for the fuse unit and excess cable. Then simply replace the main cover, battery cover and front face plate.

26th June 2009, 12:27 AM	#12
Renza Member Join Date: Dec 2004 Location: Adelaide, 5051 Posts: 2,975	is it possible to have larger batteries and have them externally mounted? also, what about multiple smaller batteries mounted in series externally? __________________ i7 3770K @ 4.5ghz \| AsRock Z77 Professional \| 16gb Corsair Vengence 1600mhz \| Gigabyte GTX580 \| Seasonic X750 \| Silverstone TJ07 \| Crucial M4 256GB \| 2x Dell 2407WFP Canon 5D Mark II \| Canon EF 24-70 f/2.8L \| Canon EF 17-40 f/4L \| Canon EF 70-200 f/2.8L IS \| Canon EF 50mm f/1.8 \| Canon EX-580II \| Manfrotto 190 Pro B Traded over $22,000 on OCAU! - PM for recent traders Last edited by Renza; 26th June 2009 at 1:41 AM.