Repeated Smart UPS 2200 problem?

[Anonymous user]

The comany I work for uses APC 2200's to back up networking racks in various buildings around the city (about 100 at least) and we repeatedly see similiar problems over and over.
I looked over three units (we have seen this problem in many more than three), and each had the same problem - two 1/4 watt 470 ohm resistors on the main board were burnt (R38, R43). Nothing else appeared to be compromised. I replaced the resistors with 1/2 watt parts, and installed fresh, matching batteries (because they're in series). After an initial charge time, the resistors continued to run hot (way too hot to touch), and the quescient operating power of the UPS (no load attached) was 77 watts!?

Measuring the voltage drop across the resistors showed between 45-60 volts, so the parts were dissipating about 5 watts (I realize a regular DMM will average the waveform, but this was just for a rough idea). Obviously the original design spec wasn't for these parts to handle this much current (because the original part was a 1/4 w resistor), so my question is why am I seeing this recurring problem in multiple units? Is this a known issue? What is causing it?

Message was edited by: johnszxr

[Anonymous user]

Thanks for the help all the way around

Had to order the proper cable... $10 for a 6ft cable, or $6 for the DB9 backshells to make my own... using a real cable and a prolific USB to serial converter... FreeBSD... apcupsd package..

Interesting the internals think the charge voltage is 55.05

>> apctest

2013-03-30 12:36:05 apctest 3.14.10 (13 September 2011) freebsd

Checking configuration ...

Attached to driver: apcsmart

sharenet.type = Network & ShareUPS Disabled

cable.type = Custom Cable Smart

mode.type = APC Smart UPS (any)

Setting up the port ...

Doing prep_device() ...

You are using a SMART cable type, so I'm entering SMART test mode

Hello, this is the apcupsd Cable Test program.

This part of apctest is for testing Smart UPSes.

Please select the function you want to perform.

1) Query the UPS for all known values

2) Perform a Battery Runtime Calibration

3) Abort Battery Calibration

4) Monitor Battery Calibration progress

5) Program EEPROM

6) Enter TTY mode communicating with UPS

Q) Quit

Select function number: 1

I am going to run through the series of queries of the UPS

that are used in initializing apcupsd.

Simulating UPSlinkCheck ...

Wrote: Y Got: SM

Attempting to use smart_poll() ...

Sent: Y Got: SM  Good -- smart_poll() works!.

Going to ask for valid commands...

Wrote: a Got: 3.?=.  -789>@ABCDEFGKLMNOPQRSUVWXYZ'abcefgjklmnopqrsuxyz~

Protocol version is: 3

Alert characters are: ?=

Command characters are: ^A^N^Z-789>@ABCDEFGKLMNOPQRSUVWXYZ'abcefgjklmnopqrsuxyz~

Now running through apcupsd get_UPS capabilities().

NA  indicates that the feature is Not Available

apctest

2013-03-30 12:36:05 apctest 3.14.10 (13 September 2011) freebsd

Checking configuration ...

Attached to driver: apcsmart

sharenet.type = Network & ShareUPS Disabled

cable.type = Custom Cable Smart

mode.type = APC Smart UPS (any)

Setting up the port ...

Doing prep_device() ...

You are using a SMART cable type, so I'm entering SMART test mode

Hello, this is the apcupsd Cable Test program.

This part of apctest is for testing Smart UPSes.

Please select the function you want to perform.

1) Query the UPS for all known values

2) Perform a Battery Runtime Calibration

3) Abort Battery Calibration

4) Monitor Battery Calibration progress

5) Program EEPROM

6) Enter TTY mode communicating with UPS

Q) Quit

Select function number: 1

I am going to run through the series of queries of the UPS

that are used in initializing apcupsd.

Simulating UPSlinkCheck ...

Wrote: Y Got: SM

Attempting to use smart_poll() ...

Sent: Y Got: SM  Good -- smart_poll() works!.

Going to ask for valid commands...

Wrote: a Got: 3.?=.  -789>@ABCDEFGKLMNOPQRSUVWXYZ'abcefgjklmnopqrsuxyz~

Protocol version is: 3

Alert characters are: ?=

Command characters are: ^A^N^Z-789>@ABCDEFGKLMNOPQRSUVWXYZ'abcefgjklmnopqrsuxyz~

Now running through apcupsd get_UPS capabilities().

NA  indicates that the feature is Not Available

UPS Status: 08

Line quality: FF

Reason for last transfer to batteries: R

Self-Test Status: NO

Line Voltage: 120.9

Line Voltage Max: 122.2

Line Voltage Min: 120.2

Output Voltage: 120.9

Batt level percent: 100.0

Batt voltage: 55.05

UPS Load: 000.0

Line freq: 60.00

Runtime left: 0397

UPS Internal temp: 029.7

Dip switch settings: 00

Register 1: 00

Register 2: 00

Register 3: 00

Sensitivity: H

Wakeup delay: 000

Sleep delay: 020

Low transfer voltage: 103

High transfer voltage: 132

Batt charge for return: 00

Alarm status: 0

Low battery shutdown level: 02

UPS Name: UPS_IDEN

UPS Self test interval: 336

UPS manufacture date: 04/27/04

UPS serial number: XXXXXXXXXXXXXXXXX

Date battery replaced: 04/27/04

Output voltage when on batteries: 115

Nominal battery voltage: 048

Percent humidity: NA

Ambient temperature: NA

Firmware revision: 80.14.D

Number of external batteries installed: 000

Number of bad batteries installed: NA

UPS model as defined by UPS: SMART-UPS 2200

UPS EPROM capabilities string: uD43132135138129uM43229234239224uA43110112114108uI43253264271280lD43103100097106lM43177172168182lA43090092081085lI43196188208204e44200155090oI43230240220225oD13115oJ13100oM13208s441HMLLq44202050710p443020180300600k4410TLNr443000060180300E443336168ON OFF

The EPROM string is 253 characters long!

Hours since last self test: NA

That is all for now.

1) Query the UPS for all known values

2) Perform a Battery Runtime Calibration

3) Abort Battery Calibration

4) Monitor Battery Calibration progress

5) Program EEPROM

6) Enter TTY mode communicating with UPS

Q) Quit

Select function number: 2

First ensure that we have a good link and

that the UPS is functionning normally.

Simulating UPSlinkCheck ...

Wrote: Y Got: SM

Attempting to use smart_poll() ...

Sent: Y Got: SM  Good -- smart_poll() works!.

Checking estimated runtime ...

Current runtime is 397 minutes

Checking for battery level ...

Battery level is 100.0 -- OK

The battery calibration should automatically end

when the battery level drops below about 25, depending

on your UPS.

I can also optionally monitor the progress

and stop the calibration if it goes below 10. However,

in the case of a new battery this may prematurely end the

calibration loosing the effect.

Do you want me to stop the calibration

if the battery level goes too low? (y/n): y

Sending Battery Calibration command. ...

UPS has initiated battery calibration.

Monitoring the calibration progress ...

To stop the calibration, enter a return.

Battery charge 100

Remaining runtime is 397 minutes

.....

Battery charge 94

Remaining runtime is 373 minutes

.....

Battery charge 91

Remaining runtime is 361 minutes

.....

[MarkC_apc]

I recognize this is an old post - just checking if you are still active.  If so, I've got some questions about several of the APC models.  Bottom line is I'm re-purposing several "families" of the APC line for off-grid/renewable power usage - the 48 volt SUA line in particular.

Mark