Replace battery signal flashing after replacing battery on SUA1500 (Smart-UPS 1500)

[abuttolph_apc]

This was originally posted on APC forums on 11/6/2016

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Yesterday, I replaced the old battery in my Smart-UPS 1500 with a new battery (identical to the one that came with the UPS).  Today, the replace battery signal is flashing and the unit is beeping.  I have powered the unit off and on a few times and also tried the self test, and it always returns to the "replace battery" state.

While charging the new battery yesterday, the unit went into and out of partially-charged battery status.

Any idea on what the issue may be or how I can correct the problem? 

I tried downloading the newest firmware (in case that is needed), but there are no instructions on how to install it and I don't know if that would help anyway.

Thanks.

[BillP]

This reply was originally posted by Jonathan on APC forums on 11/7/2016

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Hello Adele,

Before recommending a firmware update, can you provide the model number of your UPS and the firmware that you have downloaded? If you are using an SUA UPS, the firmware on this UPS is not field upgradeable and the firmware that you have downloaded could be the network management card's firmware.

If the replace battery LED of the unit is flashing, it indicates that the UPS fails to detect the battery. Common troubleshooting step that we do is to verify that the anderson connector is not broken and seated properly. If you have a spare battery, you can swap it. If it continues to flash, chances are the UPS is at fault.

[abuttolph_apc]

This was originally posted on APC forums on 11/8/2016

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Hi Jonathan,

Thanks for responding to my post.  The model number on the back simply has SUA1500. 

The replace batter LED became more stable yesterday and was showing a fully charged battery.  This morning, it is mostly showing fully charged, but will flash the "replace battery" light every once in a while.  I don't have a spare battery.  However, I can certainly try to reseat the connector.  I will do that today and will see how it responds.

[abuttolph_apc]

This was originally posted on APC forums on 11/8/2016

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Today, I disconnected the battery, ran a screwdriver over all of the contacts on the connector to clean them off, and reconnected it.  After restarting the UPS, the battery charge lights showed about half charged (before disconnecting, they were intermittently showing full charge and then no charge) for a while, then started to alternate between half charged and no charge (battery replacement signal coming back on).  Eventually, it stopped showing any charge at all and is now constantly on the battery replacement signal.

Is there a way for me to test the battery?  It is new and has been connected to the UPS for a few days now and maybe it is worth checking to make sure that the battery itself is good.  If not, the culprit would be the UPS and I guess that it would need to be replaced.

Thanks.

[UnexpectedBill_apc]

This was originally posted on APC forums on 11/8/2016

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You probably need to perform a runtime calibration on your Smart-UPS. A SUA1500 doesn't have user-upgradeable firmware.

Since the unit "believes" it has a dead battery, it probably won't perform a runtime calibration under software control. Fortunately, you can do it manually. However, especially in the case of severely worn out batteries, performing a runtime calibration may not be enough to convince the unit that it has new batteries and should adjust itself accordingly. APC at one time provided a small device upon request that could be used on your UPS to reset this information. I'm unsure if they still do.

You'll need a few things in order to perform a manual runtime calibration: a purely resistive load that is at least 30% of the unit's output capacity (incandescent light bulbs work well for this), an outlet strip with a power switch, a properly grounded outlet and the UPS itself.

Start by safely shutting down any load attached to the UPS. Shut the UPS off, disconnect it, disconnect the load and place the UPS in a location where you can easily work with it. Plug the UPS into the outlet strip, and plug the outlet strip into a working wall outlet. Turn the outlet strip and the UPS on. Leave the UPS turned on regardless of what it indicates regarding battery status for at least eight hours.

After those eight hours or so, connect your resistive load to the UPS. Make sure the load is turned on. Give the load a few minutes to stabilize. Then turn the switch on the outlet strip off. The UPS should switch over to battery. Allow it to run until it shuts off. Turn the outlet strip back on, disconnect the load from the UPS and let the UPS charge its batteries for at least eight hours.

At this point the runtime calibration should have taken place.

If the calibration was not successful, you will have to see if APC will send you a battery calibration device. Or you may, at your own risk, use a piece of software known as APCFIX (and the 940-0024 serial cable) to accomplish the same thing. (Please be aware that this software is NOT provided, endorsed, approved or recommended for use by APC/Schneider Electric. You'll be using it at your own risk. As someone who has used it extensively, I believe the risk is essentially nonexistent. However, my experiences don't cover every possible outcome, environment and UPS.)

[BillP]

This reply was originally posted by Jonathan on APC forums on 11/9/2016

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Hello Adele,

William has provided a lot of information that can help you diagnosed your unit. Like what he has said, if you opted to use the APCFix please be aware that we are not the ones who made that application and if you pursue to use that method it will be at your own risk.

If the manual runtime calibration wouldn't fix the problem you can call our support hotline to assist you with further troubleshooting. You can also use a voltmeter and measure the battery voltage on the anderson connector to check if it is within the required limit.

[abuttolph_apc]

This was originally posted on APC forums on 11/9/2016

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William - thanks so much for all of this information.  I greatly appreciate it and am going to start the manual calibration today.  This is very helpful.

[abuttolph_apc · Accepted solution]

This was originally posted on APC forums on 11/9/2016

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Jonathan - thanks for the additional information.   If the manual calibration does not work (and the battery checks out ok), I will call APC to get help before proceeding with the APCFix.