SURT5000XLT - New batteries, no load and not charging

[Anonymous user]

I apologize for the rather wordy post but had a few things that are related.

I recently had to put new batteries in to a SURT5000XLT and the first time that I put them in I think I had the polarity of the batteries mixed, i.e. negative was positive, positive was negative.  When I connected the battery modules to the UPS, there was a good sized spark inside of the UPS.  I quickly realized that I switched the polarity and corrected the issue.  Now the voltages of each battery module is showing as 102-103 volts.  When I connected the modules the second time, there was still a spark inside of the UPS, but it made some clicking sounds and the fan in the front turned on.  I was able to turn the UPS on and get the output power working, but the batteries didn't seem to be charging at all.  The indicator lights for the battery capacity keep going down until it got to 22%.  It stayed there for a few hours but finally the UPS turned off.

So the question or questions is/are:

1. If installing new batteries, is there a process that has to be done for the batteries to start charging? (Runtime Calibration, etc....)

2. With the batteries installed and it not charging, would that be an indication of a hardware failure or just a software setting?

3. Should I see 102-103 volts in each battery module or did I wire it incorrectly the second time and blow a capacitor?

Thanks

[BillP]

Hi Alex,

Are you saying you made/replaced your own batteries instead of purching RBC44 modules/strings? I ask because all that should be required by a user is to purchase as many RBC44 qty that their UPS requires, insert them into the UPS, plug in the brown DC connector to the UPS, and they should begin charging automatically. A runtime calibration can be done if the reported runtime after replacing the batteries does not appear accurate but it is not required for the UPS to charge or operate as a UPS.

If the UPS doesn't appear to be charging, the first thing I'd do if you haven't already is connect to the UPS Network Management Card that should've come pre-installed in this UPS - do you have this? Even if you don't have it configured, it'd still be operating and hopefully have some helpful information i.e. charger failure. Usually if there is a fault on these types of UPSs, it would display the fault LED (LED with an X on the front panel) and a combination of LEDs on the battery bar graph on the right that you were looking at for battery capacity charge.

For each string, so part number RBC44 comes with two strings, you should be seeing 100V-106V so that is correct. 

[Anonymous user]

Hi Angela:

I got the RBC44 modules (no batteries inside) and the cables that goes with them but used third party batteries that were certified to use with the RBC44 module (link below).  I do have the NMC which I have connected.  There was an error message that came up but only after the UPS powered down (Have to go back to look at it).  When I first started the UPS, the online led flashed orange then turned off.  I realized that I was in bypass mode.  Once I switched it over to online mode, then the led turned green.

But the biggest mystery for me is that the batteries aren't charging.  If everything is normal, status is showing as ok and the self test passed then I would think that the batteries would charge.  I read before that when you connect the batteries, that you could expect a small spark as the two connectors touch.  But the spark that I was getting would not be something that I would want to hear if I had everything connected properly..  That is why I am wondering that I blew a capacitor or did some damage on the inside.

http://www.batterysharks.com/APC-RBC44-p/apc-rbc44_ups12-5.5_x16.htm

[BillP]

Hi Alex,

Thanks for the clarification. What you did is not "supported" but if you're not covered under a warranty or contract, then you can do whatever you want and get batteries wherever you want. Many folks can handle doing that which is fine.

When you're in bypass, there should be no flashing LEDs. Just a solid orange bypass LED. Anyway, the NMC logs would be very helpful to review if you can get them (event.txt, data.txt and config.ini, instructions here -> http://www.apc.com/support/index?page=content&country=ITB〈=en&locale=en_US&id=FA156131 )

Yes, when you connect the batteries, a small spark is normal and I know you know the difference between that and what happened in your scenario which it does not sound like the normal tiny spark.

It's really hard to tell what may have happened. It is possible something could be damaged and whatever it is, is not capable of being detected by a normal diagnostic. I don't think it is likely the cause but it could also be an issue with the batteries (but you measure good voltage). Is the UPS detecting that a battery is installed and just not charging it? Or is it flashing the replace battery indicator at you?

What we'll be able to do here is review the logs for you to make sure there is nothing that catches our eye but beyond that, there is not too much you can do likely without having the UPS serviced or tinkering with it some more at your own risk. We don't offer schematics or anything like that so you'd be doing it at your own risk or need to have it looked at by a service partner in your area.

[Anonymous user]

Thanks Angela.

I will have to get the logs and post them here.  The UPS is out of warranty so I may just get another one and have that as a backup or have two in use if the one in question can be fixed at a cheap price.

I did not check the voltages after the UPS shut down but I would suspect that it should still show good voltages.

[Anonymous user]

Just a quick update on this.

I checked the voltages of each battery pack and they are only showing 43-45 volts.  I would imagine that with two packs in series, it should be enough to at least provide power to the UPS if i unplug it and replug it back in.  But that is odd that its showing that low of a voltage.

The NMC went out before I was able to get the logs but I have ordered another UPS that I will test the batteries on. 

[BillP]

Were the batteries left connected to the UPS for the past few days? They may have discharged into the UPS. 43-45VDC is going to be too low to start the UPS now. Anything below ~80VDC is usually not good so we can try to charge them up if you do have another UPS.

[Anonymous user]

Yes, the batteries were left connected.  When I get the new UPS, should I just be able to plug the batteries into it and then leave it for a day or two to charge?

[BillP · Accepted solution]

Yes, but anytime you aren't actively using a UPS or it is not actively charging, always store it with batteries disconnected. We need to hope these charge back up - I am not sure if they are too far gone now.