xl3000 fails to go online, load and battery charge leds flashing

[toddbailey]

Hi Just acquired a sua3000xlrm3u usp.  it has new batteries but fails to go on-line

self test results in both load and battery charge leds to flash. from my research this indicates a internal failure/  with out hiring out for a repair. is there any documentation on the internal workings or other materials I could reference to assist in the repair of this?

[Teken]

I would start by obtaining a copy of the legacy Power Chute Plus software. Once installed and connected to a computer using the APC proprietary serial cable see if the active fault / error codes are called out by the system. 

Once known submit the fault code to APC Technical Support to identify what that code means and report back that information. 

More than likely they will just tell you it’s an internal fault with no further details. 🤢 If you’re so inclined to open and look for any obvious component faults. 

The vast majority of failures in these legacy units are welded relays, leaking capacitors, and failed power transistors. The odd time you will see a blown fuse, zenor diode, resistors. 

In most cases Joe Public just replaces all the relays, capacitors to start. If that doesn’t correct the problem than you need to break out the DMM & Scope! 

Replacing any obvious components that show over heating, discolouration, or measure out of specification. 

Let us know what you find out from APC Technical Support as it relates to any error codes. Along with your next steps as to trash & go or repair. 👍

[toddbailey]

but with out any schematics and repair documentation, the repair is orders of magnitude more difficult

[toddbailey]

this is an ongoing saga with round 1 leaving me very disappointed with apc tech support.

they say that since the ups model was canceled late last year they won't discuss any diagnostic info with me.

Nor will they release any service, design or even basic schematics, I'd be happy to approve a NDA if it ment getting the system back on line sooner rather than later. All they did was email me sales info on the latest models.

Seriously, If I wanted to drop $3500 on a new ups why would I be shopping ebay and others?  APC may be a top class producer of ups systems but their customer relations and tech support policies are abysmal.

At this point I'm not sure if replacing relays is worth while.  sure they are pretty cheap, i can replace all 5 of the 30 amp 832A-1C-S-24 relays with the higher capacity 40 amp 832HA series for about $15.  but if that fails to resolve the issue, then what?  With out some form of service docs I'm limited what I can do.

[Teken]

APC Technical Support was never going to provide you any hardware schematic to allow you to diagnose / repair the unit. 

Im surprised they would not provide you any information as to what the LED codes mean though. 🤢👎

As stated above you should contact them to receive a copy of the legacy Power Chute software for this unit. Using the supplied proprietary serial cable or one you’ve made and tested to work.

Connect it to a computer to see if any active faults / error codes are declared. In the interim you may consider doing a Brain Dead procedure to see if the unit behaves differently:

https://www.apc.com/us/en/faqs/FA156611/

Let me know what you see and observe after completing the brain dead procedure. 👍

[toddbailey]

I don't have APC's proprietary serial cable, but I have downloaded the linux version of Power Chute. Still trying to find the user guide that outlines it's use.  I have found posts that indicate the flashing of load and batt charge indicate an internal failure 1 being one of more relays are bad.  Being somewhat easy to test this will be my starting point.  I also need to find a wiring diagram to the serial-usb cable

[toddbailey]

already did the various reset attempts with no change.

there are 5 identical relays so it will be fairly easy to locate a failed one.

Hopefully that is all that is wrong.  If not I'll have to return the ups to the seller and try a different vendor.

[Teken]

Please review this pin out resource guide to make your own Serial cable: 

https://pinoutguide.com/UPS/#APC

NOTE: It’s imperative to note an incorrect wired cable will shut down the UPS! ☝️

[Teken]

Take a few moments to review some of the APC Schematics as it relates to the Smart-UPS Series of hardware. You’ll see the topology, values, and the other expected voltages are very similar.

This will give you a better idea of what to see and measure when probing your specific unit:

https://elektrotanya.com/showresult?what=APC&kategoria=&kat2=all&page=3#res

[toddbailey]

All apc would do is send me sales info on their latest offerings. They would not share and service or technical info such as schematics etc.  I eventually sent the unit back to the seller and purchased a similar ups and now have a new problem to deal with. On a xl3000 ups the load indicators do not illuminate.

[toddbailey]

By any chance do you know the wiring for this "proprietary" usb to serial cable?  is it truly proprietary or just a common usb to serial cable?

[Teken]

The USB port on the back of the unit should be able to use a standard cable. The serial port however uses the APC proprietary (internally wired differently) cable which you can either purchase or make your self.

If you attempt to use and connect a standard RS-232 Serial Cable it will shutdown the UPS! ☝️

In my previous reply I provided a resource link to make your own serial cable. 👍

As to your (New Problem) regarding the load LED not lighting up. Does the unit power the connected loads without issue? Are there any errors / faults present on the LED Panel or beeps?

If the answer is (No) than try to add more load to the system. The LED is not very accurate as to power draw so add something to see if the LED percentage increases.

This leads me to the next thing to affirm which is to ensure you get that unit connected to a computer running APC Power Chute software as you need to reset the battery counter by entering the new installation date.

Doing so will reset the internal battery expiration counter and force the system to use the new charging tables. 

Once the battery installation date has been changed. Initiate a manual self test and let it pass.

Wait for the system to indicate a 100% battery charge. Than initiate a battery calibration through the APC PCBE software.

Ensure there is at least 30% attached load on the output. Once that process has completed let the system recharge the cells.

Once complete the battery capacity will be more accurate and the system will be able to give you a better operational runtime remaining counter in PCBE.

Let me know if you have more questions - Cheers! 👍