Back-UPS Pro 650 BP650S with New Battery: 0 Estimated Run Time, Status=Battery Discharged

[BillP]

I just installed a new battery in the unit and, even though Powerchute (9.1) shows 100% battery charged, it also shows status as Battery Discharged with zero estimated runtime.    

I have tried the "brain-dead" reset by unplugging, removing/reinstalling the battery and that initially worked after restarting with no load.  But then I shutdown and restarted with the normal load and I am back to battery discharged status, zero runtime and zero battery charge.    What is the solution here? 

[PS: my unit is an older one with serial only connection;no USB]

[Anonymous user]

Since this unit is basically a pared-down Smart-UPS, a runtime calibration probably needs to be performed. This can be done in software (by using the old Powerchute Plus or issuing commands directly to the UPS through a terminal emulator) or hardware.

To calibrate the unit using hardware, you'll need some dummy loads (a few incandescent light bulbs work well), a properly grounded outlet, an outlet strip with a switch and the UPS itself. The unit should be fully charged (ignore what it is reporting) by having been plugged in for at least eight hours prior. A connection to ground must be maintained throughout this process!

Safely power down any load that is presently attached to the UPS. Turn the UPS off and disconnect it from the wall outlet. Plug the outlet strip into the wall outlet and plug the UPS into the outlet strip. Turn the outlet strip switch ON. Connect your dummy loads to the UPS: whatever you choose to use must load the UPS to at least 30% of its capacity. A somewhat heavier load is OK. The load should be fairly constant during this entire process.

Turn on the UPS and let its self test complete. Turn on the dummy loads or plug them in to the UPS if you haven't already. Turn off the outlet strip. The UPS should start running on its battery immediately. Let it run until it shuts off.

When the UPS shuts off, the runtime calibration will have been completed. Turn the outlet strip's switch back on and let the unit charge itself back up. (The UPS will charge its battery any time it is connected to power.) It may then be placed back into service.

Sometimes it is possible, even after a successful runtime calibration, that these units won't notice they have a new battery. I'm not sure if this unit's similarities to a Smart-UPS run to its having a so-called battery calibration constant value or not. I believe they probably do, but haven't checked my own BP280S to verify.

[BillP]

The PowerChute Business Edition software I am using has a runtime calibration mode; can't that be used?  If not I will do the hardware calibration.

[voidstar_apc]

It might work, but the UPS could refuse to start the runtime calibration this way because it thinks the battery is flat. William's approach of turning off a power strip feeding the UPS doesn't give the UPS any choice in the matter: it must operate on battery for as long as it can.

If it does work, you'll still need to ensure the UPS is fully charged before starting the runtime cal, and make sure it's loaded at least 30%, same as above.

[BillP]

Ok.  I'll go the hardware route.   A Sony PS3 should provide the right load.

[Anonymous user]

A Sony PS3 might work, but the problem with electronic and computer loads is their widely varying power draw. (There's also the matter of such loads being rather highly inductive, rather than simply resistive where current drawn is far easier to figure accurately.) You want the load to remain as constant as possible during the calibration, so that the UPS's microcontroller can more accurately "learn" about the new batteries and their capabilities.

[BillP]

I proceeded with the electronics loads as I don't have many incandescent lamps these days - they have all been replaced with LEDs and CFLs which don't draw much.   At any rate it worked well - finally.   I may redo it with some incandescents per your note but I hate to stress those batteries again.  

I really appreciate the help.  This forum speaks very well of APC/Schneider.  I won't forget it when I go shopping for another UPS (rather soon I think).

[Anonymous user · Accepted solution]

I'm glad to hear that you got it to work. I wouldn't worry about doing it again if the unit appears to be operating normally.

Most of the incandescent lamps here have been changed out long ago for more efficient types, but I keep some moderate to higher wattage lamps around for these "special purpose" tasks. If you could find one small enough, a plug-in heater would also work fine as a "dummy" load.

If your question has been answered to your satisfaction, please feel free to mark the "helpful" or "answered" options on this post as appropriate.

[BillP]

Just a final note.    

The unit continues to operate normally.   However, a few hours after the first runtime calibration with electronics devices as load the UPS reverted back to previous state of battery discharged and zero runtime.    So I recalibrated this time with  two incandescant lamps (60W + 150W) making sure that the UPS got 8 hours of continuous charging before the calibration and 5 hours afterwords.  It has been working normally now for about 4-5 days.   It would appear that your suggestion to calibrate with purely resistive loads is a requirement and not an option at least for this UPS model.