Multiple BX900R Units with Issues

[Anonymous user]

I recently purchased 5 BX900R units at OfficeMax. Date of purchase was 8/20/2010. 3 of the 5 are having issues.
I can post serial numbers if needed, but according to the inspection slip inside the box, all were manufactured between 08/2007 and 02/2008. I will summarize by arbitrary unit #.

Unit 1: Plugged in and tested for a day when I was home (I've since moved and left it behind) but it appeared to be functioning normally.

Unit 2: Put in service ~9/01/2010. Connected to midrange computer and LCD monitor. Average load 175-210W according to PowerChute. Battery charged to 77% in about a day and has sat there ever since, still says battery is "Charging."

Unit 3: Put in service ~9/01/2010. Runs my Linksys router, a network switch and cable modem. 15W total. Battery charged to 98% in about a day and has sat their ever since, still says battery is "Charging."

Unit 4: Attempted to put into service 9/18/2010 connected to LCD TV. Powerchute reported 75W load, battery at ~45% and charging. Unit ran for about 10 minutes, then overload light came on, I believe constant with a short flash every so often, buzzer sounded continuously, load disconnected. I disconnected all loads and restarted unit. Ran again for about 5 minutes, reported battery charging, then went into "overload" again, with no load connected to UPS. I removed the battery and checked the voltage. It was about 23, technically dead. I bought a battery maintainer and fully charged each cell. Reinstalled battery pack today (voltage was 26.02). Reconnected unit with 50W lamp as load. Unit reported battery at only 64% and charging. Ran for about 10 minutes again and then went into same fault condition.

Unit 5: Put into service 9/23/2010. Battery was completely dead out of the box (one cell ~8.5V, other ~11V). Put unit 5 battery on charger and installed fully charged unit 4 battery in unit 5. Connected 50W lamp as load again. PowerChute reported battery 98% charged. Battery charged to 100% after being plugged in for about 20 minutes, unit reported battery "Charged." Disconnected AC power and let unit discharge with 50W load to ~70% then reconnected power. Battery has been charging now for about 1.5 hours and is back up to 85% and slowly climbing. So unit 5 appears to be operating normally.

Please advise on units not fully charging and unit faulting out.

Thanks.

[BillP]

just leave it as is - it is most likely charged but reporting incorrectly (assuming you let it charge up since you last tested a discharge with it).

[Anonymous user]

OK, The replaced unit is working great and APC sent me 3 new batteries for the other units.

I replaced the batteries in all three at the same time. Turned off unit, disconnected from power, pulled batteries, hold power button for 5 seconds to reset unit per APC tech, installed new batteries, reconnected to power and turned on and let charge for ~5 hours with no load. One unit charged to 100% and has been happy there ever since, reporting fully charged. The other two seem obsessed with 91% for some reason. Both charged to there and stuck. I let them charge for an additional day and no change.

I connected about 180W of resistive lighting to one and killed the power and let it discharge completely (until the unit turned itself off). Let it recharge with no load, stuck at 91% again.

Pulled the battery of the unit and charged each cell individually on my Battery Tender until fully charged. Then I put them both on the charger in parallel to make sure the two cells were as balanced as possible. Reinstalled, still read 91% and would not charge any higher. Connected 180W again and let unit discharge down to about 70%. Reconnected power and disconnected load. Unit charged to 100% and sat there for about 3 hours. Then dropped to 98% before I went to bed last night. Got up this morning and it was back to 91%...........

On the other unit, I just tried killing power and letting it discharge down to about 75%. Recharged to only 91% again..........

Am I missing something....... what is going on here....?
Thanks

[Anonymous user]

Ok, APC was very helpful and is sending me a replacement for the unit that was faulting out.

As for the not fully charging issue, they first wanted me to try resetting the UPS or whatever they call it- unplug everything, remove battery, hold the power button for 5 seconds, then reconnect battery and plug it back in with no load and let it charge. As can be expected, this didn't work. What is the chance they will send me new batteries? Surely they can't expect the customer to be responsible for checking the date of manufacture before purchasing.....

Thanks.

[BillP]

as long as you have a valid proof of purchase, then we will go by that as far as warranty.

[BillP]

does it say 91% charging or just 91% and indicate that its fully charged. its probably just a cosmetic thing.

i would be concerned if the runtime does not live up to what it should support.

either way, i would try a full discharge with no software or data cables attached and let the UPS turn off, then let it charge up to try and do a sort of calibration. let's see if it lasts the amount of time that it should. if it doesnt, then that is concerning. if it does, then i'd have to assume the unit was just not calibrated properly at the factory but i am not sure i am 100% right on that if they used to go to 100% at some point.

[Anonymous user · Accepted solution]

The one displays 91% charging in powerchute. The other is an untangle box running apcupsd and it doesn't say charging or charged, just that the batt level is 91%.

Runtime appeared normal with the 180w lighting load. I didn't time it or compare it to powerchute but it ran for 20-30 minutes which seems fine. I was monitoring in powerchute the whole time.

I will try running down with no data cable and see what happens. Should I leave the battery as is or fully charge it externally first?