self test creates overload

[roga]

Smart-UPS 1500: SMT1500RMI2U

Log excerpt:

• 2025-09-04 14:58:53 — UPS: Started a self-test

• 2025-09-04 14:58:59 — UPS: The load exceeds 100% of rated capacity

The unit started a self-test and then reported an overload. It did not automatically recover, so I had to go on site and manually reboot.

My concern is that the self-test seems to have caused the overload.

Would it be better at this stage to replace the battery, or replace the entire unit?

[Teken]

You’ll need to provide a lot more information about this specific unit for a definitive answer.

Provide the following information and logs via the NMC: Event, Data, UPS. Under the (About): NMC & UPS screen capture.

Call out the battery installation date and a photo of the RBC production date on the face of the cartridge.

All of the above information dictates next steps. 

Questions Ask . . . 👍

[roga]

I can only find 2 logs - I'll post at the bottom.

The battery was installed in January 2021 so is probably due a replacement, the unit itself is from 2013 which makes it 12 years old. 
I don't know how long one of these units is supposed to last but I don't think it would be worth buying a new battery for a 12 year old unit.
here is info from 'about:

Model:	Smart-UPS 1500
Serial Number:	AS1349112673
Firmware Revision:	UPS 08.8 / MCU 17.0 / UBL 08.5 / MBL 17.0 (ID18)
Manufacture Date:	12/04/2013
Apparent Power Rating:	1500 VA
Real Power Rating:	1000 W

Event log from the time:

2025-09-04	15:11:07	UPS: The output power is turned off.
2025-09-04	15:11:07	UPS: The output power is now turned on.
2025-09-04	15:11:07	UPS: The output power is turned off.
2025-09-04	15:11:07	UPS: The power for switched outlet group 1, Outlet Group 1, is off.
2025-09-04	15:11:07	UPS: The power for the main outlet group, UPS Outlets, is off.
2025-09-04	15:11:07	UPS: The load exceeds 100% of rated capacity.
2025-09-04	15:11:05	Environment: Restored the local network management interface-to-integrated Environmental Monitor (Universal I/O at Port 1) communication.
2025-09-04	15:11:05	UPS: Restored the local network management interface-to-UPS communication.
2025-09-04	15:10:52	System: Network service started. System IP is 192.168.200.41 from manually configured settings.
2025-09-04	15:10:36	System: Network Interface restarted.
2025-09-04	14:59:00	UPS: The power for switched outlet group 1, Outlet Group 1, is now turned off.
2025-09-04	14:59:00	UPS: The power for the main outlet group, UPS Outlets, is now turned off.
2025-09-04	14:58:59	UPS: The load exceeds 100% of rated capacity.
2025-09-04	14:58:53	UPS: Started a self-test.

And the data log:

Date	Time	Vmin	Vmax	Vout	Iout	%Wout	%out	FrqOut	%Cap	Vbat	Tups	T1ambC
2025-09-04	15:50:37	250.50	252.00	0.00	0.00	0.00	0.00	0.00	61.00	25.75	23.79	25.0
2025-09-04	15:40:37	250.50	252.00	0.00	0.00	0.00	0.00	0.00	61.00	25.75	24.29	25.0
2025-09-04	15:30:37	250.50	252.00	0.00	0.00	0.00	0.00	0.00	61.00	25.75	24.29	25.0
2025-09-04	15:20:37	250.50	252.00	0.00	0.00	0.00	0.00	0.00	60.00	25.75	24.29	25.0
2025-09-04	15:05:51	250.50	253.39	0.00	0.00	0.00	0.00	0.00	60.00	25.75	24.68	25.0
2025-09-04	14:55:51	250.50	252.00	252.00	1.50	29.89	24.68	50.04	100.00	27.25	25.18	25.0
2025-09-04	14:45:51	249.09	250.50	250.50	1.53	29.89	26.00	50.06	100.00	27.25	24.68	25.0
2025-09-04	14:35:51	249.09	250.50	250.50	1.50	30.50	24.68	49.93	100.00	27.25	24.68	25.0
2025-09-04	14:25:51	249.09	250.50	249.09	1.50	30.50	24.68	50.07	100.00	27.25	24.68	25.0

[Teken · Accepted solution]

Appreciate you providing the needed information and logs. Based on the information seen here the RBC has failed and needs to be replaced.

Having said this everything has a life cycle which you can review here:

https://www.apc.com/ca/en/faqs/FAQ000265093/

The average hardware service life is 7-10 years. As such you’re above the curve at 12 years of reliable performance & service.

Depending upon your specific business most have a refresh cycle of 5-10 years. As such, a decade plus (12 years) of service of anything especially a mission critical device such as a UPS should be considered for replacement.

The options are to replace the entire RBC, rebuild the RBC with new (HR) high rate battery cells, to replacing the entire unit.

Obviously finances plays a huge role as to next steps but if there is any doubt regarding the reliability & performance the unit it should be replaced.

Doing so provides you a new system, warranty, support, and latest improvements to the UPS technology.

If you decide to pursue this route I would have suggested to take advantage of the Trade-UPS Program to receive a modest discount on the next purchase but it has since been cancelled: 🤦‍♂️👎

https://www.apc.com/us/en/faqs/FAQ000275002/

NOTE: If you need to validate if the RBC is at fault vs the UPS. You may perform the following static / dynamic validation tests during a scheduled maintenance window.

Static Test: While the system is connected to AC mains. Disconnect the Anderson cable from the RBC. If the unit shuts down or drops the load than the UPS is faulty and needs to be replaced.

Dynamic Test: Simply remove AC Mains from the wall. If the system turns off shortly after or immediately the RBC is EOL and needs to be replaced. 

Questions Ask . . . 👍

[roga]

thank you for your advice It is actually very similar to my own thoughts - at 12 years old it does need replacing so thank you for your input