Assemble an APC RBC7 Smart UPS Battery
Every year, many UPS units are thrown out due to dead batteries. 700VA/XL to 1500VA size APC Smart-UPS's are high quality units and battery replacement is economical if you assemble your own battery pack. With a bit of work, you can replace the battery pack for about half the cost of buying the original replacement from APC.
This instruction is for assembling RBC7 type battery for use in (but not limited to) American Power Conversion/APC SU700XL, SU700XLNET, SU1000XL, SU1000XLNET, BP1400, SUVS1400, SU1400, SU1400NET, SUA1500, SUA1000XL and SUA750XL
Warranty is not even a matter of consideration, because APC covers the entire unit, including battery, for two years, and after that, the warranty expires anyway, so there's no warranty issue from using a self assembled battery after that point in time.
Steps
- Remove the dead battery pack from the unit. On the APC Smart UPS 1000, 1400 and 1500 series, the front plastic face is pulled away from the box by flipping it downward and lifting it away - just look for the cutout on one edge and start pulling there. Next, there will be two screws to remove from the top corners of a metal plate which is behind the front face, and then also flip downward this metal plate to reveal the batteries. The 1000 series has smaller batteries than the 1400 and 1500. You will need to power off the UPS to replace the batteries if there is any charge left in them.
- Check new batteries with a digital voltmeter. If either is less than 12.55v, they've been sitting around too long and are likely ruined already. Return to supplier.
- Carefully remove the two plastic covers on two ends. Remove the plastic block(100A fuse)joining the two halves together, then remove the cable.
- Save the removed parts!!
- Option #1: Lightly sand the face of both batteries on the side closer to the terminals. This is a step that should be performed per Plastic Weld® instruction manual.
- Squeeze about 1/4 the content of the Plastic Weld® and prepare the adhesive per packaging. Evenly apply adhesive to one battery as pictured. Stand up the batteries on a flat surface and join the two batteries together with terminal side facing each other. Let it cure for 30 minutes.
- Option #2: Set the batteries side-by-side, terminals together as with the factory battery. Apply strips of Gorilla Tape (duct tape) along each edge of the battery, pulling the tape tight across the joints. I did mine this way and it was completely stable- and ready to use in 2 minutes.
- Install the cable, then the fuse, as pictured. Do not install the fuse first as doing so increase the chance of shorting out the battery while installing the cable.
- Use double sided tape or packaging tape to attach the terminal covers. Or just stick them back on if the original adhesive is sufficient to hold the covers in place. These are sealed batteries so there is no danger of leakage- the covers are to prevent accidental contact with the terminals.
- Put the UPS back together following the instructions from step 1.
- If you want to avoid the hassle of glueing the batteries, you can purchase pre-glued and harnessed RBC7 compatible replacement battery cartridges.
- Turn on the UPS, pull the plug and make sure it runs on battery power.
- Let the new batteries charge overnight.
- Now, you need to calibrate it, so the runtime and capacity indicator reads accurately. The UPS should be loaded to 30-50% of the rated watt capacity. For 1000VA/~650W and 1500/~950W model, 300W halogen floor lamp works well.
- Connect a 30-50% non-varying load to the UPS and disconnect power to the UPS. (Rather than pull the plug, it's best to disconnect power with your circuit breaker or a power strip. See below in Tips.) Let it run until it shuts off completely. Ignore all beeping. It should take about 45 minutes to an hour.
- Immediately start charging. Let it charge overnight. The UPS is now ready to be put into service.
Tips
- Installation of fuse and cable to newly assembled pack: Cable first, fuse second.
- Make sure you set the batteries on a level surface when you join the two together and line up the sides at the same time. You have about four minutes to adjust the alignment. If Plastic Weld® sets misaligned, you will not be able to correct it.
- Removal of fuse and cable from dead pack: Remove fuse first, cable second.
- For testing and calibration, throw your circuit breaker, or plug the UPS into a power strip that does not disconnect ground and turn the power strip switch off. Doing this ensures the UPS maintains ground, which is important for calibration.
- For really long run times, you may elect to use car/marine batteries from your local auto parts store (deep cycle are the best). Keep in mind these may produce hydrogen gas while charging, so they must be vented or located where this flammable gas cannot accumulate.
Warnings
- The batteries have enough current capacity to cause a fire and serious injury if you accidentally short them.
- If you don't let the batteries charge up immediately after use, they will be ruined in a short order.
- This type of battery is mostly made of lead and dangerous acid. It is unlawful to dispose of them in the trash. Many auto parts stores, battery stores, and recycling centers will accept spent batteries for free. If you're replacing a large amount of battery packs, arrange the disposal of dead batteries with your battery distributor.
Things You'll Need
- Obtain two generic batteries.
- sandpaper
- Plastic Weld® or equivalent adhesive and tape
