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Rework A UPS With Massive Capacity
Rework A UPS With Massive Capacity
Table of Contents
Step 4: Use it . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
http://www.instructables.com/id/Rework-a-UPS-with-Massive-Capacity/
Intro: Rework a UPS with Massive Capacity
Those UPS devices you buy for your computer usually have a gel-cell battery that lasts for a few years. Less if your power goes out a lot. When you replace them, you
pay a bundle, even if it's a standard cell. This short Instructable will demonstrate how to rework an older UPS for more capacity with cheaper battery power.
The picture shows some sample UPSs and an example of the gel cell from one of them. The UPSs come in various capacities and, although you can boost the capacity,
the output power is fixed. When you start out, make sure that the UPS you're going to modify will provide the volt-amps and power that you need. Also note that the volt-
amp rating is higher than the power rating. The difference is because AC powered devices have a power factor. Check online for more info about this. Another, similar
Instructable, also warns against trying to max out the capacity of your UPS because some use transformers that will run continuously at the rated output. It really
depends upon the quality of the UPS, but plan to run at not more than about 75% of rated output capacity.
Another thing to consider is whether or not your scrap UPS has AVR or Automatic Voltage Regulation. You'll want this if you can find it.
When you open the UPS box, you'll usually find either one or two gel cell lead-acid batteries. You're going to replace it / them.
Tools:
A drill with bit set
Crimper for the lugs
Wire stripper
Sandpaper or a small file to smooth out holes in plastic
Some notes on the parts: look at the pricing of the batteries and get the capacity that gives you lowest cost per amp-hour. Sometimes the 110-140 AH batteries are only a
little more than the 70-90 AH ones. Check warehouse clubs for good pricing. Sometimes you can reclaim the core charge with an old motorcycle or car battery you have
lying around. Make sure that what you get is a deep-discharge type battery. Some batteries are labeled as marine, but not deep-discharge.
Make sure that your battery has adapter studs that clamp to the lead posts. Then, get ring lugs from your hardware store, electronics store, or online store that will fit over
the threaded studs and also accept #10 wire.
You can either get two pair of mating spade lug connectors, or get one set that are the mating connectors to the ones that come from the UPS. In the picture, these are
the black and red wires that connect to the batteries.
Note the blue wire. The batteries are in series in this UPS, so it requires 24 volts (black terminal connected to red terminal). Do not try to power it with one battery if it
comes with two! Get two more ring lugs if you need two batteries.
http://www.instructables.com/id/Rework-a-UPS-with-Massive-Capacity/
Step 2: Tap into the UPS
Since the battery / batteries will not fit into the old case, you'll use the lugs and wire to extend the wires outside the case. In the picture here, I've replaced the spade lugs
that previously connected to the gel cells with connectors that I know will mate together and accept #10 wire. It doesn't cost much and it's easier than trial and error, so
spend the extra 25 cents.
Drill two holes in the side of the case. The holes only need to be large enough for the wire to pass through. You don't want the connectors to be able to sneak outside the
case, to be safe. Make sure there are no sharp spurs or edges around the holes that might cut or damage the insulation. Thread the wires from the inside out, with the
connection inside the case as shown.
As noted in the parts list, you'll want to keep the wires short to minimize voltage drop, but long enough that you can place the UPS and batteries comfortably near each
other and the device you're powering (computer, stereo, etc.). Lay everything out, including battery box(es) if desired, and clip the wires to an appropriate length.
If you have two batteries, make sure to cut a short piece of wire before you add the ring terminals to the other end of the wires you connected into the UPS wires in the
previous step. Make sure that this jumper wire is not too short if you are putting the batteries in containers (see end of article).
Note: You might have to ream out the inside of the ring terminals if you could not find terminals with the right inside diameter.
Once you know that the ring terminals will fit, crimp them to the red and black wire ends. If you have two batteries, make the jumper with the other two ring terminals and
the small piece of wire you cut off.
Connect the red wire to the positive terminal of one battery. Connect the short jumper between that battery's negative terminal and the positive terminal of the other
battery. Then connect the black wire to the negative terminal of the second battery. If you do not connect them this way, you will not get any power into the UPS.
http://www.instructables.com/id/Rework-a-UPS-with-Massive-Capacity/
Step 4: Use it
That's pretty much it. Simple, right? The hard part is finding the right parts and connecting everything in the right order without welding anything.
1. You are using lead-acid batteries. In the photo, I've shown a plastic layer under the batteries. Even though marine batteries are typically sealed, you do not want to
take the chance of a leak. Spend $8 - $20 and get a plastic battery box for each battery you use. It will protect the batteries ... and your floor.
2. In the first step I claimed this would improve the capacity, massively. By how much you ask? The largest gel cells I've found in UPSs are 20AH. Others are more like 7
AH. Using an 85 AH marine battery to replace a 20 AH gel cell, you should expect to get at least four times the runtime. HOWEVER, do not plan to run the batteries down
by more than 50% or you will severely shorten their life. Figure more than a doubling of capacity, but less than 4 times. If you use a 115 AH battery, figure at least 3 times
the run time and a much longer battery life.
3. I have not had any problems with the UPSs recognizing the new batteries or keeping them charged. If you have the UPS monitoring software, use it and try some tests.
See how long your new rig will run before hitting the 50% charge level.
Expect the total cost to be about $80 for a single battery setup with 85 AH battery and battery case. Double battery setup with 115 AH batteries should be about $160,
max. These are using battery prices in summer 2009. Battery prices spiked briefly last year, but have come back down.
Related Instructables
http://www.instructables.com/id/Rework-a-UPS-with-Massive-Capacity/
Comments
50 comments Add Comment view all 66 comments
There's another build thread that showed a melted UPS after connecting a car battery to it, but I can't find it anymore.
People just gotta start on a good platform, no point upgrading a crap UPS. The 1250VA unit I'm using now was free. Just check out garage sales,
craigslist, and localy on ebay. If you work in a large office, talk to someone in IT, they normally pay companys to dispose of this type of
equipment.
http://www.instructables.com/id/Rework-a-UPS-with-Massive-Capacity/
You see it's been a custom of sorts for companies in Yankeeland to ship only within the continent (many times they don't ship
even to HI, AK or outside territories). They aren't the only ones to do this on eBay though, but the US companies seem to do it
with e-shops as well. I could circumvent this limitation per se but it wouldn't be feasible for small amount of goods. So my
options are pretty much limited. Still, this issue isn't that pressing for me. Thanks for the tips though.
My understanding from my research so far is that even most sealed batteries are valve regulated thus allowing a little gas to vent. This is only if you over-
charge however and I think UPSs should be pretty good at avoiding this. I will make or modify a box for my rig, ventilate it well and I will place it in a big airy
part of the house. I found heaps of info from battery university - google it. Also, I think you should avoid calcium infused lead acid batteries because when at
100% they typically sit at a higher voltage than non-calcium which means that the chargers in UPSs may not charge them fully.
I add only one warning which has been said here before repeatedly:
The bigger battery is for stand-alone power or added runtime - NOT for supporting a load beyond about 60-70% of the UPS's rated capacity.
The hydrogen gas released by any lead/acid battery has a very obvious odor and is unlike anything else -and I have never, never, never had any problem
doing this indoors.
Solar enthusiasts:
If you seek out your local PC recycling freak who has connections with places that recycle servers and big UPSs you can use those super-high quality
inverters with your batteries and save a bundle instead of branded solar-only inverters.
Last word of my opinion on this matter -> this IS the Instructables site for DIY'ers and if anyone who reads these is too afraid to experiment and learn by
doing then this I would recommend ONLY buying ready-made, UL approved devices and leaving the DIY to enthusiastic DIY'ers.
Happy DIY'ing !
http://www.instructables.com/id/Rework-a-UPS-with-Massive-Capacity/
Surferdude says: Nov 10, 2009. 7:01 PM REPLY
This isn't a big problem. It's only after discharge and amount depends upon charging efficiency. The Hindenberg was filled with it. This is a small
amount and it dissipates in the air enough that it's not usually flammable unless you enclose it in a small volume that does not breathe. You also would
have to have a source of ignition.
If it's in a closet, it's not likely to be plugged in - most closets don't have outlets and said wife, husband, girlfriend, or boyfriend that made you hide
it isn't likely to want a thick cord running from a wall outlet into a closet, and then more cords coming out of the closet into a nearby computer,
monitor, etc.
Caution yes. OCD no. If people read the article and comments and recognize the limits, they can avoid the pitfalls. That's what this is all about.
You can find some hazard in just about everything posted here, but then you wouldn't do anything.
http://www.instructables.com/id/Rework-a-UPS-with-Massive-Capacity/
Forcelord50 says: Sep 3, 2009. 1:24 PM REPLY
With a nice new Core i7, SLI graphics cards, and a dual monitor setup for a computer system, yup some people would.
Bryan A. Thompson
bryan@batee.com
http://batee.com/projectsanddesigns/offgrid/upsinverter.htm
http://www.theinstallbay.com/product_section.php?pn=1
http://www.instructables.com/id/Rework-a-UPS-with-Massive-Capacity/
Crash2108 says: Sep 3, 2009. 3:22 AM REPLY
Oh, the irony. You're terrible at those things.
http://www.instructables.com/id/Rework-a-UPS-with-Massive-Capacity/