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Guide: Adding Extra Run-Time to Your UPS - Reassembly and Final Configuration
Written by Gizmo   
Monday, 30 January 2006 00:00
Article Index
Guide: Adding Extra Run-Time to Your UPS
The Operation
The Operation - Removing the Face-Plate
The Operation - Removing the Battery
The Operation - Opening It Up
The Operation - Exposed Wiring
The Operation - Changing Connectors
The Operation - Splicing
First Smoke Test
Build the Battery Pack
Build the Battery Pack - The Wiring Harness
Second Smoke Test
Reassembly and Final Configuration
Reassembly and Final Configuration - Calibration
Reassembly and Final Configuration - All Done
All Pages

Reassembly and Final Configuration

Now you can put your UPS back together, in reverse order from when you took it apart. Once you've got it all back together and the internal battery pack installed, reinstall your UPS into your system for normal operation, connect your external battery pack, and power it up. If you have done everything properly, you will be rewarded by seeing your systems come back up and your UPS running normally. If ANYTHING seems out of the ordinary, SHUT DOWN IMMEDIATELY and reinspect all of your work. NOTE: It is normal at this stage for your UPS to think that your batteries are either somewhat or completely discharged. If this is the case, wait for your UPS to finish recharging before you proceed to the final step. Depending on how much capacity you are adding to the system and the charge state of the batteries, recharging could take anywhere from an hour to a day, or even more. An easy rule of thumb is that if your system previously took an hour to recharge and you just doubled the battery capacity, it may take upwards of three hours to recharge now. If it takes longer than 6, there is a problem.

When your system is up and running and the batteries have fully recharged, you will need to do one of two things:

  1. Run APC's battpack utility to tell the UPS that it has additional battery capacity, or

  2. Run a terminal emulation program like HyperTerminal and manually configure the UPS directly.

As APC's utility is both documented and, err, problematic when used on 'unsupported' UPSes, I will describe the process of configuring the UPS manually.

First, according to APC you need a Smart-Signaling cable to be able to do this. I don't know if this is true or not, although I've heard that it isn't. I haven't been able to test it, because all of my units have Smart-Signaling cables. Oh, and if you've got a UPS that only has a USB port, umm.........I don't know what to tell you.

Stop the services that normally communicate with the UPS. If you are running APC PowerChute, this should be the APC PBE Agent and the APC PBE Server.

Bring up HypterTerm. Open a connection to the appropriate COM port (mine is on COM1). Configure for 2400 baud, 8 bits, No Parity, 1 Stop bit, No Handshaking.

Connect to the UPS, and type the character 'Y', without the quotes. The UPS will respond with 'SM'. Now type the character '>'. The UPS will respond with a number representing the number of external battery packs it knows about. If you have had no external packs before now, or this UPS was not originally designed for external packs, the number will be '000'. Now type the character '+' for each battery pack equivalent that you have installed. For example, if you added a battery pack consisting of two 18 AH batteries to this system, you would type the '+' one time. If you added two battery packs, each consisting of two 18 AH batteries, you would type the '+' twice, and so on. Typing '-' will remove one pack. Each time you type '+' or '-', the UPS will respond with 'OK'. When you have configured the correct number of battery packs, type the '>' again, and the UPS will respond with the number of packs it is now configured for. That's all there is to it. Disconnect from the UPS, shut down HyperTerm, restart your UPS services, and run your UPS management software.

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