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Thread: UPS getting too hot

  1. #1
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    Default UPS getting too hot

    I've been using an Apollo 1200VA ups with 2x12v 70ah powder battery.
    This setup has been running well for more than a year.

    Now I've setup another power guard 650 va ups with a single 12v 70ah powder battery.
    This one is used to power a single ceiling fan only.
    But the problem is, the ups is getting too hot when in battery mode.

    I ignored the heat and continued to run it. But after running in battery mode for about 3 hours, burning smell started to come out of the ups.
    The transformer area is getting hot only.

    So, what is the reason? My 1200va ups is running without such problem and can handle higher load (my pc, couple of bulbs, two fans) just fine for hours.

    Any suggestion please?

    Mentioning a few people. Hope you won't mind.

    Edit: if you are wondering what is a powder battery.
    https://exportscooter.en.alibaba.com...are_parts.html
    Last edited by Badhon_raj; May 29th, 2018 at 06:29.

  2. #2
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    Quote Originally Posted by Badhon_raj View Post
    I've been using an Apollo 1200VA ups with 2x12v 70ah powder battery.
    This setup has been running well for more than a year.

    Now I've setup another power guard 650 va ups with a single 12v 70ah powder battery.
    This one is used to power a single ceiling fan only.
    But the problem is, the ups is getting too hot when in battery mode.

    I ignored the heat and continued to run it. But after running in battery mode for about 3 hours, burning smell started to come out of the ups.
    The transformer area is getting hot only.

    So, what is the reason? My 1200va ups is running without such problem and can handle higher load (my pc, couple of bulbs, two fans) just fine for hours.

    Any suggestion please?

    Mentioning a few people. Hope you won't mind.

    Edit: if you are wondering what is a powder battery.
    https://exportscooter.en.alibaba.com...are_parts.html
    You are using line interactive UPS. They are designed for short run. Higher capacity line int. UPS can withstand longer run time depending on mosfets configuration and cooling system which is why your other ups is doing ok for now. The regulators that converts DC to AC will eventually burn out on your small UPS if you keep pushing it. This is why you either need a IPS with built in UPS mode or a True Double conversion Online UPS. I would choose the former for most bang for the money. You will most probably experience occasional restart for the IPS UPS system on high load though.

    However your 1200 UPS will almost never be able to charge those massive batteries. Your charging system might wear out soon because those small mosfets are in use all the time. Your UPS can probably charge at 2 amp at best whereas your batteries need at least 7 to 8 amp ( assuming they are in series and 24V setup, if 12V then you will need 14 to 16amp of charge current). You will need DC Clamp meter to measure charge current & they cost about 3 to 4K. Considering current electricity situation in Dhaka, Which I believe still the same as it was 2 years ago, you will never be able to charge those batteries properly and they will wear out preTTy fast.

    If you can charge your batteries externally, they will last much longer and you will get much better run time. Just make sure not to mix different batteries.

  3. #3
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    Quote Originally Posted by minitt View Post
    You are using line interactive UPS. They are designed for short run. Higher capacity line int. UPS can withstand longer run time depending on mosfets configuration and cooling system which is why your other ups is doing ok for now. The regulators that converts DC to AC will eventually burn out on your small UPS if you keep pushing it. This is why you either need a IPS with built in UPS mode or a True Double conversion Online UPS. I would choose the former for most bang for the money. You will most probably experience occasional restart for the IPS UPS system on high load though.

    However your 1200 UPS will almost never be able to charge those massive batteries. Your charging system might wear out soon because those small mosfets are in use all the time. Your UPS can probably charge at 2 amp at best whereas your batteries need at least 7 to 8 amp ( assuming they are in series and 24V setup, if 12V then you will need 14 to 16amp of charge current). You will need DC Clamp meter to measure charge current & they cost about 3 to 4K. Considering current electricity situation in Dhaka, Which I believe still the same as it was 2 years ago, you will never be able to charge those batteries properly and they will wear out preTTy fast.

    If you can charge your batteries externally, they will last much longer and you will get much better run time. Just make sure not to mix different batteries.
    Thanks for the nice explanation. I was really expecting a reply from you.
    I charge the batteries externally on the 1200va ups. So I guess I am safe there.

    for the small ups, it's getting hot within 15 minutes in battery mode. But it used to run for 25-30 minutes just fine with it's original battery.
    That's why I was wondering why would a larger battery affect the UPS/transformer.

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    Quote Originally Posted by Badhon_raj View Post
    Thanks for the nice explanation. I was really expecting a reply from you.
    I charge the batteries externally on the 1200va ups. So I guess I am safe there.

    for the small ups, it's getting hot within 15 minutes in battery mode. But it used to run for 25-30 minutes just fine with it's original battery.
    That's why I was wondering why would a larger battery affect the UPS/transformer.
    Buy a long backup UPS from Micro for 30k. 2 hours backup on full 700w load. Its an investment that will serve you minimum 4-5 years.

  5. #5
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    Quote Originally Posted by Badhon_raj View Post
    Thanks for the nice explanation. I was really expecting a reply from you.
    I charge the batteries externally on the 1200va ups. So I guess I am safe there.

    for the small ups, it's getting hot within 15 minutes in battery mode. But it used to run for 25-30 minutes just fine with it's original battery.
    That's why I was wondering why would a larger battery affect the UPS/transformer.
    my guess would be the mosfets are already half fried. To prove this, if you hook up your original batteries you wont get the same runtime anymore.
    Last edited by minitt; May 31st, 2018 at 09:41.

  6. #6
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    Quote Originally Posted by VANGUARD View Post
    Buy a long backup UPS from Micro for 30k. 2 hours backup on full 700w load. Its an investment that will serve you minimum 4-5 years.
    Unfortunately don't have that much of a budget.
    My current setup costed 11.5k in total.

    Quote Originally Posted by minitt View Post
    I guess would be the mosfets are already half fried. To prove this, if you hook up your original batteries you wont get the same runtime anymore.
    :'( the backup time already has been reduced to 10-15 minutes, but I guess that was because the battery got old.
    anyway, I'm planing to buy a locally made IPS/UPS unit and hook it up with the battery. It'll cost 4.5k. I guess this would be the cheapest solution now to run one ceiling fan and couple led bulbs.

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