How to test an UPS system (PWJ219)

Uninterruptible Power Systems UPS must be tested after replacing batteries or for periodic maintenance. Here is my selfmade 1500W test load. Incandescent lamps are the cheapest high watt resistors you can get. But you can’t get them any longer, so hurry up 😉

[@ArztvomDienst]

Haha that is a pretty straightforward approach ^^ UPD1500 - Universal Power Dump haha

[@PlaywithJunk]

Good name 😉

[@graemedavidson499]

Gosh that is bright! It needs a Sun logo on it…

[@PlaywithJunk]

Maybe I have an old Sun badge somewhere but I fear it would melt

[@graemedavidson499]

@@PlaywithJunkAhh, maybe needs one made from (T)Itanium but beware the Sparcs inside!

[@saschah.26]

Great and simple solution for a real workload to test. for single heaveer work loads i used a heating plate . small one 1000w big one 1500w and together 2500w.

[@leopiipponen7693]

Try use braking resistor unless bulbs not are available... work nice too :)

[@PlaywithJunk]

yes but they are much more expensive

[@mumiemonstret]

That was a bright idea!

[@nucleochemist]

On smaller UPS that are used around home / non critical applications I like to remove the batteries and then test them under a load (2 small halogen lamps) and watch their voltage/current while they discharge. Can then compare to spec sheet. But my biggest UPS has 8x 12v 7Ah SLA batteries and this is too time consuming. Instead I just timed how long it can run a 500 W load with new batteries and test it every year to see how it declines. Your bulb box seems like an awesome solution for testing a range of large UPS outputs in the workplace!

[@colinstamp9053]

Nice solution! You could save on switches by wiring the bulbs in binary weighted groups. Then you could have up to 15 bulbs with only 4 switches.

[@PlaywithJunk]

But I had those switches for free….

[@colinstamp9053]

@@PlaywithJunk Imagine the resolution you could get with 10 switches! Just need to find 1023 1.5W light bulbs, or 1x1.5W, 1x3W... I think my medication may be overdue. 🙂

[@SproutyPottedPlant]

2:09 those fans sound so nice together ☺️ I bet someone with perfect pitch or an instrument nearby could tell us what chord they are playing 😃👍

[@RBLevin]

Very cool. An LED display on the front panel that shows the load would be useful.

[@PlaywithJunk]

There is a neon bulb display inside the switches. It tells me the power with 10% accuracy 😉

[@Troppa17]

Good use of obsolete bulbs. 👍 Has to be for over 10 years now in Switzerland afair. But don't leave it running unattended. 😅

[@PlaywithJunk]

Ah... someone who can read Deutsch :-)

[@benbaselet2026]

I have a couple of those 1500 and 3000 UPSes, I just run cpuz in stress test mode on the servers to make some load to the units for the battery calibration test :) You can just hook up electric heating coils instead. My Sauna has 6,6 kW heat from 3 phases so one phase is a pretty good load for one UPS. Just don't touch the red hot metal bits when in use :)

[@PlaywithJunk]

Sure… but I have no space here for a sauna 🙂

[@benbaselet2026]

@@PlaywithJunk You just need the heating element :D

[@PlaywithJunk]

Is it more expensive than 10x $2 ?

[@benbaselet2026]

@@PlaywithJunk New ones are about 40 euro per 1-2 kW resistor, old ones are free from discarded units.

[@Sine1040]

And it can serve double duty as a pizza oven. The switches need some convincing though :P

[@PlaywithJunk]

Yeah thy are pretty old and they were not the best from start on. But they were free of cost

[@douro20]

I wish more manufacturers would follow Sanyo Denki's lead and use NiMH batteries which are a far more reliable technology than unpredictable lead-acid.

[@PlaywithJunk]

I don't mind good quality lead batteries (f.e. Panasonic) They work fine for 5-10 years.

[@chrisridesbicycles]

Casemoders internal lighting, old school version 😂

[@SeanBZA]

You want the bulbs to last longer grab NTC inrush limiters from old PC power supplies, and put one in series with each lamp. 4R7 ones will work well to reduce that inrush surge, and not affect lamp output much, but make them last a lot longer in use. Failing that 150W IR heating blocks, used for reptile enclosures and chick brooders, also work well.

[@PlaywithJunk]

Good idea. I saw that 100W bulbs are still available for traffic lights. Some don’t like LEDs there because they fear icing in the winter…

[@Rob2]

@@PlaywithJunk But make sure they are 230V! Traffic light bulbs here tended to be low-voltage (before they all went LED)...

[@SomeGuyInSandy]

I use a hair dryer. It works pretty well too :)

[@PlaywithJunk]

Sure, but can you adjust the power in small steps...?

[@SomeGuyInSandy]

@@PlaywithJunk No, I get High and Low - But it is enough for a pass fail test. I just replace batteries that fail or are marginal. Love your channel!

[@PlaywithJunk]

@@SomeGuyInSandy Thanks! Before I built that tester, I used all kind of devices as a load. But this tester can be used for small UPS (300W) too.

[@thecriss88]

Why not having an old 1500W iron (for clothes) and regulate the power with some circuitry?

[@PlaywithJunk]

A phase control circuits for 1500w would certainly be possible but I like to have a clean resistive load

[@thecriss88]

@@PlaywithJunk then use 10 x 150W heaters

[@BollingHolt]

Cool!

[@PlaywithJunk]

nope… it’s hot 🔥

[@BollingHolt]

@@PlaywithJunk Touche! LOL

[@shreev9671]

Do you have the parts list and schematic for this unit? would like to build one for myself

[@PlaywithJunk]

You don’t need that because it’s really straightforward. 10 switches and 10 light bulbs and an aluminium case thats all you need. And a strong fan.

[@douro20]

Is that an online UPS or line interactive?

[@PlaywithJunk]

I don’t know. APC has both technologies. It depends on the model. My test here is only to find out if the battery capacity is ok

[@jj74qformerlyjailbreak3]

Nice JUNKCAL. Or least we know its is

[@michaelknight2342]

> Incandescent lamps are the cheapest high watt resistors you can get. What about a water bucket with metal wire inside?

[@PlaywithJunk]

That is too unsafe for a professional environment

[@colinstamp9053]

That doesn't sound much less expensive.

[@salat]

@@PlaywithJunk FYI: Oil filled dummy loads are quite a standard when it comes to RF and oil radiator heaters are a dirt cheap but decent load for bigger UPS.. (~25€ w/ free shipping for a 2.5kW unit!)

[@PlaywithJunk]

@@salat I don’t want one 2kw load. I want something with 100 or 150 W steps. Light bulbs are $2 per piece

[@johnsenchak1428]

Why not just use non inductive resistors cool !

[@PlaywithJunk]

because hey are 25 times more expensive. I’d love to use water cooled resistors but they are even more expensive

[@charliew.1122]

I'm sure there's a good reason why this is a bad idea... but can't you simply use some cheap heating elements instead of the bulbs?

[@PlaywithJunk]

Tell me what’s cheaper than a $2 lightbulb?

[@charliew.1122]

@@PlaywithJunk well if you got them from somewhere cheap and Chinese like aliexpress you could probably only end up paying about $5 per 100w heater. Granted it’s more expensive but surely the amount of space it would save and the fact that it would remove the need to replace bulbs, which you pointed out was a downside with yours, makes it worth considering? I was just curious if there was an obvious downside I’m missing haha… I think your device is really cool!

[@DataDashy]

What is this some ups tester from the 80s?! Lamest way to test an ups ever with halogen bulbs jeez, those bulbs run off from any flaky generator dont even supply sine wave. BTW those apc upses were utter crap what u pictured those after a year can do smth like 15 mins on tops

[@PlaywithJunk]

what would you recommend?

[@charliew.1122]

Damn why are you so angry... he clearly wasn't aiming for a way to test every single aspect of the UPS.