APC 2200VA UPS teardown, experiments, refurbish - Page 1
Forum section: electronics / projects

author: nexus
author_rank: Regular Contributor
timestamp: December 15, 2020, 02:22:48 am
content: Hi all,Thought I'd share a project I just recently wrapped up. This is an old APC SUA2200XL (manufactured early 2010) that I pulled out of storage, had a good look inside, and replaced a bunch of the higher risk/lower life components (mostly caps and movs).Detailed writeup, images, and spreadsheets with bill of materials and old vs new component measurements here:https://neonkev.com/2020/12/15/apc-2200xl-ups-electrical-refurbish-old-vs-new-component-comparison/I wasn't able to find a good look inside of this class of UPS on most places online, so I included a lot of high res photos that you can reverse engineer at your own leisure. Interesting to see what a mid-range product like this is made of, since it is on the border of performance vs. price in the prosumer/commercial UPS market. I'd like to see what's inside the latest 1500VA models that APC sells on Amazon for less than $200 USD, with batteries. I doubt it weights 140lbs like this beast!Enjoy!

author: trobbins
author_rank: Frequent Contributor
timestamp: December 15, 2020, 04:06:40 am
content: So the original main inverter e-caps were a titch better than the replacements for ESR and DF, and without original ESR and DF and cap value measurements it can't be identified if they have degraded at all.The MOV's can be tested using an insulation resistance megohmmeter to see if their threshold level has changed, and confirm leakage current is below max rated level.

author: BradC
author_rank: Super Contributor
timestamp: December 15, 2020, 05:57:40 am
content: Quote from: trobbins on December 15, 2020, 04:06:40 amI always replace the MOVs. The handful of bucks it costs far outweighs the time require to adequately test them. I've never found a suitable replacement for APC main inverter filter caps and I've never needed to. The originals are not significantly physically larger than the replacements for no reason. Those caps work *hard*. APC cut every possible corner when they engineer these units, but they always use monster caps in the inverter. I'm sure it's not because they are cheap.The original caps in the SU2200 are a VPR152M075N3L3A. I managed to find a data sheet for them a few years ago when looking for equivalents. The SUA2200 and later uses the same design. The specified replacements are worse in every metric, but then they're about 1/3rd of the physical size. Pay particular attention to the ripple current. Remember this UPS at full noise is pushing > 41A through that inverter.

author: nexus
author_rank: Regular Contributor
timestamp: December 15, 2020, 05:40:10 pm
content: I did make the decision to replace the main caps, despite the measurements showing that ESR and dissipation factor were marginally higher in the Nichicon replacements.The original caps in this SUA2200XL were Jianghai CD298 series 2000 hrs @ 105C. I was not able to find the datasheet for the CD298 series, but I did look at the available specs on Jianghai's CD29X lineup currently. For a 1500uF size cap, I made sure that the ripple current specs on the Nichicon met or exceeded the original brand's spec. Plus, with the Nichicon UHW in that case size being 12,000hr 105C rated, 1/2 the height and 60% of the original diameter (more airflow through inverter block), I deemed the newer capacitors to still be a reliability upgrade in spite of the 1 milliohm esr increase and 13% dissipation factor difference. I'd also imagine that today's Nichicon has their electrolyte chemistry better sorted compared to 2009 Jianghai.

author: Miyuki
author_rank: Frequent Contributor
timestamp: December 15, 2020, 05:55:14 pm
content: Oh old mains frequency transformers designWonder how low efficiency it will reachBut I just agree they tend to be pretty reliable

author: nexus
author_rank: Regular Contributor
timestamp: December 15, 2020, 06:35:00 pm
content: Yup, those big honking transformers weighed 25 pounds each. It looks like a regular ATX desktop chassis from the outside, but watch your back if you try to lift it!

author: hiperjz
author_rank: Newbie
timestamp: July 09, 2025, 12:34:50 am
content: @nexushi! its an old thread,if i could get some info or help regarding my APC 3000XL....seems like my has a same board but the only differences are my board has more mosfets on the inverter.are you still running this UPS ? how well the overall refurb project lasted for you ? how it performed later in following years...just a quick thought and simple questions.saw your detailed refurb project of APC SUA2200XL UPS and wondering if i can make my 15 Year Old SUA3000XL alive again.can you please telme what problem you were having before changing all the capacitors on the UPS board or you just recapped it because of age ? i have a similar board in 230VAC,it works for few hours and starts blinking all 6 center lights simultaniously and trips the load.wheni switch it off and power on again it doesnt work! but if i wait for 30mins i switch it on again and it starts working again for few hours!if you think you can help me it will be great!TIA