Lets Modify! Vlog 22-10-25 - Modifying an APC Back-UPS Pro 650 to use a Kings 60AH Lithium Battery

Video Description

So, why dont they make a small UPS with a BIG battery? The batteries generally seem to scale with the UPS output - who wants a 3kw UPS with 100AH of battery capacity to only run a small router or two? What if say, you want to power that 20watt router for more than just an hour or two? How about, a day or two! In this Vlog, I set out to see if I can accomplish exactly this - can we use a large capacity (compared to stock anyhow) Lithium battery in place of an SLA? I share my thoughts and findings along the way, as well as more than a few failures holding things back - causing a few head scratches! I encounter a faulty voltage meter, faulty (shorted) fuse holder, faulty current meter, fake temp sensors, then faulty replacement temp sensors, faulty 7805 regulator, AI remembering a mistake I made producing bad code, PCB manufacturing defects plus the usual hours of bug hunting that occurs with electronics projects - yeah it was a fun project alright! 3 months this project took! But the fan controller had to be completed and work - or I risk the UPS from burning out from being ran way out of spec, especially with the discovery of the stock cooling being so bad! So, yeah.. I'm sorry this one drags on a bit, I could have condensed the fan controller chapters right down so it seemed like 'Yeah, you know, 10 minutes and its done, Im a pro, easy as...' but then you would miss all the troubleshooting and thoughts involved in making a project work from scratch - it is Vlogging after all, and as such, it was mostly documented. I did condense it down from over 6 hours of work and 3.5 hours of footage, so it could have been worse! When I get around to sharing the fan controller project details, the link will be added below here so you can make your own or buy one assembled (I generally charge components + $10 for my designs) for any project you might need it for: (Not yet! eta 27/10/25) Chapters are listed so you can skip a chapter if not interested or its dragging on a bit. Remember, this is un-scripted Vlogging what I do as I do it, including any hurdles I come across. To skip a chapter, on PC press CTRL + ALT + RightArrow Chapters: 00:00:00 - Disclaimer / Intro 00:00:45 - The NEW UPS 00:02:07 - The NEW Battery 00:03:04 - Initial considerations 00:04:45 - Investigating UPS charge profile (if any) 00:09:06 - Pre made power Cabling 00:12:13 - Faulty volt meter 00:12:51 - Will Software show correct runtime? 00:16:00 - Continuing Measuring current flow to/from battery 00:16:40 - Shorted Fuse Holder 00:17:34 - Continuing Measuring current flow to/from battery 00:20:30 - Back to Bunnings... 00:20:40 - New cable strategy and current meter 00:24:29 - Initial look at heat output with thermal cam 00:26:07 - Opening up UPS and having a look... 00:27:45 - Checking what gets hot when charging 00:29:13 - Stock cooling considerations 00:30:10 - Initial measuring A/H into battery 00:31:54 - Initial measuring A/H out of battery full to empty 00:36:33 - Disclaimer reminder... 00:41:30 - A/H full to empty result 00:43:28 - Measuring A/H from flat to full 00:44:26 - Unexpected reading - Super Battery or Bad Meter? 00:44:34 - Measuring A/H from full to flat 00:45:42 - Charging with alternate smart charger to determine A/H 00:48:46 - UPS suitability for Lithium charge circuit conclusion 00:49:10 - Temp controlled fan speed controller prototype 00:50:25 - PCB Defect 00:52:56 - Prototype fan controller construction 00:53:38 - Programming Attiny85 00:54:00 - Faulty 7805 regulator... 00:57:56 - Fan controller Initial power up 01:02:45 - After initial debugging and update... 01:03:23 - The LM35 sensor and its quirks... 01:04:30 - PCB Version 2 01:05:53 - Constructing Version 2 board... 01:06:16 - Replacing old soldering iron wand after 9 years 01:07:08 - Constructing Version 2 board... 01:09:55 - 6 hours later debugging... 01:09:38 - Fake LM35's 01:12:13 - Converting to use LM335Z from Jaycar 01:14:10 - Testing Version 2 board with LM335Z's... 01:15:25 - Calibrating sensors via software 01:17:39 - 2000 years later... (software debuging) 01:19:12 - Testing again... 01:23:00 - Fans Selection 01:23:37 - Fans Location 01:25:37 - Installing Fans... 01:26:00 - Discovering top UPS ventilation fake 01:27:26 - Continuing installing fans... 01:28:22 - Installing fan module 01:31:00 - Testing Fan ON/OFF temperatures before reassembly 01:35:29 - Altronics for replacement failed LM335Z's... 01:38:23 - Testing again after sensor replacement... 01:45:05 - 24 hour burn test 01:46:40 - Completing module install into UPS 01:49:45 - Final Live testing of fan module and sensor location discussion 02:00:26 - Changing fan profile to suit fans 02:02:12 - Final discussion before UPS reassembly and conclusions 02:03:33 - Installation and final notes...