A hot UPS battery raises a real home-server safety issue
A 1000VA GreenCell Powerproof UPS became very hot even with only about 30W of load. After 3 to 4 months, there was a burning smell and smoke, and one battery suffered an internal short that melted a hole in the battery. The UPS had been sold as a new open-box unit, but dust on it made old or previously used batteries seem possible.
One proposed fix was to avoid putting new batteries back inside the hot case. The idea was to drill a side hole, keep the battery outside, make a , use , and solder in a 220V-to-12VDC plus a fan to move air through the existing vents. The later clarification was that the hole was in the battery, not the UPS body.
The likely cause was an old battery, heat, or both, and replacing the batteries with a good-quality pair appears to be the more practical fix.
Key points
- The UPS ran very hot despite a light 30W load.
- After 3 to 4 months, it produced a burning smell, smoke, and a melted battery hole.
- The proposed mod involved moving the battery outside, adding a fan, and wiring a 12VDC supply.
- The damage appears to have come from an internal short inside the battery.
- A used or old UPS can become a safety risk, even for a low-power .