Replacing the fans in an APC Smart UPS 2200VA

I recently bought a 2u 2200VA APC Smart UPS on eBay, it works great, but the fans started to make a grinding/squeaking sound. So its time to replace them.

APC apparently use a few different fans in their UPS’s, so you’ll need to open it to confirm what ones are inside. Mine contained ‘AD0824LB-A70GL’ 80mm 24v 90mA fans, but the only replacements I could find are used for $30 plus shipping from china. I did however find 80mm 24v 130mA fans at my local electronics store.

Old fans

First things first: Shutdown everything thats connected, shutdown the UPS, disconnect the power, pop the front panel off and disconnect and remove the battery.

LET THE UPS SIT WITH THE BATTERY DISCONNECTED AND THE POWER REMOVED FOR TWO HOURS OR MORE TO DISCHARGE THE CAPACITORS

Battery removed

Step two, ignore the warning…
No user serviceabe parts, yeah right.

Now we can undo all the screws on the top, theres a lot of them…
Removeing the screws

We’re inside! Try not to die.
Inside

This is the fan wall, we’re going to have to remove it. Unscrew the Black and White wires and pull them through the hole [Fig 1]. Unscrew the screw that’s holding onto the side of the case [Fig 2]. Disconnect the fans from the PCB [Fig 3] and carefully flip the fan wall over [Fig 4].
Figure 1
Figure 2
Figure 3
Figure 4

Now we have to remove the STUPID FUCKING CLIPS that hold the fans on. I used a skewer… Push the center pin on the fan side until they pop out.
Removing the clips
Fans removed

The plugs on the fans allow new ones to be installed without any soldering on wire cutting, just pop the old wires out and push the new ones in. I then used a multimeter to test the connection.
Connecting new wires
Testing the connection

Now we get to install the new fans. If I was to do this again I would buy some little bolts to install the fans instead of the STUPID FUCKING CLIPS that were infuriating to use. I’m sure there’s a tool that makes them easier, but I don’t have it. I used a pair of pliers to squeeze the clips is.
The clips
Clips installed

Now you can put the fan wall back in, pass the black and white cables through and screw them back on. Connect the fans, screw in the fan wall, and put the top back on.
New fans installed