Service FAQ

UPS DC and AC capacitor replacement

Frequently asked questions

The information in this document applies to a variety of UPS

models. Replacement recommendations will vary based on the
specific model and capacitor type.

Q: What do DC capacitors do?

A: The primary use for DC capacitors in UPS applications
is to smooth out fluctuations in voltage—a process also
known as “supply voltage filtering.” If there’s a change in
voltage input, the capacitor dampens the voltage change,
eliminating the peaks and filling in the valleys to help
maintain a constant voltage level.

Q: What do AC capacitors do?

A: They smooth out input transients and reduce the harmonic
distortion on the utility input to the UPS. More importantly,
they connect directly to the critical load output and help
control the waveform shape of the UPS output voltage.

Q: Are there particular UPS kVA sizes where capacitor

replacements are more applicable?
Eaton field engineers handle all capacitor replacements. Unlike a third party
service provider, they’re also aware of the latest engineering updates and have A: Capacitor replacement is not kVA-dependent. Any UPSs
access to 24x7 technical support. with fully removable capacitor assemblies should have the
capacitors replaced to avoid failure.

Q: Do capacitors degrade over time under normal use?

A: Like batteries, capacitors degrade over time. A typical
capacitor might be rated by the manufacturer for seven years
of around-the-clock use, and could potentially deliver up to
10 years of useful life under favorable operating conditions.
When a capacitor fails, you might not see any visible effects,
but other capacitors will have to take over the workload,
shortening their remaining lives. In many cases, a capacitor
failure triggers the UPS to switch to bypass mode, during
which it can’t protect downstream loads.
 Q: Where are DC capacitors found in my UPS? Q: If the UPS keeps working, why would I worry about
A: These capacitors are found at the rectifier(s) outputs and/ replacing capacitors?
or the inverter(s) inputs. This area is known as the DC link, A: When an individual capacitor fails, that can be a sign that
which is also where backup batteries are often connected. other capacitors are not doing their jobs. There may be
Working as filtering elements, these capacitors are evidence of one or two failed capacitors that have split
essential contributors to the overall function of the UPS, or leaked, but visible inspection would not reveal other
which is to take unpredictable or erratic supply voltage and capacitors that have failed “open” and perhaps actually
turn it into a filtered voltage for the inverter and battery. caused the other failures. This condition could trigger the
The capacitors also play a role in allowing a UPS to recover failure of still more capacitors and ultimately diminish the
from load steps and helping prevent nuisance transfers UPS’s overall performance. Replacing single capacitors
to bypass. (which have lower impedances) may lead to quicker failure.
The best strategy is to keep the impedance of all capacitors
Q: Do DC capacitors ever completely wear out? working together in the same circuit consistent.
A: Yes they do, just as batteries do, and for similar reasons.
Capacitors, when properly designed and fabricated, still Q: Why aren’t capacitor replacements covered under my
show very gradual changes in essential characteristics over service contract?
time, even when operated at normal rated voltages and A: Individual failures are covered under Eaton service
temperatures. The paper, aluminum foil and electrolyte contracts with full parts and labor coverage. Full capacitor
inside the capacitor are subject to normal breakdown. As replacements, like batteries, are excluded as they are
those materials age and start to degrade physically and high wear consumable parts. Complete power capacitor
chemically, the unit loses overall capacitance. Ultimately, replacements are recommended to proactively insure the
the capacitor no longer performs its job. Adverse operating reliability of the UPS against a catastrophic failure and
conditions such as excessive current and heat can also reduce the risk of unscheduled downtime.
hasten the demise of capacitors.
Q: What is the recommended strategy for testing and
Q: How are AC capacitors different than DC capacitors? replacing capacitors?
A: AC capacitors have much of the same characteristics as A: This depends a lot on the age and size of the system. For
DC capacitors in that they have an expected period of instance, if your large UPS system is seven to 10 years old,
useful service and should be considered as perishable piecemeal replacement of capacitors might appear to be
commodities. AC capacitors are found primarily near the more cost-effective in the short run. Ultimately, though, it’s
input and output filters. more costly and risky for the reasons stated earlier.

Q: How long do capacitors usually last? E

 aton recommends that power capacitors be inspected
for deformation, leaks and other apparent problems during
A: In practice, you can estimate expected service life based annual preventive maintenance visits. If some capacitors
on the manufacturer’s rated lifespan. This assumes that are visibly failing, their failures may have been triggered
the device is maintained under nominal rated operating by the failures of others, and it can be difficult or time
temperature and does not endure a number of charge and consuming to determine which ones. Consider also that
discharge cycles outside of its specified parameters over testing and replacing individual capacitors can take five
a specified period of time. Based on the manufacturer’s or six hours for a large three-phase system. In contrast,
rated service life, it is our recommendation to replace AC a technician can replace an entire bank of capacitors
and DC oil filled capacitors for most Eaton UPS models in less than an hour. If the capacitor failure rate has
at or before seven years of service. Failures are certainly been on the rise, you may soon find that one-by-one
possible any time after the manufacturer’s rated service replacement has led to replacing most of the capacitors
life, and increase in likelihood as the capacitor gets older. anyway, but at greater cost and inconvenience than a
Below is the estimated capacitor service life for AC and DC wholesale replacement.
capacitors across various Eaton UPS models.

Here’s an overview of the estimated capacitor service life and types of capacitors inside Eaton UPSs. When doing a full capacitor
replacement, we also recommend performing a full fan replacement at the same time.

9395
Capacitor type 9330 9355 93E 93PM 9390 9315 9395 High Performance
DC (Electrolytic) Life of UPS Life of UPS Life of UPS 10 years Life of UPS 6 years Life of UPS Life of UPS

DC (Oil filled) N/A N/A N/A N/A 7 years N/A 7 years 10 years

AC (Oil filled) 7 years N/A N/A N/A 7 years 7 years 7 years 10 years

2 EATON Capacitor replacement frequently asked questions

Q: My UPS is a very old model. Can it accept Eaton 9390 and 9395 Engineering explanation
today’s capacitors? UPS model capacitor for 9390 and 9395 capacitor
A: Yes, unless otherwise specified as incompatible by replacement policy recommendations
Eaton’s engineering team. Rated capacitor life for 9390 Life expectancy of capacitors
and 9395 UPS models: is affected by temperature
Q: Who actually replaces the capacitors? Can I use a more than anything else—
third-party service provider? • A
 C input/output capacitors
have an expected life of primarily internal heat from
A: Eaton field engineers provide this service, and have been seven years ripple current resistive
doing so reliably for many years. They are supported dissipation. Manufacturer
by our latest engineering updates and have immediate • D
 C electrolytic capacitors published data is given at
access to 24x7 technical support, including product have an expected useful rated voltage and ripple
documentation, engineering data and technical updates life equal to the product current, so at a frequency
or bulletins. Third party service providers do not have life (20+ years) of 120 Hz and either 85°C
consistent support in these areas. • D
 C (oil filled) capacitors or 105°C, the rated life is
have an expected life of usually in the vicinity of 2,000
seven years or 3,000 hours (depending
on the capacitor maximum
Unlike other models with DC
temperature rating). Every
electrolytic capacitors, 9390
10°C lower, we anticipate
and 9395 UPS models have
the expected life to double.
capacitors soldered to the
At 25°C, that would mean a
power modules and are not
multiplier of 32 for an 85°C
field-repairable. (In the rare
rated capacitor.
event that a DC electrolytic
capacitor failure is diagnosed, With regards to current, every
the power module will need UPS designed in the last 20
to be replaced.) Depending years has increasingly used
on the failed number of higher frequencies. Further,
DC capacitors, model and the 9390 and 9395 use
rating there may be multiple interleaving, which effectively
power modules requiring doubles the frequency of
replacement. the ripple current as seen
by these capacitors. This is
Eaton full parts coverage
important as the higher the
support agreement
frequency, the higher the
customers are fully covered
current the capacitor can
for DC electrolytic capacitor
handle. Or conversely, the
replacement in the event
longer it will last for a given
of a failure. Proactive
set of conditions.
DC electrolytic capacitor
replacement is not required Eaton’s designs do not use
based on engineering capacitors (or any component
data, and Eaton does not for that matter) to its
recommend it. Customers maximum ratings. Worst
requesting proactive DC case scenarios are typically
electrolytic capacitor 80 to 85 percent voltage
replacement will need to rating, perhaps less with
replace all power modules as respect to current. These
a billable (non-covered) event. “stacked” margins were used
to determine that a capacitor
Eaton solders to a board will
Capacitor lifetimes vary by model and capacitor type. For most models, we
last “forever” (or the life of
recommend a full replacement of capacitors in the UPS’s primary power-train
after every six to seven years of operation. the equipment).

To learn more about Eaton’s UPS services,

visit: Eaton.com/UPSservices
Eaton
1000 Eaton Boulevard
Cleveland, OH 44122
United States
Powerquality.eaton.com

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