O & M of DC & UPS Systems

Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.

Warning: The material contained in this document was developed for Saudi
Aramco and is intended for the exclusive use of Saudi Aramcos
employees. Any material contained in this document which is not
already in the public domain may not be copied, reproduced, sold, given,
or disclosed to third parties, or otherwise used in whole, or in part,
without the written permission of the Vice President, Engineering
Services, Saudi Aramco.
Chapter : Electrical For additional information on this subject, contact
File Reference: EEX21107 W.A. Roussel on 874-1320
Engineering Encyclopedia
Saudi Aramco DeskTop Standards
Directing the Operation
and Maintenance of DC/UPS Systems
Engineering Encyclopedia Electrical
Directing the Operation and Maintenance of DC/UPS Systems
CONTENTS PAGES
DETERMINING WHETHER BATTERIES ARE FUNCTIONING
PROPERLY............................................................................................................ 1
Preventive Maintenance Requirements ....................................................... 1
Battery Physical Checks .................................................................. 1
Battery Voltage Checks ................................................................... 7
Preventive Maintenance Frequency .......................................................... 11
Preventive Maintenance Records .............................................................. 14
Problems and Corrective Measures ........................................................... 20
Grounding...................................................................................... 20
Electrolyte Loss ............................................................................. 23
Abnormal Specific Gravity ............................................................ 24
DETERMINING WHETHER DC/UPS SUBSYSTEMS ARE
FUNCTIONING PROPERLY.............................................................................. 27
Preventive Maintenance Requirements ..................................................... 27
Visual Inspection ........................................................................... 27
Cleaning......................................................................................... 28
Battery Charger Checks and Adjustments ..................................... 31
Inverter Checks and Adjustments .................................................. 35
Preventive Maintenance Frequency .......................................................... 41
Preventive Maintenance Records .............................................................. 44
Problems and Corrective Measures ........................................................... 51
Tripping of Input/Output Breakers................................................. 51
Improper Inverter Output ............................................................... 53
SCR Failures .................................................................................. 54
WORK AID 1: MAINTENANCE SPECIFICATIONS AND TROUBLESHOOTING GUIDE COMPILED FROM SADP-P-103 AND ESTABLISHED ENGINEERING PRACTICES FOR DETERMINING WHETHER BATTERIES ARE FUNCTIONING PROPERLY
Maintenance Specifications....................................................................... 57
Troubleshooting Guide.............................................................................. 58
WORK AID 2: MAINTENANCE SPECIFICATIONS AND TROUBLESHOOTING GUIDE COMPILED FROM ESTABLISHED ENGINEERING PRACTICES FOR DETERMINING WHETHER DC/UPS SUBSYSTEMS ARE FUNCTIONING PROPERLY
Maintenance Specifications....................................................................... 59
Troubleshooting Guide.............................................................................. 61
GLOSSARY ......................................................................................................... 62
Saudi Aramco DeskTop Standards 1
DETERMINING WHETHER BATTERIES ARE FUNCTIONING PROPERLY
The checks and tests that can be performed to determine whether batteries are functioning
properly include visual observations, service and performance tests, and monitoring of
metered parameters. This section provides information on the following topics that are
pertinent to determining whether batteries are functioning properly:
Preventive Maintenance Requirements
Preventive Maintenance Frequency
Preventive Maintenance Records
Problems and Corrective Measures
Preventive maintenance consists of routine checks and tests that are performed on a piece of
equipment to determine its current condition and to identify and correct degrading equipment
conditions before such conditions result in complete equipment failure. An effective
preventive maintenance program will help to ensure that batteries meet or exceed the
manufacturer's service life.
This section of the Module will discuss the items of a battery that require preventive
maintenance, what maintenance measures are required, and why the maintenance measures
are performed. The items of the battery that require preventive maintenance are divided into
the following general categories:
Battery Physical Checks
Battery Voltage Checks
Physical checks should be performed on batteries at regularly scheduled intervals. The
specific items of a battery that should be checked are specified by the individual battery
manufacturers. The following is a list of the physical checks that generally are specified and
the reasons that the checks are performed. The descriptions also include the methods that can
be used to perform the physical checks.
General Cleanliness- A general cleanliness inspection should be performed to check for
dirt, dust, and/or electrolyte accumulation on the battery cells and the floor and for dirt
and dust accumulation in the ventilation system filters. The reason that general
cleanliness is checked is that dirt/electrolyte deposits or build-ups on the battery cells
can cause increased cell self-discharge rates, battery grounds and, in severe cases,
short circuits. Dirty or wet floors can be slippery, which results in a safety hazard;
dirty ventilation filters can decrease the battery room ventilation, which can result in
unsatisfactory ambient temperature conditions and in unsafe levels of hydrogen gas
accumulation.
The method that is used to perform the general cleanliness inspection is a visual
inspection. If the results of the visual inspection are unsatisfactory, the unsatisfactory
items must be cleaned. Loose dirt or dust that has accumulated on the battery cells can
be removed through use of a vacuum or a low pressure air sparger. Compacted dirt
can be removed through use of a moderate pressure water hose. Electrolyte residue
can be removed through washing with an appropriate neutralizing solution and then
rinsing with a moderate pressure water hose. The appropriate neutralizing solution for
lead-acid batteries is a mixture of one pound of baking soda and one gallon of water.
The appropriate neutralizing solution for nickel-cadmium batteries is a 4% solution of
boric acid. Excess water that remains after the washdown should be wiped off with a
clean cloth or removed by the air sparger.
Dry dirt or dust that is on the battery room floors should be swept or vacuumed.
Electrolyte residue that is on the battery room floors should be removed in the same
fashion as electrolyte residue that is on the battery cells.
Reusable-type ventilation filters should be cleaned and air dried. Disposable "one-
time" filters should be replaced.
Battery Rack - The battery rack should be checked for loose hardware connections, for
chips or cracks in the rack's epoxy paint coating, and for integrity of the rack-to-floor
mount connection. The reason that the battery rack should be checked is that loose
hardware or a loose floor mount connection can result in a structural failure and a
possible collapse of the battery rack. Chips and cracks in the epoxy paint can permit
exposure of the rack support steel to the highly corrosive electrolyte. Corrosion of the
rack support steel can also lead to battery rack failure.
The method that is used to perform the battery rack check is a visual inspection. All
loose connections that are found during the visual inspection must be documented, and
an immediate repair must be initiated. Cracked and chipped areas of the epoxy paint
should be washed with an appropriate neutralizing solution and rinsed with clean
water. The appropriate neutralizing solution for lead-acid batteries is a mixture of one
pound of baking soda and one gallon of water. The appropriate neutralizing solution
for nickel-cadmium batteries is a 4% solution of boric acid. After the affected areas
have dried, they should be repainted with epoxy paint.
Cell Case Integrity - The integrity of each cell case should be checked to ensure that no
leaks exist. The reason that the integrity of each cell case should be checked is that the
electrolyte is both a conductor and a corrosive. Because the electrolyte is a conductor,
electrolyte that leaks out of the cell can cause increased cell self-discharge rates,
grounds, and shorts. Because the electrolyte is a corrosive, electrolyte that leaks out of
the cell can corrode any bare metal surfaces that it contacts. The corrosive nature of
electrolyte also makes it a safety hazard because electrolyte will cause skin burns.
The method that is used to perform cell case integrity checks is a visual inspection.
Special attention should be paid to the area that is around the connection terminal
(post) seals and around the cover-to-container seals. Each cell also should be visually
checked for stress cracks and for leaking or missing vent caps/flame arrestors.
Cracked or leaking cells should be replaced with a spare cell. Cell replacement will be
discussed in more detail later in this Module.
Vent Caps/Flame Arrestors- Vent caps/flame arrestors should be checked for cracks or
other defects, clogging, and tightness. Vent caps/flame arrestors that are cracked or
that are loose can allow electrolyte to leak out of the cell during the gassing phase of a
charge. The problems that are caused by these electrolyte leaks are the same as the
problems that are caused by the electrolyte leaks that were discussed previously. Vent
caps/flame arrestors that are clogged will not allow the gases that are formed
during charges and discharges to escape and will in turn cause a buildup of pressure
inside of the cell. When the vent cap/flame arrestor is subsequently removed, the
pressure that is inside of the cell will be suddenly released. The sudden release of
pressure will cause electrolyte to spray out of the cell and onto the person that
removed the vent cap/flame arrestor. Such a spray of electrolyte presents a severe
safety hazard.
The method that is used to perform vent cap/flame arrestor checks is a combined
visual/physical inspection. The vent caps/flame arrestors should be visually inspected
for cracks or other defects and clogging, and they should be physically inspected for
tightness (i.e., the vent caps/flame arrestors should be turned by hand to ensure that
they are hand-tight). Vent caps/flame arrestors that are cracked or that are defective
must be replaced. Vent caps/flame arrestors that are clogged can be cleaned by
agitating them in pure water. Cleaning or neutralizing agents must not be used
because these agents tend to further clog the pores of the vent caps/flame arrestors
rather than to clean the pores.
Cell Terminals- The cell terminals should be checked for corrosion, tightness, and
terminal resistance. The terminals must be kept free from corrosion because corrosion
can physically weaken the terminal connection and it can cause a high resistance
connection. The tightness and the terminal resistance of the terminal connections are
checked to ensure that high resistance connections do not exist. High resistance
connections can reduce the battery voltage and can cause overheating at the
connection.
The method that is used to check the cell terminals for corrosion is a visual inspection.
Corrosion normally appears as a white powdery buildup but it may also have a slightly
blue or brown tint. If corrosion is present, it must be removed by wiping the corroded
surface with a cloth that has been dampened with the applicable neutralization agent
(bicarbonate of soda for lead-acid and boric acid for nickel-cadmium batteries). After
the neutralization agent has been applied, the surface should be wiped with a cloth that
has been dampened with clean water followed by a final wipe down with a clean dry
cloth. After the corrosion has been removed, the terminal connection should be
checked for tightness through use of a torque wrench, and a terminal resistance test
should be performed through use of a digital low resistance ohmmeter. After the
tightness has been verified and the terminal resistance test has been satisfactorily
completed, the entire terminal connection should be coated with a thin layer of No-Ox
grease or equivalent. The No-Ox grease is used to inhibit future occurrences of
oxidation or corrosion. If corrosion was not present, the tightness check and the
terminal resistance check still should be performed.
Cell Internal Inspection - The internal portion of lead-acid cells should be checked for
buildup of excess sulfate material on the plates, for excess sediment at the bottom of
the cell container (jar), and for plate damage. Excess sulfate material build-up on the
plates is an indication that the cell is being undercharged. Such a condition can limit
the overall capacity of the battery. Excess sediment at the bottom of the cell container
is an indication that the cell is being overcharged. Continuous overcharging will
reduce the life of the affected cells. In severe cases, the excess sediment can build up
to the point at which it bridges the bottom of the positive and the negative plates,
which causes an internal short circuit. Internal short circuits increase the cell's self-
discharge rate and limit overall battery capacity. Damaged cell plates can cause a
number of problems, the most severe of which is separator damage, which leads to
internal short circuits.
The method that is used to perform a cell internal inspection is a visual inspection.
Sulfate build-up appears as a white scale on the surface of the plates. Sulfate
formation is a normal result of discharging a battery; however, if the battery is being
properly charged, the sulfate material should be converted back into sponge lead and
lead peroxide when the battery is charged. If excess sulfate material build-up is
observed, additional tests and inspections should be performed to determine the cause.
If excess sulfate material is observed on a single cell, that cell probably has high
resistance terminal connections or an electrolyte problem. If excess sulfate material is
observed on a number of cells, the battery charger voltage and/or timer settings are
probably incorrect.
Sediment build-up appears as a combination of white sulfate material and grey active
plate material. Under normal conditions, the sediment build-up will be negligible and
it will amount to little more than a thin layer of dust at the bottom of the cell container.
The physical size of the space that is below the bottom of the plates is designed to
accommodate all of the sediment that will be formed during battery's designed life. If
excess sediment is observed, additional tests and inspections must be performed to
determine the cause and the extent of the damage. The possible causes are
manufacturing defects, excessive electrolyte specific gravity, and excessive battery
charger voltage and/or timer settings.
The visual inspection for plate damage consists of an observation of the plates to
ensure that they are evenly spaced and that they do not physically interfere with the
separators or the adjacent plates. Bowed and warped cell plates are an irreversible
condition. If the plates are bowed or warped to the point at which they are in physical
contact with the separators and/or adjacent plates, the only corrective action is cell
replacement.
Nickel-cadmium batteries are more ruggedly constructed than lead-acid batteries and,
as such, they are not susceptible to the same types of internal damage as lead-acid
batteries; therefore, a routine inspection of the internal portion of nickel-cadmium
batteries is not required.
Cell Operating Parameters- The cell operating parameters include voltage, temperature,
electrolyte level, and for lead-acid batteries only, specific gravity. These parameters
are checked because they provide an indication of the cell's state-of-charge and of the
overall condition of the cell. The cell's temperature and electrolyte level also are used
to correct the measured value of the specific gravity of lead-acid batteries to a standard
temperature (25
o
C, 77
o
F) and level (zero reference point for a particular cell).
The cell's voltage is measured through use of a portable voltmeter. The cell's
temperature is measured through use of a thermometer. The cell's level is measured
through use of a ruler or a height stick. The specific gravity of lead-acid cells is
measured through use of a hydrometer. The corrected value of specific gravity and the
cell voltage should be consistent with each other and should be consistent with the
current state-of-charge of the cell. If these conditions are not observed, additional tests
and inspections must be performed to determine the cause.
Capacity Test Discharge- Capacity test discharges should be performed to check the
current capacity of a battery. The reason that capacity test discharges should be
performed is that most batteries are installed to provide an emergency source of power
to critical loads for a specified period of time. If the battery is unable to supply the
needed power for the specified period of time, the critical loads will be lost, which
could result in damage to personnel, equipment, and/or product.
Before a capacity test discharge is performed, the following initial conditions must be
met:
The electrolyte level of each cell must be in the normal operational band.
The terminal resistances must be at or below the manufacturer's specified
resistance.
The battery must be in a fully charged condition.
The temperature of each cell must be a minimum of 25
o
F (12
o
C) below the
maximum cell temperature that is specified by the manufacturer.
After the initial conditions have been met, the test discharge is conducted through
placement of a rated load (in amperes) on the battery. The battery is discharged at its
rated load until it reaches the end of charge of 1.75 volts/cell times the number of cells
that are in series, or until the voltage of any individual cell drops below the end of
charge voltage of 1.75 volts. When one of these voltage limits is reached, the load is
removed from the battery to stop the discharge and the total length of time that the
battery was discharged is noted. The battery capacity (in percent) is determined
through use of the following formula:
%Capacity = 100 (actual ampere-hours discharged / rated ampere-hours)
The battery then must be recharged to a fully charged condition.
Battery float voltage, battery equalizing voltage, and battery terminal voltages need to be
checked on a routine basis to help ensure that the battery can perform its design function over
its expected service life. The importance of each voltage check and the effect that each
voltage can have on battery performance and/or battery life are explained below.
Battery Float Voltage- Stationary batteries that are installed to provide standby or
emergency power normally are maintained in a float (trickle) charge condition. In this
condition, the battery charger applies a voltage to the battery that is slightly higher
than the battery's open circuit voltage, which maintains the battery on a continuous
low rate charge. The continuous low rate charge compensates for internal losses and
for intermittent discharges and keeps the battery in a fully charged condition.
Because the float voltage setpoint directly affects battery performance and in the case
of lead-acid batteries, battery life, this value should be checked as part of the routine
maintenance that is performed on batteries. If the float voltage is set too low,
restoration of battery capacity lost through internal losses and intermittent discharges
will not occur; therefore, the battery will always be less than fully charged. A battery
that is not fully charged may be unable to deliver the required amount of standby or
emergency power for which it was installed. The long term effect of continuous
operation of lead-acid batteries at low float voltages (i.e., continuous under-charging)
is a permanent reduction of battery capacity, which leads to a reduced service life.
Nickel-cadmium batteries do not normally suffer any long term effects from operation
at low float voltages.
If the float voltage is set too high, the battery will continuously be overcharged. The
problems that result from continuously overcharging a battery depend on the extent of
the overcharge. A float voltage that is slightly higher than normal will cause an
increased rate of electrolyte loss and a small increase in the operating temperature of
lead-acid and nickel-cadmium batteries.
Provided that the battery room is air conditioned and that the electrolyte levels are
checked on a routine basis, the only real problem that is caused by minor overcharging
is that the battery will have to be watered more often.
A float voltage that is significantly higher than normal can be extremely detrimental to
performance and service life of lead-acid batteries. Severe overcharge conditions
corrode the grids of the positive plates into lead peroxide. The corrosion physically
weakens the plates and increases the resistance of the plates. Severe overcharge
conditions also result in continuous battery gassing that will erode the active material
off of the battery plates. The overall effect of the corrosion and erosion is reduced
battery capacity and reduced service life. In addition to the corrosion and erosion,
severe overcharge conditions also can result in a significant increase in operating
temperature. Operation of a battery at high temperatures, particularly at temperatures
that are above 55
o
C, will significantly reduce the service life of the battery. For
example, 11 days of float operation at 75
o
C is equivalent in service life to 365 days of
float operation at 25
o
C.
Overcharging of nickel-cadmium batteries does not generally result in any loss of
performance or service life. The only problems that are associated with severe
overcharge conditions are an increased rate of gassing and electrolyte loss.
The optimum float voltage setpoint for a given battery should be obtained from the
manufacturer. Figure 1 shows typical float voltage values for several types of lead-
acid and nickel-cadmium batteries that operate at various specific gravities. During
routine battery maintenance, the float voltage should be checked directly at the battery
positive and negative terminals through use of an installed or a portable voltmeter.
Float Voltage Per Cell
Lead-Antimony Lead-Calcium Nickel-Cadmium
2.13 - 2.16 @ 1.170 ----- 1.40 - 1.42 @ 1.190 .020
2.15 - 2.18 @1.215 2.17 - 2.21 @ 1.215 -----
----- 2.21 - 2.25 @ 1.250 -----
----- 2.25 - 2.29 @ 1.300 -----
Recommended Float Voltages for Lead-Acid and Nickel-Cadmium Batteries
Figure 1
Battery Equalizing Voltage- The battery equalizing voltage is the voltage at which an
equalizing battery charge is performed. Because an equalizing charge restores the
battery to a fully charged condition after a discharge or restores any non-uniformities
that may have occurred between individual cells, the equalizing voltage is set higher
than the float voltage. The equalizing voltage for lead-acid batteries should be set at
the maximum voltage that the connected system equipment (loads) can tolerate or at
2.39 volts per cell, whichever value is highest. The equalizing voltage for nickel-
cadmium batteries should be set at the maximum voltage that the connected system
equipment can tolerate or at 1.60 volts per cell, whichever value is highest.
The period of time that the equalizing voltage is applied to the battery is then set,
based on the equalizing voltage, at the value that is needed to restore all of the cells to
a uniform, full-charge condition; higher equalizing voltages require less charge time
than lower equalizing voltages. The manufacturer's technical literature should be
consulted for the exact values of voltage and time that are required for a given battery.
Because the equalizing voltage value is generally limited by the maximum voltage that
can be tolerated by the connected loads, and because this voltage is only applied for a
relatively short period of time (usually 8 to 24 hours), the overcharge problems that
were previously described for float voltages are not generally a concern in reference to
checking the setpoint of this voltage during routine maintenance. The major concern
of an excessive equalizing voltage is exceeding the voltage limitations of the
connected loads. However, in the case of a failed battery charger voltage regulator,
the excessive voltage that would result from such a failure would be detrimental to
both the battery and to the downstream loads.
The condition that is more likely to be detrimental to the capacity and service life of
lead-acid batteries is a low equalizing voltage. If the equalizing voltage is too low, the
battery will not be completely restored to a uniform, fully-charged condition at the end
of the equalizing charge. Any amount of undercharge that is allowed to persist for a
period of time will cause a gradual sulphation of the negative plates in lead-acid
batteries with an eventual loss of capacity and reduction of service life. Nickel-
cadmium batteries do not suffer any long-term effects from undercharge.
Most lead-acid battery chargers have an equalizing voltage adjustment that ranges
from about 2.25 to 2.40 volts per cell. Most nickel-cadmium battery chargers have an
equalizing voltage adjustment that ranges from about 1.50 to 1.60 volts per cell.
During the performance of routine battery maintenance, the equalizing voltage should
be checked at the output of the battery charger through use of an installed or a portable
voltmeter.
Battery Terminal Voltages- During the performance of routine battery maintenance,
battery terminal voltages should be checked with an installed or a portable voltmeter to
verify that the battery is free from grounds and/or high resistance connections. The
first voltage that should be measured is the voltage from the positive battery terminal
to the negative battery terminal. This voltage should be equal to the float voltage per
cell multiplied by the total number of cells that are in the battery installation. The
other voltages that should be measured are the voltage between the positive battery
terminal and ground and the voltage between the negative terminal and ground. Each
of these voltages should be equal to one half of the total battery voltage. If these
conditions do not exist, a ground or a high resistance connection is the likely cause.
Grounds will be discussed in more detail later in this Module.
The overall goal of battery preventive maintenance is to identify and correct minor or
impending problems that, if left unchecked, could result in a reduction of battery capacity, a
reduction in battery capacity, or a safety hazard. In order for a battery preventive
maintenance program to achieve its goal, the battery systems and equipment must be checked
at regularly scheduled intervals. The regularly scheduled intervals vary dependent upon the
type of battery, the battery manufacturer, the type of intended service, and the environmental
conditions that exist at the installation. The initial battery preventive maintenance inspection
frequencies are normally established on the basis of the manufacturer's recommendations.
These initial frequencies can then be modified (increased or decreased in length) on the basis
of local site operating experience and/or governing codes and standards for a particular type
of service.
As an example of how inspection frequencies can be modified on the basis of local site
operating experience, assume that a particular battery manufacturer recommends that the
electrolyte level of each cell be checked once per month. Also assume that the inspection
results of two consecutive monthly inspections showed that the electrolyte level in several of
the cells had dropped below the minimum required level. Based on these results and provided
that no other problem is responsible for the lost level, the frequency of the electrolyte level
check for this particular battery should be performed more often. The inspection frequency
for this particular item would likely be changed from a monthly requirement to a bi-weekly or
a weekly requirement.
Figure 2 shows a typical preventive maintenance schedule for stationary storage batteries.
The schedule contains the preventive maintenance requirements and the frequency of
performance. The frequency of performance section is divided into three time categories:
routine, quarterly, and annually. The routine column can represent daily, weekly, bi-weekly,
or monthly preventive maintenance requirements. The applicable frequency for all of the
preventive maintenance items should be established as previously explained.
Preventive Maintenance Frequency of Performance
Requirement Routine Quarterl
y
Annuall
y
General Cleanliness X (1)
Battery Rack X (1)
Cell Case Integrity X (1)
Vent Caps/Flame Arrestors X (1)
Cell Terminals
- Corrosion
- Tightness
- Resistance
X (2)
(2)
(2)
X
X
Cell Internals * X (1)
Cell Operating Parameters
- Specific Gravity *
- Cell Voltage
- Cell Temperature
- Electrolyte Level
X (3)
X (3)
X (3)
X (3)
X
X
X
X
Capacity Test Discharge X (4)
Float Voltage Check @ Charger Output X
Equalize Voltage Check @ Charger Output X
Battery Terminal Voltage Checks
- Voltage from Positive Terminal to Negative Terminal
- Voltage from Positive Terminal to Ground
- Voltage from Negative Terminal to Ground
X
X
X
* Not required for nickel-cadmium batteries
NOTES:
(1) Any discrepancies that are found during the check should be corrected.
(2) If corrosion is found, the condition must be corrected. After the corrosion is removed,
the tightness and the resistance of the cleaned terminal should be verified.
(3) Routine check of cell operating parameters is only required for the designated pilot cells.
(4) A battery capacity test discharge should be conducted within the first two years of
service. After the initial capacity test discharge, subsequent capacity test discharges
should be performed at five year intervals until the battery shows signs of degradation or
until it reaches 85% of its service life expectancy. When one of these conditions is met,
annual capacity test discharges should be performed.
Typical Preventive Maintenance Schedule
Figure 2
The results of all of the maintenance and testing that are performed on batteries should be
recorded on battery records, and the individual records for each battery installation should be
kept in a separate file for the life of the battery. The first step of the record keeping process is
to record the baseline data for the battery. The baseline data are the data that were obtained
during the start-up and commissioning of the battery. (These data were discussed in Module
EEX 211.06.) Future maintenance records are added as maintenance is performed to provide
a chronological history of the battery's condition. The chronological history is used to
identify and analyze trends or isolated problems. This information aids the Electrical
Engineer in making future decisions in regard to the operation, maintenance, and
troubleshooting of the battery.
Figures 3 through 5 show typical storage battery maintenance record forms. These forms
coincide with the typical storage battery maintenance schedule that previously was shown in
Figure 2.
Figure 3 shows a typical storage battery maintenance record form that can be used to record
the results of routine maintenance. The form is divided into two major parts: Identification
Data and Maintenance Data. The Identification Data section is used to record the pertinent
information that is needed to identify the particular battery on which the maintenance was
performed. The Maintenance Data section is used to record the actual results of the
maintenance that was performed. A space is provided to record the results of each of the
routine maintenance items that were previously shown on Figure 2.
Storage Battery Maintenance Record - Routine Items
Figure 3
the results of quarterly maintenance. The form is divided into two major parts: Identification
quarterly maintenance items that were previously shown in Figure 2.
Storage Battery Maintenance Record - Quarterly Items
Figure 4
the results of annual maintenance. The form is divided into two major parts: Identification
annual maintenance items that were previously shown on Figure 2. Note that the space that is
provided to record the results of the cell terminal resistance checks and the capacity test
discharge only requires that the overall result of satisfactory or unsatisfactory be entered. The
actual data for these checks are to be recorded on the Individual Cell Terminal Resistance
Test Record and the Battery Acceptance Test Data Sheet, and then these additional records
are to be attached to the annual maintenance record. The Individual Cell Terminal Resistance
Test Record and the Battery Acceptance Test Data Sheet were previously shown and
discussed in Module EEX 211.06.
Storage Battery Maintenance Record - Annual Items
Figure 5
This section of the Module will discuss the following typical battery problems:
Grounding
Electrolyte Loss
Abnormal Specific Gravity
Grounding
The following aspects of battery grounds will be discussed in this section:
Problems Caused
Indications
Corrective Actions
Problems Caused - Saudi Aramco Engineering Standard SAES-P-103 requires that the
positive and the negative dc buses of storage batteries that are installed in Saudi
Aramco industrial facilities be isolated from earth ground; therefore, Saudi Aramco
storage batteries are ungrounded. The possible exception to this requirement is an
application in which industrial and communications systems must share the same dc
bus. In these applications, Saudi Aramco consulting services must be consulted for the
grounding requirements.
Because most Saudi Aramco batteries are ungrounded, a single ground will not cause
any protective devices to operate and, from an operational point of view, no abnormal
conditions will be present other than a possible increase in the battery's discharge rate.
The real problem that is caused by a single ground is an electrical shock hazard to
persons who are working on or near the battery.
The potential problems for the battery itself occur when more than one ground exists
and the magnitude of the fault current is insufficient to trip the protective devices.
This situation can occur when several high resistance ground paths exist between two
cells or a group of cells, which effectively creates a short circuit between the effected
cells. The short circuited cells then become a load on the battery and, if the condition
is not corrected, it will lead to permanent cell damage.
Indications - For installations that have permanently installed ground detectors, battery
grounds are indicated through the routine ground checks that are performed by the
equipment operators. For installations that do not have permanently installed ground
detectors, battery grounds are indicated through measurement of battery terminal
voltages as was previously discussed. Once a battery ground is detected, the ground
can be isolated to a particular cell or group of cells through use of a technique that is
referred to as half-splitting.
Half-splitting involves the measurement and comparison of the following voltages that
are shown on Figure 6:
The total voltage that is developed across a string of cells (V
1
).
The total voltage that is developed from the beginning of the string to the mid-
point of the string (V
2
).
The total voltage that is developed from the mid-point of the string to the end
of the string (V
3
).
Voltage V
2
and voltage V
3
should both be equal to one half of V
1
. If either voltage is
less than one half of V
1
, the ground is located in the half of the string of cells that
produced the lower voltage reading. The half-splitting technique can be repeated on
successively smaller strings of cells until the exact location of the ground is identified.
Half-Splitting Voltage Measurements
Figure 6
Corrective Measures - Once the location of the ground has been identified, a detailed
visual inspection of the area should be performed to identify the cause of the ground.
In most cases, the ground path will be some combination of dirt build-up, electrolyte
residue or leakage, and terminal corrosion. The corrective measures consist of
removal of the dirt or corrosion and neutralizing the electrolyte.
Electrolyte Loss
The following aspects of electrolyte loss will be discussed in this section:
Problems Caused
Indications
Corrective Actions
Problems Caused - Because of the electrolysis that occurs during the battery charging
process, some amount of electrolyte loss is anticipated and is normal. The amount of
electrolyte loss that results from normal battery operations varies with the type of
battery, the frequency of charging, and the environmental conditions that are at the
installation site. The anticipated losses are the reason for periodically checking and
watering the battery cells as part of the battery's preventive maintenance program. If
the maintenance program is properly implemented, the electrolyte levels will not drop
below the minimum required level. Provided that the electrolyte levels do remain
above the minimum required level, no problems will result.
If the electrolyte level is allowed to drop below the minimum required level, the
problems that are caused vary dependent upon the actual extent of the level decrease.
If the level drops below the bottom of the tube that is on the flash arrestor but remains
above the plates, the problem that is caused is a slightly increased chance of fire or
explosion. When the electrolyte level drops below the bottom of this tube, the flash
arrestor is effectively bypassed. A subsequent removal of the service cap would allow
direct access to the gas space that is at the top of the cell and, if a spark was present,
the hydrogen gas that is in the gas space would be more likely to ignite. Because
several events need to occur for the hydrogen to be ignited, the overall likelihood of a
fire or an explosion is still small.
The most severe problem that can result from a loss of electrolyte is permanent plate
damage. If the electrolyte level drops below the top of the plates, the exposed portions
of the plates dry out, become extremely brittle, and completely lose their ability to be
charged and discharged.
If the loss of electrolyte is a result of spillage or leaks, other problems such as
corrosion, grounds, and safety hazards also can occur.
Indications - The indications of a loss of electrolyte level are an electrolyte level that is
below the "Min" level mark on the cell jars or electrolyte that is present on the battery
room floor.
Corrective Measures - The first corrective measure is to determine and correct the cause
of the electrolyte loss. The following are some of the typical causes of electrolyte loss:
Overcharging.
Leaks.
Spillage.
A drop in ambient temperature.
The battery is approaching the end of its service life (antimony cells).
Improperly scheduled or inadequate preventive maintenance.
If the cause can be corrected (e.g., the cause was not a leak), and if the plates were not
exposed and damaged, the affected cells should be filled to their normal level. After
the cells have been filled, normal battery operation can resume.
If the cause of the electrolyte loss was a leak, or if plate damage occurred, the battery
should be placed on open circuit and the affected cell should be drained and removed.
Also, the electrolyte that leaked out of the cell must be cleaned up and neutralized. If
a replacement cell is available, the replacement cell should be installed and normal
battery operation can resume. If a replacement cell is not available, jumpers can be
installed to re-connect the battery with one less cell. The battery can then be
temporarily operated in this condition until a replacement cell can be obtained.
Abnormal Specific Gravity
The following aspects of abnormal specific gravities will be discussed in this section:
Problems Caused
Indications
Corrective Actions
Problems Caused - Because specific gravity is a direct indicator of the state of charge of
a lead-acid battery, an abnormally low specific gravity indicates a low state of charge.
If all of the cells of a battery have a low specific gravity, the battery is in a low state of
charge and, as a result, it may not be capable of supplying the required amount of
emergency or standby power for which it was installed.
If only one or several cells have low specific gravities, these particular cells will limit
the overall capacity of the battery. When the battery is discharged, the cells that have
the low specific gravities will reach their low voltage limits (approximately 1.75V)
before the rest of the battery. If the discharge is not stopped when the first cell reaches
its low voltage limit, cell reversal will occur, which is quickly followed by cell
damage.
Because the amount of acid that is in the electrolyte does not change after the cells
have initially been filled, abnormally high specific gravities almost never occur. If
such a condition did occur, the problems that are caused are increased rates of self-
discharge and reduced service life.
Indications - Direct indications of abnormal specific gravities can be obtained through
measurement of the actual specific gravities with a hydrometer; however, before the
measured specific gravities can be called abnormal, all of the factors that affect
specific gravity readings must be taken into account. Examples of these factors
include cell temperature, electrolyte level, whether or not the battery was recently
watered, and the accuracy of the hydrometer.
Generally, a cell is said to have an abnormal specific gravity when its corrected
specific gravity is more than five points (expressed .005) above or below the average
corrected specific gravity of all of the cells that are in the installation. The battery
itself is said to have an abnormal specific gravity when one of the following conditions
exist:
The difference between the highest cell's corrected specific gravity and the
lowest cell's corrected specific gravity is more than ten points (expressed .010).
The difference between the initial and the current average corrected specific
gravity of all of the cells that are in the installation is more than ten points (i.e.,
.010).
The indirect indications of abnormal specific gravities are abnormal individual cell
voltages or abnormal total battery voltages. If these conditions are observed, a direct
measurement of the specific gravities is normally performed for confirmation.
Corrective Measures - If the abnormal specific gravity is isolated to one or several cells,
the first corrective measure would be to recheck the specific gravity readings to verify
the existence of a problem. Once the abnormal specific gravity has been confirmed,
the affected cells should be inspected for visible signs of damage and high resistance
connections. If the results of these inspections are satisfactory, the battery should be
given an equalizing battery charge in attempt to correct the problem. If the problem
still exists at the completion of the equalizing charge, the manufacturer should be
contacted to determine if any special charging procedures can be performed to correct
the problem.
If the problem cannot be corrected, a capacity test discharge should be performed to
determine whether the battery's capacity is still acceptable. If the capacity is still
acceptable, normal battery operation can be resumed; however, the affected cells
should be more closely monitored for the duration of the service life. If the battery
capacity is unacceptable, the affected cells must be replaced.
If the abnormal specific gravity pertains to the entire battery, one of the following
problems likely exists:
The float voltage setpoint is too low.
Too much time has elapsed since the last equalizing charge.
The battery is near the end of its service life
For the above problems, the first corrective measure would be to check and to adjust
the float voltage setpoint and to then perform an equalizing battery charge to correct
the abnormal specific gravities. If the float voltage setpoint was correct, and if the
equalizing charge had corrected the specific gravity problem, the frequency of the
equalizing charges should be increased to prevent reoccurrence of the problem.
If the equalizing charge did not correct the problem, the battery may be at or near the
end of its service life. A capacity test discharge should be performed to determine
whether the battery's capacity is still acceptable. The acceptable range of battery
capacity is from 80% to >.100% of its original rated capacity. However, when the
battery capacity drops below 85% of its original rated capacity, the battery shows signs
of degradation, and it should be more closely monitored for the duration of the service
life. When the battery capacity drops below 80% of its original rated capacity, the
battery has reached the end of its service life, and it must be replaced.
DETERMINING WHETHER DC/UPS SUBSYSTEMS ARE FUNCTIONING
PROPERLY
Because of the advancement of solid-state electronic circuitry, dc/UPS subsystems generally
have low maintenance requirements. The maintenance of these systems typically only
includes routine inspection and cleaning and self-diagnostic testing. This section of the
Module provides information on the following topics that are pertinent to determining
whether dc/UPS subsystems are functioning properly:
The following preventive maintenance should be performed on dc/UPS subsystems:
Visual Inspection
Cleaning
Battery Charger Checks and Adjustments
Inverter Checks and Adjustments
Visual Inspection
A visual inspection of dc/UPS subsystems is performed to check the overall condition of the
subsystem components. In general, a definitive pass/fail criterion does not exist for most of
the items that are checked during the visual inspection. The person who performs the visual
inspection must rely on his own personal judgement and experience to determine whether the
present condition of the dc/UPS subsystem is acceptable or unacceptable. If the inspector is
not comfortable about some aspect of the equipment's condition, he should seek the guidance
of more experienced personnel.
The following types of problems typically can be identified through performance of a visual
inspection:
Physical Damage
Overheating
Loose Connections
Physical Damage- The visual inspection should start with an inspection of the exterior
of dc/UPS equipment enclosures for evidence of physical damage. If physical damage
to the exterior of the enclosures is evident, the equipment must have been subjected to
some form of shock since it was last inspected. Because external shock increases the
possibility of physical damage to the internal components, the remainder of the
inspections should be performed with extra diligence. The internal inspection for
physical damage should include a check for loose or missing hardware, missing
gaskets/seals, broken wires, damaged insulation, and leaking electrical/electronic
components (e.g., electrolyte from capacitors or potting compound from transformers).
Overheating- Overheating can occur as a result of elevated enclosure temperatures or
circuitry malfunctions. Enclosure overheating can be caused by a defective or
malfunctioning enclosure ventilation fan or by dirty enclosure ventilation system
filters. If enclosure overheating is suspected, a more detailed inspection of the
following cooling components should be performed to determine the cause:
Enclosure ventilation fan
Ventilation fan thermostat
Enclosure ventilation filters
All of the interior components and wiring should be inspected for signs of excessive
heat. The typical indications of component overheating are discolorations such as
browning or charring and/or the presence of ociferous odors. Any components or
wires that show signs of excessive heat should be tested to determine whether they are
still serviceable.
Loose Connections- All of the internal terminations should be inspected to ensure that
they are tight. The most effective method of inspecting for tightness is to apply the
appropriate amount of torque to the termination while checking for any movement. If
any connection is found to be loose, the termination should be further inspected to
determine and correct the cause. The common causes of loose connections are
equipment vibration, improper initial torque, cyclic temperatures, and improper
connection hardware.
Cleaning
The interior of the dc/UPS subsystems must be cleaned on a regular basis to prevent the
accumulation of excessive dust and dirt. The accumulation of excessive amounts of dust and
dirt can lead to the following problems:
The formation of high resistance current paths between components or between
components and ground.
Excessive heat build up.
The degradation of insulation.
Because both the visual inspection and the cleaning should be performed with the dc/UPS
subsystem deenergized, they often are simultaneously performed. The cleaning can be
performed through use of the following methods:
Wiping with a clean cloth.
Vacuum cleaning.
Cleaning with low pressure air.
Solvent cleaning.
Wiping With a Clean Cloth - Initial cleaning should be performed by wiping with a clean,
dry, lint-free cloth to remove the loose dust and dirt that has accumulated. Rags that
deposit lint or that leave "stringers" on electrical and electronic components should not
be used. Lint and "stringers" will retain dirt and dust, which defeats the purpose of
cleaning the equipment.
Vacuum Cleaning- Loose dust and dirt that cannot be removed by wiping should be
removed by vacuum cleaning. The vacuum nozzle that is used should be made from
plastic or rubber; metal or other sharp materials can damage electrical components and
wiring. The effectiveness of vacuum cleaning can be increased through use of a soft
bristle brush. The brush can be used to dislodge the dirt and the vacuum can then be
used to remove the dirt.
Cleaning With Low Pressure Air - A low pressure jet of air should be used to dislodge
dust and dirt from the portions of the equipment that are difficult to reach with a cloth
or a vacuum nozzle. This method is particularly effective in dislodging the dust and
dirt that has accumulated on circuit boards. Cleaning with low pressure air is most
effective when this method is used in conjunction with vacuum cleaning. The low
pressure air jet is used to dislodge the dirt and the vacuum is used to remove the dirt.
The compressed air that is used for this type of cleaning should not exceed 30 psi;
higher air pressures can damage electrical component insulation and coverings. The
compressed air supply also must be free from contaminants such as moisture and oil.
These contaminants can lead to component degradation and short circuits.
Solvent Cleaning- Solvent cleaning is only recommended for use in the removal of
stubborn dirt that cannot be removed by any of the other methods. The following
recommended solvents are listed in order of effectiveness:
Isopropyl alcohol
1,1,1-, trichloroethane (inhibited methyl chloroform)
Freon TF
Cleaning solvents should only be used in a free-air atmosphere and should never be
used in an enclosed area. The solvent should be applied to a lint-free cleaning rag and
the rag should then be used to remove the dirt. Any excess solvent should be wiped
up before it has a chance to evaporate.
If a solvent other than those that are listed above is used, it must have a flash point in
excess of 37.8
o
C; therefore, solvents such as gasoline, naphtha, and similarly volatile
products cannot be used. Another solvent that should never be used is carbon
tetrachloride. This solvent produces highly toxic fumes that can result in sickness or
death.
The following battery charger indicators, controls, and protective devices must be checked
and/or adjusted to ensure that the battery is properly charged and that the equipment operators
will be alerted to abnormal conditions:
dc Voltmeter
dc Ammeter
Float Voltage Adjustment
Equalize Voltage Adjustment
Equalize Timer Check
End of Charge Condition Alarm
Ground Detection Alarm
Charger Overvoltage Alarm
Charger Failure Alarm
Enclosure Overtemperature alarm
Because the output of the inverter is the preferred power source for most Saudi Aramco UPS
systems, and because performance of the battery charger checks and adjustments will affect
the input of power to the inverter, the critical ac loads should be switched to the bypass source
while the maintenance is performed.
dc Voltmeter - The accuracy of the dc voltmeter should be checked and/or adjusted
during the performance of preventive maintenance. The accuracy check consists of a
mechanical zero adjustment and a comparison of the actual meter reading with the
reading of a portable, calibrated voltmeter.
The mechanical zero adjustment is performed by opening the ac supply to the battery
charger and by opening the dc battery breaker. After the breakers are opened, the
meter indicator should be adjusted to read zero by turning the mechanical adjustment
screw.
When the mechanical zero adjustment is complete, the dc battery breaker and the ac
supply breaker should be closed. A portable, calibrated voltmeter should then be
connected to the output of the battery charger. The reading of the portable, calibrated
voltmeter is compared to the reading of the dc voltmeter; the two readings should
agree to within _ 2.0%. If the readings do not agree, the dc voltmeter should be
adjusted until its reading is within the _ 2.0% tolerance. If the dc voltmeter cannot be
adjusted, it should be replaced.
dc Ammeter - The accuracy of the dc ammeter should be checked and/or adjusted
during the performance of preventive maintenance. The accuracy check consists of a
mechanical zero adjustment and a comparison of the actual meter reading with the
reading of a portable, calibrated ammeter.
charger and by opening the dc battery breaker. After the breakers are opened, the
meter indicator should be adjusted to read zero by turning the mechanical adjustment
screw.
When the mechanical zero adjustment is complete, a portable, calibrated ammeter
should then be connected in series with the output of the battery charger, and the dc
battery breaker and the ac supply breaker should be closed. The reading of the
portable, calibrated ammeter is compared to the reading of the dc ammeter; the two
readings should agree to within _ 2.0%. If the readings do not agree, the dc ammeter
should be adjusted until its reading is within the _ 2.0% tolerance. If the dc ammeter
cannot be adjusted, it should be replaced.
Float Voltage Adjustment - The float voltage setpoint of the battery charger should be
checked and/or adjusted during the performance of preventive maintenance. This
check is performed by dividing the dc voltmeter reading by the number of cells that
are in the installation. The quotient is the float voltage per cell that is being applied to
the battery. This calculated value is then compared to manufacturer's recommended
float voltage per cell. Most battery manufacturers specify an acceptable range of float
voltages. If the actual value of float voltage per cell is outside of the acceptable range,
the float voltage setpoint must be adjusted.
Equalize Voltage Adjustment - The equalize voltage setpoint of the battery charger should
be checked and/or adjusted during the performance of preventive maintenance. This
check is performed by placement of the battery charger in the equalize charge position.
After the battery charger is in the equalize charge position, the dc voltmeter reading is
divided by the number of cells that are in the installation to determine the equalize
voltage per cell that is being applied to the battery. This value is then compared to
manufacturer's recommended equalize voltage per cell. Most battery manufacturers
specify an acceptable range of equalize voltages. If the actual value of equalize
voltage per cell is outside of the acceptable range, the equalize voltage setpoint must
be adjusted. After the adjustments are complete, the battery charger should be restored
to the float charge position.
Equalize Timer Check - The equalize timer is an electromechanical or an electronic
device that is used to automatically stop the equalize charge after a specified time
period has elapsed. The timer is scaled in hours and should be accurate to within _
10% of the actual elapsed time. During the performance of preventive maintenance,
only the position of the setpoint adjustment is checked and adjusted; the actual elapsed
time should be checked each time that an equalize charge is performed.
End of Charge Condition Alarm - The End of Charge Condition alarm is intended to alert
the equipment operators that the battery has reached its low voltage limit and that the
battery discharge should be stopped. The alarm usually is set at 1.75 volts per cell for
lead-acid battery systems and at 1.10 volts per cell for nickel-cadmium battery
systems. The alarm should actuate within _ 5.0% of its setpoint.
The alarm setpoint can be checked by opening the battery charger's dc output breaker
and then adjusting the battery charger's output voltage down to the alarm setpoint. If
the alarm does not actuate within its _ 5.0% tolerance, its setpoint should be adjusted.
After the check is completed, the battery charger's output voltage setpoint should be
restored to the float voltage setpoint and the dc output breaker should be closed.
Ground Detection Alarm- The Ground Detection alarm is intended to alert the equipment
operator that a battery ground exists and to trip the battery circuit breaker to protect the
battery charger from an excessive current flow. The Ground Detection alarm should
actuate and the battery circuit breaker should trip when the current flow to earth
ground exceeds 10.0 milliamperes.
The alarm and the circuit breaker trip can be checked by placement of a 2.0k ohm
resistance between the positive battery bus and ground or between the negative battery
bus and ground. If the alarm fails to actuate or if the circuit breaker fails to trip, the
ground detection circuit and/or the battery breaker shunt trip device should be adjusted
or replaced.
Charger Overvoltage Alarm- The Charger Overvoltage alarm is intended to alert the
equipment operator that the battery is being subjected to an excessive charging
voltage. The alarm usually is set to actuate when the charger's output voltage exceeds
10.0% of the nominal cell voltage.
and then adjusting the battery charger's output voltage up to the alarm setpoint. If the
alarm does not actuate within 10% of the nominal cell voltage, its setpoint should be
adjusted. After the check is completed, the battery charger's output voltage setpoint
should be restored to the float voltage setpoint and the dc output breaker should be
closed.
Charger Failure Alarm- The Charger Failure alarm is intended to alert the equipment
operator that the battery charger is no longer charging the battery. The charger failure
alarm usually is set to actuate when the charger's output voltage drops 15% below the
nominal cell voltage.
and then adjusting the battery charger's output voltage down to the alarm setpoint. If
the alarm does not actuate when the battery charger's output drops 15% below the
nominal cell voltage, its setpoint should be adjusted. After the check is completed, the
battery charger's output voltage setpoint should be restored to the float voltage setpoint
and the dc output breaker should be closed.
Enclosure Overtemperature Alarm - The Enclosure Overtemperature alarm is intended to
alert the equipment operator of excessive temperature conditions that require
corrective action. The Enclosure Overtemperature alarm usually is set to actuate when
the battery charger enclosure exceeds the recommended maximum operating
temperature by 10%.
The operation of the alarm's thermostat and contacts can be checked by reducing the
enclosure overtemperature alarm setpoint to the actual enclosure operating
temperature. Because overtemperature alarm devices are fairly linear, successful
operation of the switch at normal temperature is a reasonable indication that the alarm
will operate satisfactorily at its normal setpoint. If the alarm fails to actuate at normal
operating temperature, the temperature switch must be repaired or replaced. At the
completion of the check, the overtemperature alarm should be set at its normal value.
The following inverter indicators, controls, and protective devices must be checked and/or
adjusted to ensure that the inverter properly operates and that the equipment operators will be
alerted to abnormal conditions:
Inverter ac Output Voltmeter
Inverter ac Output Ammeter
Inverter ac Output Frequency Meter
Alternate Source ac Input Voltmeter
High Inverter dc Input Voltage Alarm
Low Inverter dc Input Voltage Alarm
Alternate Voltage/Sync Source Not Available Alarm
Static Switch Position Indication Alarm
Inverter Output Failure Alarm
Auto Synchronization Disconnect Alarm
Static Switch Transfer to Alternate Source Voltage
Static Switch Re-Transfer to Preferred Source Voltage
Static Switch Transfer to Alternate Source Frequency
Static Switch Re-Transfer to Preferred Source Frequency
Enclosure Overtemperature Alarm
Because the output of the inverter is the preferred power source for most Saudi Aramco UPS
systems, and because performance of the inverter checks and adjustments will affect the
output of the inverter, the critical ac loads should be switched to the alternate source by
placement of the manual bypass switch in the full bypass position while the maintenance is
performed.
Inverter ac Output Voltmeter - The accuracy of the inverter ac output voltmeter should be
checked and/or adjusted during the performance of preventive maintenance. The
accuracy check consists of a mechanical zero adjustment and a comparison of the
actual meter reading with the reading of a portable, calibrated voltmeter.
charger and opening the dc battery breaker. After the breakers are opened, the meter
indicator should be adjusted to read zero by turning the mechanical adjustment screw.
supply breaker should be closed. A portable, calibrated voltmeter should then be
connected to the output of the inverter. The reading of the portable, calibrated
voltmeter is compared to the reading of the inverter ac output voltmeter; the two
readings should agree to within _ 2.0%. If the readings do not agree, the inverter ac
output voltmeter should be adjusted until its reading is within the _ 2.0% tolerance. If
the inverter ac output voltmeter cannot be adjusted, it should be replaced.
Inverter ac Output Ammeter - The accuracy of the inverter ac output ammeter should be
checked and/or adjusted during the performance of preventive maintenance. The
accuracy check consists of a mechanical zero adjustment and a comparison of the
actual meter reading with the reading of a portable, calibrated ammeter.
When the mechanical zero adjustment is complete, a portable, calibrated ammeter
should be connected in series with the output of the inverter, and the dc battery breaker
and the ac supply breaker should be closed. The reading of the portable, calibrated
ammeter is compared to the reading of the inverter ac output ammeter; the two
readings should agree to within _ 2.0%. If the readings do not agree, the inverter ac
output ammeter should be adjusted until its reading is within the _ 2.0% tolerance. If
the inverter ac output ammeter cannot be adjusted, it should be replaced.
Inverter ac Output Frequency Meter - The accuracy of the inverter ac output frequency
meter should be checked and/or adjusted during the performance of preventive
maintenance. The accuracy check consists of a mechanical zero adjustment and a
comparison of the actual meter reading with the reading of a portable, calibrated
oscilloscope.
supply breaker should be closed. A portable, calibrated oscilloscope should then be
connected to the output of the inverter. The reading of the portable, calibrated
oscilloscope is compared to the reading of the inverter ac output frequency meter; the
two readings should agree to within _ 2.0%. If the readings do not agree, the inverter
ac output frequency meter should be adjusted until its reading is within the _ 2.0%
tolerance. If the inverter ac output frequency meter cannot be adjusted, it should be
replaced.
Alternate Source ac Input Voltmeter - The accuracy of the alternate source ac input
voltmeter should be checked and/or adjusted during the performance of preventive
maintenance. The accuracy check consists of a mechanical zero adjustment and a
comparison of the actual meter reading with the reading of a portable, calibrated
voltmeter.
Before the mechanical zero adjustment can be performed, the critical ac loads must be
transferred back to the inverter. After the loads have been transferred, the mechanical
zero adjustment is performed by opening the alternate source ac supply breaker. After
the breaker is open, the meter indicator should be adjusted to read zero by turning the
mechanical adjustment screw.
When the mechanical zero adjustment is complete, the alternate source ac supply
breaker should be closed. A portable, calibrated voltmeter should then be connected
to the alternate ac power source. The reading of the portable, calibrated voltmeter is
compared to the reading of the alternate source ac input voltmeter; the two readings
should agree to within _ 2.0%. If the readings do not agree, the alternate source ac
input voltmeter should be adjusted until its reading is within the _ 2.0% tolerance. If
the alternate source ac input voltmeter cannot be adjusted, it should be replaced. After
the check is complete, the critical ac loads should be transferred back to the alternate
source.
High Inverter dc Input Voltage Alarm - The High Inverter dc Input Voltage alarm is
intended to alert the equipment operators of an inverter condition that requires
corrective action. The alarm usually is set to actuate when the dc input voltage to the
inverter rises 5% above the nominal dc input voltage.
The alarm can be tested by opening the dc battery breaker and then raising the battery
charger output voltage. If the alarm does not actuate when the dc input voltage
exceeds the nominal input voltage by 5%, the alarm setpoint must be adjusted. After
the check has been completed, the battery charger output should be returned to the
float voltage setpoint and the dc battery breaker should be closed.
Low Inverter dc Input Voltage Alarm - The Low Inverter dc Input Voltage alarm is
intended to alert the equipment operators of a problem that is associated with the input
power supply to the inverter and that requires corrective action. The alarm usually is
set to actuate when the dc input voltage to the inverter drops 5% below the nominal dc
input voltage.
The alarm can be tested by opening the dc battery breaker and by then lowering the
battery charger output voltage. If the alarm does not actuate when the dc input voltage
drops below the nominal input voltage by 5%, the alarm setpoint must be adjusted.
After the check has been completed, the battery charger output should be returned to
the float voltage setpoint and the dc battery breaker should be closed.
Alternate Voltage/Sync Source Not Available Alarm - The Alternate Voltage/Sync Source
Not Available Alarm is intended to alert the equipment operators of a potential loss of
system reliability. The alarm usually is set to actuate when the alternate source voltage
deviates from the nominal system voltage by _ 10.0% or when the alternate source
frequency deviates from the nominal system frequency by _ 5.0%.
Before this alarm can be tested, the critical ac loads must be transferred to the output
of the inverter. After the loads have been transferred, the alternate source ac supply
breaker can be opened to check the operation of this alarm. After the check has been
completed, the ac supply breaker should be closed and the critical ac loads should be
transferred back to the alternate source.
Static Switch Position Indication Alarm - The Static Switch Position Indication alarm is
intended to alert the equipment operators that the critical ac loads have been
transferred from the inverter to the alternate power source. Before this alarm can be
checked, the critical ac loads must be transferred to the output of the inverter.
After the loads have been transferred, the ac supply breaker for the battery charger can
be opened in conjunction with the dc battery breaker to check the operation of the
alarm. Opening of these breakers will cause the static switch to transfer to the
alternate power source. This transfer should actuate the alarm. After the check has
been completed, the ac supply breaker for the battery charger and the dc battery
breaker should be closed, and the manual bypass switch should be placed back in the
full bypass position.
Inverter Output Failure Alarm- The Inverter Output Failure alarm is intended to alert the
equipment operators of a problem that is associated with the preferred power source
and that requires corrective action. This alarm usually is set to actuate when the output
voltage of the inverter deviates from the nominal output voltage by _ 10.0% or when
the output frequency of the inverter deviates from the nominal value of 60 Hz by
_5.0%.
The voltage actuation of the alarm can be checked by adjusting the output voltage
potentiometer of the inverter up and down until the alarm actuates. If the alarm does
not actuate at both +10% and -10% of nominal, the alarm setpoint should be adjusted.
The frequency actuation of the alarm can be checked by adjusting the output
frequency potentiometer that is on the oscillator board up and down until the alarm
actuates. If the alarm does not actuate at both +5% and -5% of nominal, the alarm
setpoint should be adjusted. After the check is complete, the inverter's output voltage
and frequency should be returned to normal.
Auto Synchronization Disconnect Alarm - The Auto Synchronization Disconnect alarm is
intended to alert the equipment operators of a potential loss of system reliability. The
alarm usually is set to actuate when the alternate source frequency deviates from the
inverter frequency by _ 5.0%.
Before this alarm can be tested, the critical ac loads must be transferred to the output
of the inverter. After the loads have been transferred, the alternate source ac supply
breaker can be opened to check the operation of this alarm. After the check has been
completed, the ac supply breaker should be closed and the critical ac loads should be
transferred back to the alternate source by placement of the manual bypass switch in
the full bypass position.
Static Switch Transfer to Alternate Source Voltage- When the inverter's output voltage is
unsatisfactory, the static switch is designed to automatically transfer the critical ac
loads from the output of the inverter to the alternate power source. The transfer
should occur when the inverter output voltage deviates from the nominal output
voltage by more than _ 10%.
Before the automatic transfer feature can be checked, the manual bypass switch should
be placed in the test bypass position. After the switch is in this position, the inverter
output voltage potentiometer should be raised to the transfer setpoint. The successful
transfer will be indicated by the actuation of the static switch position indication alarm.
If the transfer did not occur when the inverter output voltage exceeded the nominal
voltage by 10%, the transfer setpoint must be adjusted. The check should then be
repeated for the low voltage transfer setpoint. When both checks have been
satisfactorily completed, the inverter output voltage should be adjusted to normal and
the critical ac loads should be transferred back to the alternate source by placement of
the manual bypass switch in the full bypass position.
Static Switch Re-Transfer to Preferred Source Voltage- Because the output of the inverter is
the preferred source of power for the critical ac loads, the static switch is designed to
retransfer back to the output of the inverter when the inverter's output voltage returns
to normal. The retransfer should occur when the inverter's output voltage returns to
within _ 2.0% of the nominal output voltage.
The retransfer feature should be checked in conjunction with the transfer feature.
After the inverter transfers to the alternate source, the inverter output voltage
potentiometer should be raised to the retransfer setpoint. A successful retransfer is
indicated by clearance of the static switch position indication alarm. When the check
has been satisfactorily completed, the inverter output voltage should be adjusted to
normal and the critical ac loads should be transferred back to the alternate source by
placement of the manual bypass switch in the full bypass position.
Static Switch Transfer to Alternate Source Frequency - When the inverter's output frequency
is unsatisfactory, the static switch is designed to automatically transfer the critical ac
loads from the output of the inverter to the alternate power source. The transfer should
occur when the inverter output frequency deviates from the nominal output frequency
by more than _ 5.0%.
Before the automatic transfer feature can be checked, the manual bypass switch should
be placed in the test bypass position. After the switch is in this position, the inverter
output frequency potentiometer should be raised to the transfer setpoint. The
successful transfer will be indicated by the actuation of the static switch position
indication alarm. If the transfer did not occur when the inverter output frequency
exceeded the nominal frequency by 5.0%, the transfer setpoint must be adjusted. The
check should then be repeated for the low frequency transfer setpoint. When both
checks have been satisfactorily completed, the inverter output frequency should be
adjusted to normal and the critical ac loads should be transferred back to the alternate
source by placement of the manual bypass switch in the full bypass position.
Static Switch Re-Transfer to Preferred Source Frequency - Because the output of the inverter
is the preferred source of power for the critical ac loads, the static switch is designed to
retransfer back to the output of the inverter when the inverter's output frequency
returns to normal. The retransfer should occur when the inverter's output frequency
returns to within _ 2.0% of the nominal output frequency.
The retransfer feature should be checked in conjunction with the transfer feature.
After the inverter transfers to the alternate source, the inverter output frequency
potentiometer should be raised to the retransfer setpoint. A successful retransfer is
indicated by clearance of the static switch position indication alarm. When the check
has been satisfactorily completed, the inverter output frequency should be adjusted to
normal and the critical ac loads should be transferred back to the alternate source by
placement of the manual bypass switch in the full bypass position.
Enclosure Overtemperature Alarm - The Enclosure Overtemperature alarm is intended to
alert the equipment operator of excessive temperature conditions that require
corrective action. The Enclosure Overtemperature alarm usually is set to actuate when
the UPS system enclosure exceeds the recommended maximum operating temperature
by 10%.
The operation of the alarm's thermostat and contacts can be checked by reducing the
enclosure overtemperature alarm setpoint to the actual enclosure operating
temperature. Because overtemperature alarm devices are fairly linear, successful
operation of the switch at normal temperature is a relatively reliable indication that the
alarm will operate satisfactorily at its normal setpoint. If the alarm fails to actuate at
normal operating temperature, the temperature switch must be repaired or replaced. At
the completion of the check, the overtemperature alarm should be set at its normal
value.
The overall goal of dc/UPS subsystem preventive maintenance is to identify and correct
minor or impending problems that, if left unchecked, could result in a reduction of system
reliability or in a complete system failure. In order for a dc/UPS subsystem preventive
maintenance program to achieve its goal, the dc/UPS subsystem equipment must be checked
at regularly scheduled intervals. The regularly scheduled intervals vary dependent upon the
equipment manufacturers, the type of intended service, and the environmental conditions that
exist at the installation. The initial dc/UPS subsystem preventive maintenance inspection
frequencies are normally established on the basis of the manufacturer's recommendations.
These initial frequencies can then be modified (increased or decreased in length) on the basis
of local site operating experience and/or governing codes and standards for a particular type
of service.
As an example of how inspection frequencies can be modified on the basis of local site
operating experience, assume that a particular UPS manufacturer recommends that the UPS
system be visually inspected and cleaned once per quarter. Also assume that the results of
three consecutive quarterly inspections and cleanings showed that no abnormal conditions
existed and that little or no dirt had accumulated since the previous maintenance. Based on
these results, the interval between the visual inspections and cleanings for this particular UPS
system could be increased. The visual inspection and cleaning frequency for this UPS system
could be changed from a quarterly requirement to a semi-annual or an annual requirement.
Figure 7 shows a typical preventive maintenance schedule for a dc/UPS subsystem. The
schedule contains the preventive maintenance requirements and the frequency of
performance. The frequency of performance section is divided into three time categories:
routine, quarterly, and annually. The routine column can represent daily, weekly, bi-weekly,
or monthly preventive maintenance requirements. The applicable frequency for all of the
preventive maintenance items should be established as previously explained.
Preventive Maintenance Frequency of Performance
Requirement Routine Quarterl
y
Annuall
y
Visual Inspection
Physical Damage X
Overheating X
Loose Connections X
Cleaning X
dc Voltmeter X
dc Ammeter X
Float Voltage Adjustment X
Equalize Voltage Adjustment X
Equalize Timer Check X (1)
End of Charge Condition Alarm X
Ground Detection Alarm X
Charger Overvoltage Alarm X
Charger Failure Alarm X
Enclosure Overtemperature Alarm X
Inverter ac Output Voltmeter X
Inverter ac Output Ammeter X
Inverter ac Output Frequency Meter X
Alternate Source ac Input Voltmeter X
High Inverter dc Input Voltage Alarm X
Low Inverter dc Input Voltage Alarm X
Alternate Voltage/Sync Source Not Available Alarm X
Static Switch Position Indication Alarm X
Inverter Output Failure Alarm X
Auto Synchronization Disconnect Alarm X
Static Switch Transfer to Alternate Source Voltage X
Static Switch Re-Transfer to Preferred Source Voltage X
Static Switch Transfer to Alternate Source Frequency X
Static Switch Re-Transfer to Preferred Source
Frequency
X
Enclosure Overtemperature Alarm X
NOTE (1) Only the timer setpoint is checked during routine preventive maintenance. The
actual elapsed time should be checked each time that an equalizing change is
performed.
Typical dc/UPS Subsystem Preventive Maintenance Schedule
Figure 7
The results of all of the maintenance and testing that is performed on dc/UPS systems should
be recorded on maintenance records, and the individual records for each dc/UPS system
installation should be kept in a separate file for the life of the system. The first step of the
record keeping process is to record the baseline data for the system. The baseline data are the
data that were obtained during the start-up and commissioning of the dc/UPS system, which
was discussed in Module EEX 211.06. Future maintenance records are added as maintenance
is performed to provide a chronological history of the dc/UPS system's condition. The
chronological history is used to identify and analyze trends or isolated problems. This
information aids the Electrical Engineer in making future decisions in regard to the operation,
maintenance, and troubleshooting of the dc/UPS system.
Figures 8 through 10 show typical dc/UPS subsystem maintenance record forms. These
forms coincide with the typical dc/UPS subsystem preventive battery maintenance schedule
that previously was shown in Figure 7.
Figure 8 shows a typical dc/UPS subsystem preventive maintenance record form that can be
used to record the results of routine maintenance. The form is divided into two major parts:
Identification Data and Maintenance Data. The Identification Data section is used to record
the pertinent information that is needed to identify the particular dc/UPS subsystem on which
the maintenance was performed. The Maintenance Data section is used to record the actual
results of the maintenance that was performed. A space is provided to record the results of
each of the routine maintenance items that was previously shown on Figure 7.
dc/UPS Subsystem Preventive Maintenance Record - Routine Items
Figure 8
used to record the results of quarterly maintenance. The form is divided into two major parts:
each of the quarterly maintenance items that was previously shown on Figure 7.
dc/UPS Subsystem Preventive Maintenance Record - Quarterly Items
Figure 9
used to record the results of annual maintenance. The form is divided into two major parts:
each of the annual maintenance items that was previously shown on Figure 7.
dc/UPS Subsystem Preventive Maintenance Record - Annual Items
Figure 10
This section of the Module will discuss following typical dc/UPS subsystem problems and
their corrective measures:
Tripping of Input/Output Breakers
Improper Inverter Output
SCR Failures
Tripping of Input/Output Breakers
Input and output circuit breakers are employed to protect the system equipment and
personnel. Each device is designed to trip on excessive current flow. The ac input circuit
breaker is designed to protect the battery charger and the inverter from faults that occur
upstream of the output circuit breaker. The battery breaker provides a means to isolate the
battery from the battery charger and the inverter, which, depending on the direction of current
flow, protects the inverter input circuit or the battery. The output circuit breaker protects the
inverter in the event of a critical ac load fault or overload condition. The following aspects of
the tripping of input/output circuit breakers will be discussed in this section:
Problems Caused
Indications
Corrective Measures
Problems Caused - Because a number of power supply redundancies are designed into
the dc/UPS subsystem, few problems can result from inadvertent tripping of the input
or output circuit breakers. The most serious problem of a loss of power to the critical
ac loads cannot occur following a single circuit breaker trip. If only the ac input
circuit breaker trips, a loss of power to the critical ac loads cannot occur without a
simultaneous trip of the battery breaker and the alternate source input breaker. If only
the ac output circuit breaker trips, a loss of power to the critical ac loads cannot occur
without a simultaneous trip of the alternate source input breaker. For these reasons,
the only real problem that is caused by the inadvertent trip of the input or the output
circuit breaker is a partial loss of system reliability.
Indications- An inadvertent trip of the input/output circuit breakers will cause a number
of the parameters that are monitored by the dc/UPS subsystem to change. Because
some of these parameters are monitored by alarms, the first indication of an input or an
output circuit breaker trip generally is the receipt of an alarm. Other dc/UPS
subsystem parameters also will indicate abnormal values. The following is a list of
indications and/or alarms that occur after an inadvertent trip of the input or the output
circuit breaker:
Breaker Trip Condition Indication and/or Alarm
AC Input Circuit Breaker
Inverter Output Breaker
Charger Failure Alarm
DC Ammeter Indicates Zero
Inverter Output Failure Alarm
Abnormal Inverter ac Output Voltage
Abnormal Inverter ac Output
Frequency
Corrective Actions- Because of the multitude of individual faults or failures that could
cause the input or the output circuit breaker to trip, the various corrective actions
cannot be covered in this section. Generally, the corrective actions consist first of
identifying the cause of the trip. After the cause is known, knowledge of system
operation must be applied to identify and repair/replace the defective components(s).
The following is a list of some of the possible causes of input and output circuit
breaker trips:
Breaker Trip Possible Causes
AC Input Circuit Breaker
AC Output Circuit Breaker
Battery Charger Fault
Inverter Fault
Defective ac Input Circuit Breaker
Defective ac Output Circuit Breaker
Critical ac Load Fault
Improper Inverter Output
The following aspects of improper inverter outputs will be discussed in this section:
Problems Caused
Indications
Corrective Actions
Problems Caused - The common inverter output problems are an excessive or an
insufficient inverter output voltage and an excessive or an insufficient inverter output
frequency. Because the output of the inverter is the preferred source of power for the
critical ac loads, and because many of the critical ac loads are sensitive to power
supply fluctuations, an improper inverter output could cause improper operation of the
critical ac loads. However, as previously discussed in this Module, built-in
redundancies and automatic transfers should prevent an improper inverter output from
being supplied to the critical ac loads; therefore, the only real problem that results from
improper inverter output is a partial loss of system reliability.
Indications- The indications of an improper inverter output are a combination of
abnormal panelmeter readings and audible alarms. When the inverter output voltage
or frequency exceeds its allowable tolerance, the following panelmeter indications and
alarms should be present:
The respective panelmeter (voltage/frequency) will indicate a value that is
greater than the acceptable tolerance.
The inverter output failure alarm will operate.
The static switch position indication alarm will operate.
The inverter output ac ammeter will read zero amps.
Corrective Actions- Many conditions can cause an improper inverter output. These
conditions can range from an improper dc input, through an inverter malfunction, to a
static switch malfunction. Before corrective actions are initiated, the exact location of
the malfunction must be determined. If the malfunction occurred as a result of a
problem with the inverter input, additional alarms would occur. Alarms such as Low
Charger Output Voltage alarm, Charger Overvoltage alarm, Charger Failure alarm, or
Low Battery Current alarm indicate that a problem exists with the battery charger or
the battery that is merely being transferred to the inverter. In these situations, the
problem that must be corrected is "upstream" of the inverter. Knowledge of system
operation must be applied to identify and repair/replace the defective "upstream"
component. When the "upstream" malfunction is corrected, the static switch should
retransfer to the inverter after verification of proper voltage, frequency, and phase
relationship.
If the inverter input is satisfactory, and if the inverter output is improper, the problem
most likely is in the inverter itself or in the static switch. In this situation, knowledge
of inverter and/or static switch operation must be applied to identify and replace/repair
the defective component. To deenergize the inverter and the static switch for
troubleshooting, the manual bypass switch should be placed in the full bypass position.
This position will allow maintenance to be performed on the inverter and the static
switch with no affect on the critical ac load.
After the necessary repairs are complete, the manual bypass switch should be placed in
the test bypass position to make the necessary output voltage and frequency
adjustments. When the repairs and adjustments are completed, the manual bypass
switch should be placed in the normal position. When the manual bypass switch is in
this position, the static switch should automatically retransfer to the inverter after
proper voltage, frequency, and phase relationship is verified.
SCR Failures
SCR's (silicon control rectifiers) are used in the battery charger, the inverter, and the static
switch. Battery charger SCR's are used to convert the preferred source ac into rectified dc.
The inverter SCR's are used to produce the 60 Hz ac output to the critical ac loads from the dc
input. The static switch SCR's are used to electronically switch between the inverter output
and an alternate power source. The following aspects of SCR failures will be discussed in this
section:
Problems Caused
Indications
Corrective Actions
Problems Caused - Generally, SCR's fail in one of two ways: they open circuit or they
short circuit. The type of problems that are caused by SCR failures depend on where
the SCR's are used. If the failed SCR is in the battery charger, the problem that is
caused is a high or a low battery charger output voltage. A short-circuited SCR in the
battery charger will cause a high battery charger output voltage because the short-
circuited SCR will continuously conduct. An open-circuited SCR in the battery
charger will cause a low battery charger output voltage because the open-circuited
SCR will not conduct.
If the failed SCR is in the inverter, the problems that will be caused are an improper
inverter output voltage, an improper inverter output frequency, an improper inverter
output phase relationship. Because all of these parameters (voltage, frequency, and
phase relationship) are controlled through variance of the firing and conduction times
of the SCR's, all three parameters will be affected by both open-circuited and short-
circuited SCR's.
If the failed SCR is in the static switch, the problem that is caused depends on the type
of SCR failure that occurs. An open-circuited SCR in the static switch will cause a
reduction in the inverter's output because one half of the output ac sinewave will be
lost. A short-circuited SCR in the static switch may go unnoticed until a transfer
occurs because a conducting SCR already is essentially a short-circuit connection.
However, when the static switch transfers, a short-circuited SCR will not turn off.
Indications- The indications of an SCR failure also depend on the location of the SCR
that failed. The following are possible indications of an SCR failure in the battery
Charger:
High or low dc voltmeter reading
High or low dc ammeter reading
Charger overvoltage alarm
Charger failure alarm
High inverter dc input voltage alarm
The following are possible indications of an SCR failure in the inverter:
Abnormal inverter output voltage reading
Abnormal inverter output frequency reading
Abnormal inverter output ammeter reading
Static Switch position indication alarm
Inverter output failure alarm
The following are possible indications of a SCR failure in the static switch:
Abnormal inverter output voltage reading
Abnormal inverter output frequency reading
Abnormal inverter output ammeter reading
Static Switch position indication alarm
Inverter output failure alarm
No abnormal indications
Corrective Actions- The first corrective action for an SCR failure is to observe all of the
dc/UPS subsystem indications and alarms to determine the location of the SCR failure.
Once the location of the failure is known, the dc/UPS subsystem should be completely
deenergized by placing the manual bypass switch in the Full Bypass position and by
opening the ac input, battery, and ac output circuit breakers. The suspect SCR's
should then be tested to determine which SCR has failed. The failed SCR should then
be replaced.
After satisfactory replacement of the defective SCR, placement of the manual bypass
switch in the test bypass position will permit safe testing of the system without
disruption of power to the critical ac loads. After completion of the proper tests, the
manual bypass switch should be placed in normal to return the system to normal
operation.
WORK AID 1: MAINTENANCE SPECIFICATIONS AND TROUBLESHOOTING
GUIDE COMPILED FROM SADP-P-103 AND ESTABLISHED
ENGINEERING PRACTICES FOR DETERMINING WHETHER
BATTERIES ARE FUNCTIONING PROPERLY
Maintenance Specifications
Item/Condition Checked Specifications
General Cleanliness The battery cells, battery room floor, and ventilation system filters should be free from
excessive dirt, dust, electrolyte residue, and/or water buildup.
Battery Rack All battery rack hardware and floor mount connections must be tight. The battery rack's
epoxy coating should be free from chips and cracks.
Cell Case Integrity The cell case integrity cannot be breached.
Vent Caps/Flame Arrestors The vent caps/flame arrestors should be clean, tight, and free from cracks or other defects.
Cell Terminals All cell terminals must be free from corrosion.
All cell terminal connections should be tightened to the torque that is recommended by the
manufacturer (usual range is 60-125 inch-pounds).
The terminal resistances should not vary from the previous reading by more than 20%.
Also, all terminal resistances should be within 10% or 5__ of the average of all of the
terminal resistance readings.
Cell Internals
(Lead-Acid only)
The cell plates should be free from excessive sulphation and they should not be bowed or
warped.
The bottom of the cell should be free from excessive sediment.
Specific Gravity
(Lead-Acid Only)
The corrected specific gravity should be consistent with the battery's current state of charge.
All corrected specific gravity readings should be within 10 points (.010) of the average
corrected specific gravity readings of all of the cells.
Individual Cell Voltages All individual cell voltage readings should be consistent with the battery's current state of
charge and with the current float voltage setpoint.
Electrolyte Levels The electrolyte levels must be in the normal operational band (e.g., between the high and
low level marks on the side of the cell case).
Capacity Test Discharge Degradation is indicated by a 10% decrease in capacity from the previous the previous test.
End of service life is indicated by a capacity that is less than 80% of the manufacturer's
rating.
Float Voltage The float voltage should be within _1% of the value that is recommended by the
manufacturer. The normal range of float voltage per cell for lead-antimony batteries is 2.13-
2.18 volts per cell. The normal range of float voltage per cell for lead-calcium batteries is
2.17-2.29 volts per cell. The normal range of float voltage per cell for nickel-cadmium
batteries is 1.40 to 1.42 volts per cell.
Equalizing Voltage For battery chargers that are rated at less than 10 kW, the equalizing voltage should be
within _1% of the value that is recommended by the manufacturer.
For battery chargers that are rated above 10 kW, the equalizing voltage should be within
_2% of the value that is recommended by the manufacturer.
The normal range of equalizing voltage per cell for lead-antimony batteries is 2.24-2.33
volts per cell. The normal range of equalizing voltage per cell for lead-calcium batteries is
2.29-2.39 volts per cell. The normal range of equalizing voltage per cell for nickel-
cadmium batteries is 1.50 - 1.60 volts per cell.
Battery Terminal Voltages The voltage that is measured between the positive terminal and the negative terminal should
be equal to the float voltage per cell times the number of cells that are in the installation.
The voltage that is measured between the positive terminal and ground or between the
negative terminal and ground should be equal to one half of the total battery voltage.
Troubleshooting Guide
Symptom Possible Cause(s) Possible Corrective Actions
Low Total Battery Voltage Low float voltage Raise float voltage setting and perform an
equalizing charge.
Battery ground Locate and clear the ground.
High resistance connections Locate and repair the high resistance
connections.
Excess sulphation (lead-acid cells) or
battery is discharged
Perform an equalizing charge.
Battery is nearing the end of its service life. Replace the battery.
One or more of the cells is defective or
contaminated.
Locate and repair/replace defective cells.
Undersized battery charger Verify the charger size and if necessary,
replace the charger.
Excessive battery temperature Identify and correct the ventilation problem.
Low Individual Cell
Voltage
Grounded cell Clear the ground.
High resistance connection Correct the condition that is causing the
high resistance.
High cell temperature Determine and correct the cause of the high
temperature.
Excess sulphation (lead-acid cells) Perform an equalizing charge.
Damaged or contaminated cell Replace the cell.
Low Specific Gravity
Readings
(Lead-Acid Only)
Low float voltage Raise the float voltage setpoint and perform
an equalizing battery charge.
High resistance connections Locate and repair the high resistance
connections.
Excess sulphation or battery is discharged. Perform an equalizing charge.
Electrolyte stratification If the battery recently was watered, the
condition is normal and no corrective action
is necessary.
If only one or several cells are affected, mix
electrolyte by drawing it into the
hydrometer and then discharging it back
into the cell several times.
If multiple cells are affected, perform an
equalizing battery charge.
The battery is nearing the end of its service
life.
Replace the battery.
Undersized battery charger Verify the charger size and if necessary,
replace the charger.
Excessive battery temperature Identify and correct the ventilation problem.
High Water Usage/Low
Electrolyte Levels
Excessive float voltage Lower float voltage setting.
High ambient temperature and/or low
humidity
Increase monitoring frequency to prevent
low levels.
Battery is nearing the end of its service life. Replace the battery.
WORK AID 2: MAINTENANCE SPECIFICATIONS AND TROUBLESHOOTING
GUIDE COMPILED FROM ESTABLISHED ENGINEERING
PRACTICES FOR DETERMINING WHETHER DC/UPS
SUBSYSTEMS ARE FUNCTIONING PROPERLY
Maintenance Specifications
Item/Condition Checked Specifications
Physical Damage The equipment should be free from loose or missing hardware, missing gaskets or seals, broken wires,
damaged insulation, and leaking electrical/electronic components.
Overheating Components should not show any signs of excessive heat such as browning, charring, or unusual odors.
Loose Connections All of the internal termination should be tight.
All internal terminations should be made up using the proper hardware.
Cleanliness All equipment should be free from excessive dirt, dust, or other foreign residues.
Battery Charger dc Voltmeter Reading should agree with a portable calibrated dc voltmeter to within _2%.
Battery Charger dc Ammeter Reading should agree with a portable calibrated dc ammeter to within _2%.
Float Voltage Adjustment The float voltage should be within _1% of the value that is recommended by the manufacturer. The normal
range of float voltage per cell for lead-antimony batteries is 2.13-2.18 volts per cell. The normal range of
float voltage per cell for lead-calcium batteries is 2.17-2.29 volts per cell. The normal range of float voltage
per cell for nickel-cadmium batteries is 1.40 - 1.42 volts per cell.
Equalize voltage Adjustment For battery chargers that are rated at less than 10 kW, the equalizing voltage should be within _1% of the
value that is recommended by the manufacturer.
For battery chargers that are rated above 10 kW, the equalizing voltage should be within _2% of the value
that is recommended by the manufacturer.
The normal range of equalizing voltage per cell for lead-antimony batteries is 2.24-2.33 volts per cell. The
normal range of equalizing voltage per cell for lead-calcium batteries is 2.29-2.39 volts per cell. The normal
range of equalizing voltage per cell for nickel-cadmium batteries is 1.50 - 1.60 volts per cell.
Equalize Timer The timer should be set at the number of hour that are recommended by the manufacturer.
The actual elapsed time should agree with the timer setpoint to within _10%.
End of Charge Condition Alarm The alarm should actuate at 1.75 volts, _5.0%.
Ground Detection Alarm The alarm should actuate when the current flow to exceeds 10.0 mA.
Charger Overvoltage Alarm The alarm should actuate at 10% above the nominal cell voltage.
Charger Failure Alarm The alarm should actuate at 15% below the nominal cell voltage.
Enclosure Overtemperature Alarm The alarm should actuate when the temperature reaches the maximum operating temperature that is
recommended by the manufacturer, +10%, -0.0%.
Inverter ac Output Voltmeter Reading should agree with a portable calibrated ac voltmeter to within _2%.
Inverter ac Output Ammeter Reading should agree with a portable calibrated ac ammeter to within _2%.
Inverter ac Output Frequency Meter Reading should agree with a portable calibrated oscilloscope to within _2%.
Alternate Source ac Input Voltmeter Reading should agree with a portable calibrated ac ammeter to within _2%.
High Inverter dc Input Voltage Alarm The alarm should actuate when the input voltage rises to 5% above the nominal input voltage.
Low Inverter dc Input Voltage Alarm The alarm should actuate when the input voltage drops to 5% below the nominal input voltage.
Alternate Voltage/Sync Source Not Available
Alarm
The alarm should actuate when the alternate source voltage deviates from the nominal system voltage by
_10%.
The alarm also should actuate when the alternate source frequency deviates from the nominal system
frequency by _5.0%.
Static Switch Position Indication Alarm The alarm should actuate when the static switch transfers to the alternate power source.
Inverter Output failure Alarm The alarm should actuate when the inverter output voltage deviates from the nominal output voltage by
_10%.
The alarm also should actuate when the inverter output frequency deviates from the nominal value of 60 Hz
by _5.0%.
Auto Synchronization Disconnect Alarm The alarm should actuate when the alternate source frequency deviates from the inverter frequency by
_5.0%.
Static Switch Transfer to Alternate Source
Voltage
Transfer should occur when the inverter output voltage deviates from the nominal output voltage by _10%.
Voltage
Re-transfer should occur when the inverter output returns to within _2% of the nominal output voltage.
Static Switch Transfer to Alternate Source
Frequency
Transfer should occur when the inverter output frequency deviates from the nominal output frequency by
_5.0%.
Frequency
Re-transfer should occur when the inverter output returns to within _2% of the nominal output frequency.
Enclosure Overtemperature Alarm The alarm should actuate when the temperature reaches the maximum operating temperature that is
recommended by the manufacturer, +10%, -0.0%.
Troubleshooting Guide
Symptom Possible Cause(s) Possible Corrective Actions
Overheating Clogged ventilation filters Clean filters.
Inoperable ventilation fan Repair ventilation fan.
High/Low Inverter
Output Voltage
Improper dc input voltage Adjust the input voltage.
Improperly adjusted or failed
voltage regulator
Replace and/or adjust the
voltage regulator.
High/Low Inverter
Output Frequency
oscillator board
oscillator board.
synchronizing circuit
synchronizing circuit.
Output Waveform
Distortion
Load induced harmonics Identify and filter the problem
load.
Improperly adjusted inverter Adjust the inverter.
glossary
baseline data Initially recorded data obtained during startup and
commissioning checks.
equalizing charge A prolonged charge of a storage battery; the charge is designed
to correct any inequalities of voltage and specific gravity that
may have developed between the cells during service.
flash arrestor A cell-venting device that prevents the propagation of an
external flame into a battery cell.
float charge A continuous, low-rate constant voltage charge of a storage
battery that is designed to maintain the battery in a constant full-
charge condition.
mossing To cover over with a moss-like material.
service life The period of useful service of a battery under specified
conditions. Service life usually is expressed as the time period
or number of cycles that elapses before the ampere-hour capacity
of the battery drops to a specified percentage of rated capacity.
stringers Short thread or lint-like strings.

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O &amp; M of DC &amp; UPS Systems

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Note: The source of the technical material in this volume is the Professional

Engineering Development Program (PEDP) of Engineering Services.

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O & M of DC & UPS Systems

O & M of DC & UPS Systems