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4. 1 Introduction
All standby power and associated system components need periodic maintenance and occasional
replacement of parts in order to ensure optimum reliability.
A planned maintenance program for batteries will typically include the following:
• Check and record the open-circuit battery voltage.
• Verify that the UPS float voltage is correct.
• Inspect all battery terminals and connections for corrosion.
• Inspect all batteries for cracks, leaks or swelling.
• Re-torque the intercell connections per manufacturer's specifications.
• Remove any materials and sweep the floor around the equipment.
4. 2 Battery Testing
The technology of stand-by batteries has changed dramatically in the last twenty years and
despite the designers desires to reduce maintenance it is now more essential and more sophisti-
cated than ever.
In the 1970's the vast majority of stand-by systems used flooded lead acid batteries. This type of
battery had been in use for many decades and the methods of monitoring and maintenance was
well understood. Measurements of the voltage and the specific gravity of the electrolyte were
used to determine the state of charge. Visual inspection of the plates and internal parts was made
through the glass jar containers. Both the maintenance and the design were fairly low level tech-
nology in comparison with the equipment supported.
The 1980's saw dramatic changes with the introduction of so called “maintenance free” or
“sealed” batteries which by the end of the 1980's had captured probably 90% of the market.
However, it soon became apparent that the batteries were neither sealed nor maintenance free and
the current description of Valve Regulated Lead Acid (VRLA) was introduced.
Battery maintenance companies in the main continued to treat the batteries in the traditional
manner. However, it was no longer possible to measure the Specific Gravity or to visually
inspect, as the cases were no longer transparent. Only the voltage reading was left as an indicator.
Unfortunately, the voltage available at the terminals is no indication of true battery health. Many
battery systems failed both prematurely and without warning leading to a serious loss of confi-
dence in the VRLA product generally.
The 1990's saw these problems answered by those maintenance companies prepared to learn and
accept new test methods that provided substitute parameters for those which can no longer be
measured. The most significant of these parameters was the internal impedance of the battery.
R term inals R straps and posts R separator R electrolyte R inter cell weld
40%
Results can be computer generated providing a clear pictures of battery condition as shown in
Figure 4-2 and Figure 4-3.
Float Voltages
7.00
Voltage/Impedance values
in milliohms
6.00
5.00
4.00
Individual battery
Impedance levels
Including Connectors 3.00
2.00
1.00
0.00
Individual battery 1 3
5 7
Impedance levels 9 11
13 15
17
19 21
23
25 27
29 31
5.00
2.00
1.00
0.00
Individual battery
1 3
Impedance levels 5 7 9 11 13
15 17
19 21
23 25
27 29
31
Impedance readings and computer generated results used in conjunction with other tried and
tested methods such as load discharge tests can now provide information to give a clear picture
of battery condition.
Summarising, battery maintenance has entered the technological age. Clear and concise reports
on battery health and life expectancy can be provided with maintenance costs not significantly
greater than traditional, less effective, procedures. Designed and maintained correctly, VRLA
stand-by battery systems can achieve reliability consistent with the critical nature of the loads
they support.
Cost Savings can be derived from a Battery Management Programme utilising Condition Moni-
toring to reduce the requirement for Load Testing.
4.2.2 Load Testing
Load Testing proves the capacity of the battery at the time of the test and the integrity of all the
interconnections. For this reason it is useful at specific times, for instance directly after installa-
tion and commissioning to prove the battery will supply the specified load for the specified time.
A load test is also worthwhile at two thirds of the way through the expected life to confirm pre-
dicted capacity.
However, provided the condition of the battery is correctly monitored and shows the battery to
be healthy there is no reason to think that the battery will not react as required in an emergency,
therefore further load tests are unnecessary.
Disadvantages of Load Testing.
Limited Discharge/Charge regimes were good for flooded cells and countered stratification, but
this does not apply to VRLA batteries.
Completely discharging the battery actually reduces its life. Following a discharge test the bat-
tery is unable to protect the load until it is recharged. Under some circumstances, the battery can
recharge unevenly leading to serious problems, such as the undercharging and overcharging of
battery blocks within the same string (See “Battery Charge and Discharge” on page 3-7.).
Load banks can be large and expensive to purchase, or hire, and to transport. A suitable location
has to be found for the load bank where each battery is located whereas condition monitoring
requires only hand held test equipment and does not effect the ability of the battery to perform
when necessary.
A far more dramatic disadvantage is the risk of a cell exploding. Where a poor connection exists
in a cell, drawing a large current can cause an ark that will ignite any Hydrogen gas present.
4.2.3 Condition Monitoring
Assuming an eight-year life the average battery will require approximately sixteen maintenance
visits. By using condition monitoring the costs of providing load bank equipment can be elimi-
nated on the majority of occasions.
A further benefit of condition monitoring is that results are taken under standard, specific condi-
tions related to the capacity of the battery. Results can be taken quickly but there is no time
constraint. The results are therefore very consistent and can be used to derive trends which can
be compared with new battery data and data for similar batteries in other locations. This is not
the case when discharging a battery where the state of charge and voltage on each cell is chang-
ing rapidly and time is limited to the battery discharge time.
The results taken while condition monitoring can therefore be used to predict individual cell, or
complete battery, life expectancy.
In summary condition monitoring can reduce the cost and improve quality of battery monitoring
in the following ways:
1. The equipment used is hand portable saving costs of Load Bank transportation.
2. The results are monitored under controlled conditions allowing accurate results to be
taken. There is no time constraint but tests can be completed in less time than load tests
thereby reducing time on site.
3. The tests neither reduce the life of the battery, nor leave it in a discharged condition.
4. The results can be analysed, compared with known performance of similar batteries and
benchmark database information. This can be completed in the office and not under site
pressures and the data for all sites can be centralised and retained giving greater
management control.
5. The danger of blocks exploding is minimised.
6. The results track normal battery deterioration and allow prediction of life and future
performance. This provides accurate assessment of the time when the battery needs to be
replaced and ensures the maximum reliable operational life is obtained.
7. The results are clear and easily understandable.
Specification
Supply Voltage: 220 - 240Vac 50hz ± 10% 1 Amp
Battery Voltage: Min. 9V
Max. 100V
Absolute Maximum voltage at terminals 400V DC
Current injection: Low Range 10A (type) 50Hz
High Range 25A (type) 50Hz
Ammeter Accuracy: 2% + 2 digits
Annual Calibration Recommended
Operators of the equipment must be fully conversant with the dangers of high voltage battery
strings. Please read and understand the Operators Manual completely before using the Bitbox, if
in doubt - ask!
Equipment required - Check List
a) Bitbox Model 5 complete with: Power supply lead.
Plug in test leads with Crocodile Clips.
b) Operators Manual.
c) DVM capable of reading AC millivolts accurately.
d) Blank test result sheets.
e) A 13 Amp extension lead will be required on most occasions to allow appropriate
location of the Bitbox.
Procedure
Note: It is sensible to prepare results sheets prior to the tests. These may include a
“header sheet” on which to note battery details i.e. manufacturer, model, age
etc. and columns for readings taken.
Header Sheet
1. At the top of the form fill in the Battery reference, String No. etc. to clearly identify the
string under test.
2. Complete the details regarding the battery type.
a) The Date Code is most important. It may be stamped on the terminals or lid. It may
not be recognisable as a date code.
b) Take a careful note of any markings as the manufacturer can be consulted as to their
meaning when the results are analysed.
3. Record the overall DC Float Voltage and the AC ripple voltage across the entire battery.
a) Check there is no significant charge current - the battery must be fully charged prior
to impedance testing to obtain accurate results.
4. Measure the ambient temperature and try to assess where the maximum temperature
around the battery is.
a) Excessively high temperature is the major cause of premature battery failure.
b) Use a “Comments” section to note any recommendation to improve site
environment.
5. If required record float voltages on each block.
6. Having made prior arrangements OPEN the BATTERY CIRCUIT BREAKER or
ISOLATOR.
7. Check battery cases for discolouration, distortion or damage.
8. Examine terminal seals for signs of electrolyte leakage or lifting, which could be due to
pole growth.
Note: Very defective battery systems may not respond immediately to the tests
above, particularly where one or more cells are open circuit. By careful use
of the equipment and test methods, such as the “Half Split” technique, the
defective cells can be located and “Linked out” allowing the remainder of
the cells to be tested in the normal manner.
4. 4 Impedance Test for iSDX, Realitis & Hicom Telecom. Power Systems
The following procedure is followed for the testing of iSDX, Realitis and Hicom
DC (50 volt) power systems.
4.4.1 Site Test Report
Record the following information on the site test sheet:
1. Customer name.
2. Site Address.
3. Date of test.
4. Nº of batteries, quantity & type.
Example: 2 batteries of 8 x EN100-6.
5. Ampere Hour rating at 3 hr. rate from specification table per battery
6. Measure system load current from shunt located:
a) In master cabinet of iSDX system.
b) In wall mounted distribution cabinet on old Harmer & Simmonds systems.
c) On back of CRUAB Hicom rectifiers.
7. Set DMM (Digital Multi-Meter) to DC mV
a) The shunt will normally be 75mV 150Amps.
In this case double the millivolt reading to calculate the load current.
b) On Hicom systems the shunt can be 75mV 250Amps
In this case multiply the millivolt reading by 3.333.
c) Where no shunt can be found use Clip on Ammeter to read current from rectifiers if
possible.
8. Note the overall voltage across the battery with the charger connected. (Typically 54.6
Vdc)
9. From the “Constant Current Discharge Tables to 1.85vpc” for the cell type, find the
discharge current for 1 hour.
10. Record the year of manufacture.
11. Use digital thermometer to record battery and ambient temperature.
12. Note system type e.g. iSDX give as much detail as possible.
13. Note Rectifier type and quantity.
14. Note number of empty shelves in cabinet or room for extra racks.
15. Divide the system load current by the number of strings.
16. From the “Constant Current Discharge Tables to 1.8vpc” for the cell type find the number
of hours available at the string current.
a) This time is calculated when load tests are completed.
b) This is completed following the Impedance test.
17. Usually “Age”. Note if the battery has passed its design life it must be Failed even if
working OK.
18. If conditions are good assume new battery will provide 4/5ths of its design life.
rectifiers
32A 100A 24 cell battery
AC
32A
32A
connected to earth
rectifiers
32A 24 cell battery
AC
32A
Distribution Fuses
32A
32A
connected to earth
Load Testing
Load testing demonstrates the capacity of the battery to supply energy.
Fuse Removed
–ve 54V dc
Float Charge
8 Load Bank
6 volt
block
7 6 volt
block Shunt
6 6 volt
block
100m V = 100 Am ps
5 6 volt
block
4 6 volt
block
3 6 volt
block
2 Fan
6 volt
block
1 6 volt
block
+ve 0V dc