Proactive Battery Monitoring to Reduce Downtime Risk

PROPRIETARY INFORMATION: The information contained in this presentation is the property of Emerson Network Power and is subject to change without notice. Except as specifically authorized in writing by Emerson Network Power, the holder of this presentation shall keep all information contained herein confidential and shall protect same in whole or in part from disclosure and dissemination to all third parties.

Agenda
Why is Battery Monitoring Needed? Why Use the Resistance Measurement Method?

Cell Resistance is a good indicator of the batterys State of Health

Do it Right Select the Right Test Method - Alber Monitoring advantages

Battery Life Data Safety

Alber products and their applications

The Weakest Link?

12 0 12 0 12 0 12 0 480 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0 12 0

12 0
12 0 12 0

12 0
12 0 12 0

12 0
12 0 12 0

12 0
12 0 12 0

It only takes one bad cell to bring down a UPS

12 0
12 0 12 0

12 0
12 0 12 0

12 0
12 0 12 0

12 0
12 0 12 0
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Why Monitor?
LEADING CAUSES OF LOAD LOSS
Pre-Mature End of Discharge Defective Battery REPO/EPO User error Other External 4% 4% 18% Utility/Generator Logic Board

37%!
26% 19%

Battery Related

4%

UPS components 4% 6%

7%

8%

Circuit Breaker Other (<2% each)

Battery related failures account for more than a third of all UPS System failures
Source: Liebert Global Service failure tracking

Battery Technology
Flooded Cell (unsealed, vented, wet cells) Lead acid batteries vent hydrogen gas and contain electrolyte in liquid form. Typically located in separate rooms from the equipment they support.

Racks, Large Jars, Battery Rooms

Valve Regulated Lead Acid Battery (VRLA, sealed) VRLAs recombine Hydrogen and Oxygen and release extremely low amounts of hydrogen under normal operating conditions. Typically used in distributed back-up system and located close to the equipment they protect.

Cabinets, Small Jars, Equipment Room

How are batteries made?

(-) Post

(+) Post
(+) Strap (-) Strap

Separator matl (+) Plate (-) Plate

Batteries will Fail!

Sooner or later they reach end of life

Failures Normal Aging Flooded cell failure

Positive Grid Corrosion

VRLA most common failure

Dry-out
Pre-mature Failures Battery users influence?

High or Low charge voltage High or Low temperature

Excessive discharges Excessive charge current Over Torque battery terminals Unknown factors

Manufacturing defects

How do batteries fail? Flooded Cell Grid Corrosion

Lead Paste Grid Structure Active Material Expanding Cracks Corrosion

Fully Charged

During Discharge

Aged Plate

How do batteries fail? Positive grid corrosion

Positive grid corrosion and strap joint weld deterioration is the normal failure mode for Lead-Acid batteries.

New Grid

Aged Grid

How do batteries fail?

VRLA Dry-out
VRLA Battery Charging

Hydrogen & Oxygen gases recombine

within the cell to reform water

In theory, recombination is 99%+

efficient

If over charged, gases are generated

faster than recombination can take place Pressure builds up and safety vent releases gases causing permanent loss of capacity

A 10% water loss in a VRLA cell

equates to a 25% loss in capacity

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Why Resistance Measurement Method

Metallic Resistance

Electro Chemical Resistance

Battery Component Resistance Characteristics

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Resistance of an Aged Grid will increase

Positive grid corrosion

New Grid

Aged Grid

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Why Cell Resistance Measurement?

Resistance / Battery Capacity Relationship
Capacity
80% Battery Capacity

It has been shown that when a cells resistance increase 25% above baseline, that cell is less than 80% capacity.

25% increased resistance

Resistance As battery resistance increases, battery capacity will decrease

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Battery Cell Resistance Measurement

Why cell resistance measurement?
Flooded - Major Modes of Failure Positive grid corrosion Loss of active material Internal shorts
VRLA - Major Modes of Failure Loss of Element Compression Internal Shorts Thermal Runaway Dry-Out

Detection Method: Resistance Resistance Voltage

Resistance Voltage Voltage/Temp Resistance

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All Monitors are not created equal!

Different types of monitoring methods

Overall Voltage monitoring

Rollback partial discharge test Midpoint Monitoring With or without impedance measurements Individual cell monitoring Automatic Cell equalization and AC based testing Individual cell monitoring with state-of-health assessment DC Resistance based testing

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Advantages and Considerations Capacitor Effect

Metallic Resistance

Equivalent Capacitor

Electro Chemical Resistance

16

Why are internal ohmic measurements tricky?

~ 40 % of resistance is in parallel with a capacitor

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Normal DC battery operation

When load is applied, DC current is generated

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Abnormal AC Testing

The Capacitor Effect

AC testing is an abnormal battery condition. When AC load is applied, most of the current will pass through the capacitor. Test frequency and size of capacitor will define the amount of current passing through the capacitor instead of plates.

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Mechanical Analogy
Normal Operation Aged Condition

AC Testing

Alber Test Method

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Advantages and Considerations Resolution & Test Current

Most battery test systems use very

low test currents

0.5A 4A AC test currents are

common
Ohms law: R = V / I
The battery test is performed by
1Amp

200V

200

generating a current flow through the battery and measure the resulting voltage drop over the resistance/impedance
Alber use 30A DC test current

6000V

for superior resolution and repeatability

30 Amps

200

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Advantages and Considerations AC Noise Typical ripple 40mV (40,000V)

A Low AC test signal will disappear in UPS AC noise, Trending data typically changes when noise levels change due to load and/or failing capacitors. The Alber DC test method is not affected by ripple
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Select the right test method

Albers Patented Technology

Developed and based on: Experience and knowledge about how batteries fail
Battery Cell Resistance Comparing cell capacity with resistance Accounting for the three most important battery testing obstacles The capacitor effect Resolution requirements The noise problem

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Optimize Battery Life

Monitor critical parameters and take appropriate action

Internal resistance
Replace bad cells before they affect other cells Maintain a balanced resistance level in all redundant strings

Temperature
Temperature has a direct influence on battery life Uneven temperature over the string cause cells to float differently

Voltage
Float voltage should be adjusted to ambient temperature

Float current
Excessive ripple affects the battery life

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Test Data - IEEE

Recommended Task Battery system voltage Charger current and voltage Ambient temperature Visual inspection Electrolyte levels Pilot cell voltage and specific gravity Specific gravity all cells All cell voltages All cell temperatures Cell internal ohmic values Intercell connection resistance Detailed internal visual inspection AC ripple current and voltage Capacity test FLOODED IEEE 450 Monthly Quarterly Annually X X X X X X X X X 10% Only X X X X 5 Years X X X X X UPS X X Monthly X X X X VRLA IEEE 1188 Quarterly Bi-Annually Annually

Can be monitored

Equivalent data provided

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Safety

Cell explosions and fires occur due to failing cells or inter-cell connections during a high current discharge.

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Agenda
Why is Battery Monitoring Needed? Why Use the Resistance Measurement Method?

Cell Resistance is a good indicator of the batterys State of Health

Do it Right Select the Right Test Method - Alber Monitoring advantages

Battery Life Data Safety

Alber products and their applications

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Markets and Applications

Market Large Data Center Small to Medium Data Centers NX & NXL UPS, 480V Telcom, OSP, Gen Starts Application Large UPS Wet Cells Battery Cabinets - VRLA Battery Cabinets , 12V VRLA 48V, 24V, 12V Battery Monitor BDS-256XL BDS-40 BDSi MPM-100 CRT-400 CellCorder

Manual Testing - Maintenance Trouble Shooting

BDS-40

BDSi BDS-256XL MPM-100

CRT-400
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Stationary Battery Monitors

Parameters Monitored
Overall voltage

Individual cell voltage

String charge / discharge current Charger float current (optional) Temperature

Ambient & Electrolytic Patented internal resistance test of all cells / jars Inter-cells (straps) and Inter-tiers (cables)

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Stationary Battery Monitors

BDS-256XL Battery Diagnostic System
Monitors any battery system up

to 600 volts DC Large Systems

(up to 8 strings of 256 cells / string) Modular design for expandability

Compatible with NiCad cells, 2v

cells, 4v, 6v, 8v and 12v modules Interfaces to External Load banks for performing capacity or acceptance testing

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BDS-256XL Controller - DCM Load Module

Controller - The Brain that controls the system
Collects and stores data from the Data Collector Module (DCM) Internal memory that can hold 1 years worth of data

Data Collector Module (DCM)

scanning volt meter that acquires all readings from the battery

External Load Module (ELM)

Provides the resistive load during the automatic resistance test

Controller DCM ELM

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Alber Monitor Architecture

Alarms, Report & Analysis

Controller

Remote via TCP/IP or modem

Data Collection Module

Data Collection Module

ELM
External Load Module

ELM
External Load Module

Battery String 2+

Battery String 1

DCM

DCM

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Installation Examples

33

34

BDS-40 Base and Plus Unit

BDS-40 Base unit
All-in-one: Controller, Data

Plus

Collection Module and Load Module One per system can power up to 5 Plus units
2 temperatures, 1 current transducer / string Customized harness for easy install for easy

Base

installation

BDS-40 Plus (expansion)

Connects to Base unit via fiber optic cable One unit for cabinets 2-6

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BDS-40 System max example

BDS-40 Base unit Plus
#1

<= UPS #1
Plus #2 B- Cab Plus #3 Plus #4 Plus #5

B- Cab
#1

#2

B- Cab B- Cab B- Cab #6 #5

UPS #2 =>

B- Cab #3

#4

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MPM-100
Designed for

applications below 130VDC

Telecom Applications UL and CE More than 100 battery Powered from DC bus or

configurations available Monitors 1 string of 120VDC or up to 4 strings of 12, 24 or 48VDC

115VAC Network, Serial, Modem connection options

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BDSi Integrated Solution

NX & NXL UPS
Eliminates Field Installation

Scheduling Contractors Tracking Material Delivery Incorrect Configurations Accessories, Cable Harnesses

Applications

Minimum System Configuration North American Market Include in New Cabinet Designs
Based on BDS-40

Patented Alber Technology Application Software Compatible with BDS

NXL Battery Cabinet with BDSi

Real time measurements Easy to read graphs

Cell Voltage Cell Resistance

Cell & overall voltages Current -Temp Cell & Inter-tier Resistance

39

Communication & Alarms options

BDS-256XL (rear)
RJ45 Ethernet

RJ11 Telco RS232

USB Service Connection

Alarm Notification

41

Data Reports
Automatic Reports Data analysis with explanations

of abnormal data Suggests appropriate maintenance activities

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Portable Test Equipment CRT- 400

Performs the same patented resistance test as the monitor products on batteries from 1-16V
Measures and records the three critical parameters: Cell Voltage Internal Resistance Inter-Cell Resistance Interfaces with the Digital Hydrometer for storing Specific Gravity and cell temperature

Bluetooth compatible Audible test status Data transfer USB flash drive for data transfer Wide selection of measuring test leads and probes Detailed trending analysis and reporting software

Alber Advantages
Repeatable readings Patented DC Resistance Method

Understands Battery Technology Test result shows actual battery condition Accounts for Capacitor Effect, Test Resolution and AC Noise
Tests the complete conduction path

All cells and connections are included in test results

Monitors all critical parameters

Monitors voltage real time during discharge

Easy to interpret test results
Well proven in all standby battery applications

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Alber History of Technology Innovations

1973 Alber Engineering Established 1975 Developed Battery Capacity Test system for the nuclear industry 1993 Pioneered Cell Resistance Measurement Technology

1995

2007

1974
Developed first Portable Digital Micro-ohm meter

1979

Developed the first Battery Monitor

Implemented Battery String Discrete Measurement test method

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The Value of Battery Monitoring

Reduce your Downtime Risk Avoid high cost associated with power outages and improve service level agreements
Optimize Useful Battery Life

The monitor will provide information about all parameters that

Improve Personnel and Equipment Safety Avoid catastrophic failures Maintain Reliable Test Data Support Warranty Claims Minimize Maintenance Downtime

affects battery life, allowing for corrective actions and maximal useful life.

Trust Your Batteries

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Thank You

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