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Proactive Battery Proactive Battery Monitoring to Reduce Monitoring to Reduce Downtime RiskDowntime Risk
Proactive Battery Proactive Battery Monitoring to Reduce Monitoring to Reduce Downtime RiskDowntime 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.
2
AgendaAgenda
Why is Battery Monitoring Needed?
Why Use the Resistance Measurement Method?– Cell Resistance is a good indicator of the battery’s State of Health
Do it Right – Select the Right Test Method - Alber
Monitoring advantages– Battery Life– Data– Safety
Alber products and their applications
3
12 12 12 12
12 12 12 12
12 12 12 12
12 12 12 12
12 12 12 12
12 12 12 12
12 12 12 12
12 12 12 12
12 12 12 12
12 12 12 12
480
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
00
It only takes one bad cell to bring down a UPS
The Weakest Link?The Weakest Link?
4
Battery related failures account for more than a third of all UPS System failures
Source: Liebert Global Service failure tracking
LEADING CAUSES OF LOAD LOSS
19%
18%
8%7%6%
4%4%
4%4%
26%
Pre-Mature End of Discharge
Defective Battery
REPO/EPO
User error
Other External
Utility/Generator
Logic Board
UPS components
Circuit Breaker
Other (<2% each)
BatteryRelated
37%!
Why Monitor?Why Monitor?
5
Battery TechnologyBattery TechnologyFlooded 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
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How are batteries made?
(+) Plate(-) Plate
Separator mat’l
(+) Strap
(-) Strap
(-) Post (+) Post
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Batteries will Fail! Sooner or later they reach end of lifeBatteries 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
8
How do batteries fail?Flooded Cell Grid CorrosionHow do batteries fail?Flooded Cell Grid Corrosion
Lead Paste Grid Structure
Fully Charged During Discharge
Active Material
Expanding
Cracks
Aged Plate
Corrosion
9
How do batteries fail?Positive grid corrosionHow 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
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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
How do batteries fail?VRLA Dry-outHow do batteries fail?VRLA Dry-out
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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 increaseResistance of an Aged Grid will increase
Positive grid corrosion
New Grid
Aged Grid
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Why Cell Resistance Measurement?Resistance / Battery Capacity RelationshipWhy Cell Resistance Measurement?Resistance / Battery Capacity Relationship
Capacity
Resistance
25% increased resistance
80% Battery Capacity
As battery resistance increases,battery capacity will decrease
It has been shown that when a cell’s resistance increase 25% above baseline, that cell is less than 80% capacity.
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Battery Cell Resistance MeasurementBattery Cell Resistance Measurement
Why cell resistance measurement?
Flooded - Major Modes of Failure Detection Method: Positive grid corrosion Resistance Loss of active material Resistance Internal shorts Voltage
VRLA - Major Modes of Failure Loss of Element Compression Resistance Internal Shorts Voltage Thermal Runaway Voltage/Temp Dry-Out Resistance
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All Monitors are not created equal!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
Electro Chemical ResistanceEquivalent Capacitor
17
Why are internal ohmic measurements tricky?Why are internal ohmic measurements tricky?Why are internal ohmic measurements tricky?Why are internal ohmic measurements tricky?
~ 40 % of resistance is in parallel with a capacitor
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Normal DC battery operationNormal DC battery operationNormal DC battery operationNormal DC battery operation
When load is applied, DC current is generated
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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.
The Capacitor
Effect
Abnormal AC TestingAbnormal AC TestingAbnormal AC TestingAbnormal AC Testing
20
Normal Operation
Aged Condition
AC Testing
Alber Test Method
Mechanical Analogy
21
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
generating a current flow through the battery and measure the resulting voltage drop over the resistance/impedance
Alber use 30A DC test current for superior resolution and repeatability
200µΩ1Amp
200µV
200µΩ30 Amps
6000µV
Advantages and Considerations - Resolution & Test Current
22
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.
Typical ripple 40mV (40,000µV)
The Alber DC test method is not affected by ripple
Advantages and Considerations - AC Noise
23
Select the right test methodSelect the right test method
Alber’s 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 LifeOptimize 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
25
Test Data - IEEETest Data - IEEE
FLOODED IEEE 450 VRLA IEEE 1188 Recommended Task Monthly Quarterly Annually Monthly Quarterly Bi-Annually Annually
Battery system voltage X X
Charger current and voltage
X X
Ambient temperature X X
Visual inspection X X
Electrolyte levels X
Pilot cell voltage and specific gravity
X
Specific gravity all cells X
All cell voltages X X
All cell temperatures X 10% Only
X
Cell internal ohmic values
X X
Intercell connection resistance
X X UPS X
Detailed internal visual inspection
X
AC ripple current and voltage
X X
Capacity test 5 Years X
Can be monitored Equivalent data provided
26
Safety Safety
Cell explosionsexplosions and firesfires occur due to failing cells or inter-cell connections during a high current discharge.
27
AgendaAgenda
Why is Battery Monitoring Needed?
Why Use the Resistance Measurement Method?– Cell Resistance is a good indicator of the battery’s State of Health
Do it Right – Select the Right Test Method - Alber
Monitoring advantages– Battery Life– Data– Safety
Alber products and their applications
28
Markets and ApplicationsMarkets and ApplicationsMarket Application Battery Monitor
Large Data Center Large UPS – Wet Cells BDS-256XL
Small to Medium Data Centers Battery Cabinets - VRLA BDS-40
NX & NXL UPS, 480V Battery Cabinets , 12V VRLA BDSi
Telcom, OSP, Gen Starts 48V, 24V, 12V MPM-100
CRT-400 CellCorderManual Testing - Maintenance – Trouble Shooting
BDS-40
CRT-400
BDS-256XLBDSi
MPM-100
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Parameters MonitoredParameters Monitored
Overall voltageIndividual cell voltageString charge / discharge currentCharger float current (optional)Temperature
– Ambient & ElectrolyticPatented internal resistance test of all
cells / jarsInter-cells (straps) and Inter-tiers (cables)
Stationary Battery MonitorsStationary Battery Monitors
30
Monitors any battery system up to 600 volts DC – Large Systems
• (up to 8 strings of 256 cells / string)
– Modular design for expandabilityCompatible with NiCad cells, 2v
cells, 4v, 6v, 8v and 12v modulesInterfaces to External Load
banks for performing capacity or acceptance testing
BDS-256XL Battery Diagnostic SystemBDS-256XL Battery Diagnostic SystemStationary Battery MonitorsStationary Battery Monitors
31
BDS-256XL Controller - DCM – Load ModuleBDS-256XL Controller - DCM – Load ModuleController - 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
32
Alber Monitor ArchitectureAlber Monitor Architecture
ControllerController
Alarms,Report & Analysis
Remote via TCP/IP or modem
Alarms,Report & Analysis
Remote via TCP/IP or modem
Communication
DCMData Collection Module
DCMData Collection Module
ELMExternal Load Module
ELMExternal Load Module B
atte
ry S
trin
g 1
DCMData Collection Module
DCMData Collection Module
ELMExternal Load Module
ELMExternal Load Module B
atte
ry S
trin
g 2
+
33
Installation ExamplesInstallation Examples
34
35
BDS-40 Base and Plus UnitBDS-40 Base and Plus UnitBDS-40 Base unitAll-in-one: Controller, Data
Collection Module and Load ModuleOne per system can power up to 5
Plus units2 temperatures, 1 current transducer / stringCustomized harness for easy install for easy
installation
Base
Plus
BDS-40 Plus (expansion)Connects to Base unit via fiber optic cableOne unit for cabinets 2-6
36
BDS-40 System max exampleBDS-40 System max exampleBDS-40
Base unitPlus
#1
Plus#3
Plus #2 Plus
#4 Plus#5
<= UPS #1
UPS #2 =>
B- Cab
#1
B- Cab
#2
B- Cab
#3
B- Cab
#4
B- Cab
#5
B- Cab
#6
37
MPM-100MPM-100
Designed for applications below 130VDC
Telecom ApplicationsUL and CE More than 100 battery
configurations availableMonitors 1 string of
120VDC or up to 4 strings of 12, 24 or 48VDC
Powered from DC bus or 115VAC
Network, Serial, Modem connection options
BDSi Integrated SolutionBDSi Integrated SolutionNX & NXL UPSNX & NXL UPSBDSi Integrated SolutionBDSi Integrated SolutionNX & NXL UPSNX & 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
39
Real time measurements Easy to read graphsReal time measurements Easy to read graphs
Cell VoltageCell Voltage Cell ResistanceCell Resistance
Cell & overall voltages – Current -Temp
Cell & Inter-tier Resistance
Communication & Alarms optionsCommunication & Alarms options
RJ11 Telco
RJ45 Ethernet
RS232
USB Service Connection
BDS-256XL (rear)BDS-256XL (rear)
41
Alarm Notification Alarm Notification
42
Data ReportsData Reports
Automatic ReportsData analysis with explanations
of abnormal dataSuggests appropriate
maintenance activities
Portable Test EquipmentCRT- 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
44
Alber AdvantagesAlber 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 resultsWell proven in all standby battery applications
45
2007
Alber – History of Technology InnovationsAlber – History of Technology Innovations
1973
Alber EngineeringEstablished
1975
Developed Battery Capacity Test system for
the nuclear industry
1974
Developed first Portable Digital
Micro-ohm meter
1979
Developed the first Battery
Monitor
1995
Implemented Battery String
Discrete Measurement test method
1993
Pioneered Cell Resistance
Measurement Technology
46
The Value of Battery MonitoringThe Value of Battery MonitoringReduce 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
affects battery life, allowing for corrective actions and maximal useful life.
Improve Personnel and Equipment Safety– Avoid catastrophic failures
Maintain Reliable Test Data– Support Warranty Claims
Minimize Maintenance Downtime
Trust Your Batteries
47
Thank YouThank YouThank YouThank You