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Battery Monitoring Fundamentals & Experience
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Battery Monitoring IntroductionBattery Monitoring Introduction
BTECH developed the first stationary battery monitor based on trend analysis in 1991, based on research begun in the 1980s Leading Indicator: Impedance Rise
Technology has proven itself in the past 15 years First challenge met: proving the method of
continuous battery monitoring Action Plan: Weak cells are identified and replaced
before battery system performance is affected
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Market ExperienceMarket Experience
Customers That Embraced Battery Monitoring Have: Virtually eliminated their battery failure risk Ensured performance of their critical power systems Reduced battery maintenance costs
Remote Monitoring Of Hundreds Of Battery Systems Has Demonstrated: Many previously undocumented battery conditions Proof that a need for change is required in the way critical battery
systems are managed
The End-user Base Is Largely Unaware That A Proven Solution For Their Battery Problems Exists
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Why Critical System Batteries Should Be Why Critical System Batteries Should Be MonitoredMonitored
Mission Critical Systems Require The Benefits Of On-line Battery Monitoring Systems
Best possible reliability and practices demanded Systems cannot always be taken of-line for
maintenance Extensive annual or periodic tests are expensive and
interrupt business operations Budget constraints often limit or eliminate battery
maintenance Personnel changes
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Why Critical System Batteries Should Be Monitored Why Critical System Batteries Should Be Monitored
Up To 85% Of All UPS Failures Are Battery Related UPS Monitoring Systems can’t detect failures proactively Failures occur between service intervals Inconsistent and often compromised maintenance
Lack of customer awareness and/or expertise
Battery Failure Can Happen In 2 Weeks Failure can occur at any time in the battery life cycle Successful discharges or discharge tests can speed failure A quarterly check cannot assure the battery system will perform
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Why Critical System Batteries Should Be Why Critical System Batteries Should Be MonitoredMonitored
5+% Of New Batteries Fail Within The Warranty Period Significant impact to critical system reliability
Installing new batteries does not reduce risk of failure Users need a method to find the bad ones in time
A warranty is not the same as a performance guarantee
Changes Happening In The Battery Industry China as main supplier of lead and batteries
Many new battery types have entered the market with little or no track record
Manufacturers are under pressure to reduce cost The quality of batteries in the market has suffered
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Improve the Way Batteries are ManagedImprove the Way Batteries are Managed
Move From Battery Maintenance to 24x7 Move From Battery Maintenance to 24x7 Battery ManagementBattery Management
Battery MaintenanceBattery checking and
assurance occurs only 4 days of the year -- as
quarterly battery service is
performed
Battery ManagementBattery assurance
occurs 24 X 7
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Example Battery Failures
Found At
Customer Sites
Example Battery Failures
Found At
Customer Sites
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Float Voltages vs. Unit Number
Example #1 - 2 Strings of 40-12V VRLAs
Float Voltages Show System Is OK
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Impedance vs. Unit Number
The Unit Impedances Show Another Story
Example #1 - 2 Strings of 40-12V VRLAs
Green: Initial Read (Baseline)
Red: Maintenance Limit (+20%)
Purple: Critical Limit (+30)
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Voltage vs. Time: Voltage Looks OK
Each Yellow Point = One Week
Example #2 – Unit #6
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Impedance vs. Time: Impedance Rises 120%
Green: Initial Read (Baseline)
Red: Maintenance Limit (+20%)
Purple: Critical Limit (+30)
Example #2 – Unit #6
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Voltage vs. Time: Voltage Drops 10%
Unit 50 Impedance: 5.06 Milli-ohms (180.07% of String Initial Measurement) [2.81 Milli-ohms]
Example #3 - Unit 13
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Impedance vs. Time: 120% in Two Weeks
Failure Within 2 Weeks
Example #3 - Unit 13
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Voltage vs. Time: 10% Voltage Drop within 2 Weeks
Example #4 – Wet Cell Unit 213
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Impedance vs. Time: No Change Recorded
Customer Replaced the Unit
Example #4 - Wet Cell Unit 213
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Impedance vs. Time: Effects of Re-Torquing
Example #5 - Unit 67
Customer
Notified
Service Provider Retorqu
es
Battery Finally Replace
d
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Voltage vs. Time: Note That Voltages Have Barely Changed
Example #5 - Unit 67
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Voltage vs. Time: Detecting Thermal Runaway
Example #6 - Unit 42
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Temperature vs. Time: Detecting Thermal Runaway
Example #6 - Unit 42
Temperature Sensor Mounted in Cabinet
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System Voltage vs. Time: No Changes
Example #6 - Unit 42
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Impedance vs. Unit Number
Example #7 - Unit Impedances
Notice the 5 Units With High Impedance
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Voltage vs. Unit Number During Discharge
Example #7 - Unit Voltages
These 5 Units Have the Lowest Voltage After Discharge
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Benefits of Battery MonitoringBenefits of Battery Monitoring
Critical system battery performance is assured Detection of major battery problems with enough time to
respond Reliability of backup power is increased Risk and revenue lost due to downtime are virtually eliminated
Battery management and maintenance costs can be reduced significantly Customer experience: Battery service life can be increased up
to 100% when weak cells are replaced in time Reduction of manual maintenance
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The Product
BTECH’s Fifth Generation Battery Monitoring System
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Control Module
Voltage Module Current Module
Real Time Monitoring• Cell Impedance • Ambient & Pilot
Temperature
• String & System Current
(Float/Charge/Discharge)
• Cell & System Voltage (Float/Discharge)
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Modular System Components
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Unmanned Communications: 48V VRLA Stack
S5 VRLA Stack Installation TM
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3-Phase UPS: 40-12v (480V) VRLAs
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S5 VRLA Cabinet Installation
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Measurement of key battery performance parameters for trend analysis (failure prediction & prevention)
Unit Impedance - Impedance is the leading indicator of battery failure and finds bad batteries Plate cracking, warping, corrosion, post & strap corrosion and cell dry-out are easily
detectible Interconnect problems Initial measurements for each unit used for baselines
Unit Voltage – Can also be a leading indicator of failure Dendritic shorts Thermal runaway
Ambient & Pilot Cell Temperatures – Problem prevention Environmental conditions (placement of battery cabinets)
S5 Functions
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Measurement of key battery performance parameters in real time for alarm conditions
(immediate problems)
Unit Voltage System Voltage
Float settings and system problems Discharge Events Temperature
Thermal runaway detection Air conditioning system problems
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S5 Functions
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Full Data Logging and Analysis: Building the Database
Unit Impedance, Voltage and Temperatures Future problems found through data trending and
comparisons with initial readings Alarms based on predetermined set points
Factory voltage data Initial impedance data
Discharge Data Logging of voltages and string currents Eliminates need for data logger during discharge test Full discharge analysis capabilities after any event Warranty Reporting
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S5 Functions
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Building or Facility Management System Integration Modbus over TCP/IP 6 User-configurable dry contact alarms 4 Additional alarm inputs System functions as a “Master” with the ability to initiate
communication to outside world
Transmitting Information and Alarms Remotely Ethernet (static or dynamic IP) Dial-up modem
Retrieving Information in the Battery Room RS232 and USB ports For battery service providers & real time discharge tests
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S5 Communications
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S5 System Software
BTECH’s Software Platform Serves as Your Central Monitoring Point for Multiple Systems and Locations
BTECH’s BVM Observer collects and distributes data and alarms automatically for up to 1000 systems Runs 24x7 on your network Data can be stored anywhere on your network or PC Provides e-mail and text message alarms
BTECH’s BVM Validation Manager provides full data trending, analysis and reporting Simple and easy to use graphing functions On-demand real-time interaction with the BVS
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The Leading Indicator of Failure BTECH’s Patented Impedance Method
Impedance includes the capacitive effect of the battery and provides a more accurate correlation with battery capacity…the reference measurement method
Pulsed DC Impedance at 215 Hz No sinusoidal charging/discharging No effect from AC ripple or downstream noise Multiple measurements made for data averaging and comprehensive
noise analysis No Discharge Below Open Circuit Voltage
Measurements do not place load on batteries and do not affect battery life
S5 Technology
® BTECH’s Impedance Method
BTECH Impedance Does Not Discharge Your Batteries
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Impedance vs. Resistance (i.e. “Voltage Response”) Voltage response results on battery systems on-line are affected by
the charger, line noise and battery type Requires repeated deep DC discharges to get results
“Fiber Optic” Modular Monitoring Systems Systems are powered by the batteries at all times Measurements remain dormant until called upon by PC based
master Weak load signal (1A) provides poor signal to noise ratio
Systems Using AC Ripple Or Line Voltage Measurement signal is always changing due to ripple, noise and
load, leading to inconsistent results Impossible to separate ripple effects from data
Comparison With Other Methods
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BTECH Impedance vs. Voltage Response
Effect of Testing on Batteries
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S5 System Diagram
System ComponentsSystem Components
SCM 600 (Controller) -1 per UPS or Inverter System
VM-24 – Up to 24 VSLs and 4 Ts per unit
CM-2 – Current Monitor per string (up to 4)
CT – Current Transducer (Hall Effect Clamp)
VSL – Voltage Sense Lead LCL – Load Control Lead
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Additional S5 System Features
Complete Isolation from the Battery String System is not powered by your batteries Completely invisible and passive to the battery
system, UPS/rectifier and load Factory Designed and Built Wiring Harnesses
Ensure system reliability Simple installation in 50% less time Designed to meet site requirements
BTECH’s Unique Safety Fuse System Allows easy battery replacement Reduces battery replacement costs by up to 50%
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BTECH Corporate CapabilitiesBTECH Corporate Capabilities
Complete Turn Key Services: Complete Documentation and Submittals Engineering and Design Installation Services Commissioning, Start-up and Training
Field Service and Maintenance Contracts Technical Help Desk Support World Wide Service Network
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