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Battery Monitoring Fundamentals & Experience

Battery Monitoring Fundamentals & Experience. Battery 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

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Battery Monitoring Fundamentals & Experience

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  1. Battery Monitoring Fundamentals & Experience

  2. Battery 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

  3. Market 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

  4. Why Critical System Batteries Should Be Monitored • 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

  5. 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

  6. Why Critical System Batteries Should Be Monitored • 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

  7. Battery Maintenance Battery checking and assurance occurs only 4 days of the year -- as quarterly battery service is performed Improve the Way Batteries are Managed Move From Battery Maintenance to 24x7 Battery Management Battery Management Battery assurance occurs 24 X 7

  8. Example Battery Failures Found At Customer Sites

  9. Example #1 - 2 Strings of 40-12V VRLAs Float Voltages vs. Unit Number Float Voltages Show System Is OK

  10. Example #1 - 2 Strings of 40-12V VRLAs Impedance vs. Unit Number Green: Initial Read (Baseline) Red: Maintenance Limit (+20%) Purple: Critical Limit (+30) The Unit Impedances Show Another Story

  11. Example #2 – Unit #6 Voltage vs. Time: Voltage Looks OK Each Yellow Point = One Week

  12. Example #2 – Unit #6 Impedance vs. Time: Impedance Rises 120% Green: Initial Read (Baseline) Red: Maintenance Limit (+20%) Purple: Critical Limit (+30)

  13. Example #3 - Unit 13 Voltage vs. Time: Voltage Drops 10% Unit 50 Impedance: 5.06 Milli-ohms (180.07% of String Initial Measurement) [2.81 Milli-ohms]

  14. Example #3 - Unit 13 Impedance vs. Time: 120% in Two Weeks Failure Within 2 Weeks

  15. Example #4 – Wet Cell Unit 213 Voltage vs. Time: 10% Voltage Drop within 2 Weeks

  16. Example #4 - Wet Cell Unit 213 Impedance vs. Time: No Change Recorded Customer Replaced the Unit

  17. Example #5 - Unit 67 Impedance vs. Time: Effects of Re-Torquing Battery Finally Replaced Service Provider Retorques Customer Notified

  18. Example #5 - Unit 67 Voltage vs. Time: Note That Voltages Have Barely Changed

  19. Example #6 - Unit 42 Voltage vs. Time: Detecting Thermal Runaway

  20. Example #6 - Unit 42 Temperature vs. Time: Detecting Thermal Runaway Temperature Sensor Mounted in Cabinet

  21. Example #6 - Unit 42 System Voltage vs. Time: No Changes

  22. Example #7 - Unit Impedances Impedance vs. Unit Number Notice the 5 Units With High Impedance

  23. Example #7 - Unit Voltages Voltage vs. Unit Number During Discharge These 5 Units Have the Lowest Voltage After Discharge

  24. Benefits 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

  25. The Product BTECH’s Fifth Generation Battery Monitoring System

  26. Modular System Components 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)

  27. S5 VRLA Stack Installation Unmanned Communications: 48V VRLA Stack

  28. S5 VRLA Cabinet Installation 3-Phase UPS: 40-12v (480V) VRLAs

  29. S5 Functions 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 CellTemperatures – Problem prevention • Environmental conditions (placement of battery cabinets)

  30. S5 Functions 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

  31. S5 Functions 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

  32. S5 Communications 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

  33. 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

  34. S5 Technology 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

  35. BTECH’s Impedance Method BTECH Impedance Does Not Discharge Your Batteries

  36. Comparison With Other Methods • 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

  37. Effect of Testing on Batteries BTECH Impedance vs. Voltage Response

  38. S5 System Diagram System 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

  39. 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%

  40. BTECH 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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