The UPS Battery Handbook
Contents
1. UPS Battery Handbook Battery glossary Absorbed electrolyte Electrolyte that has been Immobilized in an absorbent separator Absorbed electrolyte cell A cell usually a valve regulated sealed lead acid type which utilizes absorbed electrolyte Accessories he components required to complete the battery installation including connectors flame arrestor vents cell numbers and hardware Activation charge he process of making a dry charged cell functional by introducing electrolyte and charging Active material The material in the electrodes plates of the cell that reacts chemically to produce electric energy when the cell discharges and which is restored to Its original composition during the charge process Actual capacity The total number of ampere hours that could be withdrawn from a cell based on a specific set of operating conditions including initial state of charge discharge rate initial cell temperature and end voltage and the age of the cell Ambient temperature The average temperature of the Surrounding air that comes into contact with the battery Anode The electrode in an electrochemical cell where oxidation takes place During discharge the negative electrode of the cell is the anode During charge this reverses and the positive electrode of the cell is the anode As found condition A term used to inform the person performing a capacity test2. cell that is capable of being discharged and then recharged Secondary battery Two or more secondary cells connected together electrically Sediment The active material that separates from the battery plates and falls to the bottom of the Jar Self discharge rate The amount of capacity reduction occurring per unit of time in a battery as a result of self discharge Separator An ionic permeable non conductive spacer used to prevent metallic contact between plates of opposite polarity within a cell Series The interconnection of cells in such a manner that the positive terminal of the first is connected to the negative terminal of the second and so on Service life The period of time during which a fully charged battery is capable of delivering at least a specified percentage of its rated capacity For most lead acid battery design this is 80 Shipping vent The vent placed in the cell for the purpose of shipping the cell Specific gravity The ratio of the weight of a given volume of electrolyte to the weight of an equal volume of water at a specified temperature Standby battery A battery designed to function only when the normal source of power fails State of charge The actual capacity of a cell expressed as a percent of its rated capacity that would be available if a discharge were to occur Stationary battery A secondary battery designed for service
3. discharge the positive electrode of the cell is the cathode During charge this reverses and the negative electrode of the cell is the cathode Carbonization A condition where the electrolyte becomes contaminated with potassium carbonate to a point where it influences cell performance Capacity The ampere hour Capacity assigned to a cell by the manufacturer for a given discharge time at a specified electrolyte temperature and specific gravity to a given end of discharge voltage Cell The basic electrochemical unit characterized by an anode and a cathode used to receive store and deliver electrical energy Cell temperature The temperature at which a cell is operating In the US the reference for cell temperature is 25 C 77 F Charge The conversion of electrical energy into chemical energy within a secondary cell Closed circuit voltage The voltage of a cell when it is discharging Constant current charge A charge in which the current output of the charge is maintained at a constant value Sometimes this may be accomplished using two rate charging Constant potential charge A charge in which the potential voltage at the output terminals of the battery charger is maintained at a constant value Cycle A discharge and subsequent charge of a cell Density The weight of a given volume of electrolyte at a specified temperature Depth of discharge The a
4. in a permanent location Step rack A rack in which cells are placed at different levels in a stepped arrangement Strap The component in a cell where all the plates of like polarity are joined String A common way to refer to a number of cells connected together in series to form a battery Sulphation lead acid cell A state where the battery has developed an abnormal amount of sulphate and its Capacity is impaired This is different from normal sulphate that occurs during discharge Taper charge A charge in which both current and voltage decrease over the recharge period Terminal The part of a cell to which the external circuit is connected Thermal runaway A condition in which a cell on charge or discharge will destroy itself through internal heat generation caused by high overcharge or over discharge current or other abusive condition Tier rack A rack in which cells are placed directly above each other at different levels Trickle charge A charge given to a battery with no external load connected to it to maintain it in a fully charged condition Valve A normally sealed mechanism that allows for the controlled escape of gasses from within a cell Valve regulated sealed lead acid cell A cell that is sealed and fitted with a valve which opens to vent the cell whenever the internal pressure of the cell exceeds the pressure external to the cell by a set a
5. is very combustible and contact with organic materials may cause fire and explosion It also reacts violently with strong reducing agents metals sulfur trioxide gas strong oxidizers and water Contact with metals may produce toxic sulfur dioxide fumes and may release flammable hydrogen gas For lead compounds avoid contact with strong acids bases halides halogenates potassium nitrate permanganate peroxides nascent hydrogen and reducing agents You should always refer to the material safety data sheet for specific precautionary measures However the following are primary steps for safe handling and use Spills or leaks Stop the flow of materials contain absorb small spills with dry sand earth or vermiculite Do not use combustible materials If possible carefully neutralize spilled electrolyte with soda ash sodium bicarbonate or lime Wear acid resistant clothing boots gloves and face shield Do not allow discharge of un neutralized acid to sewer Handling and storage Store batteries in cool dry well ventilated areas with impervious surfaces and adequate containment in the event of spills Batteries should also be stored under roof for protection against adverse weather conditions Separate them from incompatible materials Store and handle only in areas with adequate water supply and spill control Avoid damage to containers Keep away from fire sparks and heat State and local governments may have regulation
6. used to connect adjacent cells on the same rack 14 EATON CORPORATION The UPS Battery Handbook Inter cell connector safety cover An insulated cover placed over the inter cell connector and post used to prevent accidental contact by personnel or accidental short circuiting of the cell Inter rack connector An electrical conductor used to connect cells on two separate racks Most often this connector Is insulated copper wire Internal impedance he resistance of a cell to an alternating current of a specific frequency Internal resistance The resistance of a cell to an electric current within a cell Internal voltage drop The product of the current passing through the cell Jar The container that holds a cell or group of cells Common jar materials include thermoplastics However hard rubber is sometimes used as well and nickel cadmium cells may even be in steel containers Jars for flooded lead acid cells are normally transparent to allow inspection of the plate and sediment Jar to cover seal he seal at the interface of the jar and cover Lead acid cell A secondary cell in which the electrolyte is a solution of sulfuric acid in water Lead acid cells include pure lead cells and lead alloy cells such as lead antimony lead calcium and lead selenium Level line A line or set of lines on the sides of the jar used to indicate the minimum or maximum of electrolyte l
7. when it reaches a certain pressure During charging of a lead acid battery hydrogen is normally liberated In a vented battery the hydrogen escapes into the atmosphere In a VRLA battery the hydrogen recombines with oxygen so water loss is minimized Under normal float conditions virtually all of the hydrogen and oxygen is VRLA batteries are frequently recombined Re sealable valves vent non recombined gases only used in UPS or other high rate when pressure exceeds a safety threshold applications O lt D ol lt D A VRLA battery is distinguished from a flooded cell battery by the rate at which oxygen is evolved from the positive plate and diffused to the negative plate ultimately forming water This rate is several orders of magnitude faster than a flooded cell battery Because water cannot be added recombination of water is critical to the life and health of a VRLA battery Any factor that increases the rate of evaporation or water loss reduces the life of the battery Such factors can include ambient temperature and heat from the charging current Positive Flag Extruded Intercell Valve Terminal Welded Connection Low Resistance Current Path Cover Lid Strap Joining Negative Plates in Parallel Negative Pasted Plate Lead Alloy Grid Polypropylene Container Jar Separator Internal and external components of a valve regulated lead acid VRLA battery www eaton com UPShbatteries 1 800 356 5
8. 794 11 S JLAL R SPNPOLd 74 0 gt Y V of 74 dt U O e ai Extending battery service hfe Eaton s ABM technology uses a unique three stage charging 15 00 s a technique that significantly extends battery service life and optimizes recharge time compared to traditional trickle charging An integrated battery management system tests and monitors battery health and remaining lifetime and provides advance notification to guide preventive maintenance Optional temperature compensated charging monitors temperature changes and adjusts the charge rate accordingly to properly charge the battery and greatly extend battery life A variable battery bus accommodates 384V to 480V configurations so the battery capacity can be matched to your exact runtime requirements either a specific runtime an extension to existing POO UPS with ABM s s 28 UPS with Trickle Charge 9 00 Battery Backup Time in minutes and seconds battery runtime or legacy battery installations With remote O 6 12 18 24 30 36 42 48 54 60 66 72 monitoring of the UPS and battery system Eaton is able to Battery Age respond to alarms and real time battery data to avert potential in months battery problems Although batteries are sold with a variety of published life spans the fact is some batteries demonstrate a useful life of as little as three to five years Eaton s exclusive ABM technology significantl
9. 794 3 s gt e Y gt O Wet cell flooded cell Wet cell flooded cell batteries have thick lead based plates that are flooded with an acid electrolyte This is a highly reliable design failures normally don t occur until halfway through their 20 year pro rated life at which time the failure mode is most often a short circuit This situation is not an extreme emergency because any one shorted cell only affects overall reserve time by a very small percentage However while they are very reliable with a long life there are downsides to wet cell batteries as well They require more safety measures and a space consuming separate battery room to use this technology Regardless of the differences in UPS battery types they both require monitoring and maintenance to ensure maximum life and system availability Wet cell batteries require more advanced maintenance but have a longer battery service life Battery arrangement and power In most UPSs you do not use just one cell at a time They are normally grouped together serially to form higher voltages or in parallel to form higher currents In a serial arrangement the voltages add up In a parallel arrangement the currents add up However batteries are not quite as linear as the two graphics to the right depict For example all batteries have a maximum current they can produce a 500 milliamp hour battery cannot produce 30 000 milliamps for one second because ther
10. A batteries is three to five years and for wet cell batteries is up to 20 years However expected life can vary greatly due to environmental conditions number and depth of discharge cycles and adequate maintenance Have a regular schedule of battery maintenance and monitoring to ensure you know when your batteries are reaching their end of life 15 Why are batteries disconnected on small single phase UPSs when they are shipped This is so that they are in compliance with Department of Transportation regulations 16 If have the serial number from the Eaton UPS or battery cabinet can I find out how old the batteries are Every Eaton battery has a manufacturer date code that indicates when the battery was made The battery or battery cabinet will also feature a sticker for each time the batteries have been recharged while in storage Stored batteries require charging periodically during storage to avoid loss of capacity Recharging stored batteries does not affect battery warranty 17 Will Eaton replace batteries for another manufacturer s UPS Yes Eaton batteries will work in nearly all other manufacturers UPSs In addition we have extensive knowledge of Best Power Deltec IPM and Exide Electronics models because these product lines were purchased by Eaton 18 What are the risks associated with a lack of battery maintenance The primary risks of improperly maintained batteries are load loss fire property damage an
11. PowerChain Management solutions ELN Powering Business Worldwide Table of contents 74 iJ 0 iJ C O W s e a j 61175 3712 ean en eee ee eee eee ee eee E a rr ne eer ree eee tee 3 Battery FICS aeon O Ce ee nee eee ene ne eee 5 Four factors that impact battery life ciinintcaracusuaiuncaracesnuninncavaasbouhimncpsench bddwianstcehobiieiend coh obaiwnen is 5 Ea Or O e A E OR 6 Battery maintenance for extended life cece ccccecceccee cece cee eeeeeaeeeeeaeeeeeeseeeeeeaeeeeeaneeeeeneeeeeas 6 Bley Se Oly pataeer tutte teenie teeta ce ele cd ened esate A nine eaemush cei eas 7 Battery rset turds Pe saan eaten Heats etd au beseech eia shale Tania aiaiaaeo Taina 8 Battery Products and Services from Eaton 0 0cccc ccc ccc cece ccc eee eeeee ee eeeeeeeeceeneeeeesaneeeeaaees 10 FOTN HU Ieee ttc ecctonrsanas cacegsctvecncincc oa nie EEEa a EA EONA iE A GEEAE EAEAN AES EOS EASE 11 Extending Daey SeN CE IO ess orator i apinn renee e EE EE EEEE AEE LOR EE AEE 12 Cu tomer 0 61 610 ate COMET aaa a E E E E re eee ee 12 Battery GLOSSY eien a O a R aa eaa 13 The UPS Battery Handbook Understanding your UPS battery can extend battery life prevent costly downtime and save time and money It s well understood that the battery in a UPS is the most vulnerable part of the system In fact battery failure is a leading cause of load loss Knowing how to maintain and manage your UPS batteries will extend battery
12. aled cells The heat generated in the cell may occur without any warning signs and may be caused by overcharging excessive charging internal physical damage internal short circuit or a hot environment Thermal runaway incident Thermal runaway effects on adjacent battery cabinet 10 Is it safe to transport sealed batteries VRLA batteries marked as non spillable are safe and approved for all transportation methods 11 What is the difference between hot swappable and user replaceable batteries Hot swappable batteries allow the batteries to be changed out while the UPS is running User replaceable batteries are usually found in smaller UPSs and require no special tools or training to replace Batteries can be both hot swappable and user replaceable Please check your user manual for details on your UPS batteries 12 How is battery runtime affected if reduce the load on the UPS The battery runtime will increase if the load is reduced As a general rule if you reduce the load by half you triple the runtime 13 If I add more batteries to a UPS can add more load Adding more batteries to a UPS can increase the battery runtime to support the load However adding more batteries to the UPS does not increase the UPS capacity Be sure your UPS is adequately sized for your load then add batteries to fit your runtime needs 14 What is the average lifespan of UPS batteries The standard lifespan for VRL
13. atteries differ markedly in the number of watts per cell A higher density battery provides more runtime for the footprint You may even find that you can reach your runtime requirements with fewer battery cabinets which reduces upfront costs and lifetime costs of battery preventive maintenance 23 How is battery performance generally measured Batteries are generally rated for 100 discharges and recharges but many batteries show a marked decline in charging capacity after as few as 10 discharges The lower the charge the battery can accept the less runtime it can deliver Look for batteries with a high rate design that sustains stable performance for a long service term www eaton com UPSbatteries 1 800 356 5794 9 ww ry or or W ol lt TI gt O 74 Q gt See 0 V o Vi J UW xe e reas QA Eaton battery products and services Eaton battery services overview Eaton provides a comprehensive set of services for batteries e Battery preventive maintenance onsite inspection technician tests inspects cleans and analyzes battery performance and provides a detailed report that includes any recommendations for corrective action e Eaton battery includes options to replace individual batteries or the entire string e Eaton CellWatch battery monitoring e 10 partial replacement coverage coverage for parts and labor for a bad battery up to 10 of the total count of batterie
14. attery service engineers who are available to install and maintain your batteries Beyond the warranty period you can choose battery monitoring services and maintenance plans that take the guesswork and administrative tasks out of battery management Easy installation No special harnesses are needed when these batteries are installed with new UPSs Harnesses are readily available for legacy UPSs For more information on Eaton batteries please visit www eaton com upsbatteries Thermal runaway Thermal runaway is the most dangerous and potentially catastrophic situation involving lead acid batteries Thermal runaway occurs when the heat generated in a lead acid cell exceeds its ability to dissipate that heat which can lead to an explosion especially in sealed cells The heat generated in the cell may occur without any warning signs and may be caused by overcharging excessive charging internal physical damage internal short circuit or a hot environment By monitoring every jar or cell in the battery system for signs of failure Eaton Cellwatch is uniquely suited to find the causes and symptoms of thermal runaway before damage is caused oe TTT ie all c Ij i ij q 7 Eaton Cellwatch battery monitoring system monitors key performance indicators for each individual battery to provide adequate time to detect and replace a bad battery mitigating the risk of downtime www eaton com UPSbatteries 1 800 356 5
15. ce free simply refers to the fact that they do not require fluid Without regular maintenance your UPS battery may experience heat generating resistance at the terminals improper loading reduced protection and premature failure With proper maintenance the end of battery life can be accurately estimated and replacements scheduled without unexpected downtime or loss of backup power Battery life design life vs actual life Determining battery life can be a tricky business Battery life is often promoted based on design life that is how long the battery can be expected to perform under ideal conditions Estimating actual battery life relies on taking into consideration the four factors that can impact battery life Repeated cycling charging and discharging damage during handling and shipping and overcharging Normal aging operating in an acidic environment and high temperatures Heat plates expand causing shorts separator failure handling and shipping and grid corrosion Human error shorting terminals and leaks Sitting discharged for an extended period not on charge or being undercharged Often due to high temperatures or overcharging Excessive gassing high temperatures or overcharging www eaton com UPSbatteries 1 800 356 5794 Ww g i e W ol lt TI g e e Wn 74 J UW LL gt See 0 P J 4e aa Battery disposal Batteries that are replaced can still contain a significa
16. d personal injury 19 Who are the major battery manufacturers There are many battery manufacturers but the major ones are C amp D Enersys CSB Yuasa Panasonic and GS to name a few 20 If have one bad battery should I only replace that faulty battery or replace the entire string of batteries Batteries in series are similar to a string of holiday lights When one unit fails the entire string no longer works When a battery or group of batteries connected in a series ceases to work not only is the battery string no longer functional but it can be difficult to determine which battery has failed The most effective way to combat this potential problem is to spot replace bad batteries that are less than three years old While the four factors affecting battery life play a large role in determining when a battery is vulnerable to failure there is no precise way to ensure that battery failure can be predicted The only way to identify bad batteries early enough for spot replacement is through continuous battery monitoring and scheduled maintenance 21 Why do batteries fail Batteries can fail for a multitude of reasons but common reasons are e High or uneven temperatures e Inaccurate float charge voltage e Loose inter cell links or connections e Loss of electrolyte due to drying out or damaged case e Lack of maintenance aging 22 What is the importance of power density when talking about batteries B
17. e is no way for the battery s chemical reactions to happen that quickly And at higher current levels batteries can produce a lot of heat which wastes some of their power 4 EATON CORPORATION The UPS Battery Handbook Like all batteries UPS batteries are electrochemical devices A UPS uses a lead acid storage battery in which the electrodes are grids of lead containing lead oxides that change in composition during charging and discharging and the electrolyte is dilute sulfuric acid In other words they contain components that react with each other to create DC electrical current These components include e Electrolyte The medium that provides the ion transport mechanism between the positive and negative electrodes of a cell in VRLA batteries the electrolyte is immobilized while in tlooded cell batteries it is in liquid form e Grid A perforated or corrugated lead or lead alloy plate used as a conductor and support for the active material e Anode The terminal where the current flows in e Cathode The terminal where the current flows out e Valve used in VRLA batteries Used to vent the build up of gas that goes beyond pre determined levels e Separator A device used for the physical separation and electrical isolation of electrodes of opposing polarities e Jar The container holding the battery components i Series connection Parallel connection Connection of the positive terminal of a cell oatte
18. enance As systems get larger increasing battery capacity to support the load gets more complicated Larger systems may require multiple strings of batteries introducing complexity to battery maintenance and support Individual batteries must be monitored to prevent a single bad battery from taking down an entire string and putting the load at risk Also as systems get larger wet cell batteries become much more common The differences in battery maintenance between VRLA and wet cell batteries discussed earlier in this handbook apply 8 EATON CORPORATION The UPS Battery Handbook 7 Our facility was damaged by a flood and our batteries were partially submerged in water What should do The first concern in this situation is safety Containing any contamination is critical to preventing hazards to workers and the environment 8 My UPS has been in storage for over a year Are the batteries still good As batteries sit unused with no charging regimen their battery life will decrease Due to the self discharge characteristics of lead acid batteries it is imperative that they be charged periodically during storage Otherwise permanent loss of capacity will occur To prolong shelf life without charging store batteries at 10 C 50 F or less 9 What is thermal runaway Thermal runaway occurs when the heat generated in a lead acid cell exceeds its ability to dissipate that heat which can lead to an explosion especially in se
19. evel for the cell Local action Ihe internal losses of a battery standing on open circuit or on float charge without considering any losses incidental to any discharge Long duration cell A cell designed to supply a duty cycle requiring a low current for a long period of time Low level line A line on the side of a jar that represents the minimum level of electrolyte that should be present in a cell Modified plante plate A lead alloy grid containing holes into which pure lead corrugate strips are placed Multi cell container A multi compartment container in which each compartment may contain an individual cell Multi cell unit A multi cell container in which cells are installed Negative plate he electrode to which current flows from the external circuit when the cell is discharging Negative terminal The terminal toward which positive charge flows in the external circuit such as from the positive terminal when the cell discharges NiCad battery A sealed storage battery having a nickel anode a cadmium cathode and an alkaline electrolyte Nominal gravity The specific gravity of the electrolyte selected for the determination of the rated capacity of the cell when it is fully charged Open circuit voltage The voltage of a cell with no current flow in either direction after the cell has had time to Stabilize Overcharge The forcing of current throug
20. g During a utility power failure a UPS operates on battery power Once utility power is restored or a switch to generator power is complete the battery is recharged for future use This is called a discharge cycle At installation the battery is at 100 percent of rated capacity Each discharge and subsequent recharge reduces the relative capacity of the battery by a small percentage The length of the discharge cycle determines the reduction in battery Capacity Lead acid chemistry like others used in rechargeable batteries can only undergo a maximum number of discharge recharge cycles before the chemistry is depleted Once the chemistry is depleted the cells fail and the battery must be replaced What can go wrong with batteries Condition Cause Plate separation Grid corrosion Internal short circuit External short circuit Sulfation of plates Excessive gassing Drying out 4 Maintenance Service and maintenance of the batteries are critical to the reliability of the UPS A gradual decrease in battery life can be monitored and evaluated through voltage checks load testing or monitoring Periodic preventive maintenance extends battery string life by preventing loose connections removing corrosion and identifying bad batteries before they can affect the rest of the string Even though sealed batteries are sometimes referred to as maintenance free they still require scheduled maintenance and service Maintenan
21. h a battery after it has been fully recharged Oxygen index The minimum concentration of oxygen expressed as volume percent in a mixture of oxygen and nitrogen that will just support flaming combustion of a material initially at room temperature Oxygen recombination A process whereby oxygen generated at the positive electrode recombines with hydrogen at the negative electrode to convert to water Oxygen recombination efficiency A ratio of the quantity of oxygen recombined to the total amount of oxygen generated Parallel The interconnection of cells in which all the like terminals are connected together Parallel strings The interconnection of two or more strings in which the like terminals of each string are connected together Pasted plate A grid filled with active material applied as a paste Performance test A constant current capacity test made on a battery after being placed in service to detect any change in the capacity determined by the acceptance test Pilot cell A selected cell whose condition is assumed to Indicate the condition of the entire battery Plante plate A pure lead plate for a lead acid cell in which the active material is formed directly from a lead substrate Plate An assembly of active materials on a Supporting framework grid frame or support strip Also called an electrode Pocket plate A plate in which the active materia
22. he first year Eaton will send a technician on site to install the replacement battery at no charge With regional stocking locations we can get replacement batteries to you quickly Eaton Cellwatch Eaton Cellwatch is an advanced battery monitoring system for three phase UPSs All information collected by Eaton Cellwatch is gathered at a central monitoring unit where It is analyzed on Windows compatible software The system uses fiber optic technology which is non conducting and introduces no electrical noise so all readings are precise and accurate Eaton Cellwatch provides continuous monitoring of your batteries to allow you to proactively identify and address battery issues This includes e Monitoring of voltage internal resistance and temperature e Immediate warning and specific battery identification of deterioration and imminent failure e Reduction of the possibility of damage to entire battery string e Replacement based on actual battery condition preventing costly premature replacement e Minimum of 120 days of activity history that enables you to trend individual battery and string performance e Continuous monitoring of string and battery discharge currents ranging from 25A to 1000A e Programmable alarm functions e Remote monitoring capabilities optional e May be used to detect thermal runaway in advance Expert technical support Eaton batteries are backed by Eaton s service network of trained and qualified b
23. ified battery service technicians Labor adder Eaton 12V 34W battery Eaton 12V 120W battery Eaton 12V 200W battery Eaton 12V 280W battery Eaton 12V 330W battery Eaton 12V 390W battery Eaton 12V 500W battery 2 year parts 1 year labor 2 year parts 2 year labor 2 year parts 1 year labor 2 year parts 2 year labor 3 year parts 1 year labor 3 year parts 3 year labor 3 year parts 1 year labor 3 year parts 3 year labor 3 year parts 1 year labor 3 year parts 3 year labor 3 year parts 1 year labor 3 year parts 3 year labor 3 year parts 1 year labor 3 year parts 3 year labor 10 EATON CORPORATION The UPS Battery Handbook Why Eaton batteries Proven performance Eaton batteries have been thoroughly tested by Eaton s engineering team and shown to adhere to our stringent performance and quality specifications High power density An optimized design delivers more watts per cell more power for the volume than other batteries on the market As a result Eaton batteries provide more runtime for the footprint more runtime per dollar High rate design Charge after charge the batteries approved for the Eaton brand sustained high runtime levels while performance of non qualified batteries dropped off markedly after only 10 discharges Extended warranty coverage Eaton offers a full three years of parts coverage with full not pro rated replacement of any failed battery In the unlikely event that a replacement battery fails within t
24. l is held in perforated metal pockets on a support strip Usually used for nickel cadmium cells Point of specific gravity One thousandath of specific gravity SG Polarization The change in voltage at the terminals of a cell when a specified current is flowing into the cell Positive plate he electrode from which the current flows to the external circuit when the battery is discharging Positive terminal he terminal from which the positive electric charge flows through the external circuit to the negative terminal when the cell discharges Power density The ratio of the available power from a cell to its volume or weight Rated capacity he ampere hour capacity assigned to a cell by its manufacturer for a given discharge time at a specified electrolyte temperature to a given end of discharge voltage Recombination vent A vent in which most of the gasses escaping from the cell are catalytically recombined and returned to the cell as water Reference electrode A special electrode that has a reproducible potential against which other electrode potentials can be referred Retainer Any material that is used to prevent the loss of active material from the positive plate Reversal A changing of the normal polarity of a cell Rundown test A partial discharge test to a voltage other than the system designed and voltage Secondary cell An electrochemical
25. leakage e Measure and record the float voltage and current of the entire bank e Record the voltage and electrolyte density of selected battery cells e Check the electrolyte level in each cell e Log the ambient temperature 6 EATON CORPORATION The UPS Battery Handbook Spot replacement of batteries Batteries in series are similar to a string of holiday lights When one unit fails the entire string no longer works When a battery or group of batteries connected in a series ceases to work not only is the battery string no longer functional but it can be difficult to determine which battery has failed The most effective way to combat this potential problem is to spot replace bad batteries that are less than three years old While the four factors affecting battery life play a large role in determining when a battery is vulnerable to failure there is no precise way to ensure that battery failure can be predicted The only way to identify bad batteries early enough for spot replacement is through continuous battery monitoring and scheduled maintenance Spot replace bad batteries that are less than three years old and replace the whole string between the fourth and fifth year Battery safety The materials in batteries make them volatile and therefore potentially hazardous Performing regular periodic maintenance on your UPS batteries can go a long way in preventing unsafe situations before they occur Sulfuric acid
26. life and save you time and trouble in the future Improvements in battery technology have been evolutionary rather than revolutionary Capabilities such as advanced charging regimens software management for accurate remaining life information and firmware adding intelligence to the batteries have reduced but not eliminated the risks inherent in depending on any battery Therefore it is prudent if not essential to take a close look at what may be increasing your risk of unexpected load loss from a failing UPS battery After all even large installations with many batteries are vulnerable to the failure of a single battery 2 EATON CORPORATION The UPS Battery Handbook UPS battery overview There are primarily two kinds of batteries used in UPSs valve VRLA regulated lead acid VRLA batteries also known as sealed or maintenance free and wet cell also called flooded cell VRLA VRLA batteries are sealed usually within polypropylene plastic batteries usually have lower up front costs but have a shorter VRLAs were developed because they have the advantage of lifetime than wet cell usually around five years Wet cell containing no sloshing liquid that might leak or drip out when batteries require more advanced maintenance but have a longer inverted or handled roughly The term valve regulated refers to lifetime up to 20 years the method of gas release If the gas pressure becomes too great inside the battery the valve will vent
27. me into the cell Flame retardant material A material capable of limiting the propagation of a fire beyond the area of influence of the energy source that initiated the fire Float current The current drawn by a cell that is being float charged Float voltage The voltage applied during Tull float operation Flooded cell A cell design that is characterized by an excess of free electrolyte and in which the products of electrolytes such as gasses and evaporation can freely exit the cell through a vent Also see wet cell Freshening charge A charge given to a battery following nonuse or storage Full float operation Operation of a DC system with the battery the battery charger and the load all connected in parallel with the battery charger supplying the normal DC load plus any self discharge or charging current or both required by the battery Fully charged The condition that exists following a long term constant current charge Gassing Evolution of gas by one or more of the plates in a cell Gassing may result trom electrolysis of water into hydrogen and oxygen within a cell during charging from overcharging or from local action Gelled electrolyte Electrolyte that has been immobilized by the addition of a gelling agent Gelled electrolyte cell A cell usually lead acid or VRLA that uses gelled electrolyte General purpose cell A cell designed to su
28. mount Vent A device that allows the escape of gasses from within a cell Voltage efficiency A ratio of the average voltage during discharge to the average voltage during recharge under specified conditions Voltage spread A term used to describe the difference between the highest and lowest individual cell voltage readings in a battery Wet cell A cell design that is characterized by an excess of free electrolyte and in which the products of electrolytes such as gasses and evaporation can freely exit the cell through a vent Also see flooded cell www eaton com UPSbatteries 1 800 356 5794 15 G O v Wn g ol lt UNITED STATES 8609 Six Forks Road Raleigh NC 27615 U S A Toll Free 1 800 356 5794 www eaton com powerquality www eaton com UPSbatteries ETN Powering Business Worldwide CANADA Ontario 416 798 0112 Toll free 1 800 461 9166 LATIN AMERICA South Cone 54 11 4124 4000 Brazil 55 11 3616 8500 Andean amp Caribbean 1 949 452 9610 Mexico amp Central America 52 55 9000 5252 EUROPE MIDDLE EAST AFRICA Denmark 45 3686 7910 Finland 358 94 52 661 France 33 1 6012 7400 Germany 49 0 7841 604 0 Italy 39 02 66 04 05 40 Norway 47 23 03 65 50 Portugal 55 11 3616 8500 Sweden 46 8 598 940 00 United Kingdom 44 1753 608 700 PowerChain Management ASIA PACIFIC Australia 61 2 9693 9366 New Zealand 64 0 3 343 3314 China 86 21 6361 5599 HK K
29. mpere hours removed trom a fully charged battery expressed as a percentage of its rated capacity at the applicable discharge rate Discharge The conversion of chemical energy into electrical energy within a cell Discharge rate he rate in amperes at which current is delivered by the battery Dry charged cell A cell that has been assembled with its plates dry and in a charged state ready to be activated by the addition of electrolyte This allows easier shipping and storage Efficiency The electrochemical efficiency expressed as a percent of the ratio of the ampere hour output of the battery to the ampere hour input required to restore the initial state of charge Electrode he site at which the electrochemical reaction takes place Electrolyte A conducting medium in which the flow of electric current takes place Element The positive and negative plate groups with separators assembled for one cell End cell A cell that can be added to or removed from a battery circuit to adjust battery voltage End voltage The cell voltage at which the discharge is terminated Energy density The ratio of the available energy from a cell to its volume or weight www eaton com UPSbatteries 1 800 356 5794 13 Q O v Wn g ol lt gt bh 74 74 2 WO Flame arrestor vent A cell venting device that prevents the propagation of an external fla
30. ng and are backed by Eaton s network of trained battery customer service engineers Prior to using a battery in an Eaton product a thorough review of the performance manufacturing and design data is conducted The presence of specific attributes of the design and manufacturing process important in the use of a battery in a UPS is confirmed Following the review and assuming the outcome was successful a Statistically significant sample of the batteries is obtained from the manufacturer This sample is required to have been built from the manufacturer s existing process for that battery A series of tests and physical examinations are conducted on this sample These include a set of discharges using various loads to characterize the performance of the battery charge tests and tests for float current stability at normal to high float voltages Failures or inconsistencies in performance are investigated further and reviewed by the manufacturer In some cases a tear down analysis is performed to identify the cause of the problem If the battery has been found acceptable and all open issues are resolved a limited series of discharges with recharge are performed This intense and thorough quality testing ensures that Eaton batteries are ready for peak performance at their stated capacity as soon as they are deployed Eaton s line of premium batteries for Eaton three phase UPS models is backed by a service network of trained and qual
31. nt amount of hazardous waste including the electrolyte and lead Therefore you must comply with EPA guidelines for the disposal of all UPS batteries There are essentially two main categories of disposal for spent batteries and for spills The primary ways to handle these two categories are Spent batteries Send to secondary lead smelter for recycling Spilled batteries Place neutralized leaked material into sealed containers and dispose of as hazardous waste as applicable Large water diluted spills after neutralization and testing should be managed in accordance with approved local state and federal requirements Consult state environmental agency and or federal EPA Recycling Recycling lead acid batteries is one of the most successful recycling efforts in the world According to Battery Council International more than 97 of lead acid batteries were recycled between 1997 and 2001 Many states require lead acid batteries be recycled and several options exist to dispose of used batteries including e f you are engaged with Eaton on a battery upgrade or replacement Eaton will take your old batteries and recycle them for you e f you participate in Eaton s UPSgrade program we take the old UPS and recycle it Visit www eaton com upsgrade for details e Check your local phone book for a local recycler or search for a recycler at http earth911 com e Some automotive stores often accept batteries for recycling e Man
32. orea Taiwan 852 2745 6682 India 91 11 4223 2300 Singapore SEA 65 6825 1668 Eaton ABM and PowerChain Management are trade names trademarks and or service marks of Eaton Corporation or its subsidiaries and affiliates All other trademarks are property of their respective owners 2010 Eaton Corporation All Rights Reserved Printed in USA BAT11LTA June 2010
33. pply a duty cycle requiring a high current for a short period of time followed by a low current for a long period of time This term is used in the US for cells designed for switchgear tripping generating stations and control applications Grid A framework for a plate in a cell that supports or retains the active material and conducts the electric current High level line A line on the side of a jar that shows the maximum level of electrolyte that should be present in a cell High performance cell A cell designed to supply a duty cycle requiring a high current for a short period of time Hit Indicates that a standby battery has been discharged Hit counter A device used to record the number of discharges experienced by a battery Hydration lead acid cell A condition caused by discharging a cell and failing to recharge it in a timely manner Immobilized electrolyte Electrolyte that is retained by a gel or absorbent mat Initial charge The charge given to a new battery before placing the battery in service Initial voltage The closed circuit voltage at the beginning of a discharge Integrity test A test used to detect conduction path problems Inter cell connection resistance he total electrical resistance of the connection between the terminals of two cells that are electrically connected to each other Inter cell connector An electrical conductor
34. ry to the negative terminal of the next cell battery increases the voltage of the battery network while keeping the Capacity constant Connecting all the positive or all the negative poles of several batteries increases the capacity of a battery network while maintaining a constant voltage Four factors that impact battery life Batteries have limited life usually showing a slow degradation of capacity until they reach 80 percent of their initial rating followed by a comparatively rapid failure Regardless of how or where a UPS is deployed and regardless of Its size there are four primary factors that affect battery life These are ambient temperature battery chemistry cycling and service 1 Ambient temperature The rated capacity of a battery is based on an ambient temperature of 25 C 77 F It is important to realize that any variation from this operating temperature can alter the performance of the battery and shorten its expected life To help determine battery life in relation to temperature remember that for every 8 3 C 15 F average annual temperature above 25 C 77 F the life of the battery is reduced by 50 percent 2 Battery chemistry UPS batteries are electrochemical devices whose ability to store and deliver power slowly decreases over time Even if you follow all of the guidelines for proper storage usage and maintenance batteries still require replacement after a certain period of time 3 Cyclin
35. s installed e Customer Support Center complete 7x24 command center for all of Eaton s services Battery preventive maintenance Preventive maintenance ensures uptime and extends battery life by eliminating problems before they happen Whether a battery tails from defect or deterioration the best time to find out is during preventive maintenance service not when the battery is called upon to support the critical load Eaton will custom design a preventive maintenance package that is best for you including the following features e Comprehensive maintenance schedule for your VRLA or wet cell batteries per IEEE guidelines e Measure cell voltage levels e Visual inspection for leaks or bad cells e Spot check for connection torques e Load testing e Inspection of battery environment e Detailed hard copy of battery test and inspection results e Written inspection report and recommendation This also includes spot replacement of batteries When we identify one or two bad batteries we replace them at that time because Eaton technicians have the batteries with them when they perform the preventive maintenance regimen Eaton Battery Models available Model Warranty Eaton batteries As a part of its commitment to delivering the highest reliability in power availability Eaton offers a line of premium batteries for Eaton three ohase UPS models Eaton batteries combine field proven performance and quality at competitive prici
36. s over how and where your UPS batteries are installed usually depending on the amount of electrolyte the batteries contain Flooded cell batteries require special ventilation because of the amount of hydrogen they emit and their liquid electrolyte They are usually stored away trom the load and other equipment VRLA batteries are much less hazardous due to their immobilized electrolyte so they are often not subject to the more stringent regulations covering tlooded cell batteries and are often located in the data center or near the protected load dll Il nT Hil HH i me k Appropriate personal protective equipment is essential when working on batteries or any UPS equipment www eaton com UPSbatteries 1 800 356 5794 7 Ww g i e W ol lt TI g e e Wn S LL gt 0 Pa J Le aa Battery FAQ 1 What is the end of useful life The IEEE defines end of useful life for a UPS battery as being the point when it can no longer supply 80 percent of its rated capacity in ampere hours When your battery reaches 80 percent of its rated capacity the aging process accelerates and the battery should be replaced 2 How can I ensure that my UPS batteries are maintained and serviced properly With proper maintenance battery life can be predicted and replacements scheduled without interrupting your operations These are IEEE and OEM recommendations for general maintenance e Comprehensi
37. that the battery should be tested without performing certain checks so that the test results will reflect the effect good or bad of the maintenance practice followed for the installation Average temperature he average of the individual cell temperatures of all the cells in a battery Average voltage he average of the individual cell voltages of all the cells in a battery This term may be applied to a variety of conditions including average float voltage and average discharge voltage Battery Iwo or more cells connected together electrically Cells may be connected in series or parallel or both to provide the required operating voltage and current levels Battery charger An apparatus that restores the charge of a secondary battery Also known as a rectifier Battery duty cycle he load a battery is expected to supply for a specified time period Battery monitor A piece of equipment used to monitor various parameters of a battery such as individual cell voltage battery voltage and temperature Battery nominal voltage The nominal voltage of one cell multiplied by the number of cells in the battery Battery rack A structure used to support a group of cells The most common rack material is steel with a corrosion resistant coating Boost charge An overcharge of any length Cathode The electrode in an electrochemical cell where reduction takes place During
38. ve maintenance programs with regular inspections e Re torque all connections as required e Load testing e Cleaning the battery area as required 3 Do have to replace my UPS batteries with the same brand of batteries Eaton recommends that if you use brand X and need to replace one or two batteries in the string you should use the same brand because they will have the same characteristics If you need to replace the whole string then you can change brands with fewer risks 4 Are maintenance free batteries maintenance free Though sealed batteries are sometimes referred to as maintenance free they still require scheduled maintenance and service The term maintenance free refers to the fact that they do not require fluid Preventive maintenance is the key to maximizing your UPS battery service life 5 What about the disposal of batteries It is imperative that your service technicians adhere to EPA guidelines for the disposal of all UPS batteries Remember it is the owner s responsibility to make sure these guidelines are followed 6 Is there any difference between the batteries used by smaller UPSs from 250 VA to 3 kVA and the ones used by larger UPSs While basic battery technology and the risks to battery life remain the same regardless of UPS size there are some inherent differences between large and small applications First smaller UPSs typically have only one VRLA battery that supports the load and needs maint
39. y increases the life of UPS batteries Customer Support Center Eaton s global 7x24 service operations command center is a hardened secure facility for all UPS product service scheduling technical support and remote monitoring support Customer support staff is trained to qualify and prioritize all incoming calls using defined processes complemented by a knowledge database with tech support and domain experts at their disposal 7x24 The Eaton Customer Support l l Center stands ready to assist 7x24 The benefits of the Customer Support Center include e Increased reliability via remote diagnostic and remote repair tools delivered by Eaton product experts e Expedited service response to critical UPS and battery alarms reduce risk and cost of downtime E T N PATON UPS MATT AY SPLectoe e 7x24 notification of critical alarms or trends e Ease customer hassle of managing battery health e Saves time for busy facility or IT managers e Enhanced internal self monitoring resources and capabilities e Monthly reports designed for both technical and non technical use E Megi pearwa O ary e Development of trending database on both UPS and battery Looking for replacement batteries for your Eaton UPS Use Eaton s online UPS Battery Selector tool for small single phase units to help you find the appropriate replacement batteries for your Eaton UPS www eaton com UPSbatteries 12 EATON CORPORATION The
40. y municipalities have dump or recycling locations that will accept batteries for recycling When disposing of batteries in this manner be sure to get a receipt clearly detailing what batteries were dropped off when quantity and has the recycler s full name address and phone on it in the unlikely event you get audited Battery maintenance for extended life Quantifying the combined effect of these four factors is difficult You need a way to determine when a battery is near the end of its useful life in order to replace it while it still works before the critical load is left unprotected The only sure way to determine battery capacity is to perform a battery run down test The module is taken off line connected to a load bank and operated at rated power until the specified runtime elapses or the unit shuts down due to low battery voltage If battery capacity is less than 80 percent of its rated capacity the battery should be replaced Thermal scanning of battery connections during the battery run down test identifies loose connections This test gives you the chance to see the battery during an extended high current discharge Scanning should take place during both discharge and recharge cycles An effective battery maintenance program must include regular inspections adjustments and testing of UPS batteries with thorough records of all readings Trained technicians should e Inspect batteries and racks for signs of corrosion or
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