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

8. Example Battery Failures
Found At
Customer Sites

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

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

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

13. Voltage vs. Time: Voltage Drops 10%
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. Impedance vs. Time: 120% in Two Weeks
Example #3 - Unit 13
Impedance vs. Time: 120% in Two Weeks
Failure Within 2 Weeks

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

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

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

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

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

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

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

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

23. Voltage vs. Unit Number During Discharge
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. BTECH’s Fifth Generation Battery Monitoring System
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. Unmanned Communications: 48V VRLA Stack
S5 VRLA Stack Installation
Unmanned Communications: 48V VRLA Stack

28. 3-Phase UPS: 40-12v (480V) VRLAs
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 Cell Temperatures – 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. Full Data Logging and Analysis: Building the Database
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 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. The Leading Indicator of Failure
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 Impedance Does Not Discharge Your Batteries
BTECH’s Impedance Method
BTECH Impedance Does Not Discharge Your Batteries

36. Impedance vs. Resistance (i.e. “Voltage Response”)
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. BTECH Impedance vs. Voltage Response
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