1. Inspection and test data analysis
John Polenz
Supervisor Battery Technical Support - Vertiv
06/11/2017

2. Data collection
Why collect the data if you aren’t going to do anything with it - Except file it!

3. discussion
Preventive Maintenance Inspection Data
Consistent readings taken and recorded
Baselines established
Analysis of the data
Single report data analysis
Capacity Testing Data Analysis
Data recording
Unit and system data recording
Final analysis

4. Data analysis
So many times with battery analysis – IT DEPENDS! ASK Questions to help get the answers: Was the battery recently cycled? How long has the value been that way? Is it recovering or getting worse? Has anything changed that could impact the battery? Have any corrective measures been attempted? Have you verified system readings at the battery – not at the charger?
*Additional Notes

5. Collecting Consistent readings! Getting the right readings!
PM Inspection DATA
Collecting Consistent readings!
Getting the right readings!
Importance of test equipment lead placement consistency
Different technicians will place test leads differently
Can negatively impact readings
Can impact trending
Misleading on actions to take
*Additional Notes

6. Establish ohmic Baselines
Trending is best method
*Additional Notes

7. Establish baselines
Establish Proper Baselines - Thresholds Voltage Internal Ohmic Temperature Ambient/unit System Float Unit float Specific gravity
*Additional Notes

8. Proper baselines Example: 7500 = 11250 (50% above first reading)
3750 = (50% above 6 months reading)
Incorrect baselines can mask potential concerns!
*Additional Notes

9. Specific gravity data analysis
Can be hard to make correct determination
*Additional Notes

10. Temperature swings
*Additional Notes

11. Validation of data Float = 2.179 v/c Actual battery float requirement
*Additional Notes

12. Investigation for: Unit Float issues Internal Resistance increase
Validation of data
Investigation for: Unit Float issues Internal Resistance increase
Actual float should be
535 VDC
Nom. Float – 2.23 v/c
Recorded – v/c
At the battery – 2.245
Exceeds manufacturer recommendations
*Additional Notes

13. Take the Readings and move on
Sometimes it is plain Sight!
*Additional Notes

14. Don’t only record the data
Low voltages
Lower temperatures
Low float setting
*Additional Notes

15. Alarm triggers
*Additional Notes

16. Single data set analysis
Improper threshold It did not identify Suspect units! Quick visual look!
The 3 units all exceed 50% above baseline using present data set
*Additional Notes

17. Single data set analysis
*Additional Notes

18. Contributing factors can be identified with analysis
Voltage drop
Over charge
Under charge
*Additional Notes

19. Lack of data for evaluation
*Additional Notes

20. Capacity test Analysis
Capturing useable data Capturing only system level vs. unit level Voltage, temperature, current, time Where the data is collected is important UPS application – at the battery and at the UPS to aid in system design verification,
*Additional Notes

21. Don’t assume the battery has failed - Didn’t make time
Data analysis
Don’t assume the battery has failed -
Didn’t make time
Didn’t meet the ECV requirement
Cell/unit dropped out early
Example:
The following discharge testing results were observed:
 On an 11 minute backup time rating, the batteries ran for approximately 16.5 minutes.
The batteries supplied over 100% capacity using the industry standard IEEE 1188, rate adjusted calculations.
At the 15 minute discharge point (before voltage drop-off) the lowest battery voltage was 9.871
The test ran until the end cell voltage reached 1.60 volts/cell and the batteries supported an average load of 55.66kw for minutes.
*Additional Notes

22. Verifying report alarm thresholds
Default software setting to 1.67v/c
Changed to 1.50 v/c
*Additional Notes

23. Data logging helps to make analysis easier and quicker
Test data
Data logging helps to make analysis easier and quicker
*Additional Notes

24. Uniform test results
*Additional Notes

25. Do not make battery performance assumptions till the data is analyzed
Analyze the data collected
Verify the load applied to UPS/battery
Verify published performance specification for the battery
Verify ECV cutoff setting
Verify temperature of the battery during the test
Calculate the battery capacity per IEEE 1188
*Additional Notes

26. Summary
Some data is better than none The more data the better for evaluation More data provides better trending Better trending leads to better prevention to failures Baselines need to be established properly Data analysis can help to identify: Charger issues Environmental concerns Failing battery Voltage drop identification Improper maintenance practice
*Additional Notes

27. Thank you for your attention!