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Overview
traditional batteries. they’re very reliable with a long life, there are downsides to
flooded-cell batteries. They require more safety measures and a
In addition, their high cycle-count (charge-discharge cycles), and space-consuming separate battery room to use.
faster recharge times compared with lead batteries allows their
use in non-traditional UPS applications, like grid sharing, peak Regardless of the differences in UPS battery types, both
shaving, and industrial or process control support. require monitoring and maintenance to ensure maximum life
and system availability.
The battery management
system is deployed in each
battery, as well as in a system
level master controller. It
manages charge current,
voltage, and cell voltage
balance, while making
adjustments as necessary
to eliminate any chance
of overtemperature. If
temperatures rise above safe
levels, the management system
will independently disconnect
the battery or string via multiple
different disconnection means,
and notify the user via the
battery cabinet monitor, and an
alarm on the UPS.
Capacitors: A capacitor is a fairly Filters: Because dust may block Fans: They may slow down or stall
simple device that stores and releases air filters and cause a UPS to shut as they age, and a resulting over
electrical energy. They can be as small down due to overheating, they must temperature condition will shut down
as a thumbnail or as large as a soda be inspected every month. Replacing the UPS unexpectedly. Watch for fan
can. A typical UPS contains a dozen or filters is an inexpensive component of fail alarms every week, and plan for
more of different types and sizes. Like an effective UPS maintenance plan. replacement at the 8-10 year mark
batteries, capacitors degrade over time. at the latest.
There may not be visible effects upon
immediate failure, but one failure will
leave other capacitors to work harder
and shorten lifespan.
+24V
+ - + -
12V 12V
+12V
+ +
12V 12V
- -
Battery Facts
1.2 acid. Once the chemistry is depleted, the cells fail and the battery
must be replaced.
1.0
4. Maintenance
0.8 Battery service and maintenance are critical to UPS reliability. A
Relative Life
Condition Cause
Battery life: design life vs. actual life
Repeated cycling (charging and discharging),
Plate separation damage during handling and shipping, and Determining battery life can be a tricky business. It’s often
overcharging promoted based on design life, defined as how long the
Normal aging, operating in an acidic environment battery can be expected to perform under ideal conditions.
Grid corrosion and high temperatures Estimating actual battery life relies on taking into
Heat (plates expand causing shorts), separator consideration the four factors discussed on this page
Internal short circuit failure, handling and shipping, and grid corrosion that can affect it.
Batteries that are replaced can still for extended life Batteries in series are similar to a string
of holiday lights. When one unit fails, the
contain a significant amount of hazardous entire string no longer works. When a
waste, including the electrolyte and lead. Quantifying the combined effect of
the four factors that affect battery life battery or group of batteries connected in
Therefore, you must comply with EPA a series ceases to work, not only is the
guidelines for the disposal of all UPS discussed in the previous page is difficult.
battery string no longer functional, but it
batteries. There are essentially two main You need a way to determine when a can be difficult to determine which battery
categories of disposal, one for spent battery is near the end of its useful life has failed.
batteries and another for spills. The primary so you can replace it while it still works,
before the critical load is left unprotected. The most effective way to combat this
ways to handle these two categories are: potential problem is to “spot” replace bad
The only sure way to determine battery
capacity is to perform a battery run- batteries that are less than three years
Spent batteries
down test. The module is taken off line, old. While the four factors affecting battery
Send to secondary lead smelter for connected to a load bank and operated life play a large role in determining when a
recycling. For lithium-ion, return to original at rated power until the specified runtime battery is vulnerable to failure, there’s no
vendor or an authorized 3rd party recycler elapses or the unit shuts down due to low precise way to ensure that battery failure
equipped to handle lithium batteries. battery voltage. If battery capacity is less can be predicted. The only way to identify
than 80 percent of its rated capacity, the bad batteries early enough for spot
Spilled batteries replacement is through continuous battery
battery should be replaced.
monitoring and scheduled maintenance.
Place neutralized leaked material into
Thermal scanning of battery connections Spot replace bad VRLA batteries that are
sealed containers and dispose of as
Battery Facts
during the battery run-down test identifies less than three years old and replace the
hazardous waste, as applicable. Large
loose connections. This test gives you whole string between the fourth and fifth
water-diluted spills, after neutralization
the chance to see the battery during year (10th year for lithium-ion).
and testing, should be managed in
accordance with approved local, state and an extended, high-current discharge.
Scanning should take place during Used batteries: good for the
federal requirements. Consult your state environment?
environmental agency and/or the EPA. discharge and recharge cycles.
Which commonly used product has the
Recycling An effective UPS battery maintenance
highest rate of recyclability? Paper? Only
program must include regular inspections,
73 percent of paper is recycled for reuse.
One of the most successful recycling adjustments and testing, with thorough
Aluminum at 54 percent and glass at
efforts in the world is for lead-acid records kept of all readings. Trained
25 percent also fall short of the leader.
batteries. According to Battery Council technicians should:
More than 96 percent of all battery lead is
International, more than 96 percent of
• Inspect batteries and racks or cabinets recycled. Lead-acid batteries top the list of
lead-acid batteries were recycled between
for signs of corrosion most highly recycled consumer product.
1997 and 2001. Many states require lead-
acid batteries be recycled, and several vertical return alignment leakage The processes for lead-acid battery
options exist to dispose of used batteries, recycling support agriculture needs and
• M
easure and record the float voltage
including: enhance energy conservation. Beyond the
and current of the
successful reuse of nearly 100 percent of
• If you’re engaged with Eaton on a entire bank
the battery components, lead recycling
battery upgrade or replacement, we’ll • R
ecord the terminal voltage of selected facilities harness radiant heat from their
take your old batteries and recycle them batteries furnaces to offset traditional heating costs.
for you Residual sulfur trapped during recycling is
• C
heck the electrolyte level in each cell, processed into fertilizer. Even the plastic
• If you participate in Eaton’s UPSgrade if visible casings are crushed into pellets and are
program, we take the old UPS and
• C
heck voltage balance and internal used to manufacture new battery covers
recycle it. Visit Eaton.com/upsgrade for
temperature of lithium-ion cells and cases.
details
Recycling lead is also more energy
• C
heck your local phone book for a local • Log the ambient temperature
efficient than smelting or mining new
recycler, or search for a recycler at lead. The recycled lead can be refined into
• C
ompare data collected to previous
www.earth911.com new alloy repeatedly, giving it unmatched
maintenance inspections to accurately
identify issues sustainability and cost stability—a trait
• S
ome automotive stores accept batteries
unlike most raw materials.
for recycling
Lithium-ion recycling Lithium batteries from a UPS are highly
• M
any municipalities have dump or likely to have a ‘second life’ in a solar
Lithium-ion batteries contain no toxic
recycling locations that will accept or electric vehicle application, before
materials, but should be recycled or
batteries for recycling. When disposing ultimately being recycled. Contact the
re-used, i.e. redeployed in solar, home
of batteries in this manner, be sure to battery vendor to see if this is
backup, or refurb automotive use.
get a dated receipt clearly detailing what
batteries were dropped off, including
quantities with the recycler’s full name,
address and phone noted in the unlikely
event you get audited.
Battery Facts
Battery safety Handling and storage
The materials in batteries make them volatile and therefore Store batteries in cool, dry, well-ventilated areas with impervious
potentially hazardous. Performing regular periodic maintenance surfaces and adequate containment in the event of spills.
on your UPS batteries can go a long way in preventing unsafe Batteries should also be stored under a roof for protection against
situations before they occur. adverse weather conditions. Separate them from incompatible
materials. Store and handle only in areas with adequate water
Sulfuric acid is very combustible and contact with organic supply and spill control. Avoid damage to containers. Keep away
materials may cause fire and explosion. It also reacts violently from fire, sparks and heat.
with strong reducing agents, metals, sulfur trioxide gas, strong
oxidizers and water. Contact with metals may produce toxic State and local governments may have regulations concerning
sulfur dioxide fumes and may release flammable hydrogen gas. how and where your UPS batteries are installed, usually
depending on the amount of electrolyte the batteries contain.
For lead compounds, avoid contact with strong acids, bases, Flooded-cell batteries require special ventilation because of the
halides, halogenates, potassium nitrate, permanganate, amount of hydrogen they emit and their liquid electrolyte. They
peroxides, nascent hydrogen and reducing agents. Lithium-ion are usually stored away from the load and other equipment.
batteries actually contain no toxic substances, and pose no VRLA batteries are much less hazardous due to their immobilized
hazard in normal handling. If a battery case is broken, consult electrolyte, so they’re often not subject to the more stringent
the vendor’s Material Safety Data Sheet (MSDS) for appropriate regulations covering flooded-cell batteries and are often located in
action. Different lithium-ion battery models use a variety of the data center or near the protected load. Lithium-ion batteries
different chemical components, and safety procedures will vary. may be stored and handled in the same way as VRLA batteries.
Note that shipping procedures must comply with UN Class 9
You should always refer to the material safety data sheet for requirements for lithium batteries.
specific precautionary measures. Primary steps for safe handling
and use are noted below.
It’s imperative that your service technicians adhere to EPA Thermal runaway effects
guidelines for the disposal of all UPS batteries. Remember, on adjacent battery
cabinet
it’s the owner’s responsibility to make sure these guidelines
are followed.
Adding more batteries to a UPS can increase the battery runtime 21. Why do batteries fail?
to support the load, but it doesn’t increase the UPS capacity.
Batteries can fail for a multitude of reasons, but common
Be sure your UPS is adequately sized for your load, then add
reasons are:
batteries to fit your runtime needs.
• High or uneven temperatures
14. What is the average lifespan of UPS batteries?
• Inaccurate float charge voltage
The standard service lifespan for VRLA batteries is three to five
• Loose inter-cell links or connections
years; lithium-ion, 10 years, and for flooded-cell batteries it’s
up to 20 years. However, expected life can vary greatly due to • Loss of electrolyte due to drying out or damaged case
environmental conditions, number and depth of discharge cycles, • Lack of maintenance, aging
and adequate maintenance. Having a regular schedule of battery
maintenance and monitoring will ensure you know when your 22. What is the importance of power density when talking
batteries are reaching their end-of-life. about batteries?
15. Why are batteries disconnected on small, single-phase Batteries differ markedly in the number of watts per cell. A higher
UPSs when they’re shipped? density battery provides more runtime for the footprint. You may
even find you can reach your runtime requirements with fewer
This is so that they’re in compliance with Department of
battery cabinets, which reduces upfront and lifetime costs of
Transportation regulations.
battery preventive maintenance.
16. If I have the serial number from the Eaton UPS or battery
23. How is battery performance generally measured?
cabinet, can I find out how old the batteries are?
Batteries are generally rated for 100+ discharges and recharges,
Every Eaton battery has a manufacturer date code that indicates
but many show a marked decline in charging capacity after as
when it was made. The battery or battery cabinet will also feature
few as 10 discharges. The exception is lithium-ion batteries which
a sticker for each time the batteries have been recharged while
are typically rated for up to 2000 discharges over their service
in storage. Stored batteries require charging periodically during
life. The lower the charge the battery can accept, the less runtime
storage to avoid loss of capacity. Recharging stored batteries
it can deliver. Look for batteries with a high-rate design that
Battery FAQ
doesn’t affect battery warranty as long as it does not exceed a
sustains stable performance for a long service term.
battery manufacturer’s guidelines for the number of recharges
before a battery is put into service. 24. When are 10-year design life SVRLA batteries typically
replaced in standard UPS applications?
17. Will Eaton replace batteries for other manufacturers’
UPSs? UPS battery life depends on a number of factors, including
Yes. Eaton batteries works on nearly all other manufacturers’ operating temperature, number and duration of discharges,
UPSs. In addition, we have extensive knowledge of Best Power, and if regular preventive maintenance is performed. While
Deltec, IPM and Exide Electronics models because these product it’s theoretically possible for SVRLA batteries to last 10 years
lines were purchased by Eaton. under optimum conditions, the industry typically recommends
full replacement between years four and five for reliability
18. What are the risks associated with a lack of battery purposes in UPS applications. Note that lithium-ion battery typical
maintenance? replacement interval is 10 years.
The primary risks of improperly maintained batteries are: load 25. How can I determine the age of a battery?
loss, fire, property damage and personal injury.
Batteries shipped on or after January 1, 2000 have a four-digit
19. Who are the major battery manufacturers? shipping code with the first two digits as the year and the
following two as the month in which the battery was shipped
There are many battery manufacturers, but the major ones are: from the factory. For example, a code of 1710 would be
C&D, Enersys, CSB, Samsung, Yuasa, Panasonic and GS – to interpreted as 2017, October.
name a few.
20. If I have one bad battery, should I only replace that faulty
battery, or replace the entire battery string?
Having one faulty battery doesn’t mean you have to replace the
entire battery string, which can be very costly. You can replace
the bad battery with a fully charged unit but you also need to
test the health of the entire string to the cell level to identify if
additional strain from the faulty battery damaged other units.
Eaton’s line of premium batteries for Eaton three-phase UPS models is backed by a service network of
trained and qualified battery service technicians
90%
80% I I I I I I I I I I I I I
0 10 20 30 40 50 60 70 80 90 100 110 120
Battery Age
(in months)
Eaton’s global 24x7 service operations command center is a hardened, secure facility
for all UPS product service scheduling, technical support and remote monitoring support.
Customer support staff are The benefits of the Customer • E
ases customer hassle of managing
trained to qualify and prioritize all Monitoring Center include: battery health
incoming calls using defined • Increased reliability via remote • S
aves time for busy facility or IT
processes, complemented by a diagnostic and remote repair tools managers
knowledge database, with tech delivered by Eaton product experts • E
nhanced internal self-monitoring
support and domain experts at
• E
xpedited service response to resources and capabilities
their disposal 24x7.
critical UPS and battery alarms • M
onthly reports designed for both
(reduces risk and cost of downtime) technical and non-technical use
• 2
4x7 notification of critical alarms • D
evelopment of trending database
or trends on both UPS and battery
In winter, the Mt. Washington Observatory is an ice and snow palace, battered
by hurricane-force wind gusts
Absorbed electrolyte – Actual capacity – The total Average voltage – The Battery nominal voltage –
Electrolyte that’s been number of ampere-hours that average of the individual The nominal voltage of one cell
immobilized in an absorbent could be withdrawn from a cell voltages of all the cells multiplied by the number of
separator. cell based on a specific set of in a battery. This term may cells in the battery.
operating conditions (including be applied to a variety of
Absorbed electrolyte cell – A initial state-of-charge, discharge conditions, including average Battery rack – A structure
cell, usually a valve-regulated rate, initial cell temperature float voltage and average used to support a group of
sealed lead-acid type, which and end voltage) and the age discharge voltage. cells. The most common
utilizes absorbed electrolyte. of the cell. rack material is steel with a
Battery – Two or more cells corrosion-resistant coating.
Absorged glass mat (AGM) Ambient temperature – The connected together electrically.
battery – Designed with average temperature of the Cells may be connected in Boost charge – An overcharge
electrolytes held in thin glass surrounding air that comes into series or parallel, or both, to of any length.
fibers woven into a mat to contact with the battery. provide the required operating
increase surface area enough voltage and current levels.
Cathode – The electrode
to hold sufficient electrolyte on Anode – The electrode in an in an electrochemical cell
the cells for their lifetime. AGM electrochemical cell where Battery charger – An where reduction takes place.
batteries are also known as oxidation takes place. During apparatus that restores the During discharge, the positive
“starved electrolyte” or “dry” discharge, the negative charge of a secondary battery. electrode of the cell is the
because the fiberglass mat has electrode of the cell is the Also known as a rectifier. cathode. During charge, this
no excess fluid. anode. During charge, this reverses and the negative
reverses and the positive Battery duty cycle – The load electrode of the cell is the
Accessories – The components electrode of the cell is the a battery is expected to supply cathode.
required to complete the anode. for a specified time period.
battery installation, including Carbonization – A condition
connectors, flame-arrestor As found (condition) – A term Battery management system where the electrolyte becomes
vents, cell numbers and used to inform the person – Required for lithium-ion contaminated with potassium
hardware. performing a capacity test that systems, this monitors and carbonate to a point where it
the battery should be tested controls cell balance and can influences cell performance.
Activation charge – The without performing certain take action to disconnect
process of making a dry- checks, so the test results will a failing battery string Capacity – The ampere-hour
charged cell functional by reflect the effect (good or bad) automatically. capacity assigned to a cell by
introducing electrolyte and of the maintenance practice
the manufacturer for a given
charging. followed for the installation.
Battery monitor – A piece of discharge time, at a specified
equipment used to monitor electrolyte temperature and
Active material – The material Average temperature – The various parameters of a specific gravity to a given end-
in the electrodes (plates) of average of the individual cell battery, such as individual cell of-discharge voltage.
the cell that reacts chemically temperatures of all the cells in voltage, battery voltage and
to produce electric energy a battery. temperature. Cell – The basic electrochemical
when the cell discharges, unit, characterized by an anode
which is restored to its original and cathode, used to receive,
composition during the charge store and deliver electrical
process. energy.
Glossary
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