John Polenz Emerson Network Power Liebert Services

 Prior to the test  During the test  After the test

Just kill the input and let’er run till she drops and see how long it runs!

 Do you use IEEE 1188, 450, &1106 as a reference and guide?  Do you know what the Battery Manufacturer requirements are?

 Most require initial/equalize charge – Really?  72 hour float after equalize and prior to testing  Cool down?  Dissipation of Gas build up on plates  Initial/equalize Timelines for VLA can be extensive  150 hrs vs 24 hrs  Ensuring Full state of Charge  Construction events  Constant current testing vs constant power

 System functionality vs Battery capacity  More than not with UPS applications  Primarily acceptance testing  No planning or knowledge of battery manufacturers requirements for capacity testing  IOM not reviewed  Timeline issues

 Test requirements What is the actual sizing of the battery? You mean I have to know the sizing for the battery?

 KVA/KW load  Inverter efficiencies  Power factor  Aging factor  Temperature  Number of cells/string  Put the info into the formulas- KVA Rating X Power Factor = KW Load KW Load ÷ Inverter Efficiency = KW Battery Load KW Battery Load ÷ # of Cells = W/Cell requirement This is the “WHY” you want to test as a system!

 What prepping?  The battery has been on float for a couple of days  You discover that the battery has been discharged multiple times due to SAT requirements  UPS voltage setting not verified prior to the test  UPS End Cell Voltage not verified or known  Voltage drop in system  Battery and UPS to battery connections

 Temperature is not considered as an issue  Not prepped as required by the manufacturer Not enough time in schedule Didn’t have the information Didn’t realize the requirements existed Assumed just a 15 minute battery

 No data recording  Data logging equipment issues  Inadequate data collected  System data only at the UPS  At the beginning and at the end of the test  IR testing -Thermal concerns –when do we stop the test?  Connection concerns High resistance –high temperatures  Battery temperature No parameters established  Cell reversal  Equipment malfunctions

 It didn’t make the time !  The system only ran for 6.5 minutes instead of 8 minutes  Battery temperature was found to be 62F  Not all the units met the ECV requirement!  System vs. individual cell/unit ECV  Some units fell below specified ECV  Test ran for 15 minutes, but battery was sized for 10 minutes?  Not tested at 77F(25C)  Temperature was at 62F  Didn’t ensure battery was at FSOC

 Didn’t perform initial charge  Didn’t perform initial charge properly  Didn’t provide 72hr float prior to testing  No monitoring for the test – only system level monitoring  No data to prove or disprove

 Metering not calibrated  Only using UPS meters to collect system data  Time not monitored during the test  Not every cell/unit met the ECV cutoff –  v/c

 Didn’t make time!  No final data review  No calculations to verify test results  Are not familiar with IEEE rate adjusted or time adjusted calculations  No one knows actual sizing of the battery  Test stopped before it should be  Wrong ECV  Wrong time  No agreement on “stop test” criteria

 Lack of prior planning  When to stop the test is not known  Improper equipment used  Wrong size (voltage)load bank  Can cause a fire  Issues with equipment  Out of calibration  Doesn't measure properly  Doesn’t record good data to be reviewed  Doesn’t record the data at all

 Test Equipment failures  Facility damage  Misinterpretation of battery capacity  Delays in commissioning  Additional costs incurred  Expect tests to be run until the battery makes the numbers!  Customer dissatisfaction  Battery failed

 Make no Judgment calls prior to data analysis  Alarms customer!  Plan the testing  Agreement on: Testing parameters Testing procedures Capacity calculations/analysis process Timelines  Know the battery parameters  Sizing  Temperature impact  ECV

 Collect proper data  System level  Cell/unit level  The more the better!  Analyze the data collected  IEEE 1188, 450, 1106  Rate adjusted method  Consult the battery manufacturer’s if there are questions/concerns