This document provides guidance on maintaining direct current (DC) and uninterruptible power supply (UPS) battery systems. It discusses preventative maintenance requirements and schedules for batteries and DC/UPS subsystems. Key maintenance checks for batteries include visual inspections, voltage checks, and monitoring for issues like electrolyte loss or abnormal specific gravity. Maintenance of subsystems focuses on charger and inverter checks and cleaning. Record keeping is also emphasized. Troubleshooting guides address problems such as grounding issues, component failures, and improper outputs. The document aims to help ensure batteries and systems meet design life through effective maintenance practices.
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Operation and Maintenance of DC & UPS System from Saudi Aramco
This document provides guidance on maintaining direct current (DC) and uninterruptible power supply (UPS) battery systems. It discusses preventative maintenance requirements and schedules for batteries and DC/UPS subsystems. Key maintenance checks for batteries include visual inspections, voltage checks, and monitoring for issues like electrolyte loss or abnormal specific gravity. Maintenance of subsystems focuses on charger and inverter checks and cleaning. Record keeping is also emphasized. Troubleshooting guides address problems such as grounding issues, component failures, and improper outputs. The document aims to help ensure batteries and systems meet design life through effective maintenance practices.
This document provides guidance on maintaining direct current (DC) and uninterruptible power supply (UPS) battery systems. It discusses preventative maintenance requirements and schedules for batteries and DC/UPS subsystems. Key maintenance checks for batteries include visual inspections, voltage checks, and monitoring for issues like electrolyte loss or abnormal specific gravity. Maintenance of subsystems focuses on charger and inverter checks and cleaning. Record keeping is also emphasized. Troubleshooting guides address problems such as grounding issues, component failures, and improper outputs. The document aims to help ensure batteries and systems meet design life through effective maintenance practices.
Note: The source of the technical material in this volume is the Professional
Engineering Development Program (PEDP) of Engineering Services.
Warning: The material contained in this document was developed for Saudi Aramco and is intended for the exclusive use of Saudi Aramcos employees. Any material contained in this document which is not already in the public domain may not be copied, reproduced, sold, given, or disclosed to third parties, or otherwise used in whole, or in part, without the written permission of the Vice President, Engineering Services, Saudi Aramco. Chapter : Electrical For additional information on this subject, contact File Reference: EEX21107 W.A. Roussel on 874-1320 Engineering Encyclopedia Saudi Aramco DeskTop Standards Directing the Operation and Maintenance of DC/UPS Systems Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards CONTENTS PAGES DETERMINING WHETHER BATTERIES ARE FUNCTIONING PROPERLY............................................................................................................ 1 Preventive Maintenance Requirements ....................................................... 1 Battery Physical Checks .................................................................. 1 Battery Voltage Checks ................................................................... 7 Preventive Maintenance Frequency .......................................................... 11 Preventive Maintenance Records .............................................................. 14 Problems and Corrective Measures ........................................................... 20 Grounding...................................................................................... 20 Electrolyte Loss ............................................................................. 23 Abnormal Specific Gravity ............................................................ 24 DETERMINING WHETHER DC/UPS SUBSYSTEMS ARE FUNCTIONING PROPERLY.............................................................................. 27 Preventive Maintenance Requirements ..................................................... 27 Visual Inspection ........................................................................... 27 Cleaning......................................................................................... 28 Battery Charger Checks and Adjustments ..................................... 31 Inverter Checks and Adjustments .................................................. 35 Preventive Maintenance Frequency .......................................................... 41 Preventive Maintenance Records .............................................................. 44 Problems and Corrective Measures ........................................................... 51 Tripping of Input/Output Breakers................................................. 51 Improper Inverter Output ............................................................... 53 SCR Failures .................................................................................. 54 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards WORK AID 1: MAINTENANCE SPECIFICATIONS AND TROUBLESHOOTING GUIDE COMPILED FROM SADP-P-103 AND ESTABLISHED ENGINEERING PRACTICES FOR DETERMINING WHETHER BATTERIES ARE FUNCTIONING PROPERLY Maintenance Specifications....................................................................... 57 Troubleshooting Guide.............................................................................. 58 WORK AID 2: MAINTENANCE SPECIFICATIONS AND TROUBLESHOOTING GUIDE COMPILED FROM ESTABLISHED ENGINEERING PRACTICES FOR DETERMINING WHETHER DC/UPS SUBSYSTEMS ARE FUNCTIONING PROPERLY Maintenance Specifications....................................................................... 59 Troubleshooting Guide.............................................................................. 61 GLOSSARY ......................................................................................................... 62 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 1 DETERMINING WHETHER BATTERIES ARE FUNCTIONING PROPERLY The checks and tests that can be performed to determine whether batteries are functioning properly include visual observations, service and performance tests, and monitoring of metered parameters. This section provides information on the following topics that are pertinent to determining whether batteries are functioning properly: Preventive Maintenance Requirements Preventive Maintenance Frequency Preventive Maintenance Records Problems and Corrective Measures Preventive Maintenance Requirements Preventive maintenance consists of routine checks and tests that are performed on a piece of equipment to determine its current condition and to identify and correct degrading equipment conditions before such conditions result in complete equipment failure. An effective preventive maintenance program will help to ensure that batteries meet or exceed the manufacturer's service life. This section of the Module will discuss the items of a battery that require preventive maintenance, what maintenance measures are required, and why the maintenance measures are performed. The items of the battery that require preventive maintenance are divided into the following general categories: Battery Physical Checks Battery Voltage Checks Battery Physical Checks Physical checks should be performed on batteries at regularly scheduled intervals. The specific items of a battery that should be checked are specified by the individual battery manufacturers. The following is a list of the physical checks that generally are specified and the reasons that the checks are performed. The descriptions also include the methods that can be used to perform the physical checks. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 2 General Cleanliness- A general cleanliness inspection should be performed to check for dirt, dust, and/or electrolyte accumulation on the battery cells and the floor and for dirt and dust accumulation in the ventilation system filters. The reason that general cleanliness is checked is that dirt/electrolyte deposits or build-ups on the battery cells can cause increased cell self-discharge rates, battery grounds and, in severe cases, short circuits. Dirty or wet floors can be slippery, which results in a safety hazard; dirty ventilation filters can decrease the battery room ventilation, which can result in unsatisfactory ambient temperature conditions and in unsafe levels of hydrogen gas accumulation. The method that is used to perform the general cleanliness inspection is a visual inspection. If the results of the visual inspection are unsatisfactory, the unsatisfactory items must be cleaned. Loose dirt or dust that has accumulated on the battery cells can be removed through use of a vacuum or a low pressure air sparger. Compacted dirt can be removed through use of a moderate pressure water hose. Electrolyte residue can be removed through washing with an appropriate neutralizing solution and then rinsing with a moderate pressure water hose. The appropriate neutralizing solution for lead-acid batteries is a mixture of one pound of baking soda and one gallon of water. The appropriate neutralizing solution for nickel-cadmium batteries is a 4% solution of boric acid. Excess water that remains after the washdown should be wiped off with a clean cloth or removed by the air sparger. Dry dirt or dust that is on the battery room floors should be swept or vacuumed. Electrolyte residue that is on the battery room floors should be removed in the same fashion as electrolyte residue that is on the battery cells. Reusable-type ventilation filters should be cleaned and air dried. Disposable "one- time" filters should be replaced. Battery Rack - The battery rack should be checked for loose hardware connections, for chips or cracks in the rack's epoxy paint coating, and for integrity of the rack-to-floor mount connection. The reason that the battery rack should be checked is that loose hardware or a loose floor mount connection can result in a structural failure and a possible collapse of the battery rack. Chips and cracks in the epoxy paint can permit exposure of the rack support steel to the highly corrosive electrolyte. Corrosion of the rack support steel can also lead to battery rack failure. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 3 The method that is used to perform the battery rack check is a visual inspection. All loose connections that are found during the visual inspection must be documented, and an immediate repair must be initiated. Cracked and chipped areas of the epoxy paint should be washed with an appropriate neutralizing solution and rinsed with clean water. The appropriate neutralizing solution for lead-acid batteries is a mixture of one pound of baking soda and one gallon of water. The appropriate neutralizing solution for nickel-cadmium batteries is a 4% solution of boric acid. After the affected areas have dried, they should be repainted with epoxy paint. Cell Case Integrity - The integrity of each cell case should be checked to ensure that no leaks exist. The reason that the integrity of each cell case should be checked is that the electrolyte is both a conductor and a corrosive. Because the electrolyte is a conductor, electrolyte that leaks out of the cell can cause increased cell self-discharge rates, grounds, and shorts. Because the electrolyte is a corrosive, electrolyte that leaks out of the cell can corrode any bare metal surfaces that it contacts. The corrosive nature of electrolyte also makes it a safety hazard because electrolyte will cause skin burns. The method that is used to perform cell case integrity checks is a visual inspection. Special attention should be paid to the area that is around the connection terminal (post) seals and around the cover-to-container seals. Each cell also should be visually checked for stress cracks and for leaking or missing vent caps/flame arrestors. Cracked or leaking cells should be replaced with a spare cell. Cell replacement will be discussed in more detail later in this Module. Vent Caps/Flame Arrestors- Vent caps/flame arrestors should be checked for cracks or other defects, clogging, and tightness. Vent caps/flame arrestors that are cracked or that are loose can allow electrolyte to leak out of the cell during the gassing phase of a charge. The problems that are caused by these electrolyte leaks are the same as the problems that are caused by the electrolyte leaks that were discussed previously. Vent caps/flame arrestors that are clogged will not allow the gases that are formed during charges and discharges to escape and will in turn cause a buildup of pressure inside of the cell. When the vent cap/flame arrestor is subsequently removed, the pressure that is inside of the cell will be suddenly released. The sudden release of pressure will cause electrolyte to spray out of the cell and onto the person that removed the vent cap/flame arrestor. Such a spray of electrolyte presents a severe safety hazard. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 4 The method that is used to perform vent cap/flame arrestor checks is a combined visual/physical inspection. The vent caps/flame arrestors should be visually inspected for cracks or other defects and clogging, and they should be physically inspected for tightness (i.e., the vent caps/flame arrestors should be turned by hand to ensure that they are hand-tight). Vent caps/flame arrestors that are cracked or that are defective must be replaced. Vent caps/flame arrestors that are clogged can be cleaned by agitating them in pure water. Cleaning or neutralizing agents must not be used because these agents tend to further clog the pores of the vent caps/flame arrestors rather than to clean the pores. Cell Terminals- The cell terminals should be checked for corrosion, tightness, and terminal resistance. The terminals must be kept free from corrosion because corrosion can physically weaken the terminal connection and it can cause a high resistance connection. The tightness and the terminal resistance of the terminal connections are checked to ensure that high resistance connections do not exist. High resistance connections can reduce the battery voltage and can cause overheating at the connection. The method that is used to check the cell terminals for corrosion is a visual inspection. Corrosion normally appears as a white powdery buildup but it may also have a slightly blue or brown tint. If corrosion is present, it must be removed by wiping the corroded surface with a cloth that has been dampened with the applicable neutralization agent (bicarbonate of soda for lead-acid and boric acid for nickel-cadmium batteries). After the neutralization agent has been applied, the surface should be wiped with a cloth that has been dampened with clean water followed by a final wipe down with a clean dry cloth. After the corrosion has been removed, the terminal connection should be checked for tightness through use of a torque wrench, and a terminal resistance test should be performed through use of a digital low resistance ohmmeter. After the tightness has been verified and the terminal resistance test has been satisfactorily completed, the entire terminal connection should be coated with a thin layer of No-Ox grease or equivalent. The No-Ox grease is used to inhibit future occurrences of oxidation or corrosion. If corrosion was not present, the tightness check and the terminal resistance check still should be performed. Cell Internal Inspection - The internal portion of lead-acid cells should be checked for buildup of excess sulfate material on the plates, for excess sediment at the bottom of the cell container (jar), and for plate damage. Excess sulfate material build-up on the plates is an indication that the cell is being undercharged. Such a condition can limit the overall capacity of the battery. Excess sediment at the bottom of the cell container is an indication that the cell is being overcharged. Continuous overcharging will reduce the life of the affected cells. In severe cases, the excess sediment can build up to the point at which it bridges the bottom of the positive and the negative plates, which causes an internal short circuit. Internal short circuits increase the cell's self- discharge rate and limit overall battery capacity. Damaged cell plates can cause a Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 5 number of problems, the most severe of which is separator damage, which leads to internal short circuits. The method that is used to perform a cell internal inspection is a visual inspection. Sulfate build-up appears as a white scale on the surface of the plates. Sulfate formation is a normal result of discharging a battery; however, if the battery is being properly charged, the sulfate material should be converted back into sponge lead and lead peroxide when the battery is charged. If excess sulfate material build-up is observed, additional tests and inspections should be performed to determine the cause. If excess sulfate material is observed on a single cell, that cell probably has high resistance terminal connections or an electrolyte problem. If excess sulfate material is observed on a number of cells, the battery charger voltage and/or timer settings are probably incorrect. Sediment build-up appears as a combination of white sulfate material and grey active plate material. Under normal conditions, the sediment build-up will be negligible and it will amount to little more than a thin layer of dust at the bottom of the cell container. The physical size of the space that is below the bottom of the plates is designed to accommodate all of the sediment that will be formed during battery's designed life. If excess sediment is observed, additional tests and inspections must be performed to determine the cause and the extent of the damage. The possible causes are manufacturing defects, excessive electrolyte specific gravity, and excessive battery charger voltage and/or timer settings. The visual inspection for plate damage consists of an observation of the plates to ensure that they are evenly spaced and that they do not physically interfere with the separators or the adjacent plates. Bowed and warped cell plates are an irreversible condition. If the plates are bowed or warped to the point at which they are in physical contact with the separators and/or adjacent plates, the only corrective action is cell replacement. Nickel-cadmium batteries are more ruggedly constructed than lead-acid batteries and, as such, they are not susceptible to the same types of internal damage as lead-acid batteries; therefore, a routine inspection of the internal portion of nickel-cadmium batteries is not required. Cell Operating Parameters- The cell operating parameters include voltage, temperature, electrolyte level, and for lead-acid batteries only, specific gravity. These parameters are checked because they provide an indication of the cell's state-of-charge and of the overall condition of the cell. The cell's temperature and electrolyte level also are used to correct the measured value of the specific gravity of lead-acid batteries to a standard temperature (25 o C, 77 o F) and level (zero reference point for a particular cell). Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 6 The cell's voltage is measured through use of a portable voltmeter. The cell's temperature is measured through use of a thermometer. The cell's level is measured through use of a ruler or a height stick. The specific gravity of lead-acid cells is measured through use of a hydrometer. The corrected value of specific gravity and the cell voltage should be consistent with each other and should be consistent with the current state-of-charge of the cell. If these conditions are not observed, additional tests and inspections must be performed to determine the cause. Capacity Test Discharge- Capacity test discharges should be performed to check the current capacity of a battery. The reason that capacity test discharges should be performed is that most batteries are installed to provide an emergency source of power to critical loads for a specified period of time. If the battery is unable to supply the needed power for the specified period of time, the critical loads will be lost, which could result in damage to personnel, equipment, and/or product. Before a capacity test discharge is performed, the following initial conditions must be met: The electrolyte level of each cell must be in the normal operational band. The terminal resistances must be at or below the manufacturer's specified resistance. The battery must be in a fully charged condition. The temperature of each cell must be a minimum of 25 o F (12 o C) below the maximum cell temperature that is specified by the manufacturer. After the initial conditions have been met, the test discharge is conducted through placement of a rated load (in amperes) on the battery. The battery is discharged at its rated load until it reaches the end of charge of 1.75 volts/cell times the number of cells that are in series, or until the voltage of any individual cell drops below the end of charge voltage of 1.75 volts. When one of these voltage limits is reached, the load is removed from the battery to stop the discharge and the total length of time that the battery was discharged is noted. The battery capacity (in percent) is determined through use of the following formula: %Capacity = 100 (actual ampere-hours discharged / rated ampere-hours) The battery then must be recharged to a fully charged condition. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 7 Battery Voltage Checks Battery float voltage, battery equalizing voltage, and battery terminal voltages need to be checked on a routine basis to help ensure that the battery can perform its design function over its expected service life. The importance of each voltage check and the effect that each voltage can have on battery performance and/or battery life are explained below. Battery Float Voltage- Stationary batteries that are installed to provide standby or emergency power normally are maintained in a float (trickle) charge condition. In this condition, the battery charger applies a voltage to the battery that is slightly higher than the battery's open circuit voltage, which maintains the battery on a continuous low rate charge. The continuous low rate charge compensates for internal losses and for intermittent discharges and keeps the battery in a fully charged condition. Because the float voltage setpoint directly affects battery performance and in the case of lead-acid batteries, battery life, this value should be checked as part of the routine maintenance that is performed on batteries. If the float voltage is set too low, restoration of battery capacity lost through internal losses and intermittent discharges will not occur; therefore, the battery will always be less than fully charged. A battery that is not fully charged may be unable to deliver the required amount of standby or emergency power for which it was installed. The long term effect of continuous operation of lead-acid batteries at low float voltages (i.e., continuous under-charging) is a permanent reduction of battery capacity, which leads to a reduced service life. Nickel-cadmium batteries do not normally suffer any long term effects from operation at low float voltages. If the float voltage is set too high, the battery will continuously be overcharged. The problems that result from continuously overcharging a battery depend on the extent of the overcharge. A float voltage that is slightly higher than normal will cause an increased rate of electrolyte loss and a small increase in the operating temperature of lead-acid and nickel-cadmium batteries. Provided that the battery room is air conditioned and that the electrolyte levels are checked on a routine basis, the only real problem that is caused by minor overcharging is that the battery will have to be watered more often. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 8 A float voltage that is significantly higher than normal can be extremely detrimental to performance and service life of lead-acid batteries. Severe overcharge conditions corrode the grids of the positive plates into lead peroxide. The corrosion physically weakens the plates and increases the resistance of the plates. Severe overcharge conditions also result in continuous battery gassing that will erode the active material off of the battery plates. The overall effect of the corrosion and erosion is reduced battery capacity and reduced service life. In addition to the corrosion and erosion, severe overcharge conditions also can result in a significant increase in operating temperature. Operation of a battery at high temperatures, particularly at temperatures that are above 55 o C, will significantly reduce the service life of the battery. For example, 11 days of float operation at 75 o C is equivalent in service life to 365 days of float operation at 25 o C. Overcharging of nickel-cadmium batteries does not generally result in any loss of performance or service life. The only problems that are associated with severe overcharge conditions are an increased rate of gassing and electrolyte loss. The optimum float voltage setpoint for a given battery should be obtained from the manufacturer. Figure 1 shows typical float voltage values for several types of lead- acid and nickel-cadmium batteries that operate at various specific gravities. During routine battery maintenance, the float voltage should be checked directly at the battery positive and negative terminals through use of an installed or a portable voltmeter. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 9 Float Voltage Per Cell Lead-Antimony Lead-Calcium Nickel-Cadmium 2.13 - 2.16 @ 1.170 ----- 1.40 - 1.42 @ 1.190 .020 2.15 - 2.18 @1.215 2.17 - 2.21 @ 1.215 ----- ----- 2.21 - 2.25 @ 1.250 ----- ----- 2.25 - 2.29 @ 1.300 ----- Recommended Float Voltages for Lead-Acid and Nickel-Cadmium Batteries Figure 1 Battery Equalizing Voltage- The battery equalizing voltage is the voltage at which an equalizing battery charge is performed. Because an equalizing charge restores the battery to a fully charged condition after a discharge or restores any non-uniformities that may have occurred between individual cells, the equalizing voltage is set higher than the float voltage. The equalizing voltage for lead-acid batteries should be set at the maximum voltage that the connected system equipment (loads) can tolerate or at 2.39 volts per cell, whichever value is highest. The equalizing voltage for nickel- cadmium batteries should be set at the maximum voltage that the connected system equipment can tolerate or at 1.60 volts per cell, whichever value is highest. The period of time that the equalizing voltage is applied to the battery is then set, based on the equalizing voltage, at the value that is needed to restore all of the cells to a uniform, full-charge condition; higher equalizing voltages require less charge time than lower equalizing voltages. The manufacturer's technical literature should be consulted for the exact values of voltage and time that are required for a given battery. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 10 Because the equalizing voltage value is generally limited by the maximum voltage that can be tolerated by the connected loads, and because this voltage is only applied for a relatively short period of time (usually 8 to 24 hours), the overcharge problems that were previously described for float voltages are not generally a concern in reference to checking the setpoint of this voltage during routine maintenance. The major concern of an excessive equalizing voltage is exceeding the voltage limitations of the connected loads. However, in the case of a failed battery charger voltage regulator, the excessive voltage that would result from such a failure would be detrimental to both the battery and to the downstream loads. The condition that is more likely to be detrimental to the capacity and service life of lead-acid batteries is a low equalizing voltage. If the equalizing voltage is too low, the battery will not be completely restored to a uniform, fully-charged condition at the end of the equalizing charge. Any amount of undercharge that is allowed to persist for a period of time will cause a gradual sulphation of the negative plates in lead-acid batteries with an eventual loss of capacity and reduction of service life. Nickel- cadmium batteries do not suffer any long-term effects from undercharge. Most lead-acid battery chargers have an equalizing voltage adjustment that ranges from about 2.25 to 2.40 volts per cell. Most nickel-cadmium battery chargers have an equalizing voltage adjustment that ranges from about 1.50 to 1.60 volts per cell. During the performance of routine battery maintenance, the equalizing voltage should be checked at the output of the battery charger through use of an installed or a portable voltmeter. Battery Terminal Voltages- During the performance of routine battery maintenance, battery terminal voltages should be checked with an installed or a portable voltmeter to verify that the battery is free from grounds and/or high resistance connections. The first voltage that should be measured is the voltage from the positive battery terminal to the negative battery terminal. This voltage should be equal to the float voltage per cell multiplied by the total number of cells that are in the battery installation. The other voltages that should be measured are the voltage between the positive battery terminal and ground and the voltage between the negative terminal and ground. Each of these voltages should be equal to one half of the total battery voltage. If these conditions do not exist, a ground or a high resistance connection is the likely cause. Grounds will be discussed in more detail later in this Module. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 11 Preventive Maintenance Frequency The overall goal of battery preventive maintenance is to identify and correct minor or impending problems that, if left unchecked, could result in a reduction of battery capacity, a reduction in battery capacity, or a safety hazard. In order for a battery preventive maintenance program to achieve its goal, the battery systems and equipment must be checked at regularly scheduled intervals. The regularly scheduled intervals vary dependent upon the type of battery, the battery manufacturer, the type of intended service, and the environmental conditions that exist at the installation. The initial battery preventive maintenance inspection frequencies are normally established on the basis of the manufacturer's recommendations. These initial frequencies can then be modified (increased or decreased in length) on the basis of local site operating experience and/or governing codes and standards for a particular type of service. As an example of how inspection frequencies can be modified on the basis of local site operating experience, assume that a particular battery manufacturer recommends that the electrolyte level of each cell be checked once per month. Also assume that the inspection results of two consecutive monthly inspections showed that the electrolyte level in several of the cells had dropped below the minimum required level. Based on these results and provided that no other problem is responsible for the lost level, the frequency of the electrolyte level check for this particular battery should be performed more often. The inspection frequency for this particular item would likely be changed from a monthly requirement to a bi-weekly or a weekly requirement. Figure 2 shows a typical preventive maintenance schedule for stationary storage batteries. The schedule contains the preventive maintenance requirements and the frequency of performance. The frequency of performance section is divided into three time categories: routine, quarterly, and annually. The routine column can represent daily, weekly, bi-weekly, or monthly preventive maintenance requirements. The applicable frequency for all of the preventive maintenance items should be established as previously explained. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 12 Preventive Maintenance Frequency of Performance Requirement Routine Quarterl y Annuall y Battery Physical Checks General Cleanliness X (1) Battery Rack X (1) Cell Case Integrity X (1) Vent Caps/Flame Arrestors X (1) Cell Terminals - Corrosion - Tightness - Resistance X (2) (2) (2) X X Cell Internals * X (1) Cell Operating Parameters - Specific Gravity * - Cell Voltage - Cell Temperature - Electrolyte Level X (3) X (3) X (3) X (3) X X X X Capacity Test Discharge X (4) Battery Voltage Checks Float Voltage Check @ Charger Output X Equalize Voltage Check @ Charger Output X Battery Terminal Voltage Checks - Voltage from Positive Terminal to Negative Terminal - Voltage from Positive Terminal to Ground - Voltage from Negative Terminal to Ground X X X * Not required for nickel-cadmium batteries NOTES: (1) Any discrepancies that are found during the check should be corrected. (2) If corrosion is found, the condition must be corrected. After the corrosion is removed, the tightness and the resistance of the cleaned terminal should be verified. (3) Routine check of cell operating parameters is only required for the designated pilot cells. (4) A battery capacity test discharge should be conducted within the first two years of service. After the initial capacity test discharge, subsequent capacity test discharges Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 13 should be performed at five year intervals until the battery shows signs of degradation or until it reaches 85% of its service life expectancy. When one of these conditions is met, annual capacity test discharges should be performed. Typical Preventive Maintenance Schedule Figure 2 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 14 Preventive Maintenance Records The results of all of the maintenance and testing that are performed on batteries should be recorded on battery records, and the individual records for each battery installation should be kept in a separate file for the life of the battery. The first step of the record keeping process is to record the baseline data for the battery. The baseline data are the data that were obtained during the start-up and commissioning of the battery. (These data were discussed in Module EEX 211.06.) Future maintenance records are added as maintenance is performed to provide a chronological history of the battery's condition. The chronological history is used to identify and analyze trends or isolated problems. This information aids the Electrical Engineer in making future decisions in regard to the operation, maintenance, and troubleshooting of the battery. Figures 3 through 5 show typical storage battery maintenance record forms. These forms coincide with the typical storage battery maintenance schedule that previously was shown in Figure 2. Figure 3 shows a typical storage battery maintenance record form that can be used to record the results of routine maintenance. The form is divided into two major parts: Identification Data and Maintenance Data. The Identification Data section is used to record the pertinent information that is needed to identify the particular battery on which the maintenance was performed. The Maintenance Data section is used to record the actual results of the maintenance that was performed. A space is provided to record the results of each of the routine maintenance items that were previously shown on Figure 2. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 15 Storage Battery Maintenance Record - Routine Items Figure 3 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 16 Figure 4 shows a typical storage battery maintenance record form that can be used to record the results of quarterly maintenance. The form is divided into two major parts: Identification Data and Maintenance Data. The Identification Data section is used to record the pertinent information that is needed to identify the particular battery on which the maintenance was performed. The Maintenance Data section is used to record the actual results of the maintenance that was performed. A space is provided to record the results of each of the quarterly maintenance items that were previously shown in Figure 2. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 17 Storage Battery Maintenance Record - Quarterly Items Figure 4 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 18 Figure 5 shows a typical storage battery maintenance record form that can be used to record the results of annual maintenance. The form is divided into two major parts: Identification Data and Maintenance Data. The Identification Data section is used to record the pertinent information that is needed to identify the particular battery on which the maintenance was performed. The Maintenance Data section is used to record the actual results of the maintenance that was performed. A space is provided to record the results of each of the annual maintenance items that were previously shown on Figure 2. Note that the space that is provided to record the results of the cell terminal resistance checks and the capacity test discharge only requires that the overall result of satisfactory or unsatisfactory be entered. The actual data for these checks are to be recorded on the Individual Cell Terminal Resistance Test Record and the Battery Acceptance Test Data Sheet, and then these additional records are to be attached to the annual maintenance record. The Individual Cell Terminal Resistance Test Record and the Battery Acceptance Test Data Sheet were previously shown and discussed in Module EEX 211.06. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 19 Storage Battery Maintenance Record - Annual Items Figure 5 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 20 Problems and Corrective Measures This section of the Module will discuss the following typical battery problems: Grounding Electrolyte Loss Abnormal Specific Gravity Grounding The following aspects of battery grounds will be discussed in this section: Problems Caused Indications Corrective Actions Problems Caused - Saudi Aramco Engineering Standard SAES-P-103 requires that the positive and the negative dc buses of storage batteries that are installed in Saudi Aramco industrial facilities be isolated from earth ground; therefore, Saudi Aramco storage batteries are ungrounded. The possible exception to this requirement is an application in which industrial and communications systems must share the same dc bus. In these applications, Saudi Aramco consulting services must be consulted for the grounding requirements. Because most Saudi Aramco batteries are ungrounded, a single ground will not cause any protective devices to operate and, from an operational point of view, no abnormal conditions will be present other than a possible increase in the battery's discharge rate. The real problem that is caused by a single ground is an electrical shock hazard to persons who are working on or near the battery. The potential problems for the battery itself occur when more than one ground exists and the magnitude of the fault current is insufficient to trip the protective devices. This situation can occur when several high resistance ground paths exist between two cells or a group of cells, which effectively creates a short circuit between the effected cells. The short circuited cells then become a load on the battery and, if the condition is not corrected, it will lead to permanent cell damage. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 21 Indications - For installations that have permanently installed ground detectors, battery grounds are indicated through the routine ground checks that are performed by the equipment operators. For installations that do not have permanently installed ground detectors, battery grounds are indicated through measurement of battery terminal voltages as was previously discussed. Once a battery ground is detected, the ground can be isolated to a particular cell or group of cells through use of a technique that is referred to as half-splitting. Half-splitting involves the measurement and comparison of the following voltages that are shown on Figure 6: The total voltage that is developed across a string of cells (V 1 ). The total voltage that is developed from the beginning of the string to the mid- point of the string (V 2 ). The total voltage that is developed from the mid-point of the string to the end of the string (V 3 ). Voltage V 2 and voltage V 3 should both be equal to one half of V 1 . If either voltage is less than one half of V 1 , the ground is located in the half of the string of cells that produced the lower voltage reading. The half-splitting technique can be repeated on successively smaller strings of cells until the exact location of the ground is identified. Half-Splitting Voltage Measurements Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 22 Figure 6 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 23 Corrective Measures - Once the location of the ground has been identified, a detailed visual inspection of the area should be performed to identify the cause of the ground. In most cases, the ground path will be some combination of dirt build-up, electrolyte residue or leakage, and terminal corrosion. The corrective measures consist of removal of the dirt or corrosion and neutralizing the electrolyte. Electrolyte Loss The following aspects of electrolyte loss will be discussed in this section: Problems Caused Indications Corrective Actions Problems Caused - Because of the electrolysis that occurs during the battery charging process, some amount of electrolyte loss is anticipated and is normal. The amount of electrolyte loss that results from normal battery operations varies with the type of battery, the frequency of charging, and the environmental conditions that are at the installation site. The anticipated losses are the reason for periodically checking and watering the battery cells as part of the battery's preventive maintenance program. If the maintenance program is properly implemented, the electrolyte levels will not drop below the minimum required level. Provided that the electrolyte levels do remain above the minimum required level, no problems will result. If the electrolyte level is allowed to drop below the minimum required level, the problems that are caused vary dependent upon the actual extent of the level decrease. If the level drops below the bottom of the tube that is on the flash arrestor but remains above the plates, the problem that is caused is a slightly increased chance of fire or explosion. When the electrolyte level drops below the bottom of this tube, the flash arrestor is effectively bypassed. A subsequent removal of the service cap would allow direct access to the gas space that is at the top of the cell and, if a spark was present, the hydrogen gas that is in the gas space would be more likely to ignite. Because several events need to occur for the hydrogen to be ignited, the overall likelihood of a fire or an explosion is still small. The most severe problem that can result from a loss of electrolyte is permanent plate damage. If the electrolyte level drops below the top of the plates, the exposed portions of the plates dry out, become extremely brittle, and completely lose their ability to be charged and discharged. If the loss of electrolyte is a result of spillage or leaks, other problems such as corrosion, grounds, and safety hazards also can occur. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 24 Indications - The indications of a loss of electrolyte level are an electrolyte level that is below the "Min" level mark on the cell jars or electrolyte that is present on the battery room floor. Corrective Measures - The first corrective measure is to determine and correct the cause of the electrolyte loss. The following are some of the typical causes of electrolyte loss: Overcharging. Leaks. Spillage. A drop in ambient temperature. The battery is approaching the end of its service life (antimony cells). Improperly scheduled or inadequate preventive maintenance. If the cause can be corrected (e.g., the cause was not a leak), and if the plates were not exposed and damaged, the affected cells should be filled to their normal level. After the cells have been filled, normal battery operation can resume. If the cause of the electrolyte loss was a leak, or if plate damage occurred, the battery should be placed on open circuit and the affected cell should be drained and removed. Also, the electrolyte that leaked out of the cell must be cleaned up and neutralized. If a replacement cell is available, the replacement cell should be installed and normal battery operation can resume. If a replacement cell is not available, jumpers can be installed to re-connect the battery with one less cell. The battery can then be temporarily operated in this condition until a replacement cell can be obtained. Abnormal Specific Gravity The following aspects of abnormal specific gravities will be discussed in this section: Problems Caused Indications Corrective Actions Problems Caused - Because specific gravity is a direct indicator of the state of charge of a lead-acid battery, an abnormally low specific gravity indicates a low state of charge. If all of the cells of a battery have a low specific gravity, the battery is in a low state of charge and, as a result, it may not be capable of supplying the required amount of emergency or standby power for which it was installed. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 25 If only one or several cells have low specific gravities, these particular cells will limit the overall capacity of the battery. When the battery is discharged, the cells that have the low specific gravities will reach their low voltage limits (approximately 1.75V) before the rest of the battery. If the discharge is not stopped when the first cell reaches its low voltage limit, cell reversal will occur, which is quickly followed by cell damage. Because the amount of acid that is in the electrolyte does not change after the cells have initially been filled, abnormally high specific gravities almost never occur. If such a condition did occur, the problems that are caused are increased rates of self- discharge and reduced service life. Indications - Direct indications of abnormal specific gravities can be obtained through measurement of the actual specific gravities with a hydrometer; however, before the measured specific gravities can be called abnormal, all of the factors that affect specific gravity readings must be taken into account. Examples of these factors include cell temperature, electrolyte level, whether or not the battery was recently watered, and the accuracy of the hydrometer. Generally, a cell is said to have an abnormal specific gravity when its corrected specific gravity is more than five points (expressed .005) above or below the average corrected specific gravity of all of the cells that are in the installation. The battery itself is said to have an abnormal specific gravity when one of the following conditions exist: The difference between the highest cell's corrected specific gravity and the lowest cell's corrected specific gravity is more than ten points (expressed .010). The difference between the initial and the current average corrected specific gravity of all of the cells that are in the installation is more than ten points (i.e., .010). The indirect indications of abnormal specific gravities are abnormal individual cell voltages or abnormal total battery voltages. If these conditions are observed, a direct measurement of the specific gravities is normally performed for confirmation. Corrective Measures - If the abnormal specific gravity is isolated to one or several cells, the first corrective measure would be to recheck the specific gravity readings to verify the existence of a problem. Once the abnormal specific gravity has been confirmed, the affected cells should be inspected for visible signs of damage and high resistance connections. If the results of these inspections are satisfactory, the battery should be given an equalizing battery charge in attempt to correct the problem. If the problem still exists at the completion of the equalizing charge, the manufacturer should be Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 26 contacted to determine if any special charging procedures can be performed to correct the problem. If the problem cannot be corrected, a capacity test discharge should be performed to determine whether the battery's capacity is still acceptable. If the capacity is still acceptable, normal battery operation can be resumed; however, the affected cells should be more closely monitored for the duration of the service life. If the battery capacity is unacceptable, the affected cells must be replaced. If the abnormal specific gravity pertains to the entire battery, one of the following problems likely exists: The float voltage setpoint is too low. Too much time has elapsed since the last equalizing charge. The battery is near the end of its service life For the above problems, the first corrective measure would be to check and to adjust the float voltage setpoint and to then perform an equalizing battery charge to correct the abnormal specific gravities. If the float voltage setpoint was correct, and if the equalizing charge had corrected the specific gravity problem, the frequency of the equalizing charges should be increased to prevent reoccurrence of the problem. If the equalizing charge did not correct the problem, the battery may be at or near the end of its service life. A capacity test discharge should be performed to determine whether the battery's capacity is still acceptable. The acceptable range of battery capacity is from 80% to >.100% of its original rated capacity. However, when the battery capacity drops below 85% of its original rated capacity, the battery shows signs of degradation, and it should be more closely monitored for the duration of the service life. When the battery capacity drops below 80% of its original rated capacity, the battery has reached the end of its service life, and it must be replaced. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 27 DETERMINING WHETHER DC/UPS SUBSYSTEMS ARE FUNCTIONING PROPERLY Because of the advancement of solid-state electronic circuitry, dc/UPS subsystems generally have low maintenance requirements. The maintenance of these systems typically only includes routine inspection and cleaning and self-diagnostic testing. This section of the Module provides information on the following topics that are pertinent to determining whether dc/UPS subsystems are functioning properly: Preventive Maintenance Requirements Preventive Maintenance Frequency Preventive Maintenance Records Problems and Corrective Measures Preventive Maintenance Requirements The following preventive maintenance should be performed on dc/UPS subsystems: Visual Inspection Cleaning Battery Charger Checks and Adjustments Inverter Checks and Adjustments Visual Inspection A visual inspection of dc/UPS subsystems is performed to check the overall condition of the subsystem components. In general, a definitive pass/fail criterion does not exist for most of the items that are checked during the visual inspection. The person who performs the visual inspection must rely on his own personal judgement and experience to determine whether the present condition of the dc/UPS subsystem is acceptable or unacceptable. If the inspector is not comfortable about some aspect of the equipment's condition, he should seek the guidance of more experienced personnel. The following types of problems typically can be identified through performance of a visual inspection: Physical Damage Overheating Loose Connections Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 28 Physical Damage- The visual inspection should start with an inspection of the exterior of dc/UPS equipment enclosures for evidence of physical damage. If physical damage to the exterior of the enclosures is evident, the equipment must have been subjected to some form of shock since it was last inspected. Because external shock increases the possibility of physical damage to the internal components, the remainder of the inspections should be performed with extra diligence. The internal inspection for physical damage should include a check for loose or missing hardware, missing gaskets/seals, broken wires, damaged insulation, and leaking electrical/electronic components (e.g., electrolyte from capacitors or potting compound from transformers). Overheating- Overheating can occur as a result of elevated enclosure temperatures or circuitry malfunctions. Enclosure overheating can be caused by a defective or malfunctioning enclosure ventilation fan or by dirty enclosure ventilation system filters. If enclosure overheating is suspected, a more detailed inspection of the following cooling components should be performed to determine the cause: Enclosure ventilation fan Ventilation fan thermostat Enclosure ventilation filters All of the interior components and wiring should be inspected for signs of excessive heat. The typical indications of component overheating are discolorations such as browning or charring and/or the presence of ociferous odors. Any components or wires that show signs of excessive heat should be tested to determine whether they are still serviceable. Loose Connections- All of the internal terminations should be inspected to ensure that they are tight. The most effective method of inspecting for tightness is to apply the appropriate amount of torque to the termination while checking for any movement. If any connection is found to be loose, the termination should be further inspected to determine and correct the cause. The common causes of loose connections are equipment vibration, improper initial torque, cyclic temperatures, and improper connection hardware. Cleaning The interior of the dc/UPS subsystems must be cleaned on a regular basis to prevent the accumulation of excessive dust and dirt. The accumulation of excessive amounts of dust and dirt can lead to the following problems: The formation of high resistance current paths between components or between components and ground. Excessive heat build up. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 29 The degradation of insulation. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 30 Because both the visual inspection and the cleaning should be performed with the dc/UPS subsystem deenergized, they often are simultaneously performed. The cleaning can be performed through use of the following methods: Wiping with a clean cloth. Vacuum cleaning. Cleaning with low pressure air. Solvent cleaning. Wiping With a Clean Cloth - Initial cleaning should be performed by wiping with a clean, dry, lint-free cloth to remove the loose dust and dirt that has accumulated. Rags that deposit lint or that leave "stringers" on electrical and electronic components should not be used. Lint and "stringers" will retain dirt and dust, which defeats the purpose of cleaning the equipment. Vacuum Cleaning- Loose dust and dirt that cannot be removed by wiping should be removed by vacuum cleaning. The vacuum nozzle that is used should be made from plastic or rubber; metal or other sharp materials can damage electrical components and wiring. The effectiveness of vacuum cleaning can be increased through use of a soft bristle brush. The brush can be used to dislodge the dirt and the vacuum can then be used to remove the dirt. Cleaning With Low Pressure Air - A low pressure jet of air should be used to dislodge dust and dirt from the portions of the equipment that are difficult to reach with a cloth or a vacuum nozzle. This method is particularly effective in dislodging the dust and dirt that has accumulated on circuit boards. Cleaning with low pressure air is most effective when this method is used in conjunction with vacuum cleaning. The low pressure air jet is used to dislodge the dirt and the vacuum is used to remove the dirt. The compressed air that is used for this type of cleaning should not exceed 30 psi; higher air pressures can damage electrical component insulation and coverings. The compressed air supply also must be free from contaminants such as moisture and oil. These contaminants can lead to component degradation and short circuits. Solvent Cleaning- Solvent cleaning is only recommended for use in the removal of stubborn dirt that cannot be removed by any of the other methods. The following recommended solvents are listed in order of effectiveness: Isopropyl alcohol 1,1,1-, trichloroethane (inhibited methyl chloroform) Freon TF Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 31 Cleaning solvents should only be used in a free-air atmosphere and should never be used in an enclosed area. The solvent should be applied to a lint-free cleaning rag and the rag should then be used to remove the dirt. Any excess solvent should be wiped up before it has a chance to evaporate. If a solvent other than those that are listed above is used, it must have a flash point in excess of 37.8 o C; therefore, solvents such as gasoline, naphtha, and similarly volatile products cannot be used. Another solvent that should never be used is carbon tetrachloride. This solvent produces highly toxic fumes that can result in sickness or death. Battery Charger Checks and Adjustments The following battery charger indicators, controls, and protective devices must be checked and/or adjusted to ensure that the battery is properly charged and that the equipment operators will be alerted to abnormal conditions: dc Voltmeter dc Ammeter Float Voltage Adjustment Equalize Voltage Adjustment Equalize Timer Check End of Charge Condition Alarm Ground Detection Alarm Charger Overvoltage Alarm Charger Failure Alarm Enclosure Overtemperature alarm Because the output of the inverter is the preferred power source for most Saudi Aramco UPS systems, and because performance of the battery charger checks and adjustments will affect the input of power to the inverter, the critical ac loads should be switched to the bypass source while the maintenance is performed. dc Voltmeter - The accuracy of the dc voltmeter should be checked and/or adjusted during the performance of preventive maintenance. The accuracy check consists of a mechanical zero adjustment and a comparison of the actual meter reading with the reading of a portable, calibrated voltmeter. The mechanical zero adjustment is performed by opening the ac supply to the battery charger and by opening the dc battery breaker. After the breakers are opened, the meter indicator should be adjusted to read zero by turning the mechanical adjustment screw. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 32 When the mechanical zero adjustment is complete, the dc battery breaker and the ac supply breaker should be closed. A portable, calibrated voltmeter should then be connected to the output of the battery charger. The reading of the portable, calibrated voltmeter is compared to the reading of the dc voltmeter; the two readings should agree to within _ 2.0%. If the readings do not agree, the dc voltmeter should be adjusted until its reading is within the _ 2.0% tolerance. If the dc voltmeter cannot be adjusted, it should be replaced. dc Ammeter - The accuracy of the dc ammeter should be checked and/or adjusted during the performance of preventive maintenance. The accuracy check consists of a mechanical zero adjustment and a comparison of the actual meter reading with the reading of a portable, calibrated ammeter. The mechanical zero adjustment is performed by opening the ac supply to the battery charger and by opening the dc battery breaker. After the breakers are opened, the meter indicator should be adjusted to read zero by turning the mechanical adjustment screw. When the mechanical zero adjustment is complete, a portable, calibrated ammeter should then be connected in series with the output of the battery charger, and the dc battery breaker and the ac supply breaker should be closed. The reading of the portable, calibrated ammeter is compared to the reading of the dc ammeter; the two readings should agree to within _ 2.0%. If the readings do not agree, the dc ammeter should be adjusted until its reading is within the _ 2.0% tolerance. If the dc ammeter cannot be adjusted, it should be replaced. Float Voltage Adjustment - The float voltage setpoint of the battery charger should be checked and/or adjusted during the performance of preventive maintenance. This check is performed by dividing the dc voltmeter reading by the number of cells that are in the installation. The quotient is the float voltage per cell that is being applied to the battery. This calculated value is then compared to manufacturer's recommended float voltage per cell. Most battery manufacturers specify an acceptable range of float voltages. If the actual value of float voltage per cell is outside of the acceptable range, the float voltage setpoint must be adjusted. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 33 Equalize Voltage Adjustment - The equalize voltage setpoint of the battery charger should be checked and/or adjusted during the performance of preventive maintenance. This check is performed by placement of the battery charger in the equalize charge position. After the battery charger is in the equalize charge position, the dc voltmeter reading is divided by the number of cells that are in the installation to determine the equalize voltage per cell that is being applied to the battery. This value is then compared to manufacturer's recommended equalize voltage per cell. Most battery manufacturers specify an acceptable range of equalize voltages. If the actual value of equalize voltage per cell is outside of the acceptable range, the equalize voltage setpoint must be adjusted. After the adjustments are complete, the battery charger should be restored to the float charge position. Equalize Timer Check - The equalize timer is an electromechanical or an electronic device that is used to automatically stop the equalize charge after a specified time period has elapsed. The timer is scaled in hours and should be accurate to within _ 10% of the actual elapsed time. During the performance of preventive maintenance, only the position of the setpoint adjustment is checked and adjusted; the actual elapsed time should be checked each time that an equalize charge is performed. End of Charge Condition Alarm - The End of Charge Condition alarm is intended to alert the equipment operators that the battery has reached its low voltage limit and that the battery discharge should be stopped. The alarm usually is set at 1.75 volts per cell for lead-acid battery systems and at 1.10 volts per cell for nickel-cadmium battery systems. The alarm should actuate within _ 5.0% of its setpoint. The alarm setpoint can be checked by opening the battery charger's dc output breaker and then adjusting the battery charger's output voltage down to the alarm setpoint. If the alarm does not actuate within its _ 5.0% tolerance, its setpoint should be adjusted. After the check is completed, the battery charger's output voltage setpoint should be restored to the float voltage setpoint and the dc output breaker should be closed. Ground Detection Alarm- The Ground Detection alarm is intended to alert the equipment operator that a battery ground exists and to trip the battery circuit breaker to protect the battery charger from an excessive current flow. The Ground Detection alarm should actuate and the battery circuit breaker should trip when the current flow to earth ground exceeds 10.0 milliamperes. The alarm and the circuit breaker trip can be checked by placement of a 2.0k ohm resistance between the positive battery bus and ground or between the negative battery bus and ground. If the alarm fails to actuate or if the circuit breaker fails to trip, the ground detection circuit and/or the battery breaker shunt trip device should be adjusted or replaced. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 34 Charger Overvoltage Alarm- The Charger Overvoltage alarm is intended to alert the equipment operator that the battery is being subjected to an excessive charging voltage. The alarm usually is set to actuate when the charger's output voltage exceeds 10.0% of the nominal cell voltage. The alarm setpoint can be checked by opening the battery charger's dc output breaker and then adjusting the battery charger's output voltage up to the alarm setpoint. If the alarm does not actuate within 10% of the nominal cell voltage, its setpoint should be adjusted. After the check is completed, the battery charger's output voltage setpoint should be restored to the float voltage setpoint and the dc output breaker should be closed. Charger Failure Alarm- The Charger Failure alarm is intended to alert the equipment operator that the battery charger is no longer charging the battery. The charger failure alarm usually is set to actuate when the charger's output voltage drops 15% below the nominal cell voltage. The alarm setpoint can be checked by opening the battery charger's dc output breaker and then adjusting the battery charger's output voltage down to the alarm setpoint. If the alarm does not actuate when the battery charger's output drops 15% below the nominal cell voltage, its setpoint should be adjusted. After the check is completed, the battery charger's output voltage setpoint should be restored to the float voltage setpoint and the dc output breaker should be closed. Enclosure Overtemperature Alarm - The Enclosure Overtemperature alarm is intended to alert the equipment operator of excessive temperature conditions that require corrective action. The Enclosure Overtemperature alarm usually is set to actuate when the battery charger enclosure exceeds the recommended maximum operating temperature by 10%. The operation of the alarm's thermostat and contacts can be checked by reducing the enclosure overtemperature alarm setpoint to the actual enclosure operating temperature. Because overtemperature alarm devices are fairly linear, successful operation of the switch at normal temperature is a reasonable indication that the alarm will operate satisfactorily at its normal setpoint. If the alarm fails to actuate at normal operating temperature, the temperature switch must be repaired or replaced. At the completion of the check, the overtemperature alarm should be set at its normal value. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 35 Inverter Checks and Adjustments The following inverter indicators, controls, and protective devices must be checked and/or adjusted to ensure that the inverter properly operates and that the equipment operators will be alerted to abnormal conditions: Inverter ac Output Voltmeter Inverter ac Output Ammeter Inverter ac Output Frequency Meter Alternate Source ac Input Voltmeter High Inverter dc Input Voltage Alarm Low Inverter dc Input Voltage Alarm Alternate Voltage/Sync Source Not Available Alarm Static Switch Position Indication Alarm Inverter Output Failure Alarm Auto Synchronization Disconnect Alarm Static Switch Transfer to Alternate Source Voltage Static Switch Re-Transfer to Preferred Source Voltage Static Switch Transfer to Alternate Source Frequency Static Switch Re-Transfer to Preferred Source Frequency Enclosure Overtemperature Alarm Because the output of the inverter is the preferred power source for most Saudi Aramco UPS systems, and because performance of the inverter checks and adjustments will affect the output of the inverter, the critical ac loads should be switched to the alternate source by placement of the manual bypass switch in the full bypass position while the maintenance is performed. Inverter ac Output Voltmeter - The accuracy of the inverter ac output voltmeter should be checked and/or adjusted during the performance of preventive maintenance. The accuracy check consists of a mechanical zero adjustment and a comparison of the actual meter reading with the reading of a portable, calibrated voltmeter. The mechanical zero adjustment is performed by opening the ac supply to the battery charger and opening the dc battery breaker. After the breakers are opened, the meter indicator should be adjusted to read zero by turning the mechanical adjustment screw. When the mechanical zero adjustment is complete, the dc battery breaker and the ac supply breaker should be closed. A portable, calibrated voltmeter should then be connected to the output of the inverter. The reading of the portable, calibrated voltmeter is compared to the reading of the inverter ac output voltmeter; the two readings should agree to within _ 2.0%. If the readings do not agree, the inverter ac output voltmeter should be adjusted until its reading is within the _ 2.0% tolerance. If the inverter ac output voltmeter cannot be adjusted, it should be replaced. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 36 Inverter ac Output Ammeter - The accuracy of the inverter ac output ammeter should be checked and/or adjusted during the performance of preventive maintenance. The accuracy check consists of a mechanical zero adjustment and a comparison of the actual meter reading with the reading of a portable, calibrated ammeter. The mechanical zero adjustment is performed by opening the ac supply to the battery charger and opening the dc battery breaker. After the breakers are opened, the meter indicator should be adjusted to read zero by turning the mechanical adjustment screw. When the mechanical zero adjustment is complete, a portable, calibrated ammeter should be connected in series with the output of the inverter, and the dc battery breaker and the ac supply breaker should be closed. The reading of the portable, calibrated ammeter is compared to the reading of the inverter ac output ammeter; the two readings should agree to within _ 2.0%. If the readings do not agree, the inverter ac output ammeter should be adjusted until its reading is within the _ 2.0% tolerance. If the inverter ac output ammeter cannot be adjusted, it should be replaced. Inverter ac Output Frequency Meter - The accuracy of the inverter ac output frequency meter should be checked and/or adjusted during the performance of preventive maintenance. The accuracy check consists of a mechanical zero adjustment and a comparison of the actual meter reading with the reading of a portable, calibrated oscilloscope. The mechanical zero adjustment is performed by opening the ac supply to the battery charger and opening the dc battery breaker. After the breakers are opened, the meter indicator should be adjusted to read zero by turning the mechanical adjustment screw. When the mechanical zero adjustment is complete, the dc battery breaker and the ac supply breaker should be closed. A portable, calibrated oscilloscope should then be connected to the output of the inverter. The reading of the portable, calibrated oscilloscope is compared to the reading of the inverter ac output frequency meter; the two readings should agree to within _ 2.0%. If the readings do not agree, the inverter ac output frequency meter should be adjusted until its reading is within the _ 2.0% tolerance. If the inverter ac output frequency meter cannot be adjusted, it should be replaced. Alternate Source ac Input Voltmeter - The accuracy of the alternate source ac input voltmeter should be checked and/or adjusted during the performance of preventive maintenance. The accuracy check consists of a mechanical zero adjustment and a comparison of the actual meter reading with the reading of a portable, calibrated voltmeter. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 37 Before the mechanical zero adjustment can be performed, the critical ac loads must be transferred back to the inverter. After the loads have been transferred, the mechanical zero adjustment is performed by opening the alternate source ac supply breaker. After the breaker is open, the meter indicator should be adjusted to read zero by turning the mechanical adjustment screw. When the mechanical zero adjustment is complete, the alternate source ac supply breaker should be closed. A portable, calibrated voltmeter should then be connected to the alternate ac power source. The reading of the portable, calibrated voltmeter is compared to the reading of the alternate source ac input voltmeter; the two readings should agree to within _ 2.0%. If the readings do not agree, the alternate source ac input voltmeter should be adjusted until its reading is within the _ 2.0% tolerance. If the alternate source ac input voltmeter cannot be adjusted, it should be replaced. After the check is complete, the critical ac loads should be transferred back to the alternate source. High Inverter dc Input Voltage Alarm - The High Inverter dc Input Voltage alarm is intended to alert the equipment operators of an inverter condition that requires corrective action. The alarm usually is set to actuate when the dc input voltage to the inverter rises 5% above the nominal dc input voltage. The alarm can be tested by opening the dc battery breaker and then raising the battery charger output voltage. If the alarm does not actuate when the dc input voltage exceeds the nominal input voltage by 5%, the alarm setpoint must be adjusted. After the check has been completed, the battery charger output should be returned to the float voltage setpoint and the dc battery breaker should be closed. Low Inverter dc Input Voltage Alarm - The Low Inverter dc Input Voltage alarm is intended to alert the equipment operators of a problem that is associated with the input power supply to the inverter and that requires corrective action. The alarm usually is set to actuate when the dc input voltage to the inverter drops 5% below the nominal dc input voltage. The alarm can be tested by opening the dc battery breaker and by then lowering the battery charger output voltage. If the alarm does not actuate when the dc input voltage drops below the nominal input voltage by 5%, the alarm setpoint must be adjusted. After the check has been completed, the battery charger output should be returned to the float voltage setpoint and the dc battery breaker should be closed. Alternate Voltage/Sync Source Not Available Alarm - The Alternate Voltage/Sync Source Not Available Alarm is intended to alert the equipment operators of a potential loss of system reliability. The alarm usually is set to actuate when the alternate source voltage deviates from the nominal system voltage by _ 10.0% or when the alternate source frequency deviates from the nominal system frequency by _ 5.0%. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 38 Before this alarm can be tested, the critical ac loads must be transferred to the output of the inverter. After the loads have been transferred, the alternate source ac supply breaker can be opened to check the operation of this alarm. After the check has been completed, the ac supply breaker should be closed and the critical ac loads should be transferred back to the alternate source. Static Switch Position Indication Alarm - The Static Switch Position Indication alarm is intended to alert the equipment operators that the critical ac loads have been transferred from the inverter to the alternate power source. Before this alarm can be checked, the critical ac loads must be transferred to the output of the inverter. After the loads have been transferred, the ac supply breaker for the battery charger can be opened in conjunction with the dc battery breaker to check the operation of the alarm. Opening of these breakers will cause the static switch to transfer to the alternate power source. This transfer should actuate the alarm. After the check has been completed, the ac supply breaker for the battery charger and the dc battery breaker should be closed, and the manual bypass switch should be placed back in the full bypass position. Inverter Output Failure Alarm- The Inverter Output Failure alarm is intended to alert the equipment operators of a problem that is associated with the preferred power source and that requires corrective action. This alarm usually is set to actuate when the output voltage of the inverter deviates from the nominal output voltage by _ 10.0% or when the output frequency of the inverter deviates from the nominal value of 60 Hz by _5.0%. The voltage actuation of the alarm can be checked by adjusting the output voltage potentiometer of the inverter up and down until the alarm actuates. If the alarm does not actuate at both +10% and -10% of nominal, the alarm setpoint should be adjusted. The frequency actuation of the alarm can be checked by adjusting the output frequency potentiometer that is on the oscillator board up and down until the alarm actuates. If the alarm does not actuate at both +5% and -5% of nominal, the alarm setpoint should be adjusted. After the check is complete, the inverter's output voltage and frequency should be returned to normal. Auto Synchronization Disconnect Alarm - The Auto Synchronization Disconnect alarm is intended to alert the equipment operators of a potential loss of system reliability. The alarm usually is set to actuate when the alternate source frequency deviates from the inverter frequency by _ 5.0%. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 39 Before this alarm can be tested, the critical ac loads must be transferred to the output of the inverter. After the loads have been transferred, the alternate source ac supply breaker can be opened to check the operation of this alarm. After the check has been completed, the ac supply breaker should be closed and the critical ac loads should be transferred back to the alternate source by placement of the manual bypass switch in the full bypass position. Static Switch Transfer to Alternate Source Voltage- When the inverter's output voltage is unsatisfactory, the static switch is designed to automatically transfer the critical ac loads from the output of the inverter to the alternate power source. The transfer should occur when the inverter output voltage deviates from the nominal output voltage by more than _ 10%. Before the automatic transfer feature can be checked, the manual bypass switch should be placed in the test bypass position. After the switch is in this position, the inverter output voltage potentiometer should be raised to the transfer setpoint. The successful transfer will be indicated by the actuation of the static switch position indication alarm. If the transfer did not occur when the inverter output voltage exceeded the nominal voltage by 10%, the transfer setpoint must be adjusted. The check should then be repeated for the low voltage transfer setpoint. When both checks have been satisfactorily completed, the inverter output voltage should be adjusted to normal and the critical ac loads should be transferred back to the alternate source by placement of the manual bypass switch in the full bypass position. Static Switch Re-Transfer to Preferred Source Voltage- Because the output of the inverter is the preferred source of power for the critical ac loads, the static switch is designed to retransfer back to the output of the inverter when the inverter's output voltage returns to normal. The retransfer should occur when the inverter's output voltage returns to within _ 2.0% of the nominal output voltage. The retransfer feature should be checked in conjunction with the transfer feature. After the inverter transfers to the alternate source, the inverter output voltage potentiometer should be raised to the retransfer setpoint. A successful retransfer is indicated by clearance of the static switch position indication alarm. When the check has been satisfactorily completed, the inverter output voltage should be adjusted to normal and the critical ac loads should be transferred back to the alternate source by placement of the manual bypass switch in the full bypass position. Static Switch Transfer to Alternate Source Frequency - When the inverter's output frequency is unsatisfactory, the static switch is designed to automatically transfer the critical ac loads from the output of the inverter to the alternate power source. The transfer should occur when the inverter output frequency deviates from the nominal output frequency by more than _ 5.0%. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 40 Before the automatic transfer feature can be checked, the manual bypass switch should be placed in the test bypass position. After the switch is in this position, the inverter output frequency potentiometer should be raised to the transfer setpoint. The successful transfer will be indicated by the actuation of the static switch position indication alarm. If the transfer did not occur when the inverter output frequency exceeded the nominal frequency by 5.0%, the transfer setpoint must be adjusted. The check should then be repeated for the low frequency transfer setpoint. When both checks have been satisfactorily completed, the inverter output frequency should be adjusted to normal and the critical ac loads should be transferred back to the alternate source by placement of the manual bypass switch in the full bypass position. Static Switch Re-Transfer to Preferred Source Frequency - Because the output of the inverter is the preferred source of power for the critical ac loads, the static switch is designed to retransfer back to the output of the inverter when the inverter's output frequency returns to normal. The retransfer should occur when the inverter's output frequency returns to within _ 2.0% of the nominal output frequency. The retransfer feature should be checked in conjunction with the transfer feature. After the inverter transfers to the alternate source, the inverter output frequency potentiometer should be raised to the retransfer setpoint. A successful retransfer is indicated by clearance of the static switch position indication alarm. When the check has been satisfactorily completed, the inverter output frequency should be adjusted to normal and the critical ac loads should be transferred back to the alternate source by placement of the manual bypass switch in the full bypass position. Enclosure Overtemperature Alarm - The Enclosure Overtemperature alarm is intended to alert the equipment operator of excessive temperature conditions that require corrective action. The Enclosure Overtemperature alarm usually is set to actuate when the UPS system enclosure exceeds the recommended maximum operating temperature by 10%. The operation of the alarm's thermostat and contacts can be checked by reducing the enclosure overtemperature alarm setpoint to the actual enclosure operating temperature. Because overtemperature alarm devices are fairly linear, successful operation of the switch at normal temperature is a relatively reliable indication that the alarm will operate satisfactorily at its normal setpoint. If the alarm fails to actuate at normal operating temperature, the temperature switch must be repaired or replaced. At the completion of the check, the overtemperature alarm should be set at its normal value. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 41 Preventive Maintenance Frequency The overall goal of dc/UPS subsystem preventive maintenance is to identify and correct minor or impending problems that, if left unchecked, could result in a reduction of system reliability or in a complete system failure. In order for a dc/UPS subsystem preventive maintenance program to achieve its goal, the dc/UPS subsystem equipment must be checked at regularly scheduled intervals. The regularly scheduled intervals vary dependent upon the equipment manufacturers, the type of intended service, and the environmental conditions that exist at the installation. The initial dc/UPS subsystem preventive maintenance inspection frequencies are normally established on the basis of the manufacturer's recommendations. These initial frequencies can then be modified (increased or decreased in length) on the basis of local site operating experience and/or governing codes and standards for a particular type of service. As an example of how inspection frequencies can be modified on the basis of local site operating experience, assume that a particular UPS manufacturer recommends that the UPS system be visually inspected and cleaned once per quarter. Also assume that the results of three consecutive quarterly inspections and cleanings showed that no abnormal conditions existed and that little or no dirt had accumulated since the previous maintenance. Based on these results, the interval between the visual inspections and cleanings for this particular UPS system could be increased. The visual inspection and cleaning frequency for this UPS system could be changed from a quarterly requirement to a semi-annual or an annual requirement. Figure 7 shows a typical preventive maintenance schedule for a dc/UPS subsystem. The schedule contains the preventive maintenance requirements and the frequency of performance. The frequency of performance section is divided into three time categories: routine, quarterly, and annually. The routine column can represent daily, weekly, bi-weekly, or monthly preventive maintenance requirements. The applicable frequency for all of the preventive maintenance items should be established as previously explained. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 42 Preventive Maintenance Frequency of Performance Requirement Routine Quarterl y Annuall y Visual Inspection Physical Damage X Overheating X Loose Connections X Cleaning X Battery Charger Checks and Adjustments dc Voltmeter X dc Ammeter X Float Voltage Adjustment X Equalize Voltage Adjustment X Equalize Timer Check X (1) End of Charge Condition Alarm X Ground Detection Alarm X Charger Overvoltage Alarm X Charger Failure Alarm X Enclosure Overtemperature Alarm X Inverter Checks and Adjustments Inverter ac Output Voltmeter X Inverter ac Output Ammeter X Inverter ac Output Frequency Meter X Alternate Source ac Input Voltmeter X High Inverter dc Input Voltage Alarm X Low Inverter dc Input Voltage Alarm X Alternate Voltage/Sync Source Not Available Alarm X Static Switch Position Indication Alarm X Inverter Output Failure Alarm X Auto Synchronization Disconnect Alarm X Static Switch Transfer to Alternate Source Voltage X Static Switch Re-Transfer to Preferred Source Voltage X Static Switch Transfer to Alternate Source Frequency X Static Switch Re-Transfer to Preferred Source Frequency X Enclosure Overtemperature Alarm X Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 43 NOTE (1) Only the timer setpoint is checked during routine preventive maintenance. The actual elapsed time should be checked each time that an equalizing change is performed. Typical dc/UPS Subsystem Preventive Maintenance Schedule Figure 7 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 44 Preventive Maintenance Records The results of all of the maintenance and testing that is performed on dc/UPS systems should be recorded on maintenance records, and the individual records for each dc/UPS system installation should be kept in a separate file for the life of the system. The first step of the record keeping process is to record the baseline data for the system. The baseline data are the data that were obtained during the start-up and commissioning of the dc/UPS system, which was discussed in Module EEX 211.06. Future maintenance records are added as maintenance is performed to provide a chronological history of the dc/UPS system's condition. The chronological history is used to identify and analyze trends or isolated problems. This information aids the Electrical Engineer in making future decisions in regard to the operation, maintenance, and troubleshooting of the dc/UPS system. Figures 8 through 10 show typical dc/UPS subsystem maintenance record forms. These forms coincide with the typical dc/UPS subsystem preventive battery maintenance schedule that previously was shown in Figure 7. Figure 8 shows a typical dc/UPS subsystem preventive maintenance record form that can be used to record the results of routine maintenance. The form is divided into two major parts: Identification Data and Maintenance Data. The Identification Data section is used to record the pertinent information that is needed to identify the particular dc/UPS subsystem on which the maintenance was performed. The Maintenance Data section is used to record the actual results of the maintenance that was performed. A space is provided to record the results of each of the routine maintenance items that was previously shown on Figure 7. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 45 dc/UPS Subsystem Preventive Maintenance Record - Routine Items Figure 8 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 46 Figure 9 shows a typical dc/UPS subsystem preventive maintenance record form that can be used to record the results of quarterly maintenance. The form is divided into two major parts: Identification Data and Maintenance Data. The Identification Data section is used to record the pertinent information that is needed to identify the particular dc/UPS subsystem on which the maintenance was performed. The Maintenance Data section is used to record the actual results of the maintenance that was performed. A space is provided to record the results of each of the quarterly maintenance items that was previously shown on Figure 7. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 47 dc/UPS Subsystem Preventive Maintenance Record - Quarterly Items Figure 9 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 48 Figure 10 shows a typical dc/UPS subsystem preventive maintenance record form that can be used to record the results of annual maintenance. The form is divided into two major parts: Identification Data and Maintenance Data. The Identification Data section is used to record the pertinent information that is needed to identify the particular dc/UPS subsystem on which the maintenance was performed. The Maintenance Data section is used to record the actual results of the maintenance that was performed. A space is provided to record the results of each of the annual maintenance items that was previously shown on Figure 7. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 49 dc/UPS Subsystem Preventive Maintenance Record - Annual Items Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 50 Figure 10 Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 51 Problems and Corrective Measures This section of the Module will discuss following typical dc/UPS subsystem problems and their corrective measures: Tripping of Input/Output Breakers Improper Inverter Output SCR Failures Tripping of Input/Output Breakers Input and output circuit breakers are employed to protect the system equipment and personnel. Each device is designed to trip on excessive current flow. The ac input circuit breaker is designed to protect the battery charger and the inverter from faults that occur upstream of the output circuit breaker. The battery breaker provides a means to isolate the battery from the battery charger and the inverter, which, depending on the direction of current flow, protects the inverter input circuit or the battery. The output circuit breaker protects the inverter in the event of a critical ac load fault or overload condition. The following aspects of the tripping of input/output circuit breakers will be discussed in this section: Problems Caused Indications Corrective Measures Problems Caused - Because a number of power supply redundancies are designed into the dc/UPS subsystem, few problems can result from inadvertent tripping of the input or output circuit breakers. The most serious problem of a loss of power to the critical ac loads cannot occur following a single circuit breaker trip. If only the ac input circuit breaker trips, a loss of power to the critical ac loads cannot occur without a simultaneous trip of the battery breaker and the alternate source input breaker. If only the ac output circuit breaker trips, a loss of power to the critical ac loads cannot occur without a simultaneous trip of the alternate source input breaker. For these reasons, the only real problem that is caused by the inadvertent trip of the input or the output circuit breaker is a partial loss of system reliability. Indications- An inadvertent trip of the input/output circuit breakers will cause a number of the parameters that are monitored by the dc/UPS subsystem to change. Because some of these parameters are monitored by alarms, the first indication of an input or an output circuit breaker trip generally is the receipt of an alarm. Other dc/UPS subsystem parameters also will indicate abnormal values. The following is a list of indications and/or alarms that occur after an inadvertent trip of the input or the output circuit breaker: Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 52 Breaker Trip Condition Indication and/or Alarm AC Input Circuit Breaker Inverter Output Breaker Charger Failure Alarm Static Switch Position Indication Alarm DC Ammeter Indicates Zero Inverter Output Failure Alarm Static Switch Position Indication Alarm Abnormal Inverter ac Output Voltage Abnormal Inverter ac Output Frequency Corrective Actions- Because of the multitude of individual faults or failures that could cause the input or the output circuit breaker to trip, the various corrective actions cannot be covered in this section. Generally, the corrective actions consist first of identifying the cause of the trip. After the cause is known, knowledge of system operation must be applied to identify and repair/replace the defective components(s). The following is a list of some of the possible causes of input and output circuit breaker trips: Breaker Trip Possible Causes AC Input Circuit Breaker AC Output Circuit Breaker Battery Charger Fault Inverter Fault Defective ac Input Circuit Breaker Defective ac Output Circuit Breaker Critical ac Load Fault Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 53 Improper Inverter Output The following aspects of improper inverter outputs will be discussed in this section: Problems Caused Indications Corrective Actions Problems Caused - The common inverter output problems are an excessive or an insufficient inverter output voltage and an excessive or an insufficient inverter output frequency. Because the output of the inverter is the preferred source of power for the critical ac loads, and because many of the critical ac loads are sensitive to power supply fluctuations, an improper inverter output could cause improper operation of the critical ac loads. However, as previously discussed in this Module, built-in redundancies and automatic transfers should prevent an improper inverter output from being supplied to the critical ac loads; therefore, the only real problem that results from improper inverter output is a partial loss of system reliability. Indications- The indications of an improper inverter output are a combination of abnormal panelmeter readings and audible alarms. When the inverter output voltage or frequency exceeds its allowable tolerance, the following panelmeter indications and alarms should be present: The respective panelmeter (voltage/frequency) will indicate a value that is greater than the acceptable tolerance. The inverter output failure alarm will operate. The static switch position indication alarm will operate. The inverter output ac ammeter will read zero amps. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 54 Corrective Actions- Many conditions can cause an improper inverter output. These conditions can range from an improper dc input, through an inverter malfunction, to a static switch malfunction. Before corrective actions are initiated, the exact location of the malfunction must be determined. If the malfunction occurred as a result of a problem with the inverter input, additional alarms would occur. Alarms such as Low Charger Output Voltage alarm, Charger Overvoltage alarm, Charger Failure alarm, or Low Battery Current alarm indicate that a problem exists with the battery charger or the battery that is merely being transferred to the inverter. In these situations, the problem that must be corrected is "upstream" of the inverter. Knowledge of system operation must be applied to identify and repair/replace the defective "upstream" component. When the "upstream" malfunction is corrected, the static switch should retransfer to the inverter after verification of proper voltage, frequency, and phase relationship. If the inverter input is satisfactory, and if the inverter output is improper, the problem most likely is in the inverter itself or in the static switch. In this situation, knowledge of inverter and/or static switch operation must be applied to identify and replace/repair the defective component. To deenergize the inverter and the static switch for troubleshooting, the manual bypass switch should be placed in the full bypass position. This position will allow maintenance to be performed on the inverter and the static switch with no affect on the critical ac load. After the necessary repairs are complete, the manual bypass switch should be placed in the test bypass position to make the necessary output voltage and frequency adjustments. When the repairs and adjustments are completed, the manual bypass switch should be placed in the normal position. When the manual bypass switch is in this position, the static switch should automatically retransfer to the inverter after proper voltage, frequency, and phase relationship is verified. SCR Failures SCR's (silicon control rectifiers) are used in the battery charger, the inverter, and the static switch. Battery charger SCR's are used to convert the preferred source ac into rectified dc. The inverter SCR's are used to produce the 60 Hz ac output to the critical ac loads from the dc input. The static switch SCR's are used to electronically switch between the inverter output and an alternate power source. The following aspects of SCR failures will be discussed in this section: Problems Caused Indications Corrective Actions Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 55 Problems Caused - Generally, SCR's fail in one of two ways: they open circuit or they short circuit. The type of problems that are caused by SCR failures depend on where the SCR's are used. If the failed SCR is in the battery charger, the problem that is caused is a high or a low battery charger output voltage. A short-circuited SCR in the battery charger will cause a high battery charger output voltage because the short- circuited SCR will continuously conduct. An open-circuited SCR in the battery charger will cause a low battery charger output voltage because the open-circuited SCR will not conduct. If the failed SCR is in the inverter, the problems that will be caused are an improper inverter output voltage, an improper inverter output frequency, an improper inverter output phase relationship. Because all of these parameters (voltage, frequency, and phase relationship) are controlled through variance of the firing and conduction times of the SCR's, all three parameters will be affected by both open-circuited and short- circuited SCR's. If the failed SCR is in the static switch, the problem that is caused depends on the type of SCR failure that occurs. An open-circuited SCR in the static switch will cause a reduction in the inverter's output because one half of the output ac sinewave will be lost. A short-circuited SCR in the static switch may go unnoticed until a transfer occurs because a conducting SCR already is essentially a short-circuit connection. However, when the static switch transfers, a short-circuited SCR will not turn off. Indications- The indications of an SCR failure also depend on the location of the SCR that failed. The following are possible indications of an SCR failure in the battery Charger: High or low dc voltmeter reading High or low dc ammeter reading Charger overvoltage alarm Charger failure alarm High inverter dc input voltage alarm The following are possible indications of an SCR failure in the inverter: Abnormal inverter output voltage reading Abnormal inverter output frequency reading Abnormal inverter output ammeter reading Static Switch position indication alarm Inverter output failure alarm Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 56 The following are possible indications of a SCR failure in the static switch: Abnormal inverter output voltage reading Abnormal inverter output frequency reading Abnormal inverter output ammeter reading Static Switch position indication alarm Inverter output failure alarm No abnormal indications Corrective Actions- The first corrective action for an SCR failure is to observe all of the dc/UPS subsystem indications and alarms to determine the location of the SCR failure. Once the location of the failure is known, the dc/UPS subsystem should be completely deenergized by placing the manual bypass switch in the Full Bypass position and by opening the ac input, battery, and ac output circuit breakers. The suspect SCR's should then be tested to determine which SCR has failed. The failed SCR should then be replaced. After satisfactory replacement of the defective SCR, placement of the manual bypass switch in the test bypass position will permit safe testing of the system without disruption of power to the critical ac loads. After completion of the proper tests, the manual bypass switch should be placed in normal to return the system to normal operation. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 57 WORK AID 1: MAINTENANCE SPECIFICATIONS AND TROUBLESHOOTING GUIDE COMPILED FROM SADP-P-103 AND ESTABLISHED ENGINEERING PRACTICES FOR DETERMINING WHETHER BATTERIES ARE FUNCTIONING PROPERLY Maintenance Specifications Item/Condition Checked Specifications General Cleanliness The battery cells, battery room floor, and ventilation system filters should be free from excessive dirt, dust, electrolyte residue, and/or water buildup. Battery Rack All battery rack hardware and floor mount connections must be tight. The battery rack's epoxy coating should be free from chips and cracks. Cell Case Integrity The cell case integrity cannot be breached. Vent Caps/Flame Arrestors The vent caps/flame arrestors should be clean, tight, and free from cracks or other defects. Cell Terminals All cell terminals must be free from corrosion. All cell terminal connections should be tightened to the torque that is recommended by the manufacturer (usual range is 60-125 inch-pounds). The terminal resistances should not vary from the previous reading by more than 20%. Also, all terminal resistances should be within 10% or 5__ of the average of all of the terminal resistance readings. Cell Internals (Lead-Acid only) The cell plates should be free from excessive sulphation and they should not be bowed or warped. The bottom of the cell should be free from excessive sediment. Specific Gravity (Lead-Acid Only) The corrected specific gravity should be consistent with the battery's current state of charge. All corrected specific gravity readings should be within 10 points (.010) of the average corrected specific gravity readings of all of the cells. Individual Cell Voltages All individual cell voltage readings should be consistent with the battery's current state of charge and with the current float voltage setpoint. Electrolyte Levels The electrolyte levels must be in the normal operational band (e.g., between the high and low level marks on the side of the cell case). Capacity Test Discharge Degradation is indicated by a 10% decrease in capacity from the previous the previous test. End of service life is indicated by a capacity that is less than 80% of the manufacturer's rating. Float Voltage The float voltage should be within _1% of the value that is recommended by the manufacturer. The normal range of float voltage per cell for lead-antimony batteries is 2.13- 2.18 volts per cell. The normal range of float voltage per cell for lead-calcium batteries is 2.17-2.29 volts per cell. The normal range of float voltage per cell for nickel-cadmium batteries is 1.40 to 1.42 volts per cell. Equalizing Voltage For battery chargers that are rated at less than 10 kW, the equalizing voltage should be within _1% of the value that is recommended by the manufacturer. For battery chargers that are rated above 10 kW, the equalizing voltage should be within _2% of the value that is recommended by the manufacturer. The normal range of equalizing voltage per cell for lead-antimony batteries is 2.24-2.33 volts per cell. The normal range of equalizing voltage per cell for lead-calcium batteries is 2.29-2.39 volts per cell. The normal range of equalizing voltage per cell for nickel- cadmium batteries is 1.50 - 1.60 volts per cell. Battery Terminal Voltages The voltage that is measured between the positive terminal and the negative terminal should be equal to the float voltage per cell times the number of cells that are in the installation. The voltage that is measured between the positive terminal and ground or between the negative terminal and ground should be equal to one half of the total battery voltage. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 58 Troubleshooting Guide Symptom Possible Cause(s) Possible Corrective Actions Low Total Battery Voltage Low float voltage Raise float voltage setting and perform an equalizing charge. Battery ground Locate and clear the ground. High resistance connections Locate and repair the high resistance connections. Excess sulphation (lead-acid cells) or battery is discharged Perform an equalizing charge. Battery is nearing the end of its service life. Replace the battery. One or more of the cells is defective or contaminated. Locate and repair/replace defective cells. Undersized battery charger Verify the charger size and if necessary, replace the charger. Excessive battery temperature Identify and correct the ventilation problem. Low Individual Cell Voltage Grounded cell Clear the ground. High resistance connection Correct the condition that is causing the high resistance. High cell temperature Determine and correct the cause of the high temperature. Excess sulphation (lead-acid cells) Perform an equalizing charge. Damaged or contaminated cell Replace the cell. Low Specific Gravity Readings (Lead-Acid Only) Low float voltage Raise the float voltage setpoint and perform an equalizing battery charge. High resistance connections Locate and repair the high resistance connections. Excess sulphation or battery is discharged. Perform an equalizing charge. Electrolyte stratification If the battery recently was watered, the condition is normal and no corrective action is necessary. If only one or several cells are affected, mix electrolyte by drawing it into the hydrometer and then discharging it back into the cell several times. If multiple cells are affected, perform an equalizing battery charge. The battery is nearing the end of its service life. Replace the battery. Undersized battery charger Verify the charger size and if necessary, replace the charger. Excessive battery temperature Identify and correct the ventilation problem. High Water Usage/Low Electrolyte Levels Excessive float voltage Lower float voltage setting. High ambient temperature and/or low humidity Increase monitoring frequency to prevent low levels. Battery is nearing the end of its service life. Replace the battery. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 59 WORK AID 2: MAINTENANCE SPECIFICATIONS AND TROUBLESHOOTING GUIDE COMPILED FROM ESTABLISHED ENGINEERING PRACTICES FOR DETERMINING WHETHER DC/UPS SUBSYSTEMS ARE FUNCTIONING PROPERLY Maintenance Specifications Item/Condition Checked Specifications Physical Damage The equipment should be free from loose or missing hardware, missing gaskets or seals, broken wires, damaged insulation, and leaking electrical/electronic components. Overheating Components should not show any signs of excessive heat such as browning, charring, or unusual odors. Loose Connections All of the internal termination should be tight. All internal terminations should be made up using the proper hardware. Cleanliness All equipment should be free from excessive dirt, dust, or other foreign residues. Battery Charger dc Voltmeter Reading should agree with a portable calibrated dc voltmeter to within _2%. Battery Charger dc Ammeter Reading should agree with a portable calibrated dc ammeter to within _2%. Float Voltage Adjustment The float voltage should be within _1% of the value that is recommended by the manufacturer. The normal range of float voltage per cell for lead-antimony batteries is 2.13-2.18 volts per cell. The normal range of float voltage per cell for lead-calcium batteries is 2.17-2.29 volts per cell. The normal range of float voltage per cell for nickel-cadmium batteries is 1.40 - 1.42 volts per cell. Equalize voltage Adjustment For battery chargers that are rated at less than 10 kW, the equalizing voltage should be within _1% of the value that is recommended by the manufacturer. For battery chargers that are rated above 10 kW, the equalizing voltage should be within _2% of the value that is recommended by the manufacturer. The normal range of equalizing voltage per cell for lead-antimony batteries is 2.24-2.33 volts per cell. The normal range of equalizing voltage per cell for lead-calcium batteries is 2.29-2.39 volts per cell. The normal range of equalizing voltage per cell for nickel-cadmium batteries is 1.50 - 1.60 volts per cell. Equalize Timer The timer should be set at the number of hour that are recommended by the manufacturer. The actual elapsed time should agree with the timer setpoint to within _10%. End of Charge Condition Alarm The alarm should actuate at 1.75 volts, _5.0%. Ground Detection Alarm The alarm should actuate when the current flow to exceeds 10.0 mA. Charger Overvoltage Alarm The alarm should actuate at 10% above the nominal cell voltage. Charger Failure Alarm The alarm should actuate at 15% below the nominal cell voltage. Enclosure Overtemperature Alarm The alarm should actuate when the temperature reaches the maximum operating temperature that is recommended by the manufacturer, +10%, -0.0%. Inverter ac Output Voltmeter Reading should agree with a portable calibrated ac voltmeter to within _2%. Inverter ac Output Ammeter Reading should agree with a portable calibrated ac ammeter to within _2%. Inverter ac Output Frequency Meter Reading should agree with a portable calibrated oscilloscope to within _2%. Alternate Source ac Input Voltmeter Reading should agree with a portable calibrated ac ammeter to within _2%. High Inverter dc Input Voltage Alarm The alarm should actuate when the input voltage rises to 5% above the nominal input voltage. Low Inverter dc Input Voltage Alarm The alarm should actuate when the input voltage drops to 5% below the nominal input voltage. Alternate Voltage/Sync Source Not Available Alarm The alarm should actuate when the alternate source voltage deviates from the nominal system voltage by _10%. The alarm also should actuate when the alternate source frequency deviates from the nominal system frequency by _5.0%. Static Switch Position Indication Alarm The alarm should actuate when the static switch transfers to the alternate power source. Inverter Output failure Alarm The alarm should actuate when the inverter output voltage deviates from the nominal output voltage by _10%. The alarm also should actuate when the inverter output frequency deviates from the nominal value of 60 Hz by _5.0%. Auto Synchronization Disconnect Alarm The alarm should actuate when the alternate source frequency deviates from the inverter frequency by _5.0%. Static Switch Transfer to Alternate Source Voltage Transfer should occur when the inverter output voltage deviates from the nominal output voltage by _10%. Static Switch Re-Transfer to Preferred Source Voltage Re-transfer should occur when the inverter output returns to within _2% of the nominal output voltage. Static Switch Transfer to Alternate Source Frequency Transfer should occur when the inverter output frequency deviates from the nominal output frequency by _5.0%. Static Switch Re-Transfer to Preferred Source Frequency Re-transfer should occur when the inverter output returns to within _2% of the nominal output frequency. Enclosure Overtemperature Alarm The alarm should actuate when the temperature reaches the maximum operating temperature that is Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 60 recommended by the manufacturer, +10%, -0.0%. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 61 Troubleshooting Guide Symptom Possible Cause(s) Possible Corrective Actions Overheating Clogged ventilation filters Clean filters. Inoperable ventilation fan Repair ventilation fan. High/Low Inverter Output Voltage Improper dc input voltage Adjust the input voltage. Improperly adjusted or failed voltage regulator Replace and/or adjust the voltage regulator. High/Low Inverter Output Frequency Improperly adjusted or failed oscillator board Replace and/or adjust the oscillator board. Improperly adjusted or failed synchronizing circuit Replace and/or adjust the synchronizing circuit. Output Waveform Distortion Load induced harmonics Identify and filter the problem load. Improperly adjusted inverter Adjust the inverter. Engineering Encyclopedia Electrical Directing the Operation and Maintenance of DC/UPS Systems Saudi Aramco DeskTop Standards 62 glossary baseline data Initially recorded data obtained during startup and commissioning checks. equalizing charge A prolonged charge of a storage battery; the charge is designed to correct any inequalities of voltage and specific gravity that may have developed between the cells during service. flash arrestor A cell-venting device that prevents the propagation of an external flame into a battery cell. float charge A continuous, low-rate constant voltage charge of a storage battery that is designed to maintain the battery in a constant full- charge condition. mossing To cover over with a moss-like material. service life The period of useful service of a battery under specified conditions. Service life usually is expressed as the time period or number of cycles that elapses before the ampere-hour capacity of the battery drops to a specified percentage of rated capacity. stringers Short thread or lint-like strings.