Uninterruptable Power Supply and Battery Technology: Change Is Now

When it comes to data communications, one of the most critical infrastructure elements is the uninterruptible power supply (UPS), especially when it comes to distributed IT, data centers, or network closets. UPS equipment can help protect your datacom hardware against damage from unexpected power failures, surges, or unclean power. UPS devices provide power backup to your systems, and the UPS battery ensures that there are no interruptions between your systems and the main power supply. Let’s explore the world of UPS and, more specifically, focus on key questions you should be asking about the changes in UPS battery technology. While UPS technology has been with us for decades, battery technology is rapidly evolving. It is no longer one size fits all. Change is happening. Change is now. The Role of a UPS UPS equipment safeguards your critical infrastructure. When incoming utility power drops below or rises above safe voltage levels, the UPS switches to DC battery power and then inverts it to AC power to run connected equipment. UPS batteries are a critical component of any UPS. Overview of UPS Batteries When it comes to UPS, there have been two main battery types: Legacy valve-regulated lead-acid (VRLA) Relatively new lithium-ion Lithium-ion UPS represents a significant progression in UPS battery technology, which has been dominated by lead-acid batteries for decades. Because lithium-ion batteries offer an 8-10-year lifespan — as opposed to their lead-acid counterparts, which generally need to be replaced every three to five years — the technology offers several advantages. Important Questions Regarding UPS Battery Technology What are the primary benefits of switching to lithium-ion UPS batteries? The most common reason cited is the significantly longer service life. Lithium-ion also provides a greater cycle life — the number of charge/discharge cycles ranges into the thousands for larger three-phase UPS, versus approximately 500 for VRLA batteries — as well as a longer warranty. Small single-phase lithium-ion UPS will not typically exhibit the thousands of full discharge cycles sometimes advertised for lithium-ion cells in perfect conditions. However, they do offer two to three times longer life than their lead-acid battery counterparts, and the lighter weight and smaller footprint are additional benefits. In addition, IT professionals can easily deploy lithium-ion UPS without the maintenance and refresh challenges of those utilizing lead-acid. The extended battery life provided by lithium-ion enables users to align their UPS refresh cycles with the rest of the IT stack, saving time and money spent on labor and replacement batteries. Furthermore, lithium-ion UPS boasts a “set it and forget it” value proposition, which is especially conducive at sites where UPS protects critical network operations, yet IT resources are not extensive. Lithium-ion batteries versus VRLA – is there a downside? The primary downside is that because the technology is so new, many manufacturers have limited experience in UPS applications. However, this is changing rapidly, with successful deployments now exceeding four years. What about fire risk with lithium-ion versus VRLA battery technology? While any battery has the potential to catch fire if abused, lithium-ion does have a reputation for more dramatic “thermal events.” However, in UPS applications, the presence of a battery management system (BMS) — which controls charge rate, voltage, and temperature — makes lithium-ion batteries less likely to enter thermal runaway than traditional UPS batteries. If the battery and its packaging are designed to dissipate more heat than can be created on overcharge, the battery cannot go into thermal runaway. All UPS vendors and battery vendors are ensuring that this is the case for lithium-ion products. Have lithium-ion UPS experienced any battery failures or fires? The presence of a BMS has been instrumental in the detection and mitigation of any anomalies. While there have been cases of individual batteries failing to retain a charge, these rare instances were not thermal-related and occurred only after the batteries were abused in a lab with stress testing. Are lithium-ion batteries more expensive? Yes, they vary from slightly more expensive than good quality VRLA, to two times more expensive, especially when shipping costs and commissioning services are considered. However, it is important to note that when vendors start shipping battery cabinets pre-loaded with batteries, the shipping costs for lithium-ion batteries should be slightly less than VRLA batteries. Are there different recharge rates between lithium-ion and VRLA batteries? Lithium-ion batteries can be recharged significantly faster than traditional UPS batteries; however, keep in mind that the manufacturers limit the amount of battery charge current that the UPS can supply. During recharge, the BMS monitors not only voltage levels, but also the temperature of the cells. In this manner, the system will automatically limit the charge if a cell gets too warm, which can potentially lengthen the recharge time. In general, the VRLA rule-of-thumb of “10 times the discharge time to 90 percent capacity” may not apply to single- or three-phase lithium-ion UPS batteries. What is the shelf life of lithium-ion batteries before they need to be checked or charged? A good rule of thumb if the battery modules are connected, i.e. installed in a cabinet, the storage time is six months at 25 degrees Celsius; however, it is always recommended to recharge every six months. This is due to parasitic losses from the BMS. If the battery modules are not connected (either power or communication connections), then the storage time is one year at 25 degrees C. Can lithium-ion be mixed with other types of batteries (e.g., VRLA)? No, lithium-ion cannot be put in series or parallel with other types of batteries. Do lithium-ion batteries have recycling and/or disposal issues? Lithium-ion batteries are disposable. However, various recycling options are expected soon. Recycling is preferred, and several national recycling agencies may be able to assist. Learn more about your recycling options for lithium-ion batteries.   While UPS technology has been around for multiple decades, UPS battery technology is rapidly changing. We explored and compared the two main UPS battery types – the legacy VRLA and the more recent lithium-ion battery. We addressed and compared significant issues from a benefit versus a downside perspective. We looked at comparisons of cost, fire risk, recharge rates, and many other key issues. The bottom line is that while it seems like the UPS has always been around, the battery technology that powers the UPS is rapidly evolving, leading to longer-lasting and better UPS battery solutions. Lithium-ion batteries are here to stay and will ultimately lead to better, safer, and more cost-effective UPS solutions. Make sure the manufacturer you approach to fulfill your UPS needs has the long-term industry knowledge, experience, and partnerships you can count on to help you make the right choices today and tomorrow. Value-added benefits: Performance – 2-3 times longer battery lifespan Resiliency – Three times faster recharge Safety – Onboard battery management system (BMS) Intelligence – BMS provides up-to-date insight into battery performance Installation – 40 percent lighter than comparable lead-acid UPS Confidence – 5-year all-inclusive warranty (electronics and battery) Call your local WESCO representative to learn more about Eaton power solutions today. The opinions expressed in this piece are solely Eaton's. They do not necessarily represent WESCO’s views.

Best Practices for Mine Breaker Maintenance

When it comes to testing breaker function and safety, it’s possible that there are substantial risks that have gone unnoticed for years. Breakers are typically tested just once a year, in accordance with most manufacturer’s recommendations. However, there are often circumstances where this standard schedule might not be enough to prevent hazardous situations.  Factors such as the environment surrounding the breaker, the degree of usage and the required function all play important roles in determining how often breakers should be tested. The mining industry in particular creates a perfect storm where all of these factors come together placing more extreme demands on breakers, ultimately increasing their risk of failure. This article examines the unique circumstances of breakers within the mining industry and details best practices for testing and maintenance to help keep your mine safe and operating at peak performance. Main Causes of Malfunction and Failure It goes without saying that mines are not clean environments — but what is the impact on equipment? The constant presence of dirt and debris in a mining operation has a major impact on breakers, both in functionality and longevity. Many of the materials found in mines are conductive and abrasive, leading to a significant increase in wear. This build up can also cause the breakers to malfunction, ultimately resulting in an unexpected shut down of operations until the breaker can be repaired or replaced. Some operations rely heavily on breakers for their power needs, putting increased strain on the breakers. Knowing the costs associated with unplanned failures or malfunctions, shifting to a model of more frequent breaker testing can help mitigate loss. A good approach is to consider planning the testing frequency in direct relation to the frequency of use. A breaker with higher use will inherently have a shorter lifespan and be at greater risk of malfunction or failure. Implementing Maintenance Checkpoints Having a system of maintenance checkpoints will help you prepare for repairs or replacements in the future. Below is a list of issues to monitor when testing. Each system should be scored with a good, satisfactory, or marginal rating in each of the following system issues to determine when it is time to refurbish or replace the breaker. Code/safety/security Remaining life capacity Reliability/redundancy Flexibility Physical distribution Energy efficiency Ease of operation Maintainability Expansion capability You can then prioritize risks based on life/safety code compliance, litigation exposure, facility-operation vulnerability/occurrence likelihood, and life expectancy need. This will help reduce the company’s downtime and control costs for unexpected repairs. Refurbish or replace? One of the largest concerns when it comes to breaker maintenance is the overall cost of replacing them. It can be difficult — and at times risky — to determine when to fully replace a breaker and when refurbishing is a viable option.  This depends both on the company and their circumstances and on the breaker itself. The benefits to replacing breakers include having a brand new breaker that is ready to use, there will be minimal downtime associated with replacing, and you will be equipped with the newest technologies increasing safety throughout the site. Refurbishing will offset some of the costs of replacing the breaker, it will expose other flaws in the breaker giving you an opportunity to fix those at the same time, and it will improve the lifespan of the breaker by making it as close to new as a manufacturer can. However, both depend on the age of the breakers. There are instances when a breaker cannot be replaced with a new unit. Refurbishing becomes the only option unless you are willing to replace the whole system which can become costly. Although, having an updated system increases safety in the field and carries its own set of advantages.  At times, you may be forced to upgrade your system because what you have been using is now obsolete and can no longer be refurbished. When deciding to replace or refurbish you also need to consider the amount of downtime that is acceptable for your company. Refurbishing a breaker takes longer than replacing. You need to have someone come to find the root cause, order parts, and replace them. Frequent maintenance can reduce this downtime, but typically the needed parts are not on hand increasing the length of time operations are shut down. The best way to minimize downtime and keep the company’s operations running at full capacity is to replace the breaker. Your company will have to make the call on how long it can handle being without proper gear when deciding whether to replace or refurbish. Stay up to Code With Regular Testing and Replacement To help reduce downtime, minimize costs, and keep operations running at full speed, it is best to test breakers regularly. It is recommended that breakers be tested at least twice a year in the mining industry. Depending on company needs, testing requirements may need to be increased to insure the best outcomes. Performing regular maintenance on the breakers will help prevent failures and extend the lifespan of the breakers. This will also ensure that breakers are keeping up with NFPA 70 requirements. When it comes time to replace breakers, choose breakers that integrate well with your current systems. The new technologies have capabilities that will help reduce arc flash hazards and increase safety throughout the mines. The opinions expressed in this piece are solely Eaton's. They do not necessarily represent WESCO’s views.

The Relay Race: Choosing the Right Equipment for Your Mine

Over the last fifty years or so, advancement in technology has created incredible diversity of choice in the world of generation protective relay – however, many operations are relying on the same relay systems they implemented close to thirty years ago without much thought. With options ranging from solid-state, to electromechanical and microprocessing, how can decision makers be sure that they’re using the best tool for the job? Understanding the differences between the types of relays available and their features will help you determine if an equipment update might be necessary or simply worth considering to improve your operational processes. Three Main Relay Types In mining environments, the three most commonly used relay types are: Solid-state relays (SSRs) Electromechanical relays Microprocessor relays SSRs are considered the “old standard” in mining. They are designed to use a system of switches with each switch controlling a single process. One of their major benefits is size as they are the smallest-profile relay available allowing for the greatest flexibility in application. They are much less sensitive to vibration or shock, consume less power with lower operating voltage and produce no magnetic field or electrical noise. Electromechanical relays offer a greater level of control than SSRs as they can rely on a power source (battery or circuit) to incorporate features such as push-to-test manual operation and time delays allowing for adjustable speeds. They might feature expandable decks to allow for additional switch poles and convertible contacts that allow for reconfiguration of standard state between closed or open. They are also safe for explosion-proof applications as they will not spark or produce other thermal effects under conditions that may ignite a gas mixture. Microprocessor relays are they newest and most advanced technology to enter the market. They are more accurate than SSRs or electromechanical relays and requires less maintenance. Since the relay units are comprised of a single enclosed system designed to operate multiple switching functions, they are less susceptible to dirt and debris and have a lifespan of approximately 15 years. This type of relay helps enhance personnel and equipment protection by allowing networked communication and control of an entire breaker system, including the ability to program complex control logic. What to Consider When Replacing Relays If the time has come to upgrade your relay system, there are several factors to consider, including: Average Temperature: If the wrong relay is selected, overheating and malfunction or failure can occur in instances where the environment is extremely hot. Other Environmental Factors: Consider the levels of moisture or gas in the air, as well as the amount of dirt and debris, or the presence of corrosive materials. Choose the relay that will best meet the demands of your operation. Critical Need: How critical is the specific function of the relay being upgraded? Is it tied to major operational and/or safety functions, or would a certain level of downtime be acceptable? Depending on how extensive the damage from potential incidents may be, operations could be shut down for days, weeks or months, costing your company hundreds of thousands of dollars in lost production time. Avoiding Downtime and Hazards Although equipment upgrades can be costly and time-consuming, taking a proactive approach to evaluating and upgrading your relay system(s) when possible is the best way to prevent greater exposure to safety hazards and operational downtime. In many cases, a consultant can help conduct an audit of your existing equipment in collaboration with your maintenance or operations managers and determine any recommended next steps. The opinions expressed in this piece are solely Eaton's. They do not necessarily represent WESCO’s views.