Case Study #146 | When to Upgrade or Repair a UPS System – Eaton 9315 UPS System

Case Study #146 | When to Upgrade or Repair a UPS System – Eaton 9315 UPS System

Case Study

Case Study #146 | When to Upgrade or Repair a UPS System – Eaton 9315 UPS System

Part of the job of our Critical Power Professionals™ (CPP™) is to educate our customers on their Uninterruptible Power Supply (UPS) equipment over the lifespan of their system.

In this Nationwide Power ™ case study, we feature a scenario where our CPPs serviced an Eaton 9315 UPS unit that was over 20 years old and provide a cost-benefit analysis to the customer on upgrading the UPS system.

Product Eaton 9315 UPS
Application Government Facility
Synopsis

Finding the right timing to upgrade a UPS system can often be a complex decision based on many factors: age of unit, customer budget, risk of critical failure and level of impact to the business, lack of replacement parts on the market, and the consistency of preventive maintenance performed over the life of the unit as a few examples.

Part of our responsibilities at Nationwide Power is to provide our customers with the best possible direction and guidance, based on all known factors.

Preliminary Actions

Nationwide Power has been servicing this customer’s unit intermittently over the past several years. In 2017, our CPP made the first recommendation for a full unit replacement. While Nationwide Power has the capacity to continue servicing the unit even passed its OEM-stated end-of-life, that was not in the customer’s best interests in this scenario.

Factors for the customer to consider include:

  • Age of equipment
  • Inconsistent routine maintenance over the life of the unit
  • Risk of critical failure and impact to the business
  • Cost benefit analysis, with more efficient equipment on the market today that would not require costly repairs over the remainder of the equipment’s life
Resolution

The customer had not been in a position to upgrade the unit and has elected to have Nationwide Power continue servicing it.

With over 57,000 square feet of warehouse space and over $10 million in parts and equipment inventory, Nationwide Power is one of the very few service providers able to continue maintaining this customer’s equipment.

So far, the customer has been able to stretch the end-of-life on the unit for an additional 3 years, however, not without intermittent failures and downtime.

Root Cause Eventually, the customer will have no other option but to upgrade the unit due to age. In doing so, they should expect to find a quick break-even point simply due to more efficient models on the market with lower energy usage, coupled with lower overall maintenance cost.
Additional Reading

For a common list of questions to ask when receiving quotes from multiple service providers, visit us at:

hhttps://nationwidepower.com/news/case-study-138-powerware-9315-repair-end-of-life

https://nationwidepower.com/news/case-study-126-eaton-9315-160kva-load-los/

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.

Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

Latest News

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies (UPS) and UPS batteries. Our 57,000 square foot warehouse, with over $10 million in parts and...

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Case Study #145 | Another Reason Why Preventive Maintenance Is So Important (Liebert NX 40kVA)

Case Study #145 | Another Reason Why Preventive Maintenance Is So Important (Liebert NX 40kVA)

Case Study

Case Study #145 | Another Reason Why Preventive Maintenance Is So Important (Liebert NX 40kVA)

At Nationwide Power, we make it a top priority to educate our customers on their critical power equipment and keep them informed of any maintenance items on the horizon.

In this case study, a customer had regularly scheduled preventive maintenance (PM) for their Liebert NX 40kVA Uninterruptible Power Supply (UPS) system. Recommendations were made that saved the customer both money and possible downtime.

The customer was so impressed with the service and recommendations, he provided the following comment:

“Fantastic job by Darren. This is why everyone should have a maintenance contract in place. Had I not had a contract, then I would not have known I had batteries failing and would have been up a creek if something had happened. Darren explained in detail what needed to be done, and I am thankful you have such a conscientious worker. Hats off once again for his dedication to his job and working with us to ensure we don’t have any issues with our UPS. Thanks Darren.”

Product Liebert NX 40kVA
Application Restaurant Equipment Supplier
Synopsis A Critical Power Professional™ (CPP™) conducted regularly scheduled preventive maintenance on the customer’s Liebert NX 40kVA UPS. During the PM, faulty batteries were detected and recommended for replacement.
Preliminary Actions

As part of standard PM protocols, the CPP reviewed alarms and unit performance; recorded measurements for line input/output, bypass, and battery voltages and currents; verified meter calibrations; performed infrared temperature checks; and inspected fans for proper operation.

While measuring battery system line voltages, currents, and ohmic values, the CPP identified four weak and/or failing batteries.

Resolution The CPP recommended immediate replacement. Had the failing batteries gone undetected, those batteries could have brought down the entire string and ultimately, the entire UPS system.
Root Cause Through regular routine maintenance, this issue was detected in the very early stages, and as a result, had minimal impact to the customer.
Additional Reading

For a common list of questions to ask when receiving quotes from multiple service providers, visit us at:

https://nationwidepower.com/news/case-study-125-preventive-maintenance-only-vs-full-service-contract-schneider-electric/

https://nationwidepower.com/news/case-study-124-preventive-maintenance-only-vs-full-service-contract-liebert-ap367-75kva/

 

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.

Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

Latest News

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies (UPS) and UPS batteries. Our 57,000 square foot warehouse, with over $10 million in parts and...

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October 15, 2020

"Brian is always professional and makes sure to explain things. Never send anyone other than him please."

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Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies (UPS) and UPS batteries. Our 57,000 square foot warehouse, with over $10 million in parts and equipment inventory, provides us the ability to service nearly all major makes and models of UPS equipment.

In this case study, a customer had regularly scheduled preventive maintenance (PM) with Nationwide Power for their Liebert Npower UPS system. The Critical Power Professional™ (CPP™) proactively identified faulty component parts, which prevented a possible future alarm and critical load loss.

Product Liebert Npower UPS
Application Medical Center
Synopsis A Critical Power Professional™ (CPP™) conducted regularly scheduled preventive maintenance on the customer’s Liebert Npower UPS. During the minor PM, the CPP found the control wire to the static switch B phase control to be burnt and discolored with an abnormal temperature reading.
Preliminary Actions

The faulty component parts were identified through visual inspection during a routine minor PM, while the unit was still online. The Critical Power Professional found a static switch B phase control wire burnt and bus bar discolored, along with a 141° temperature reading.

Parts were ordered, shipped, and replaced with minimal downtime to the UPS system and to the critical load.

Resolution As a result of routine maintenance by a qualified professional, the issue was caught early and resolved before resulting in an alarm and/or potential critical failure and load loss.
Root Cause

There should be no substitution for routine preventive maintenance on critical power equipment. Monitoring systems, no matter how thorough or expensive, would not have detected this.

If this situation had gone undetected, especially since the faulty wires were associated with the static switch, it could have resulted in complete system failure and resulting load loss.

Additional Reading

For a common list of questions to ask when receiving quotes from multiple service providers, visit us at:

https://nationwidepower.com/news/case-study-125-preventive-maintenance-only-vs-full-service-contract-schneider-electric/

https://nationwidepower.com/news/case-study-124-preventive-maintenance-only-vs-full-service-contract-liebert-ap367-75kva/

 

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.

Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

Latest News

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies (UPS) and UPS batteries. Our 57,000 square foot warehouse, with over $10 million in parts and...

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October 15, 2020

"Brian is always professional and makes sure to explain things. Never send anyone other than him please."

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Case Study #143 | Eaton 9395 450kVA

Case Study #143 | Eaton 9395 450kVA

Case Study

Case Study #143 | Eaton 9395 450kVA

 

Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies and UPS batteries. Our 57,000 square foot warehouse, with over $10 million in parts and equipment inventory, provides us the ability to service nearly all major makes and models of UPS equipment.

Additionally, Nationwide Power has built strong relationships with each of the original equipment manufacturers (OEMs) over the past two decades, allowing for the best possible support for our customers.

In this case study, a customer’s Eaton 9395 450kVA UPS system was in alarm. In collaboration with Eaton, the OEM, the issue was fully resolved within just 48 hours, and with no out-of-pocket expense to the customer.

 

Product Eaton 9395 450kVA
Application Aerospace and Defense Technology Company
Synopsis

A contracted customer called the 24/7 technical support line to report an Eaton 9395 450kVA UPS system in alarm status. After initial troubleshooting, Nationwide Power engaged the OEM. Thanks to the strong OEM relationships our team has established over the years, our customers have confidence in knowing that their equipment will be serviced in the best possible manner, which sometimes requires OEM involvement.

Since the customer had a full-service contract with Nationwide Power, all expenses to repair the unit were covered by Nationwide Power, including the three OEM site visits.

Preliminary Actions

On a technical support call, a Nationwide Power Critical Power Professional™ conducted initial troubleshooting and found the universal power module (UPM) 2 to be offline and DC current in limited condition.

At this point, the OEM was engaged and arrived on site the same day. The Eaton Customer Service Engineer (CSE) determined that a wiring harness had been rubbing against a fan blade that shorted out the harness and caused a DC overcurrent on UPM 2. Parts were ordered for next day delivery, and the Eaton CSE returned the next day to complete the repair.

After replacing the bad harness, the positive DC current was still measuring high. After further troubleshooting, it was determined that the DC link current transformer (CT) was damaged after they shorted out. Additional parts were ordered, and the OEM returned for a third site visit for final repair.

Resolution

Replacement parts were shipped with priority service. Once the damaged CT was replaced, all alarms were cleared. Preventive maintenance (PM) was performed and the Eaton 9395 450kVA UPS was calibrated. There were no further issues and the UPS was left online and supporting the critical load.

Occasionally, it is necessary to engage the OEM during a service call, either due to proprietary software or escalated repair needs. Over the past two decades, Nationwide Power has been committed to building strong relationships with all major OEMs, in an effort to provide a seamless service to our customers.

Whenever an OEM is engaged under a full-service contract, there is no out-of-pocket cost to the customer.

Root Cause

From time to time, at no fault to the customer, component parts in a UPS system fail.

Because this customer has a full-service contract with Nationwide Power, the customer had no out-of-pocket expenses, which otherwise would have included time and material for the original troubleshoot, shipping expense, and the additional cost to engage the OEM.

Additional Reading

Not all critical service providers have made the commitment to building strong relationships with each of the OEMs they support. As a result, there may be times when these service providers attempt to self-perform tasks that should require OEM engagement.

For a common list of questions to ask when receiving quotes from multiple service providers, visit us at:

https://nationwidepower.com/news/case-study-127-read-the-fine-print/

https://nationwidepower.com/news/why-size-matters/

 

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.

Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

Latest News

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies (UPS) and UPS batteries. Our 57,000 square foot warehouse, with over $10 million in parts and...

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October 15, 2020

"Brian is always professional and makes sure to explain things. Never send anyone other than him please."

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Case Study # 141 | APC Symmetra LX Power Module Replacement

Case Study # 141 | APC Symmetra LX Power Module Replacement

Case Study

Case Study # 141 | APC Symmetra LX Power Module Replacement

 

Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies and UPS batteries. Our 57,000 square foot warehouse, with over $10 million in parts and equipment inventory, provides us the ability to service nearly all major makes and models of UPS equipment, even UPS equipment that OEM’s themselves may deem obsolete.

In this case study, we highlight a service call from a contracted customer who needed assistance on their APC Symmetra LX UPS equipment. With no out-of-pocket expense to the customer, we were able to troubleshoot, expedite parts shipment, and be on site for full resolution by the following business day.

Product APC Symmetra LX
Application Marketing & Advertising Agency
Synopsis

A contracted customer called the 24/7 Technical Support line at Nationwide Power, a service offered to all contracted customers. This support call was in reference to the customer’s APC Symmetra LX UPS, which was in an alarm status.

With quick action and immediate access to all necessary parts inventory, the customer’s issue was fully resolved, and their UPS equipment was back online by the next business day.

Preliminary Actions

Through our 24/7 Technical Support line, a Critical Power Professional™ was able to troubleshoot remotely and identify a faulty power module as the cause of the alarm.

This process saved the customer downtime, as we were able to quickly identify the cause of the alarm without a physical trip to the site location.

Resolution A replacement power module for the APC Symmetra LX was ordered from the Nationwide Power warehouse and scheduled to arrive the following day. Once the part delivery was confirmed, the Critical Power Professional™ scheduled an immediate site visit for installation
Root Cause Occasionally, at no fault to the customer, component parts in UPS units fail. Because this customer has a full-service contract with Nationwide Power, all time and materials to resolve the failure is covered by Nationwide Power, with no out-of-pocket expense to the customer.
Additional Reading Emergency Service on an Eaton 93PM 16kVA UPS

 

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.

Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

Latest News

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies (UPS) and UPS batteries. Our 57,000 square foot warehouse, with over $10 million in parts and...

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October 15, 2020

"Brian is always professional and makes sure to explain things. Never send anyone other than him please."

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Case Study # 140 | Eaton 9PX – Installation Error by Competitor

Case Study # 140 | Eaton 9PX – Installation Error by Competitor

Case Study

Case Study # 140 | Eaton 9PX – Installation Error by Competitor

 

Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies and UPS batteries, along with supporting other critical power components such as emergency generators, switch gear, and HVAC. We publish critical power related case studies, highlighting best practices and quality standards.

At Nationwide Power, we believe strongly in providing quality service for our customers, and periodically, we try to educate businesses on the value of selecting a qualified service provider.

In this case study, we highlight a service call from a non-contracted customer who needed assistance on several Eaton 9PX systems. The original service provider (not Nationwide Power) incorrectly installed the UPS units, and then became unresponsive post-installation.

 

Product Eaton 9PX
Application Technology Company
Synopsis

Nationwide Power was contacted for assistance after a previous service provider improperly installed several 9PX UPS units, causing intermittent system failure. The previous service company became unresponsive post-installation and was either unable or unwilling to provide resolution.

A Nationwide Power Critical Power Professional™ (CPP™) arrived on site and discovered that the Eaton 9PX units fed to robot tools upstairs. The robots perform an acid wash for a semiconductor wafer process and were located in a clean room. The customer said that the robot input voltage drops to about 90 Vac, which causes the low-voltage power supplies to drop out (+12, -12, +24, -24, various low voltages used by the robotic equipment to perform their unique functions). The UPS was setup as a 208 in/208 out configuration and they were told by the previous critical power company that they required an output transformer so the robot equipment would not see the voltage drop. The external transformer was configured for a 208 Vac in and a 208 Vac output.

The CPP™ noted this as a classic example of the “Single Phase 208 Vac” problem with the “Low Leg (88 Vac from line 1 neutral)”.

With over 22+ years of average industry experience, our Critical Power Professionals are among the most experienced in the industry and have completed an extensive and comprehensive training curriculum spanning all major UPS manufacturers.

Preliminary Actions The solution was tested on the first system that was offline, which included switching the output of the transformer to 240Vac single phase (which provided 120Vac from each phase to neutral), configuring input voltage accordingly, and then restarting the system. Once the solution was tested and confirmed, and the UPS system was no longer failing, the solution was applied to the remaining UPS systems.
Resolution Input/output configuration was corrected and, as a result, all UPS systems were fully operational.
Root Cause

The root cause of this situation was poor workmanship performed by the original service provider, as the original service provider failed to complete the scope of work for the Eaton 9PX UPS installation.

At Nationwide Power, we take the work we do very seriously and place a lot of value on completing projects completely and without error the first time, avoiding any headaches for our customers down the road. We follow the principles of Philip Crosby closely, measuring quality by a zero-defect environment. Choosing a well-qualified, reputable critical power service provider would have eliminated the need for rework for this customer.

Additional Reading Case Study #138: Powerware 9315 Repair (End-of-Life)

 

Nationwide Power provides 24/7/365 technical support to ensure that everything operates and transitions successfully before, during, and after any power outage.

Request a quote Call | 800-868-2780 E-Mail

We are your critical power infrastructure partner!

Latest News

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study #144 | Early Detection on Liebert Npower Faulty Wires

Case Study Nationwide Power™ is the leading provider in the critical power supply industry. Our core business is the sales and service of uninterruptible power supplies (UPS) and UPS batteries. Our 57,000 square foot warehouse, with over $10 million in parts and...

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October 15, 2020

"Brian is always professional and makes sure to explain things. Never send anyone other than him please."

View All - Stacie O
Illinois

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