Case Study #154 | Check Battery Alarm

Case Study #154 | Check Battery Alarm

Case Study

Case Study #154 | Check Battery Alarm

In this Nationwide Power™ (NP™) case study, we show the importance of regularly scheduled maintenance inspections and replacements of age-based components. This case study focuses specifically on the replacement of batteries on a Best FerrUPS FE18kVA.

An existing time and materials (T&M) customer who chooses to operate on a “break/fix” maintenance program placed a service call after their “Check Battery” alarm came on. This customer has used NP for a few years and has always acted on the advice of our age-based replacements, although not always in a timely manner.

Product Best FerrUPS FE18kVA
Application Security Company
Synopsis The customer noticed an active “Check Battery” alarm on the UPS display. The customer proceeded to place a T&M call to our service team.
Preliminary Actions A Critical Power Professional™ (CPP™) was dispatched to the site where the CPP found that several batteries were “open” and posed a severe risk of thermal runaway/fire. The UPS battery date code showed that the batteries were 7 years old. This is 2 years passed the typical replacement age, however the customer tried to stretch the life and budget of the batteries.
Resolution The customer was provided with a full-string replacement quote and expedited a purchase order to have the batteries replaced. Fortunately, all batteries were successfully replaced, there were no safety issues or harm caused to any employees, and no critical loads were lost as a result. The customer will be set until the next scheduled battery cycle changeout in 3-5 years.
Root Cause “Break/fix” maintenance plans and trying to stretch the life of critical components often expose customers to greater risk and higher costs. Had these batteries reached thermal runaway, the cost and damage of the fire would have greatly exceeded the cost of an annual preventive maintenance inspection each year.
Additional Reading

https://nationwidepower.com/news/case-study-145-another-reason-why-preventive-maintenance-is-so-important-liebert-nx-40kva/

https://nationwidepower.com/news/case-study-146-when-to-upgrade-or-repair-a-ups-system-eaton-9315-ups-system/

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 #154 | Check Battery Alarm

Case Study #154 | Check Battery Alarm

Case StudyIn this Nationwide Power™ (NP™) case study, we show the importance of regularly scheduled maintenance inspections and replacements of age-based components. This case study focuses specifically on the replacement of batteries on a Best FerrUPS FE18kVA. An...

Top Workplace of 2022

Top Workplace of 2022

News Article Corks popping and fireworks fireworkin’. That’s the sound of our team celebrating! Each year, approximately 1,500 companies are invited to compete for a spot on the “Top Workplaces” list . The process is extensive and relies on anonymous surveys and...

Case Study #153 | DIRFT (Doing It Right the First Time)

Case Study #153 | DIRFT (Doing It Right the First Time)

Case StudyNationwide Power™ (NP™) 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...

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Case Study #153 | DIRFT (Doing It Right the First Time)

Case Study #153 | DIRFT (Doing It Right the First Time)

Case Study

Case Study #153 | DIRFT (Doing It Right the First Time)

Nationwide Power™ (NP™) 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, NP 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, we highlight the importance of having a service provider that is committed to quality by “Doing It Right the First Time.” This case study specifically looks at an Eaton/Powerware 9315-300kVA UPS.

Product Eaton/Powerware 9315-300kVA UPS
Application Medical
Synopsis The customer requested onsite support for a Critical Power Professional™ (CPP™) to check the battery connections on an Eaton/Powerware 9315-300kVA UPS that recently had them replaced by a different vendor.
Preliminary Actions

Upon inspection of the UPS batteries, the CPP found the following conditions left by the other service provider’s installer:

  • All cables were not torqued using a torque wrench
  • Most cables were considerably below required torque
  • Cable lugs were not cleaned before installing
  • One lug was visibly corroded and not cleaned before use
  • All battery posts were not cleaned before installation
  • All battery posts were oxidized and should have been cleaned
  • No oxidation resistant grease was used before installing the battery lugs to the battery posts
  • Cables were turned different directions making normal maintenance exceedingly difficult
Resolution

After thoroughly documenting the findings and informing the customer, the CPP performed the re-installation that includes the following:

  • Removed all battery cables and cleaned lugs
  • Cleaned all battery posts
  • Used antioxidant grease that is specially formulated for batteries on all battery posts
  • Using a calibrated torque wrench, aligned battery cables properly and torqued battery connection hardware to original equipment manufacturer (OEM) specifications
  • Using a torque seal indicator marker, marked all battery posts as torqued
  • Re-assembled all battery tray connections
  • Recorded battery string AC current on both battery strings
  • Cleaned the area and updated the onsite electrician
  • UPS was left online and supporting all critical loads
Root Cause

The customer’s Eaton/Powerware 9315-300kVA UPS is covered by an NP full-service contract. However, to save money by going with the lowest-priced bidder, the battery replacement was awarded to and performed by a different vendor. Since Nationwide Power did not perform the initial battery replacement, the work performed to bring the UPS and UPS batteries back to factory specifications became billable and was not covered under the full-service contract.

The added cost ended up equaling or exceeding the amount that was saved by going with the lowest-priced bidder. Because the UPS is under a full-service agreement with NP, the UPS battery replacement would have been done right the first time to avoid risk of downtime, dropping the critical load, and adding otherwise avoidable expenses to NP and the customer.

Additional Reading

https://www.prnewswire.com/news-releases/finding-the-right-ups-service-provider-read-the-fine-print-300717713.html

https://nationwidepower.com/news/case-study-140-eaton-9px-installation-error-by-competitor/

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 #154 | Check Battery Alarm

Case Study #154 | Check Battery Alarm

Case StudyIn this Nationwide Power™ (NP™) case study, we show the importance of regularly scheduled maintenance inspections and replacements of age-based components. This case study focuses specifically on the replacement of batteries on a Best FerrUPS FE18kVA. An...

Top Workplace of 2022

Top Workplace of 2022

News Article Corks popping and fireworks fireworkin’. That’s the sound of our team celebrating! Each year, approximately 1,500 companies are invited to compete for a spot on the “Top Workplaces” list . The process is extensive and relies on anonymous surveys and...

Case Study #153 | DIRFT (Doing It Right the First Time)

Case Study #153 | DIRFT (Doing It Right the First Time)

Case StudyNationwide Power™ (NP™) 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...

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June 30, 2022

"Joseph was very kind over the phone and in person. He was very knowledgeable and willing to answer any questions I had."

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Kansas

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Case Study #152 | The Importance of the Critical Power Environment

Case Study #152 | The Importance of the Critical Power Environment

Case Study

Case Study #152 | The Importance of the Critical Power Environment

In this Nationwide Power™ Case Study, we show the importance of a controlled environment and how one can never be over-prepared for the unexpected. This case study specifically looks at the Eaton/Powerware 9330-30kVA UPS.

Product Eaton/Powerware 9330-30kVA UPS
Application Distribution
Synopsis Our Critical Power Professional (CPP™) was onsite for age-based full capacitor and fan replacements. After completing the installation and trying to bring the unit back online, the display had no characters, and the unit would not come back online.
Preliminary Actions After some initial troubleshooting and tracing back from the display, the CPP™ found that a lizard had shorted out the power supply and damaged the display board.
Resolution The CPP™ ordered a replacement power supply and display boards for next-day delivery. After replacing both boards, the CPP™ was able to bring the unit back online. With a full-service contract to stand behind, the customer was able to secure parts and labor for next-day installation.
Root Cause Component failure was caused by an external source, in this case a lizard that was most likely searching for warmth. From time to time, and in different geographic regions, we encounter some unique environmental situations. Some of these can be prevented with strict environment controls, while others can be more challenging. Use best practices to keep your critical electrical equipment safe.
Additional Reading

https://nationwidepower.com/news/case-study-133-overheated-ups-batteries-in-eaton-93e-30kva/

https://nationwidepower.com/news/case-study-147-what-could-possibly-go-wrong-eaton-9330-15kva/

 

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 #154 | Check Battery Alarm

Case Study #154 | Check Battery Alarm

Case StudyIn this Nationwide Power™ (NP™) case study, we show the importance of regularly scheduled maintenance inspections and replacements of age-based components. This case study focuses specifically on the replacement of batteries on a Best FerrUPS FE18kVA. An...

Top Workplace of 2022

Top Workplace of 2022

News Article Corks popping and fireworks fireworkin’. That’s the sound of our team celebrating! Each year, approximately 1,500 companies are invited to compete for a spot on the “Top Workplaces” list . The process is extensive and relies on anonymous surveys and...

Case Study #153 | DIRFT (Doing It Right the First Time)

Case Study #153 | DIRFT (Doing It Right the First Time)

Case StudyNationwide Power™ (NP™) 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...

Newsletter Signup

Sign up below to stay informed with latest industry trends, products, and news.



Solutions

Feedback

June 30, 2022

"Joseph was very kind over the phone and in person. He was very knowledgeable and willing to answer any questions I had."

View All - Rachel J
Kansas

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Case Study #151 | The Cost of Deferred Maintenance

Case Study #151 | The Cost of Deferred Maintenance

Case Study

Case Study #151 | The Cost of Deferred Maintenance

In this Nationwide Power™ Case Study, we show the importance of performing preventive maintenance and completing recommendations. This case study is about a Mitsubishi 9900A 150kVA UPS.

After several attempts over the course of many months trying to schedule the first major preventive maintenance inspection (PM), a new customer finally responded by placing an emergency call indicating that there was smoke coming from their uninterruptible power supply (UPS).

Product Mitsubishi 9900A 150kVA UPS
Application Communications/Technology
Synopsis The customer was notified by the original equipment manufacturer (OEM) of an AC capacitor recall, which was covered under warranty at no cost. For over a year, the customer did not respond to the OEM to take corrective action, and as a result the AC capacitors failed. This caused smoke, damage, and forced the UPS into bypass, putting their critical load at risk to downtime.
Preliminary Actions A Critical Power Professional™ (CPP™) was dispatched to the site for the first time since this was a new customer. Upon arrival, the CPP found the UPS against a wall with no rear access and was unable to remove the rear panels for proper inspection. The customer was notified that the UPS requires three feet of rear clearance and the CPP returned two days later, after rear access clearance had been provided.
Resolution After the customer cut the wall open behind the UPS for access, the CPP was able to remove the rear panels where a visual inspection presented damage to 3 of the 4 capacitor assemblies. The CPP then shut the UPS down with the load on maintenance bypass. The OEM was onsite two days later and replaced the recalled capacitors, followed by the CPP performing the major PM.
Root Cause Often, businesses choose to defer maintenance for a variety of reasons. In this case study, a deferred recall preceded a PM that may have identified the failing capacitors and avoided an outage. Additionally, the UPS was installed with no rear access, significantly increasing the time to repair. Fortunately, the section of wall that needed to be removed was not a block or exterior wall.
In this scenario, it is reasonable to expect that the customer would have avoided all the risk for downtime and costs of having a unit on bypass had the recall been performed. Additionally, the failing capacitors and lack of rear access that hindered the repair would have been identified sooner had Nationwide Power been allowed to perform the major PM.
Additional Reading

https://nationwidepower.com/news/case-study-150-the-importance-of-prevention

https://nationwidepower.com/news/case-study-145-another-reason-why-preventive-maintenance-is-so-important-liebert-nx-40kva/

 

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 #154 | Check Battery Alarm

Case Study #154 | Check Battery Alarm

Case StudyIn this Nationwide Power™ (NP™) case study, we show the importance of regularly scheduled maintenance inspections and replacements of age-based components. This case study focuses specifically on the replacement of batteries on a Best FerrUPS FE18kVA. An...

Top Workplace of 2022

Top Workplace of 2022

News Article Corks popping and fireworks fireworkin’. That’s the sound of our team celebrating! Each year, approximately 1,500 companies are invited to compete for a spot on the “Top Workplaces” list . The process is extensive and relies on anonymous surveys and...

Case Study #153 | DIRFT (Doing It Right the First Time)

Case Study #153 | DIRFT (Doing It Right the First Time)

Case StudyNationwide Power™ (NP™) 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...

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June 30, 2022

"Joseph was very kind over the phone and in person. He was very knowledgeable and willing to answer any questions I had."

View All - Rachel J
Kansas

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Case Study #150 | The Importance of Prevention

Case Study #150 | The Importance of Prevention

Case Study

Case Study #150 | The Importance of Prevention

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.

In this case study, we highlight batteries in a Liebert NXb, in which the Critical Power Professional™ found loose battery connections during a routine preventive maintenance (PM) inspection.

Product Liebert NXb UPS
Application Manufacturing Data Center
Synopsis During the first visit with a new customer, a regularly scheduled minor battery PM inspection was performed by the Critical Power Professional (CPP™), who identified three batteries that load tested as weak.
Preliminary Actions

Part of the CPP’s standard procedure for performing preventive battery maintenance is to load test each battery. While batteries may show correct voltages with a standard Fluke meter, placing a battery under load will identify true cell integrity and any degradation weaknesses.

With the CPP measuring battery system voltages, currents, and ohmic values, a final load test of each battery identified three batteries load testing under 60% (56%, 41%, 17% respectively).

Resolution

Upon further inspection of the three weaker load tested batteries, the CPP found that all three batteries had loose battery cable connections, one of which was only finger tight. After torquing to the correct battery hardware specifications, the batteries were load tested again and readings were in acceptable ranges.

Since the customer was under an emergency service contract with Nationwide Power, this preventive maintenance inspection was part of the included coverage and there was no out-of-pocket expense to the customer.

Root Cause The battery connections were improperly torqued by the previous service provider. As a result of routine preventive maintenance inspections, system load loss was avoided. Additionally, loose connections could have caused excessive resistance/heat, leading to a possible “thermal condition” or fire.
Additional Reading

https://nationwidepower.com/news/case-study-145-another-reason-why-preventive-maintenance-is-so-important-liebert-nx-40kva/

ttps://nationwidepower.com/news/case-study-133-overheated-ups-batteries-in-eaton-93e-30kva

 

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 #154 | Check Battery Alarm

Case Study #154 | Check Battery Alarm

Case StudyIn this Nationwide Power™ (NP™) case study, we show the importance of regularly scheduled maintenance inspections and replacements of age-based components. This case study focuses specifically on the replacement of batteries on a Best FerrUPS FE18kVA. An...

Top Workplace of 2022

Top Workplace of 2022

News Article Corks popping and fireworks fireworkin’. That’s the sound of our team celebrating! Each year, approximately 1,500 companies are invited to compete for a spot on the “Top Workplaces” list . The process is extensive and relies on anonymous surveys and...

Case Study #153 | DIRFT (Doing It Right the First Time)

Case Study #153 | DIRFT (Doing It Right the First Time)

Case StudyNationwide Power™ (NP™) 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...

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June 30, 2022

"Joseph was very kind over the phone and in person. He was very knowledgeable and willing to answer any questions I had."

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Kansas

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Case Study #149 | The Additional Hidden Costs of Choosing the Lowest Price

Case Study #149 | The Additional Hidden Costs of Choosing the Lowest Price

Case Study

Case Study #149 | The Additional Hidden Costs of Choosing the Lowest Price

In this Nationwide Power™ case study, we show the importance of having a qualified Critical Power Professional™ (CPP™) perform maintenance on your critical infrastructure equipment. This case study specifically looks at the Liebert NX 120kVA UPS.

A Nationwide Power CPP was onsite to perform a regularly scheduled preventive maintenance (PM) inspection. During the PM inspection, the CPP noticed that the input voltages were running high, and the output voltages were unbalanced.

Product Liebert NX 120kVA UPS
Application Medical Facility
Synopsis During a regularly scheduled PM inspection, high input and unbalanced output readings were found. To further troubleshoot, the uninterruptible power supply (UPS) was placed into maintenance bypass to observe the voltages. No changes were observed and as the unit was being transferred back out of bypass, a short buzzing sound was heard. The transfer had failed, and the critical load was lost.
The downtime was further extended because the failure cleared a fuse in the maintenance bypass panel. Site electricians were called in to help repair the bypass panel. After several hours, a replacement fuse was found and installed, and the maintenance bypass was operational again.
Preliminary Actions A Critical Power Professional™ (CPP™)initiated troubleshooting and found 3 blown output fuses, 3 failed static switch silicon controlled rectifiers (SCRs), and a possible bad SCR driver board. Parts were ordered and shipped from Nationwide Power’s inventory via next day air. Upon returning to the site to repair, the CPP replaced all the parts that were ordered. Continuing the troubleshoot, the CPP focused on the output capacitor section, based upon the output voltage symptoms. Additionally, the output capacitors were recently replaced by another vendor who was awarded the job based upon lowest price, and therefore seemed like a logical place to start.
Resolution After in-depth troubleshooting and removing UPS covers, the CPP was able to determine that the capacitor pan assembly wiring harness plug was not plugged into the UPS. After plugging the capacitor pan connector into the UPS and returning all other parts that were removed, the UPS was restarted, with customer approval, and placed back online in normal mode.
Root Cause Human error caused by a simple electrical connection not being completed.
Even though Nationwide Power was the service provider contracted to maintain the customer’s critical power infrastructure, a lower price option was selected to replace the UPS capacitors. The quality of service, or lack thereof by the other vendor resulted in the “lowest price” costing an additional $5,000 in repairs. The cost of downtime is not included.
Unfortunately, the lowest price is not always the best price, and true cost of total ownership.
Additional Reading

https://nationwidepower.com/news/case-study-145-another-reason-why-preventive-maintenance-is-so-important-liebert-nx-40kva/

https://nationwidepower.com/news/case-study-146-when-to-upgrade-or-repair-a-ups-system-eaton-9315-ups-system/

 

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 #154 | Check Battery Alarm

Case Study #154 | Check Battery Alarm

Case StudyIn this Nationwide Power™ (NP™) case study, we show the importance of regularly scheduled maintenance inspections and replacements of age-based components. This case study focuses specifically on the replacement of batteries on a Best FerrUPS FE18kVA. An...

Top Workplace of 2022

Top Workplace of 2022

News Article Corks popping and fireworks fireworkin’. That’s the sound of our team celebrating! Each year, approximately 1,500 companies are invited to compete for a spot on the “Top Workplaces” list . The process is extensive and relies on anonymous surveys and...

Case Study #153 | DIRFT (Doing It Right the First Time)

Case Study #153 | DIRFT (Doing It Right the First Time)

Case StudyNationwide Power™ (NP™) 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...

Newsletter Signup

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Feedback

June 30, 2022

"Joseph was very kind over the phone and in person. He was very knowledgeable and willing to answer any questions I had."

View All - Rachel J
Kansas

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