Case Study #156 | Importance of Following Age Based Recommendations

Case Study #156 | Importance of Following Age Based Recommendations

Case Study

Case Study #156 | Importance of Following Age Based Recommendations

In this Nationwide Power™ (NP™) case study, we highlight the importance of following your service provider’s age-based components. The most common age-based components are batteries (every 3-5 years), fans (every 5 years), capacitors (every 5-7 years), and air filters (annually as needed). This case study specifically looks at the GE SG Series 80kVA.

Product SG Series 80kVA UPS
Application Aeronautics
Synopsis An existing customer placed a service call stating their GE SG 80kVA had a blown fuse, the load was lost, and they could not get the unit into bypass.
Preliminary Actions Initial phone troubleshooting was not able to place the unit back online, so one of our Critical Power Professionals™ (CPPs™) was dispatched and on site in less than one hour.
Resolution

Upon arrival, our CPP found the unit was in maintenance bypass supporting the load. In the alarm history, there was a blown DC fuses alarm. He placed the unit into internal bypass and powered the unit off with the load in bypass.

Troubleshooting indicated that all battery fuses were good, however all 6 DC capacitor fuses were blown. Checking the capacitor date code showed that the capacitors were manufactured in 2014 (8-years old). The age-based replacement recommendation for capacitors is manufacturer-specific, between 5-7 years.

Fortunately, Nationwide Power made age-based recommendations to replace the DC capacitors and all fans from prior maintenance inspections. The customer followed our expert advice, and the DC capacitors and fans were already on site waiting for a maintenance window to install.

As a precaution, the CPP also requested that a replacement power interface board and rectifier board be sent to the site, in the event they were also damaged at the time of failure. This would minimize the risk of a return trip and increased downtime in the event there was additional damage.

All parts were replaced during a maintenance window and the UPS was placed back online and supporting the load.

Root Cause

Following the timely replacement of your service provider’s age-based recommendations is critical to minimizing unnecessary downtime. Too often, the downtime incurred will cost more than the recommended replacements. While not perfect in timing, having parts on site and ready to be replaced at least reduced the downtime in this case.

Preventive maintenance and age-based recommendations are meant to PREVENT costly downtime.

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 #156 | Importance of Following Age Based Recommendations

Case Study #156 | Importance of Following Age Based Recommendations

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of following your service provider’s age-based components. The most common age-based components are batteries (every 3-5 years), fans (every 5 years), capacitors (every 5-7 years), and...

Case Study #155 | Knowing Your Infrastructure

Case Study #155 | Knowing Your Infrastructure

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of knowing what your electrical infrastructure is, and what is supported by your UPS. This case study specifically looks at the Eaton Powerware 9330-15kVA UPS. Product 9330-15kVA UPS...

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...

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"Craig was very helpful and informative. I greatly appreciate him! Thank you, Nationwide Power. Dan was also awesome in assisting before Craig came."

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Case Study #155 | Knowing Your Infrastructure

Case Study #155 | Knowing Your Infrastructure

Case Study

Case Study #155 | Knowing Your Infrastructure

In this Nationwide Power™ (NP™) case study, we highlight the importance of knowing what your electrical infrastructure is, and what is supported by your UPS. This case study specifically looks at the Eaton Powerware 9330-15kVA UPS.

Product 9330-15kVA UPS
Application 911 Center
Synopsis An existing customer placed a service call stating their Eaton 9330 UPS went into bypass and that there was an electrical smell in the room.
Preliminary Actions Initial phone troubleshooting was not able to place the unit back online, so one of our Critical Power Professionals™ (CPPs™) was dispatched to the site.
Resolution

Upon arrival, our CPP began troubleshooting and found the unit in maintenance bypass. A visual inspection showed nothing outstanding. After downloading the alarm history, multiple overload alarms were logged with some above 125%.

Further review of the load on the UPS identified laser printers, air purifiers, and shredders plugged into receptacles supported by the UPS. Once these non-essential loads were removed from the UPS, there were no more overload issues.

To avoid a possible return call, the CPP also performed a load test on the batteries while onsite, which all batteries passed.

As for the electrical smell the customer identified, it was not related to the UPS and possibly came from another piece of equipment in the room.

Root Cause

Without knowing what the electrical infrastructure/receptacles supported by the UPS are, as well as connecting non-essential equipment into UPS supported receptacles, a business is opening themselves up to possible downtime and costly repairs.

It is also best practice to track data over time during maintenance inspections to look for any trends. The PM inspection prior to this visit showed normal loads on the UPS.

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 #156 | Importance of Following Age Based Recommendations

Case Study #156 | Importance of Following Age Based Recommendations

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of following your service provider’s age-based components. The most common age-based components are batteries (every 3-5 years), fans (every 5 years), capacitors (every 5-7 years), and...

Case Study #155 | Knowing Your Infrastructure

Case Study #155 | Knowing Your Infrastructure

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of knowing what your electrical infrastructure is, and what is supported by your UPS. This case study specifically looks at the Eaton Powerware 9330-15kVA UPS. Product 9330-15kVA UPS...

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...

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October 24, 2022

"Craig was very helpful and informative. I greatly appreciate him! Thank you, Nationwide Power. Dan was also awesome in assisting before Craig came."

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Florida

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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 #156 | Importance of Following Age Based Recommendations

Case Study #156 | Importance of Following Age Based Recommendations

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of following your service provider’s age-based components. The most common age-based components are batteries (every 3-5 years), fans (every 5 years), capacitors (every 5-7 years), and...

Case Study #155 | Knowing Your Infrastructure

Case Study #155 | Knowing Your Infrastructure

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of knowing what your electrical infrastructure is, and what is supported by your UPS. This case study specifically looks at the Eaton Powerware 9330-15kVA UPS. Product 9330-15kVA UPS...

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...

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October 24, 2022

"Craig was very helpful and informative. I greatly appreciate him! Thank you, Nationwide Power. Dan was also awesome in assisting before Craig came."

View All - Jovanna N
Florida

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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 #156 | Importance of Following Age Based Recommendations

Case Study #156 | Importance of Following Age Based Recommendations

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of following your service provider’s age-based components. The most common age-based components are batteries (every 3-5 years), fans (every 5 years), capacitors (every 5-7 years), and...

Case Study #155 | Knowing Your Infrastructure

Case Study #155 | Knowing Your Infrastructure

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of knowing what your electrical infrastructure is, and what is supported by your UPS. This case study specifically looks at the Eaton Powerware 9330-15kVA UPS. Product 9330-15kVA UPS...

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...

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October 24, 2022

"Craig was very helpful and informative. I greatly appreciate him! Thank you, Nationwide Power. Dan was also awesome in assisting before Craig came."

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Florida

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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 #156 | Importance of Following Age Based Recommendations

Case Study #156 | Importance of Following Age Based Recommendations

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of following your service provider’s age-based components. The most common age-based components are batteries (every 3-5 years), fans (every 5 years), capacitors (every 5-7 years), and...

Case Study #155 | Knowing Your Infrastructure

Case Study #155 | Knowing Your Infrastructure

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of knowing what your electrical infrastructure is, and what is supported by your UPS. This case study specifically looks at the Eaton Powerware 9330-15kVA UPS. Product 9330-15kVA UPS...

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...

Newsletter Signup

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



Solutions

Feedback

October 24, 2022

"Craig was very helpful and informative. I greatly appreciate him! Thank you, Nationwide Power. Dan was also awesome in assisting before Craig came."

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Florida

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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 #156 | Importance of Following Age Based Recommendations

Case Study #156 | Importance of Following Age Based Recommendations

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of following your service provider’s age-based components. The most common age-based components are batteries (every 3-5 years), fans (every 5 years), capacitors (every 5-7 years), and...

Case Study #155 | Knowing Your Infrastructure

Case Study #155 | Knowing Your Infrastructure

Case StudyIn this Nationwide Power™ (NP™) case study, we highlight the importance of knowing what your electrical infrastructure is, and what is supported by your UPS. This case study specifically looks at the Eaton Powerware 9330-15kVA UPS. Product 9330-15kVA UPS...

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...

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Feedback

October 24, 2022

"Craig was very helpful and informative. I greatly appreciate him! Thank you, Nationwide Power. Dan was also awesome in assisting before Craig came."

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Florida

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