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ALBR PRODUCTS
Who is Alber?
Established 1972
Based in Boca Raton Florida
We manufacture battery test equipment based on extensive experience in and knowledge about Battery design and Battery aging characteristics.
We are the Battery Test Experts!
Products
Our main products are: Battery Capacity Test Systems Cellcorder (Battery Multi-meter) Battery monitoring Systems
Presentation Outline
The need for our products
Battery Basics and why Batteries fail Early detection of failures
Because: Our equipment is the most reliable in detecting problems while there is still time to take corrective action. That is a Technical Fact!
Battery Basics
BASIC LEAD ACID CELL
PBO2
PB
ELECTROLYTE - H2SO4
Descargando
Cargando
+ 2H2O
Construccion de Baterias
PASTED PLATE
TYPICAL GRID
BATTERY TYPES
FLOODED Characterized by
abundance of free floating electrolyte
VRLA Battery Positive (dark) plates isolated from negative (gray) plates by absorbing mat that also holds the electrolyte
Colchoneta
WATER LOSSES
Once a cell is fully charged, the float current breaks down the water (H2O) in the electrolyte into hydrogen and oxygen gasses.
Hydrogen and oxygen gases leave the cell and water has to be added typically once a year for Lead Calcium cells.
BATTERY LIFE
All batteries have a finite life
BATTERY LIFE
Battery life is determined by how long it takes for the positive plates to corrode.
Corrosion is accelerated by high temperatures and high float voltages.
BATTERY FAILURE
The grid cross section narrows, causing high internal resistance The grid structure grows, causing paste to lose contact with it, further resulting in high internal resistance
Examples:
Sulfation Post corrosion problems Copper contamination Hidden inter-cell problems Dryout
DRYOUT
This is strictly a VRLA failure mode VRLA also suffers from all the same failures as Vented Cells
PROBLEM
Discharge without recharge - Permanent damage (Hydration)
Copper Contamination
Initial loss of capacity, then abrupt failure of conduction path
POST CORROSION
POST CORROSION
Creep corrosion which leads to high resistance at post to inter cell connectors.
EFFECTS OF FAILURE
REDUCED BACKUP TIME ABRUPT FAILURE
Early Detection
How are Battery failures detected before they cause a costly system failure?
Early Detection
A Battery capacity test is the most accurate measurement of a batterys ability to perform Capacity testing realistically 1-3 years Batteries can fail in between capacity tests Cell resistance is a very reliable indicator of State of Health that can be monitored continuously
Because almost every single cell failure is preceded by an increase in the internal cell resistance
CONDUCTION PATH
When a battery supplies current to an external load, the current must travel through the following:
Terminal Post Strap Grid structure The connection between Grid and Paste Paste Electrolyte Separator
R2 represents the resistance that is in parallel with the Capacitor formed by the parallel plates C = 1.5 Farads per 100 A-Hr of battery capacity
R1~55%
R2~45%
AC Measurements
The Capacitor becomes a partial short circuit around part of the Resistance path and therefore masks problems that develop in the R2 path
R1~55%
R2~45%
Resistance = V/I
Cell Resistance
It has been shown that when a Cells resistance increases more than 25% above its baseline value, that Cell will not pass a 3 hour capacity test. It may pass an 8 hour capacity test but it will absolutely NOT pass a 30min capacity test
800
RESISTANCE
200
300 AMP-HR
400
500
RESISTANCE
120
115
110
600
700
800
900 AMP-HR
1000
1200
1400
1600
Our experience shows that at a 25% increase from baseline most batteries will not pass a 3 hour or shorter capacity test. Our recommendation is 25% --either replace or confirm with capacity test (single cell or full string). Batt. Mfgs.want fudge factor for inexperienced testers and their warranty normally states 50% increase in resistance.
Case Study
How does a failing cell look like and how can we detect and prevent a catastrophic failure? The following case study Illustrates how the Alber monitor detects a failing cell and how a discharge test confirm the internal resistance reading.
The 941 microohm value of Jar 41 is 22% higher than the other jars in the string and has triggered an alarm turning the bar red.
Playback
The following is an actual 20 min battery discharge test with the playback accelerated
It is a battery string consisting of 60 - 6 volt jars. One of the cells in jar 41 fails. Without the real time display ability during the test this failing cell would not have been detected prior to it becoming a hazard.
Jar 41
By 18 minutes, the charger has walked back in and there is 90 amps of charge current.
Without the internal resistance alarm, real time capture and storage, this failing cell would have been overlooked and left in service only to fail during an outage!
Albr Products
CRT-300 Cellcorder
Data Storing Battery Multi meter - Standardized By Many Large Companies Performs Internal And Intercell Resistance Tests Unlimited storing and communication capability Stores Specific Gravity And Temp. Readings Detailed Trending Analysis And Reporting Software
Automatic Operation No Supervision Required (Program & Go) Two Cells Can Be Tested Sequentially
Complements the Cellcorder by Capacity Testing Questionable Cells
Continuous Load Unit (CLU) product line easily interfaces with the BDS for performing IEEE capacity testing
Battery Monitors
BDS-256
Battery Diagnostic System
UL Certified CE Approved
Monitor any battery system up to 600 volts DC UPS systems Generating stations Industrial
BDS Controller
The Brain that control the system.
Collects and stores data from the DCMs Stand alone No on site PC required. 8 strings of 256 cells per Controller Internal memory that can hold 1 years worth of data
Configuration examples
1 controller Fiber optics for data transfer and 24VAC power supply between DCM and Controller
String 1
String 2
Configuration examples
1 controller
String 1
String 2
String 3
Configuration examples
Configuration examples
1 controller Fiber optics for data transfer and 24VAC power supply between DCM and Controller
String 1
String 2
Ease of Installation
Modular design allows the DCMs to be located near the battery, reducing wire lengths
One 120 vac power connection required for up to 8 strings of 256 cells.
BDS-256 Installation
BDS-256 Installation
BDS-256 Installation
BDS-256 Installation
BDS-256 Installation
Parameters Monitored
Overall voltage Discharge current Charger float current (optional) 2v cells, NiCad cells, 4v, 6v, 8v and 12v modules Temperature Resistance of all cell/jars, inter-cells, and intertiers
Communication
Two RS-232 for local computer RJ-11 for telco dial up RJ-45 for Ethernet connection Standard Modbus protocol
OPC Compliant
Computer Options
Lockable computer cabinet with desktop computer and optional printer
BDS-40
BDS-40 Base unit All-in-one controller, Data Collection Module and Load Module One per system. Can power up 5 Plus units 2 temperatures, 1 current transducer / string Customized harness for easy install Simplified setup 4 U high, 16 deep, 19 wide to be mounted on top of cabinet
BDS-40
BDS-40 Plus unit All-in-one Data Collection Module and Load Module Connects to Base unit via fiber optic cable One unit for cabinets 2-6 2 temperatures, 1 current transducer Customized harness for easy install Simplified setup 3 U high, 16 deep, 19 wide to be mounted on top of cabinet
BEFORE
AFTER
Executive summary and detailed reports Pop-up screens with real time data
Email alert
MPM-100
Designed for applications below 130VDC UL and CE approved More than 100 battery configurations available Monitors 1 string of 120VDC or up to 4 strings of 12, 24 or 48VDC
Modbus protocol Powered from DC bus or 115VAC Network, Serial, Modem connection options
MPM-100
Alber