Even though batteries are susceptible to premature failure, you can take steps to avoid it. In this article, we share five common causes of premature battery failure and how you can prevent it.
UPS batteries are electro-chemical devices that gradually lose their ability to store and deliver power over time. Despite proper maintenance, storage, and usage, they eventually need replacement when they reach their end-of-service life.
Typically, a Valve Regulated Lead Acid (VRLA) battery’s lifespan should be three to five years. However, environmental, chemical, and user-related impacts can significantly reduce a battery’s life. To maximize your UPS battery’s life, it’s crucial to avoid the following mistakes:
Unused Batteries that are Poorly Stored – Even when unused, a battery’s life decreases due to automatic small energy discharge. To extend a battery’s storage life, it’s recommended to charge it every three to four months and store it at a temperature of 50°F (10°C) or less.
High Ambient Temperature – The rated capacity of every battery is based on an ambient temperature of 77°F (25°C). Any variation, especially increased temperature, can affect performance and lifespan. Every 15°F above the recommended ambient temperature reduces the battery’s life by 50%. Regular maintenance checks can identify thermal hotspots and verify proper ventilation.
Over-Cycling – Each discharge and recharge cycle slightly reduces the battery’s capacity, affecting its lifespan.
Improper Float Voltage – Charging a battery outside the manufacturer’s specified voltage range can cause significant damage. Low voltage can cause sulfate crystal formation, reducing the battery’s capacity, while high voltage can cause excessive hydrogen and oxygen gases, leading to dryout and thermal runaway, resulting in failure or even fire and explosion.
Incorrect Battery Application – UPS batteries are designed for short high-energy delivery of up to 15 minutes, unlike telecom and switchgear batteries built for longer periods of time. Using a UPS battery for a telecom application will force the battery to run longer than intended, causing overheating and plate failure.
The most common failure mode of a VRLA battery is an open circuit, caused mainly by cell dryout. In UPS systems, if one cell in a SERIES connected battery system fails, it can bring down the entire infrastructure. In short, even a single failed battery cell can cause significant damage to your entire system.
Preventing Battery Failure is About Maintenance
To ensure the reliability of your UPS, regular preventative maintenance is necessary. This includes visual inspections, thermal scans to detect abnormal conditions, testing the voltage of the battery, and retesting the torque on the battery terminal connections. If any issues are identified, it is essential to determine their severity and decide whether battery replacement is necessary.
Regular battery service and maintenance are crucial for identifying unhealthy batteries before they fail and ensuring connections are corrosion-free. While you cannot extend the life of your UPS battery indefinitely, proper storage, care, and maintenance can help increase its longevity and detect a failing battery before it causes a catastrophic failure.
