Determination of Status of Stationary Battery Systems
Manfred R. Laidig
BTECH Inc., Whippany NJ 07981
Abstract:
The prevention of downtime losses due to
premature and unexpected failure of stationary
batteries to perform when called upon is of vital
interest to those involved in managing and
operating facilities which rely on fail safe battery
performance. This paper discusses a proven and
reliable method which will allow the user to
understand the health of individual battery units
and their interconnections in stationary battery
systems while the units are on-line and to predict
hture performance.
Since the first paper discussing the
predictive technology associated with on-line
battery validation equipment using impedance
measurements and trending was presented at the
1993 Annual Battery Conference, this relatively
new method continues to demonstrate excellent
capability to find developing batterykell and cell
interconnection problems in their early
deterioration phase such that proactive corrective
action can be scheduled before battery generated
system problems arise. Over the past year,
measured data from hundreds of additional cells
and cell types has been collected and analyzed.
This pager will discuss some of this data as well as
discuss the rather obvious conclusions reached.
The findings continue to collaborate with previous
experience.
Relative impedance trending over time can
predict batterykell health. Compared to other
alternatives such as discharge testing, this
evaluation method is relatively passive, cost
effective and can be performed automatically with
the batteries fblly on-line. Data acquisition,
archiving and trending can be achieved remotely
via a single PC over standard telephone lines.
0-7803-2459-5/95/$4.00 0 1995 IEEE
Introduction
Government and industry alike spend mega
dollars in the purchase of elaborate and often
Redundant UPS, generator and switchgear
equipment only to experience shut down due to
premature and unexpected failure of one cell in the
battery string.
These back-up systems all depend on
healthy batteries to support them. The key
question therefore is, is it possible to determine the
health status of the batteries and to predict their
future performance with a high degree of
confidence?
The answer is an anticipated yes based on
theoretical derivations. However, proof of concept
is sometimes more difficult to obtain. In this case,
the proof is substantiated by archived data
obtained from hundreds of batteries over the past
five years from many independent sources. [i.z,3,4,q.
The rapidly growing mountain of data continues to
correlate with theory and early laboratory
experiments.
The following sections will cover the
fbndamental electrical concepts involved followed
by examples and a discussion of actual data
obtained from battery installations which employ
commercially available on-line' battery monitoring
equipment designed to trend and measure
impedance's and other key parameters. In short,
the viability of this validation approach will be
developed.
Fundamental Theory
Back in 1988, a technical paper was
presented at an INTELEC Conference entitled "A
Look At The Impedance of A Cell" [a]. At that
early point in time, the question was whether
227
impedance measured using A.C. can fbnction as a
reliable indicator of cell health as measured by AH
performance capability on discharge. Experiments
were performed using large 7000 AH lead
antimony telephone cells. The conclusion reached
was that AC impedance measurements could be
used as a substitute for discharge testing. Although
this work concluded in demonstrating correlation
between impedance levels for a particular cell type,
the work was primarily involved with measurement
techniques which could be used while the battery
was in service.
Another report based on experimental data
conducted by a team of AT&T researchers
concluded with the statements: "A strong
correlation between measured impedance using
commercially available resistance meters and
battery performance has been demonstrated for a
particular battery type." "The results confirm the
linear relationship between capacity and
impedance." In this study, the group used 38 AH
at the 20 hour rate valve regulated cells packaged
in 6 cell (12V) modules in their experiment. A.C.
impedance measurements were performed at 40
=. 111
Other work by other researchers would
later demonstrate the statistical significance of the
impedance measurement technique as an indicator
of cell health.
Theory and logic supports these early
findings. In theory, any device through which an
electrical current flows exhibits in generalized
terms, a resistance or impedance to that flow. In a
storage battery, these two terms can be used
interchangeably.
The absolute value of impedance as
measured is a function of the integrity of the
current carrying conductors (battery post, internal
straps, plates, interface on the post with external
hardware, etc.) as well as the electrochemical
portion. For example, the cross section of plates
and internal cell connections erode and generally
change in cross sectional dimension over time.
Similarly, as corrosion and loss of clamping torque
between inter-cell current carrying conductors and
their respective battery posts takes place,
measured impedance levels also increase. These
issues are common to both valve regulated and
flooded battery types. Water loss in starved
electrolyte or VR type cells is more unique to
these cells due to the inability to replace lost
electrolyte. The water loss increases the impedance
or internal resistance due to the breakdown of
electrolyte continuity between the plates. As any of
these changes progress, resistance to current flow
increases. Obviously, a significant increase in the
interface resistance can result in serious
overheating problems at the post during high
discharge rates. Furthermore, experience
demonstrates that impedance levels which measure
30% or more above mean on a consistent basis
correlates to significantly lower AH capacity on
discharge to the point where the entire battery is at
risk of collapsing due to one weak cell.
Fortunately, these changes for the most
part are relatively gradual at first since the
deterioration phenomena takes time to develop.
Over time however, the rate of change or
deterioration often accelerates. As previously
mentioned, AC impedance measurements, when
taken periodically, can be used to understand the
rate of change. Given sufficient data points,
projections can be made regarding future cell
health - a predictive capability.
If periodic impedance measurements are
made over time using an on-line monitor such as
the BTECH Battery Validation System model S3,
the deterioration rate or trend can be automatically
captured and plotted on a remote PC. Useful data
includes plots of individual jar impedance's and
voltage, overall system voltage, as well as cell and
ambient temperatures. All provide ready
information regarding the relative health of each
measured battery jar, the integrity of its respective
connection and it's rate of change. Conservative
alarm thresholds can be set to provide an early
warning of a specific devehping problem in its
early stages of deterioration, thus enabling service
groups to proactively schedule corrective action.
The following section will cover data
obtained at various user sites. All of the data was
obtained using a BTECH Battery Validation
System monitor. Before reviewing the findings, it
is useful to understand how these measurements
were made.
The equipment employed connects to
individual cells or battery jars as shown in the
following illustration:
System Diagram
ALARM OUlPvT
AUBIUIT TEMP
Remote PC
Fig. 1
Impedance is calculated by measuring a
voltage while a known current is flowing between
the hsed current leads as depicted in Fig. 1. A 10
A. load is drawn switched on and off at a 220 Hz
229
rate. The voltmeter responds to the 220 Hz
fbndamental component only while the computer
performs the appropriate calculation. In this way a
small AC voltage (indicative of impedance) can be
measured in the presence of a much larger DC
voltage with the entire measurement operation
performed on-line with the batteries hlly in
service.
In the following examples, impedance
alarm thresholds are set at 15% above the average
of all measurements taken once a week, for
example. This procedure is useful in identifjring the
highest cellhnterconnect combination. The precise
impedance number the monitor returns matches
the number given by other commercially available
impedance measuring instruments but for this
purpose, the exact number in less important. In
fact, this approach is not concerned with an
absolute number to be compared against a
standard. With the exception of one recently
released impedance chart, these standards are not
readily available fiom the major battery companies.
We do not anticipate this to change in the near
future due to the risk involved in publishing them
perhaps mainly due to the many variables involved
such as temperature, time since last discharge, etc.,
when performing the measurements.
Analysis of Data Obtained From User Sites
Data continues to accumulate fiom the
rapidly expanding user base. The following
examples are typical of many.
UPS Batteries in Bank CLocation #21
This set of measured data was taken fiom
batteries which back up a large UPS installation
located within a financial institution. The afore
described monitor was retrofit onto an existing
battery and as such, problems were identified and
confirmed by a discharge test which occurred as a
normal course of events. The location is identified
as #2. Location identifiers are programmed into
each monitor to identie a specific battery
installation.
 Figure 2 shows consecutive impedance impedance is approximately 25% above the
values as measured on September 9, 1994. The population.
graph covers battery units #90 through #120.
When viewing this data on a PC screen, all units in 15.8
the battery string can be viewed by scrolling with L
C 14.9
the m o w key on the keyboard, either to the left or 13.6
to the right. This particular screen is illustrated as f 12.9
it shows the battery jar with the highest impedance
value, # 112, as measured on that day.
: 12.2 t. i i . 4

9.88
8.48
I
n 7.88
7.88
6.a
C
f 6.a
5.40
4.83
Fig. 3
n
E
t4 4.88
Y

9.a
It so happens that this location 6equently
3 .ea
experiences power outages. Figure 4 shows the
archived record of all power outages. During a
power outage when the battery experiences a
discharge, the monitor will record each event by
Fig. 2 date, time and duration to the nearest second. In
addition, the monitor will measure and record the
The measured impedance values are voltage decay of individual celldjars and total
defined by the black diamond. The calculated system provided the event is sufficiently long
average or mean is shown by the "X". The alarm enough to permit measurements to be taken. The
limit, which in this case is set at a 15% above record shows an 18 minute 53 second event on
average threshold, is depicted by the rectangle. September 9.
The upper and lower triangles show the observed t o r &ooatloa &
minimum and maximum values as measured during
that measurement sequence. This is useful since
-------=
Data Tim
I:lb:S7
8:27:0b
Intonal
0 : 00101
0 :00 101
-
Intwrval
0 : 00 :04
Ot80tO5
the highest or lowest unit may not be on the 10:42:08
1:4s:oa
t I
011s110
I
I
t
t
8 :44:OS 0100:01
immediate viewing screen. 9:lS:4b
9:11:01
1 :
0 : 00 I01
0 :00: 01
0:OO:Ol
0: 00: 01
9:14:17 0:00:01 I 1
9: 1 4 :4J O:OO105 I 1
B:4S:4b 0:00:0I
Figure 3 shows the measured float voltage 9:&6:za
9:41:1*
0:ooaoa
0:12:41
0 : DO :02
I t 0 : IO: 18
for the same set of battery units. Although not 10:oa:24
10:02:t1
0 : 00: 01
I 1
0:00:01
I :
10:04 : 4 1 0 :00101
always the case, it is interesting to note that the 10:12:s2
10:z1:11
S I
0:00:02
0:00:01
0 :00102 0:tOIOl
voltage of #112 is well below the normal limit 10:11:44
10:29:1b
I t
0:00102
O:lB:¶J
m:oa:is
lO:z9:¶0 0:00101
range as shown by the dashed upper and lower lO:l@:sa
10:11101
0 100 101
0:04:29
0:00:01
0:00:01 0:00:01
lines above and below the other cells depicted. lo:llrl1
11181118
OrOOrOs
I t
0:00:01
I t
This battery unit is obviously a problem unit as the 11~01112 0:oOIol I t

charger is unable to keep it up at float and the Fig. 4

230
 Consecutive voltage measurements as 15.9
shown on Figure 5 clearly show battery #112 L 14.3
O
collapSmg early. Unit #68 is also relatively weak. n 13.6
E 12.9
12.e
14.9 'Lc 11.5
i 13.3 10.8
0 V
m 12.6 f 10.1
0
11.9
c .11.e
:
G
9.4
E 8.7
c'
L
18.5
8 .e
9.8
f 9.1
. .
4
8.4
---. . . . .a. .--

7.7
I

+ .
I

.
I

.-: .
I

Fig 7
7.8
U P S Batteries in Investment ComDanv U c . #SI
The data from this installation was taken
Fig 5 shortly after the monitor was installed on an older
existing battery. Note that the impedance of unit
The actual voltage decay curve of battery #5 in Figure 8 measures so high that it is off the
unit #112 is shown in Figure 6. In comparison, .de.
observe the excellent performance of battery unit
#l 11 in Figure 7. 6.00

.. .
I I I

.
I I

15.0 ! I

L 14.9 n
0
5.48
13.6 c
0 E 3.m
e.68
e.m
1.88
L e )I
18.8 1.48
L" 10.1

Fig 8

It is interesting to note that despite the fact

that unit #5 registers high in impedance, its voltage
Fig 6 at float appears normal. This confirms that voltage
measurements when taken at float are not always a
viable indicator of cell health,

231
 c 10.0
E
L 9.s
"
L
9.0
Fig. I 1
tT
8.5
6 8.0
Conclusion
0 7.5
T The data depicted above is highly
7.8
representative of many such battery installations
6.5 I
I 1- being monitored by the Battery Validation System
f 6.0
monitor. The illustrations used were chosen as they
5.5
clearly demonstrate the capability of an on-line
5.0
IO R I I O
impedance monitor to predict battery performance
under load. This technology has matured to the
point where major users are now employing the
Fig. 9 use of this predictive technology to protea against
the potentia! of system downtime losses due to
Figure 10 shows consecutive voltage levels premature and unanticipated battery failure. The
at discharge. Unit #5 immediately dropped below excellent correlation using relative impedance
the other cells falling below 4 volts which is out- trending techniques over time makes this technical
of-scale. This poor performance was predicted solution a viable and cost effective altemative to
based on the high impedance reading measured the older, labor intensive, and risky, procedure of
while in service and on float charge. Note the short discharge testing. In addition, it is also possible to
(less than 45 seconds) discharge time shown on the reduce maintenance costs and cell replacements.
Power Outage Intervals Report. (Figure 11) Unit #
5 collapsed immediately after the charger went off. References;
The gradual increase in voltage as shown in Figure 1. E J. Vaccan, & P. Casson: AT&T Bell
Laboratories Technical Memorandum, "InternalRtsistancc:
10 beginning with cell number 28 is due to the Harbinger of Capacity Loss in Starved Eleclrolylcstaled
charger going back in service during the time the Lead Acid Batteries"Proceedings of the 1987 INlELEC
monitor was data logging the voltage decay. -
Conference, pp 128 135.
2. Dr. D. 0.Feder, M. Mavac, D.Ogden: Weld
Application of ConductanceMeasurements Used to
Ascertain CelVBattery and Inter-Cell Connection State-of-
Health In Electric Power Utility Applications'
3. M. R Laidig and J. W.Wurst:"Batter>.Failure
Prediction,' Proceedings of Predictive Technology
Symposium,PiCatiMeY Arsenal,Dover,N.J.Nov.1991.
4. G. J. Markle: "ACImpedanceTesting For Valve
Regulated Cells"Proceedings of the 1992 INTEIIC
-
Conference, pp 212 217.
5. M.R.Laidig & J. W.Wurst: "Technology
Implementation of Stationary Battery Failure Prediction",
Proceedings of the Annual Battery Conference, Long
Beach,Januaxy 12,1994.
6. S.L. Debardelaben:"A Look At The Impedance of
A Cell"Proceedings of the 1988 INTELEC Conference, pp
Fig. 10
-
394 397.

232