ABOUT MIDTRONICS
Global Reach
Dedicated offices/personnel to
service our customers:
•USA
•Canada
•United Kingdom
•France
•The Netherlands
•China
•India
•Singapore (2009)
Affiliates/Distributors in more
than 40 countries, including:
•Germany
Greece/Balkans
•Spain
•Italy
•Switzerland
•Poland
•Russia
•Japan
•Korea
ABOUT MIDTRONICS
Advancing and Leveraging Technology
CONDUCTANCE TECHNOLOGY
DRIVES ALL PRODUCTS
•Recognized, accepted technology worldwide—more than 20
peer-reviewed white papers and IEEE acknowledgement
• Innovations through patent portfolio (150+)
• Created “electronic” / “Ohmic” testing category
• Continuous evolution – fully dedicated R&D on 3 continents
ABOUT MIDTRONICS
Committed to Quality
Quality in every product
1997
ISO-9001: 1994 Certification
1999
QS-9000: 1998 Certification
2005
ISO-9001: 2000 Certification
2006
Passed registration audit for ISO-14001: 2004
ABOUT MIDTRONICS
Proven Partners
Midtronics Confidential! Do not
distribute without written consent
Stationary Division
What Is Conductance?
 Conductance is a measurement of the batteries
electronic and ionic components to determine how
much power the battery can supply
 As the batteries age, their ability to deliver power
decreases along with conductance
 Accurate correlation to discharge testing
 Reliable indication of battery state-of-health
 Conductance can identify most battery failures before
they happen
 Conductance is a passive, quick, safe, easy and
reliable way to determine a battery’s relative
condition or state of health
How Conductance
Is Measured

A low A/C current signal is impressed
across the battery terminals (IAC)

The A/C voltage (VAC) response is
measured

Conductance (G) is the ratio of the AC
test current impressed on the circuit
to the AC voltage.
Battery Conductance
Tester


Using Ohm’s Law: G = IAC/VAC
Significant changes in the
conductance value typically indicate a
significant change in the performance
of a cell.

Change in ohmic values in excess of
20% loss should be considered
significant.
% Rated Capacity
Conductance vs. Battery Life
Correlation
100
95
% Rated Capacity
90
85
80
% Original Value
130
120
110
100
Conductance
90
80
90
80
Source: Johnson Controls Form 41-7271 Rev. 8/94
70
60
50
% Life
40
30
20
10
Conductance vs. Discharge
Correlation
Conductance Testing
vs. Discharge Testing
CONDUCTANCE TEST
DISCHARGE TEST
 Test battery at any time to identify
major problems
 Fast, low-frequency AC test, does
not affect battery
 Does not prematurely age the
battery
 No heat produced, which increases
safety. Is ideal to qualify battery as
safe for further discharge testing
 Test can be repeated immediately
with same accuracy to verify result
 Test results are available in
seconds per battery, with no further
calculations
 Portable, lightweight, easy to use
and operate. No external power
required
 Battery must be fully charged for
test data to be meaningful
 Requires large amount of energy to
be removed in order to be accurate
 Each test is a cycle, shortening
battery life
 Dangerous potential for heat and
sparks. Serious injury and damage
can occur if battery is faulty.
 Battery needs to be recharged after
each test
 Battery is not available to support
network for up to 24 hours during
test
 Capacity testers are cumbersome
and costly
Factors Effecting Battery
Life, Performance & Reliability
Factor
Effect on Conductance
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








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


Grid Corrosion
Grid Swelling and Expansion
Loss of Active Material
Discharge
Sulfation
Internal Short Circuits
Temperature Decrease
Temperature Increase
Dryout
Negative Plate Discharge
Negative Strap Corrosion
Loss of Compression
Decrease
Decrease
Decrease
Decrease
Decrease
Decrease
Decrease
Increase
Decrease
Decrease
Decrease
Decrease
Conductance testing will find most problem batteries early!
Conductance Testing
Benefits
 On-line testing capability
 No system down time required to test
 Reliable & repeatable test data
 Reduce potential battery failures
 Identify problem batteries before they fail

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Eliminate catastrophic losses
Extending system battery life
Diagnose and trend battery state-of-health
Develop battery replacement strategy
Maintain quality control programs
Manage & reduce maintenance costs
Minimize crisis management costs
Manage budgets
Conductance Testing
Telecom Applications
Main
Switching
Station
Customer Locations
Remote
Cabinets
Base Stations
Battery Management, Simplified
Complete Solutions
STATIONARY POWER PRODUCTS
Analyzers for All Applications
Celltron MAX: UPS, Telecom,
Generators
• Celltron ULTRA: UPS Systems
• Celltron ADVANCED: Telecom
• Celltron START: Generators
• Celltron ESSENTIAL: Broadband
• SCP 6/12: Emergency Lighting
Monitoring Solutions
• CellGuard: UPS Systems
• CellGuard TRACE: Telecom
Asset Management
•CellTraq: Enterprise Data System
Introduction to:
MAX
www.midtronics.com
Midtronics Confidential! Do not
distribute without written consent
Advancing the Battery Analyzer Standard: Celltron Max
What is Celltron Max?
Latest in Midtronics line of portable
stationary battery analyzers (6th Generation)
A true integrated test system
Fully combines analyzer with software
management tool and can work handin-hand with automated monitoring
Maximizes the value of trending data
for better state-of-health diagnostics
A multi-function platform, incorporating
traditional stationary battery testing,
generator/fleet vehicle battery testing, a
capacity test manager and multi-meter
functions
Celltron MAX Interface
Data Upload
To Main
New Measurement Data
Celltron MAX
Willowbrook
West Lab
String 1
Battery 1
Battery 2
Battery 3
Battery 4
Battery 5
String 2
Battery 1
Battery 2
Battery 3
Battery 4
Battery 5
P1
S1
East Lab
String 1
Delete
Configure
New Measurement Date Range
Start Date: Wednesday, March 19, 2008
End Date: Thursday, March 20, 2008
Summary
Plants:
3
Strings:
4
Batteries:
20
Measurements:
57
Selected
String 1
5 Batteries
Total Voltage: 60
Average Conductance: 2498
Upload
Uploading data to CellTraq
Exit
Advancing the Battery Analyzer Standard: Celltron Max
How does the MAX compare to the industry-leading Celltron
Ultra?
•
Same Applications: UPS Service, Power
Utility, Telecom
•
Same Voltage range: tests up to 16 volts
•
Same Capacity Range: Measures up to
6000 AH batteries
•
Same Accuracy: 3 decimal point voltage
accuracy
CELLTRON MAX
Differences and Advantages
• Testing without a reference value
• New function reviews the test results, looks at
conductance variation in those results, and
statistically computes reference value
– If variation is low, research has proven that is an
indication of solid battery health
– If variation is high, this indicates battery aging.
Tester will inform technician of this issue and not
provide % of reference.
CELLTRON MAX
Differences and Advantages
• Integrated battery temperature testing
– IR temp sensor is built into unit, increasing the
accuracy of the battery test and eliminating the
need for a separate tool
– Testing can be performed once per string, or on
each cell / monoblock
• Capacity Test Manager function
Provides easy to use interval and duration timing as
well as jar voltage capture and recording during
capacity testing.
CELLTRON MAX
Differences and Advantages
• Multiple and easy data storage and movement options
– USB cable to the PC / Software
 Data can be transferred to analyzer from PC as
well traditional download from analyzer to PC.
– USB Memory drive
– IR to printer
• Generator starting / cranking battery test capability.
Provides flexibility for generators used at UPS, Central
Offices and can be used on fleet vehicles.
• Dual screen guides technician during setup and test
process.
Advancing the Battery Analyzer Standard: Celltron Max
Celltron Max Kit includes:
•Tester
•Interchangeable cable
•One pair of probe ends
•Extra tips
•One pair of clamp ends
•Probe extenders (similar, but not same,
as CTU)
•Printer (same as CTU/CTA)
•Extra paper roll…
•USB cable for connection to computer
•USB memory drive available as
accessory, compatible with any offthe-shelf drive
Advancing the Battery Analyzer Standard: Celltron Max
Celltron Max Kit also includes:
•Celltraq single user application
•Same full feature set, but with only single user
log-in
•USB cable for connection to computer
•USB memory drive available as accessory,
compatible with any off-the-shelf drive
•Extra battery pack and charger
•Charger is 6-8 hour charger
•Rapid (one hour) charger available as
accessory April 2010
•Custom molded hard case
•Insert conforms to tester and accessories
•Secure compartment for cables
•Molded, durable handle
•Eyelet for lock
Battery Management, Simplified
Proven Diagnostics
Celltron Ultra leads the market for battery testing
Application: UPS Systems/Telecom
•
•
•
•
•
•
•
•
•
Enhanced conductance methodology: highly
accurate yet user friendly
Test a 240 cell UPS string in one hour
Data Storage: 500 string locations of 480 test results
stored internally
Digital Multi Meter: Measures AC & DC voltage,
Current and Scope mode
Measures up to 6000 AH batteries
Compatible with new 16 volt batteries
3 decimal point voltage accuracy
Measuring circuit matches CellGuard Battery
Monitoring System for diagnostic integrity/crosscompatibility
Data compatible with CellTraq Enterprise Data
System as well as PowerSure Software
Celltron Advanced™
Tester
 Application: Telecom Batteries
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


Test Battery Conductance & Voltage
Test 2 – 16 Volt Lead-Acid Batteries
Test Up To 6,000 Ah Batteries
On or Off-Line Testing
Stores Test Data (16 Locations/480
Tests Each)
Power Sure Test Data Mgmt. Software
Fast Testing (10-12 Sec. Per Battery)
Tests Inter-cell Connections
Over-Voltage & Polarity Protection
Self-Calibrating
Available in Complete “Kit” Form
CTA-4000 Kit
Celltron Essential
Battery Conductance Tester
 Application: Basic Telecom
Testing
 2, 6 & 12 Volt on-line testing
 2000 AH testing capability
 Stores 1 string of 480 test
results
 Compatible With PowerSure
Test Data Mgmt. Software
Kit Includes:
 Celltron Essential
 Probes
 Printer
 Soft Vinyl Carrying Case
PowerSure Key Benefits
 Quick and easy installation takes minutes to
complete without PC expertise
 New User Wizard™ allows user to use the
major functions of the system, without prior
training, in minutes
 Full capabilities to download and capture test
data as well as select site, system, and string
identifiers from Midtronics Stationary Battery
testers via infra red or memory cards
 Relational database provides simple means to
view, compare and trend historical data on
batteries, strings, and sites
 Centralize key network data records, including
site installation/commissioning, last
maintenance visit and more
Celltron Start & Start +
Generator/Starting Battery Analyzer
APPLICATION: Generator Start
Batteries
Start
 Tests CCA-rated starting
batteries
 Provides test decision, CCA
and voltage
Start +
 Multiple battery test algorithm
 Tests 1-4 batteries as a pack
or individually
 Tests Starting & Charging for
12 & 24-volt systems
Secure Power™
Battery Conductance Tester
Applications:
6V and 12V VRLA batteries for security systems,
emergency lighting systems and small
UPS Systems
Conductance:
20 to 600 Siemens
Features:
 Ampere-hour testing capability (1.2 to 25 Ah)
 Three LED’s indicating:
Conductance
Voltage
Percent of reference
 Four-position LED display
 Dual conductor Kelvin clamps
 Hand held and light weight
Technical Algorithms:
 > 70% = strong battery
 60% to 70% = marginal battery
 < 60% = weak battery
SCP-100 Tester
Introduction to CellGuard Trace
Low Voltage String Battery Monitor
What is CellGuard Trace?
 A Conductance-based 12-volt
monoblock battery monitoring
module designed for use in 24 or
48-volt, low AC ripple system
applications
 Telecommunications
 Alarm/telemetry systems
 Specialty systems (process controls,
metering, etc.)
 Directly interfaces with an
embedded controller system
(Building Management System, Site
Monitors) or to a PC for data
processing, fault communications
and external communications
 System measures monoblock
conductance and voltage and
temperature, key variables for
determining battery state-of-health
Key Features and Benefits of
CellGuard Trace
• Flexible communications
options
– Binary alarm outputs compatible
with most site management
systems
– Serial output with included PC
software for local status monitoring
• Simple installation
– Can be completed by a single
technician in under two hours in
most cases
• Economical
– System designed for deployment
throughout an entire infrastructure
for consistency in a
monitoring/maintenance program
Basic Specs
Basic System Specifications
•
•
String Voltage Ranges
– 21V < V < 27.6V for 24 Volt operation
– 42V < V < 62V for 48 Volt operation
Battery Types
– The Monitor is capable of monitoring
three major types of stationary
batteries including:
• VRLA (Valve Regulated Lead
Acid)
– AGM (Absorbed Glass Mat)
– Gel
• Capacity Range: 7 Ah to 600 Ah
(approximate)
Basic Specs
Basic Module Specifications
•
•
•
•
Battery Conductance Range
– 100 s < Siemens < 5,000 s for 12 Volt
Batteries
Battery Voltage Range
– 10.5 V < V < 13.8 V (12 Volt Battery)
– Note: Monitor is capable of reading
above this range
Battery Temperature Measurement
Range
– -20° C < T < 75° C
String Voltage
– 21V < V < 27.6V for 24 Volt operation
– 42V < V < 62V for 48 Volt operation
Basic Specs
Configuration and
Communications
• Measured parameters can also be
displayed on PC
• Communicated via RS-232
connection
• From this interface, new tests can
be manually initiated or automatic
updates will be posted
• Out of tolerance results are
highlighted for easy identification
Basic Specs
Configuration and
Communications
Universal Battery
Monitor
• Faults are also available via
Form-C binary alarm
contacts
• One contact for minor alarm,
one for major
• These are set via the
software or at the factory
• Local, visual indication of
faults is provided via LEDs
on the face of the unit
A4,B4,C4,D4
A3,B3,C3,D3
A2,B2,C2,D2
A1,B1,C1,D1
Battery
Battery_IF
Hardware
Serial_IF
Communications
Interface
Major Alarm
Relay Contacts
Battery Temp
Sensor
Amb_Temp_IF
Ambient Temp IF 1
Ambient Temp IF 2
Ambient Temp IF 3
Ambient Temp IF 4
Minor Alarm
Relay Contacts
Battery Management, Simplified
State of the Art Automated Monitoring
Why Battery Monitoring?
The CellGuard System
provides:
• Peace of mind—dramatically
reduces the potential for #1
UPS/back-up power failure
mode
• A user-friendly and cost
effective approach to managing
battery assets and system
maintenance
• The state of the art in system
architecture and analysis
technologies
Battery Management, Simplified
State of the Art Automated Monitoring
CellGuard Key
Attributes/Advantages
• Conductance methodology—less
invasive, highly proven
•Wireless intra-system
communications architecture for
simplified, reliable installation
• Reduces total cost of
ownership
• Improves ROI
•Intercell connection resistance
monitoring (only system on the
market offering this feature)—true
“system” integrity
Battery Management, Simplified
State of the Art Automated Monitoring
CellGuard Key Attributes/Advantages
• Temperature measurement at every
jar: key to battery performance and
warranty integrity
• Peak-set Conductance Reference Value
(first in industry): true maximum
performance baseline tracking
•Server-based software option: data
from every system flowing to secure
access and storage point
• Web enabled communications
•Immediate notification of battery issues
via email or text message, 24X7, 365
Battery Management, Simplified
State of the Art Automated Monitoring
CellGuard System Architecture
Battery Management, Simplified
State of the Art Automated Monitoring
Clean, Organized and Simple Installation: Minimal Wiring
Battery Management, Simplified
Key to Efficiency: Managing Data
What is CellTraq?
•Enterprise database
system designed to manage
battery system data from
one or many systems or
locations
•Companion to CellGuard
automated remote monitoring
equipment; also compatible
with Celltron Ultra handheld
battery testers
•Server based architecture
for maximum data security
and integrity
Battery Management, Simplified
Key to Efficiency: Managing Data
Key CellTraq Advantages
•Global data access from server
•Streamlines review of
information and safeguards
historical data
•Instant indication of battery
asset conditions throughout
enterprise from one on-screen
indicator
•Simple “Red, Yellow,
Green” status indicator
•Ensures efficient review of
system state of health
•Simple, familiar user-friendly setup, navigation and reporting
Battery Management, Simplified
Key to Efficiency: Managing Data
Key CellTraq Advantages
•System-derived notification of
battery faults via e-mail and text
message
•Includes suggested corrective
action for technician
•Multiple contact notification
•Records corrective action and
audit trail
•Graphical presentation of battery
system trends for rapid
identification of potential future
faults
•Centralized repository of battery
information, including installation
date, cost and performance
specifications
Why Battery Management?
Reasons for Investment
Costs Associated with an Outage
•Customer losses: Loss of trust and dissatisfaction lead
to lost relationships
•Data Recovery: Losses associated with the recovery of
lost and/or corrupted data files and re-programming
computers and process control systems.
•Labor Costs: High rates for recovery, premiums for
immediate replacement batteries rather than planned
replacement .
•Equipment Costs: Repair, maintenance or replacement
of equipment damaged as a result of the outage.
Why Battery Management?
Reasons for Investment
Return on Investment
An accurate ROI calculation depends on a number of factors, most
notably the cost of downtime for the operation.
These costs can vary dramatically depending on the situation.
Case Study — Data Center
New Transfer Switch
New UPS Batteries
Recovery of Data Files
Re-Programming and Misc. IT Charges
Lost Transactions/customer contracts
Total Losses
Losses
€ 25,000.
€ 15,000.
€ 40,000.
€ 115,000.
€ 700,000
€ 895,000.
Why Battery Management?
Reasons for Investment
It’s been well documented that only 2% of all UPS failures are due to electronics
within the UPS?
The other 98% are due to failures within the battery system.
Batteries
Should your UPS have a weak or
failed battery, it could affect the entire
system, rendering the UPS useless
and leaving your entire system
vulnerable should a power event
occur.
UPS
Why Battery Management?
Reasons for Investment
The reasons for battery failure are numerous
including:
•Improper installation
•Environmental factors, especially temperature*
•Battery manufacturing defects
•Frequent cycling
•Deep discharges of the battery string
•Inappropriate UPS float charge and equalization settings
•Normal aging
Battery monitoring detects those anomalies a visual inspection alone
cannot detect including sudden internal impedance rise, discharge
history and cabinet and ambient temperature.
*Note: for every five degrees over 25 degree Celsius a battery operates in,
its useful life will be halved
Why Battery Management?
Reasons for Investment
The only reliable way to ensure the health of your batteries, and in turn
your entire system, is to install a reliable battery monitoring system.
The benefits of battery monitoring include:
•Accurate measurements of
•Individual battery cell voltage – every cell vs String voltage
•Conductance – linear correlation to an actual load test
•Cell temperature - detect THERMAL RUN-AWAY
•Current and Voltage during a discharge – measures actual
state of health
•Intercell strap resistance – detect loose connections/corrosion
•Battery data is collected automatically and regularly so problems
can be detected before failure occurs.
•Predictive analysis on battery trends for early warning signs of
failure
•Alarming, notification and acknowledgement of unhealthy batteries
Why Choose Midtronics?
Reasons for Investment
•Complete focus and dedication to battery diagnostics
•Established and leading experts in battery asset management
•The latest technologies
•Continuous improvement of the state-of-the-art
•Proven history of effective products and approaches
•More than 250,000 battery diagnostic systems deployed worldwide
•Quality orientation
•Customer service and global support
•Help is right around the corner
THANK YOU