Batteries: Testing, Replacement, and Removal
Batteries are a critical component of many commercial electrical systems – especially within Uninterruptible Power Supplies (UPS), emergency lighting, fire alarms, and backup power systems. Proper testing, replacement, and safe removal of batteries ensures reliability, safety, and compliance with regulations.
Why It Matters
| Function | Importance |
|---|---|
| Emergency backup | Ensures power during grid outages |
| System reliability | Prevents downtime in critical operations |
| Safety | Reduces fire and chemical hazards from failed batteries |
| Compliance | Meets maintenance standards (NFPA 70, IEEE, OSHA, etc.) |
Battery Testing
Regular testing helps identify weak or failing batteries before they cause failures.
Key Testing Procedures:
| Test Type | Purpose |
|---|---|
| Visual Inspection | Check for swelling, leakage, corrosion, or cracks |
| Voltage Testing | Confirms battery is charging and holding proper voltage |
| Impedance / Conductance Testing | Detects internal deterioration (non-invasive) |
| Load Testing | Simulates real load to measure actual performance (more invasive) |
| Specific Gravity Testing (for flooded lead-acid) | Measures acid concentration in each cell |
| Temperature Monitoring | Overheating can indicate imminent failure or poor environment |
Testing Frequency:
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Monthly: Visual and voltage checks
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Quarterly/Semi-Annually: Impedance or load tests
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Annually: Full battery system evaluation
Follow manufacturer and standards like IEEE 1188 for VRLA or IEEE 450 for flooded batteries.
Battery Replacement
When batteries fail tests or reach end-of-life (usually 3–5 years for VRLA, 10–15 years for wet cell), replacement is necessary.
Signs Batteries Need Replacing:
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Constant low voltage
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Unable to hold charge
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Excessive heat or swelling
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Failing impedance or load test
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Manufacturer recommended life reached
Battery Removal & Disposal
Batteries contain hazardous materials (lead, acid, lithium) and must be disposed of following environmental and safety regulations.
Disposal:
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Partner with a licensed hazardous waste recycler
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Maintain chain of custody documentation
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Comply with EPA, DOT, and local environmental regulations
Document:
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Quantity and type removed
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Date of disposal
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Recycling facility info
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Regulatory paperwork (e.g., manifests)
Risks of Neglecting Battery Service
| Risk | Consequence |
|---|---|
| Failed backup system | Loss of critical power during outage |
| Fire or explosion | From thermal runaway or short circuits |
| Compliance violation | Legal and insurance issues |
| Costly emergency repairs | Due to unplanned downtime or equipment damage |
Infra-red provides testing, replacement and removal services for your commercial batteries. Contact us to find out more.