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UPS Service Plan Options: Which is Right for You?

Mon, 18 Aug 2025 18:33:17 GMT

Imagine this: a severe storm rolls through overnight, knocking out grid power to your facility. Your UPS system, the backbone of your backup power, should bridge the gap until generators kick in. But instead, batteries fail and your critical systems go dark.

Servers crash mid-operation, manufacturing lines grind to a halt, and data is lost. Recovery takes hours or days, costing tens of thousands in lost productivity, potential regulatory fines, and reputational damage.

This scenario isn’t hypothetical. It’s a real risk that facility managers, IT leaders, and operations professionals face every day. And often, it comes down to one overlooked factor: failing to maintain and proactively service the very equipment meant to protect your business from downtime.

Why a UPS Service Plan Isn’t Optional

A UPS is your facility’s shield against power disruptions, voltage fluctuations, and unexpected outages. But like any piece of mission-critical equipment, it can fail, especially without regular maintenance and expert oversight.

Batteries degrade, internal components wear out, and dust or environmental conditions can undermine performance. That’s why a proactive UPS service plan isn’t a luxury. It’s essential to safeguard your facility, your data, and your bottom line.

Benefits of a Regular UPS Service Plan

A strong UPS service plan offers clear, practical advantages:

What is Typically Included in UPS Service Plans

While details vary, most UPS service plans include:

Preventive maintenance visits and detailed reports

Battery testing, replacement recommendations, and safe disposal

Emergency on-site service (depending on plan level)

Remote monitoring with real-time alerts

Discounted or included parts and labor

24/7 access to technical support

FGC’s UPS Service Plans: What You Get

At Facility Gateway Corporation, we offer flexible, nationwide service plans designed to fit your facility’s needs, equipment status, and risk tolerance. Here’s how each option compares:

PM Only Contract

Scheduled preventive maintenance visits, testing, and detailed reporting

Emergency service dispatched by FGC with best-effort guaranteed response time

Technical support provided by FGC

For systems where the OEM warranty has expired

Parts and labor are quoted separately as needed

This plan is ideal if you want routine maintenance and support but prefer to handle parts and repairs on a pay-as-you-go basis.

PM Plus Contract

Includes all features of the PM Only Contract

Emergency service dispatched by FGC

Guaranteed response time for emergency calls

Technical support provided by FGC

For systems where the OEM warranty has expired

Parts and labor quoted separately, but you receive priority scheduling

PM Plus offers extra peace of mind with guaranteed response times, making it a great fit for facilities that require faster service but want to manage parts and repair costs separately.

Full Service Contract

Includes all features of the PM Plus Contract

Emergency service dispatched by FGC

Guaranteed response time included

Technical support provided by FGC

For systems where the OEM warranty has expired

Parts covered by FGC

Labor covered by FGC

Full Service provides the most comprehensive protection, covering both parts and labor along with guaranteed response times. It’s the best choice for facilities where downtime isn’t an option and budget predictability is key.

How to Choose the Right UPS Service Plan

Choosing the right plan isn’t just about price. It’s about understanding your facility’s risks, equipment condition, and operational demands.

Assess Your Critical Power Needs

How much does downtime cost you? Facilities supporting healthcare, data centers, and continuous manufacturing often need the most robust coverage.

Evaluate Your Current Equipment & UPS Age

Older UPS systems typically require more frequent checks and proactive component replacements.

Compare Plan Features, Not Just Price

Cheaper plans may leave you paying out-of-pocket during emergencies, which can cost far more in the long run.

Consider Your Budget & Risk Tolerance

Balance immediate costs against the potential price of downtime, repairs, and lost productivity.

Protect Your Facility with a Proactive UPS Maintenance Plan

Your UPS system protects your operations, but it needs proactive care to do its job. Facility Gateway Corporation offers the expertise, nationwide reach, and fast response times to keep your power protected and your facility running.

Don’t wait for failure to find out what your downtime truly costs. Contact FGC today to build the right UPS service plan for your facility.

Understanding the Importance of Data Center UPS Systems

Thu, 29 May 2025 15:00:06 GMT

Facilities such as schools, offices, hospitals, restaurants, and hotels may utilize uninterruptible power supply (UPS) systems in their operations to keep machinery and emergency lights in operation when there is a power disruption or failure. In addition, companies may also have data center UPS to protect important computing information and network equipment. Learn more about how uninterruptible power supply data center systems are essential for operations.

What is a Data Center UPS System?

A data center UPS system is a backup power unit designed to offer protection for sensitive equipment and data. Depending on the type of UPS, it can monitor incoming power supplies and switch over to battery backup power when sensing any power fluctuations such as surges, lags, brownouts, blackouts, and other transient power anomalies.

Why UPS Systems Are Essential for Data Centers

A UPS unit can be connected to all types of data center equipment including routers, network systems, servers, computers, and other devices. It can become a bridge between the main power supply and delicate IT equipment that can become easily damaged from voltage variations. Some UPS can even out power variations so that the equipment receives the appropriate amount of current and voltage throughout operations. A UPS becomes a failsafe mechanism to minimize downtime and protect data.

Benefits of Uninterruptible Power Supply Systems in Data Centers

UPS systems keep equipment running for a specified time when the power goes out. By providing backup power, it gives workers the opportunity to save data to prevent loss, safely power down equipment, allow for backup generators to be turned on, and troubleshoot electrical problems that may have caused the power failure. The UPS can also prevent damage to connected equipment that may occur from surges and power spikes.

Improving Data Center Efficiency and Uptime

Data center UPS can have various features that help to improve the efficiency and uptime of your IT equipment. Some functions include battery management and voltage regulation. If the voltage is not correct for the IT equipment, it can cause damage or failure. The UPS system monitors the incoming "dirty" power and can clean it by providing a steady voltage for the IT equipment. This feature can prevent downtime and allow equipment to operate at the fullest capacity.

Safeguarding Sensitive Data and Equipment

Data center equipment may handle a multitude of data and transactions 24 hours a day and 7 days a week. If a power failure or fluctuation occurs, the equipment may become damaged and the data corrupted or lost. The UPS center can safeguard the sensitive equipment and data to prevent immediate failure. Instead, the data can become saved during a power interruption or failure. The equipment can be safely shut down to prevent damage until the main power is restored.

Power Continuity and Protection Against Outages

Power continuity can be obtained when utilizing a data center UPS. It can protect against outages by also being up and running. When the power fails, the backup power can turn on in seconds without having equipment lose its efficiency. These units provide enough power to allow workers to switch on generators as equipment can continue to stay on.

Proactive Response and Meeting Regulatory Compliance

A UPS can boost response times for data center facilities. It allows for remote monitoring of battery health and management, allowing IT staff to react efficiently when finding possible issues. In addition, many industries must abide by regulatory compliance when it comes to protecting sensitive data from loss or corruption. A UPS system provides an extra layer of data continuity.

Types of Data Center UPS Systems

Data centers can use various uninterruptible power supply data center units based on the size of their operations as well as the types of data and equipment that needs protection.

Common data center UPS include standby, line interactive, and online double conversion. Standby units offer simple surge protection and power backup supplies. Line interactive UPS offer additional functions such as voltage regulation and power filtering while online double conversion UPS also offers these features as well as load isolation to protect devices from power irregularities.

Factors to Consider When Choosing a Data Center UPS System

You want to decide on a data center UPS that will handle the power load of the connected IT devices. It should provide enough power for an intended amount of time. Here are several factors to keep in mind when evaluating UPS systems.

Size

UPS units come in various sizes -- from as small as a regular CPU unit to larger capacity systems that can fill a room. You should select a unit based on available free space as well as the battery capacity it can provide.

Runtime

Runtime involves the amount of power that a battery will provide for a specific length of time . UPS batteries can operate from a few minutes to several hours depending on the size and number of available battery cells. You should evaluate the types of IT systems that will be connected and how long the devices will need to operate to determine the UPS that can provide the required runtime.

Capacity

Capacity signifies the amount of power that a device will require from the battery. To determine capacity, you need to calculate the total power load for all the connected devices. It is ideal to select a UPS that has a higher capacity than the actual total load of all connected devices. This factor ensures that there will be enough power for certain equipment that may have varying power demands during operation.

Call FGC to Learn More About Data Center Uninterruptible Power Solutions

Facility Gateway Corporation offers UPS systems for data centers to ensure that your connected IT devices are protected. In addition to UPS sales, we also offer m aintenance contracts , billable technical support, and onsite repair services 24 hours a day and 7 days a week. Whether you are looking for a data center UPS for your facility, or you are in need of other services , we have the field engineers who can provide the work. Contact us today about your UPS needs.

The Importance of Medical UPS Maintenance for Hospitals

Wed, 28 May 2025 15:00:03 GMT

Hospitals depend on a steady power supply to keep life-saving equipment running, protect sensitive patient data, and maintain daily operations. A sudden outage or voltage fluctuation can disrupt everything from surgical procedures to laboratory tests, putting patients at risk and delaying urgent care. Medical UPS (Uninterruptible Power Supply) systems act as a safeguard, providing backup power when the main supply falters. However, like any power system, they require routine maintenance to perform at their best. Without proper upkeep, even the most advanced UPS units can fail, leading to costly disruptions. Regular inspections, battery checks, and system testing help keep hospitals powered, protecting both patients and critical infrastructure from unexpected power failures.

Understanding Medical UPS Maintenance

Medical UPS maintenance involves a structured approach to keeping backup power systems in top working condition. Medical facilities depend on backup power to support ventilators, imaging machines, and life-saving equipment. Over time, batteries degrade, capacitors wear out, and internal components accumulate dust or heat stress, all of which can lead to failures if left unchecked.

Routine maintenance includes battery inspections, load testing, thermal scans, and firmware updates to detect and correct potential issues before they cause disruptions. Preventive servicing also helps extend the lifespan of UPS units, reducing emergency repair costs and unexpected downtime. Hospitals operating without a comprehensive maintenance plan risk sudden power interruptions that can compromise patient safety and delay essential medical procedures.

Partnering with a specialized UPS service provider ensures hospital power systems remain reliable at all times. Expert technicians can identify hidden risks, perform timely repairs, and recommend upgrades that keep medical facilities prepared for any power-related emergency.

Key Components of UPS Maintenance

A medical UPS system requires routine maintenance to stay reliable. Several components need regular inspection and servicing to prevent failures and extend equipment life.

Battery Maintenance : UPS batteries lose capacity over time, which can weaken backup power. Voltage checks, thermal scans, and regular testing help identify failing batteries before they cause disruptions.
Capacitor and Fan Inspections : Over time, capacitors and cooling fans wear out, leading to overheating and reduced efficiency. Replacing them at recommended intervals helps prevent unexpected shutdowns and system damage.
Firmware and Software Updates : Outdated firmware can create performance issues or compatibility problems. Regular updates improve efficiency, correct vulnerabilities, and keep the system running smoothly.
Load Testing and Performance Checks : Testing the UPS under simulated power loss conditions confirms that it will function properly in an actual outage. Routine performance checks help identify weaknesses early, reducing the risk of unexpected failures when backup power is needed most.

The Critical Role of UPS Maintenance in Hospitals

Power disruptions in a hospital setting can have serious consequences. From life-saving equipment to patient records, nearly every aspect of hospital operations relies on a steady power supply. A well-maintained UPS system provides backup power during outages, keeping vital systems running without interruption. Routine maintenance helps prevent failures, extend equipment life, and minimize costly downtime. Hospitals that invest in regular UPS servicing can protect patients, staff, and critical infrastructure from the risks associated with unexpected power loss.

Protecting Patient Safety

When power fluctuates or fails, medical equipment such as ventilators, infusion pumps, and monitoring systems must continue operating without delay. A malfunctioning UPS system can put patients at risk, especially in emergency and intensive care units. Routine maintenance helps prevent battery failures and ensures that backup power is available when needed, providing uninterrupted care for patients in critical condition.

Safeguarding Medical Records and Data

Hospitals store vast amounts of patient data, from medical histories to test results. An unexpected power loss can lead to data corruption, system crashes, or even permanent loss of records. Regular UPS maintenance helps prevent disruptions to hospital servers, keeping electronic health records intact and accessible. Testing and monitoring also ensure that network infrastructure remains protected, preventing delays in diagnosis and treatment.

Powering Surgical Precision

Surgical procedures require precise, uninterrupted power. A sudden outage can compromise operating room equipment, forcing surgeons to halt procedures or switch to manual methods. UPS maintenance helps avoid these high-risk situations by keeping backup power systems fully functional. Preventive servicing reduces the risk of power-related complications, allowing surgical teams to focus on patient care without worrying about electrical failures.

Supporting Pharmaceutical and Lab Accuracy

Pharmacies and hospital laboratories rely on refrigeration units, testing equipment, and automated dispensing systems. A power failure can lead to spoiled medications, inaccurate test results, or delays in providing essential treatments. UPS maintenance ensures that these critical systems remain operational, preventing costly product losses and maintaining accuracy in medical testing.

Ensuring Food Safety in Hospital Cafeterias

Hospital cafeterias provide meals to patients, staff, and visitors, making food safety a priority. Refrigeration failures caused by power loss can lead to spoiled food and health risks. A well-maintained UPS system keeps kitchen appliances running during outages, preventing foodborne illnesses and reducing waste. Routine maintenance helps cafeteria operations remain safe, efficient, and compliant with health regulations.

How to Choose the Right Medical UPS Maintenance Partner

Selecting the right UPS maintenance provider for a hospital requires experience, reliability, and a deep understanding of healthcare power systems. Look for a partner with a proven track record in medical environments and nationwide service coverage. A strong provider offers 24/7 emergency support , preventive maintenance plans, and real-time monitoring to detect issues early. They should also provide compliance reporting to meet healthcare regulations. Customized service agreements ensure maintenance aligns with hospital needs, reducing the risk of unexpected failures. Choosing a trusted partner helps hospitals maintain continuous power, protect patient safety, and avoid costly disruptions in critical medical operations.

Contact FGC for Healthcare UPS Maintenance Services

Facility Gateway Corporation provides expert UPS maintenance to keep hospitals powered and protected. Our team offers preventive servicing, real-time monitoring, and 24/7 emergency support to prevent downtime and safeguard patient care. Don’t wait for a power failure to take action. Contact FGC today to discuss a customized maintenance plan and keep your hospital’s backup power running at peak performance.

UPS Maintenance Guide: Best Practices & Checklist

Tue, 27 May 2025 15:00:06 GMT

Unexpected outages don’t usually stem from dramatic, catastrophic events–they build up over time. Batteries quietly lose capacity. Dust gathers in vents. Cooling fans wear down. Connections loosen with every temperature swing. Then one day, the power flickers, and the uninterruptible power supply (UPS) doesn’t hold. Imaging suites stall, production lines freeze, or server racks go dark.

These avoidable failures quickly escalate into high-cost emergencies. That’s why facilities across industries rely on UPS systems to shield critical infrastructure and safeguard uptime. But having a UPS in place isn’t enough.

Like any complex electrical system, a UPS requires regular attention to operate at peak performance. Without ongoing maintenance and inspections, a system that looks fine on the outside may be seconds from failure. For already-stretched facility managers, this lack of visibility means risks often go undetected until it's too late.

Routine UPS maintenance helps catch problems early, before they become outages. It prevents dust buildup, identifies aging batteries, tightens loose connections, and flags overlooked warning signs. The result? Fewer emergency repairs, extended equipment lifespan, and more reliable performance across the board.

Beyond just keeping the lights on, proactive UPS care helps reduce repair costs, avoid compliance risks, and ensure smooth, uninterrupted operations. And staying ahead of UPS failures can provide peace of mind and keep every part of your operation moving without interruption.

Why Regular UPS Maintenance Is Critical for Facility Operations

Every UPS is designed to be a buffer between your facility and power instability, but that protection is only reliable when the system is maintained. Skipping regular maintenance doesn’t just increase the risk of unexpected shutdowns; it creates blind spots in an otherwise carefully managed environment. Without scheduled inspections and servicing, these wear points can compromise system reliability without any visible warning.

UPS maintenance helps keep equipment online during an outage and protects the systems connected to it. From expensive imaging equipment and PLCs to HVAC controls and network infrastructure, the downstream impact of a UPS failure can be massive. Regular testing, cleaning, and component checks reduce that risk and help your team stay in control of power continuity.

UPS systems are often treated like a one-time install when they should be part of a facility’s ongoing preventative maintenance strategy . Just like HVAC or fire suppression systems, they require attention over time to deliver peak performance when it matters most.

UPS Maintenance Best Practices for Uninterruptible Power Supply Reliability

Effective UPS maintenance starts with consistency. While the specific needs of each system may vary based on size, age, and environment, there are foundational best practices every facility can follow to improve performance and reduce risk.

1. Stick to a Preventative Maintenance Schedule

Treat the UPS like any other mission-critical system. Create and follow a scheduled maintenance plan that includes inspections, firmware updates, performance testing, and part replacements. Consistency helps catch issues early, before they evolve into failures.

2. Control the Operating Environment

Keep the UPS in a temperature-controlled, dust-free, and ventilated space. Heat is a major contributor to premature battery failure and electronic degradation. Use temperature and humidity monitoring in the UPS room when possible.

3. Test and Monitor Batteries Regularly

Batteries are the most failure-prone component in any UPS. Even sealed lead-acid batteries degrade over time. Perform battery testing quarterly, look for swelling or corrosion, and log voltage readings. Replace weak cells before they impact load capacity.

4. Use Remote Monitoring for Real-Time Visibility

Network Operation Center (NOC) monitoring or cloud-based UPS monitoring platforms can alert you to real-time faults, alarms, or environmental conditions, critical for catching silent failures between manual inspections.

5. Document Every Maintenance Event

Record test results, service calls, part replacements, and alarm events. This historical data helps identify trends and plan budgeted replacements instead of paying for reactive repairs.

6. Partner with Experts

Make sure someone on your team knows what UPS alarms mean and how to respond. For deeper support, partner with a maintenance provider that can dispatch certified technicians quickly and handle long-term system health planning.

UPS Maintenance Checklist: What to Inspect and When

UPS reliability depends on regular attention at set intervals. A structured maintenance checklist helps teams stay on top of potential issues before they escalate. Below is a tiered breakdown of daily, weekly, monthly, quarterly, and annual UPS tasks that support consistent performance and long-term system health.

Daily and Weekly Checks

Routine checks keep your team aware of the UPS’s current state and help catch early warning signs.

Review front panel displays for alarms, fault codes, or unusual readings
Confirm the unit is operating in the correct mode (online, bypass, etc.)
Verify ambient temperature and ventilation are within acceptable range
Listen for abnormal fan noise or excessive heat coming from the unit
Log any irregularities and follow up on alerts immediately

Monthly UPS Maintenance Tasks

These monthly checks go deeper into system behavior and site conditions.

Inspect for dust accumulation around vents and filters; clean as needed
Check battery terminals for corrosion or signs of swelling
Review event logs and system performance metrics
Confirm communication links to remote monitoring platforms are active
Visually inspect cables, wiring, and conduit for wear or damage

Quarterly UPS Maintenance Inspections

Quarterly reviews focus on performance, internal health, and electrical condition.

Perform battery testing and voltage measurements
Verify load levels are within system capacity
Inspect internal connections and torque to manufacturer specifications
Test alarm functions and communication protocols
Document condition of components like capacitors and fans

Annual Professional UPS Maintenance Services

Annual visits from certified technicians help detect issues that aren’t visible externally.

Perform thermal imaging on internal components and electrical panels
Load test the UPS under simulated outage conditions
Inspect and test bypass switches
Replace aging batteries, capacitors, or fans if nearing end-of-life
Provide a full written report with recommended corrective actions

Battery Replacement Timelines

UPS batteries are the most failure-prone component in any system, and the most overlooked. Even in ideal conditions, batteries degrade over time due to chemical aging, temperature fluctuations, and charge/discharge cycles. A healthy UPS is only as strong as its battery bank, so staying ahead of battery failure is critical for reliable performance.

Most sealed lead-acid (SLA) batteries, which are common in UPS systems, have a service life of 3 to 5 years. Lithium-ion batteries, by comparison, offer a longer lifespan (around 8 to 10 years) along with benefits like improved thermal stability, faster recharge times, and reduced weight.

However, actual lifespan depends heavily on environmental conditions, usage patterns, and maintenance practices. High ambient temperatures, poor ventilation, and deep discharges can shorten that window significantly.

Here are general battery replacement benchmarks to keep in mind:

3 Years : Begin performance testing quarterly if not already part of your schedule. Monitor for voltage imbalance, internal resistance, and signs of swelling or leakage.
4 Years : Budget for proactive replacement, especially in high-load or mission-critical environments. Waiting until failure at this stage invites unnecessary risk.
5 Years : Replace all batteries regardless of apparent condition unless continuous testing data proves capacity is within the manufacturer's specifications.

Visual inspections alone aren’t enough. Even a battery that looks fine may have lost a significant percentage of its runtime capacity. That’s why consistent testing, such as load tests and impedance scans, are important throughout the battery’s lifecycle .

Partnering with a UPS Maintenance Provider

Between batteries, capacitors, load testing, firmware updates, and monitoring, maintaining a UPS system really requires specialized expertise and a consistent schedule. For many facility teams already managing HVAC, fire protection, and mechanical systems, UPS maintenance can fall through the cracks or become a reactive task after something goes wrong.

Partnering with a dedicated UPS maintenance provider brings structure, accountability, and expert insight to your power protection strategy. Certified technicians know what to look for, how to interpret system behavior, and when to recommend part replacements before failures occur. They also come equipped with tools and knowledge that most in-house teams don’t have, such as thermal imaging, impedance testing, and manufacturer-specific diagnostics.

A service partner like Facility Gateway Corporation (FGC) offers nationwide coverage and tailored maintenance programs that align with your facility’s needs. Whether you require scheduled preventative maintenance , 24/7 emergency service, or ongoing NOC monitoring, FGC delivers consistent support and fast response times from experienced technicians.

Protect Your Facility with a Proactive UPS Maintenance Plan

Power interruptions aren’t always preventable, but UPS failure is. The difference lies in how the system is maintained. Waiting for alarms or warning lights isn’t enough . That’s why facilities that treat UPS systems as part of their regular maintenance strategy see fewer emergencies, longer equipment life, and better performance when the stakes are high.

From daily walk-throughs and monthly inspections to quarterly testing and annual service calls, every task on your maintenance checklist plays a role in reducing downtime risk. And when replacement timelines, load testing, and monitoring are built into your routine (not handled in response to failure), you’re operating from a place of control, not damage control.

If your facility runs on uptime, it pays to have a team that specializes in protecting it. Facility Gateway Corporation (FGC) offers preventative UPS maintenance programs, nationwide service coverage, and rapid-response support from experienced technicians who understand what’s on the line. Whether you’re responsible for a hospital, school, data center, or manufacturing plant, FGC helps keep your power protection strategy ahead of the curve.

Ready to build a smarter UPS maintenance plan? Contact FGC today to learn how we can help keep your operation running, no matter what.

UPS Battery Maintenance Best Practices: 10 Essential Tips

Mon, 26 May 2025 15:00:09 GMT

Backup power systems are a key line of defense against unexpected outages, keeping operations running and valuable equipment protected. At the heart of every reliable UPS is a healthy battery. When batteries are neglected, even the best systems can fail when needed most, putting critical data, production lines, and safety systems at risk.

Regular care extends battery life, boosts performance, and lowers the risk of costly downtime. Managing a hospital, school, manufacturing plant, or data center means every power event puts operations to the test. Building strong maintenance habits keeps systems steady and dependable. Proper UPS battery care plays a major role in overall facility reliability, helping teams avoid unnecessary expenses, protect equipment, and stay focused on their core operations.

Why UPS Battery Maintenance Matters

UPS systems are critical for protecting operations against unexpected power losses, but it’s the batteries behind them that do the heavy lifting. Hospitals, data centers, manufacturing facilities, schools, government offices, and corporate buildings all depend on UPS systems to keep life-saving equipment operational, safeguard critical data, prevent costly production shutdowns, and maintain security and communications during outages. Without reliable backup power, even a brief disruption can damage sensitive equipment, interrupt essential services, and lead to significant financial losses.

Over time, however, even the best batteries degrade. Without regular maintenance, their ability to hold a charge diminishes, increasing the risk of failure when backup power is needed most. Minor issues, like loose connections, temperature fluctuations, or corrosion, can quickly escalate into major vulnerabilities. Routine battery maintenance identifies these problems early, ensuring systems remain dependable. For facility managers, prioritizing battery care means fewer emergencies, lower replacement expenses, and stronger uptime across critical operations. Protecting your batteries protects your entire facility.

How to Properly Take Care of Your UPS

Proper care starts long before a UPS shows signs of trouble. Start by following the manufacturer's recommended service schedule, including load testing to verify battery performance under realistic conditions. Document all maintenance activities, test results, and battery replacements to track trends and predict when service is needed. Environmental control also plays a major role in battery performance. Focus on maintaining proper ventilation, humidity levels, and consistent temperature in battery rooms.

Use battery monitoring systems (BMS) to enable real-time tracking of voltage, temperature, and internal resistance, offering early warning signs before problems occur. Invest in periodic recalibration of the UPS system itself to keep sensing and charging circuits accurate. Working with certified UPS professionals improves maintenance programs, making it easier to catch hidden risks and strengthen long-term system reliability. A disciplined, data-driven approach to battery care dramatically extends system life, reduces operational risks, and helps maintain critical systems stay protected no matter what challenges arise.

How Often Should You Service UPS Batteries?

UPS batteries should be inspected at least once every six months, though many facilities benefit from quarterly checks, especially in demanding environments. Routine servicing helps catch signs of wear, corrosion, or performance loss before they turn into major failures. Load testing, connection tightening, and battery health evaluations should be part of a standard maintenance plan. Environmental factors like temperature swings, humidity, and heavy usage can accelerate battery aging, making frequent checks even more important. Regular service keeps backup systems ready when they are needed most.

10 Essential UPS Battery Maintenance Tips

Beyond your service schedule, knowing what to look for during inspections and how to handle basic maintenance can help make every check more effective. Below are practical steps every facility manager can take to keep UPS systems running at their best.

Perform Regular Visual Inspections

Look for signs of swelling, discoloration, or damage during routine checks. Early detection of physical changes can help stop bigger problems before they start.

Monitor Battery Voltage and Internal Resistance

Tracking these readings helps identify batteries that are starting to weaken. Sudden changes in values often signal deeper issues that need attention.

Keep Batteries Clean and Dust-Free

Dust buildup traps heat and can lead to reduced performance. Wipe surfaces clean using a dry cloth and keep surrounding areas free from debris.

Check for Corrosion or Leakage

Inspect terminals and connections closely. Any sign of corrosion or fluid leaks could mean the battery is nearing the end of its useful life.

Keep Batteries at the Correct Temperature

Batteries operate best within a specific temperature range. Avoid placing UPS systems near heat sources or vents to maintain stable conditions.

Tighten Battery Connections

Loose connections create resistance and heat, both of which reduce battery life. Regular tightening during inspections supports better power delivery.

Test Batteries Under Load

Load testing provides a true measure of battery strength and can uncover hidden problems that simple voltage checks miss.

Keep Track of Maintenance and Performance Data

Detailed records make it easier to spot trends, schedule replacements , and plan future maintenance efficiently.

Replace Batteries Proactively (Not Just When They Fail)

Waiting for failure increases the risk of unexpected downtime. Planned replacements help keep systems reliable.

Work with Certified Professionals for Major Service

Trained technicians can perform deeper diagnostics, battery replacements , and repairs that keep the entire UPS system running at full strength.

Common Problems with UPS Batteries

After building a strong UPS maintenance routine, it’s important to understand the warning signs that can still appear over time. Recognizing the warning signs early can help facility managers avoid unexpected failures and costly downtime. Some problems show up physically, while others affect electrical performance or result from environmental factors.

Physical Issues

Physical Swelling or Leaking: Bulging casings or fluid leaks indicate internal damage and a battery nearing failure.
Corrosion at Terminals: Corroded connections weaken power flow and increase the risk of overheating.

Electrical Performance Issues

Decreased Capacity Over Time: Batteries lose charge capacity over years of use, reducing backup runtime.
Internal Resistance Buildup: Higher resistance inside the battery makes it harder to deliver reliable power during an outage.
Loose or Poor Connections: Unsecured cables or connectors cause intermittent failures and inconsistent performance.

Environmental and Maintenance Issues

Thermal Runaway: Overheating during charging can cause dangerous chemical reactions and permanent system damage.
Improper Environmental Conditions: Exposure to high temperatures, poor ventilation, or excessive humidity shortens battery life.
Neglected Maintenance: Skipping inspections and testing allows small problems to develop into major failures.

Catching minor problems before they grow helps protect battery performance, extends system life, and keeps operations ready for any power event.

When to Replace Your UPS Batteries

Even the best-maintained UPS batteries have a limited lifespan. Most batteries need replacement every three to five years, depending on usage patterns, environmental conditions, and maintenance practices. Signs that a battery may be nearing the end of its service life include swelling, leaking, slower recharge times, or decreased runtime during power events. Higher internal resistance readings and frequent alarm triggers also signal that replacement is approaching.

Proactively replacing aging batteries helps prevent unexpected system failures and protects connected equipment. Facilities operating in high-temperature or high-use environments may need to replace batteries sooner. Regular testing and performance tracking make it easier to plan replacements before problems arise. Timely action keeps backup systems strong and avoids the high costs associated with emergency repairs and unplanned downtime.

How Facility Gateway Corporation Can Help

Protecting UPS batteries over the long term requires a structured plan, specialized tools, and experienced service technicians. Facility Gateway Corporation helps facility managers across the country build stronger maintenance programs that protect operations when they matter most. From routine inspections and proactive battery replacements to real-time monitoring and emergency service, FGC’s team brings the technical expertise needed to keep backup systems dependable and ready.

Every facility has unique needs based on its environment, workload, and equipment demands. FGC works closely with your team to create service schedules, recommend upgrades, and respond quickly if issues arise. Whether you manage a hospital, data center, manufacturing plant, or school, partnering with Facility Gateway Corporation gives you access to a national network of certified UPS professionals who know how to keep your operations running smoothly.

Stay ahead of battery problems before they lead to costly downtime. Contact Facility Gateway Corporation today to strengthen your UPS maintenance strategy and protect your most important operations.

UPS Battery Installation Guide

Fri, 23 May 2025 13:59:40 GMT

In environments like hospitals, manufacturing facilities, or data centers, power backup keeps systems online and prevents equipment or data from being compromised. UPS systems are the first line of defense, keeping systems powered long enough to prevent bigger problems. Most facility teams count on them daily, whether to smooth out voltage spikes or carry the load until generators come online.

But even the most advanced UPS is only as dependable as the batteries inside it. These batteries take the brunt of every outage, and over time, their performance fades. That decline isn’t always obvious… until the moment they’re needed most.

Proper battery installation helps extend performance, reduce surprise failures, and protect the investment made in power continuity. Done right, it also simplifies maintenance, supports clean service records, and keeps warranties intact.

When Should You Replace a UPS Battery?

UPS batteries typically last between three to five years , but several factors can shorten that window, like ambient temperature, load levels, and charge cycles. Preventive replacement based on manufacturer guidelines or real-world performance testing helps avoid unexpected downtime. And rather than waiting for a failure, facility teams should track battery age and monitor performance indicators regularly.

Warning signs for battery degradation include reduced runtime during outages, alarms from the UPS unit, or visible swelling or corrosion on the batteries themselves. For high-demand facilities, it’s common to schedule replacements at the three-year mark to stay ahead of degradation. Routine load tests and visual inspections during scheduled maintenance can also reveal early signs of wear.

If batteries are nearing the end of their rated lifespan or failing performance checks, it’s time to plan a replacement. Delaying can risk system failure during an outage, when performance matters most.

Preparing for UPS Battery Installation

Before swapping out UPS batteries, take time to plan. Skipping preparation often leads to delays, safety risks, or compatibility issues. A smooth installation starts with reviewing the current system setup, understanding power requirements, and confirming the right parts are on hand.

Assessing Your Power Needs

Start by reviewing load requirements and runtime expectations. The number of connected devices, their power draw, and how long you need backup coverage all factor into battery sizing. If any equipment has been added or removed since the last battery cycle, it’s worth recalculating. Underestimating power needs can reduce runtime. Overcompensating can waste budget.

Choosing the Right UPS Battery

Not all UPS batteries are the same. Check voltage, capacity, connector type, and form factor. Cross-reference the model against the manufacturer’s spec sheet, and confirm it matches your UPS system’s configuration.

Take Safety Precautions

Wear PPE, disconnect power sources, and work in a well-ventilated area. Keep fire extinguishers nearby and follow lockout/tagout procedures if required. When teams have a solid plan in place, the install moves faster and avoids surprises.

Step-By-Step New UPS Battery Installation Process

Replacing UPS batteries isn't complicated, but it does require attention to detail. Following a consistent process helps prevent errors, protects equipment, and ensures the system performs as expected after the swap.

Step 1: Power Down and Disconnect the UPS

Start by shutting down connected equipment in a controlled manner. Once everything is safely powered off, disconnect the UPS from any input power sources. Use lockout/tagout procedures where applicable to prevent accidental re-energizing.

Step 2: Remove the Old Battery (If Applicable)

If you're replacing existing batteries , unfasten any mounting hardware and carefully disconnect the terminals. Some systems may have multiple battery blocks wired in series; take note of their arrangement for proper reinstallation.

Step 3: Install New Batteries

Place the new batteries in position, following the same configuration as the original setup. Secure each battery firmly and connect all terminals according to the manufacturer’s wiring schematic. Check for tight, clean connections to avoid voltage drops or poor performance.

Step 4: Reconnect and Test the UPS

Reconnect the input power and allow the UPS to initialize. Run a self-test or manual load test to confirm proper operation and charge function.

Step 5: Perform a Final Inspection

Check for loose connections, signs of heat, or error messages. Document the installation and update maintenance records for future reference.

Common Installation Issues and Troubleshooting

Even a straightforward battery installation can run into problems if a few key details are missed. Spotting and addressing these issues early helps prevent downtime and avoids repeat service calls.

Here are some common issues to watch for:

Loose or corroded terminals – Can lead to poor power transfer or unexpected shutdowns. Always clean and tighten connections.
Incorrect battery placement or orientation – May cause overheating or short circuits. Follow the unit’s exact layout requirements.
Mismatched battery types or voltages – Using the wrong battery can damage the UPS or cause performance drops.
Incomplete or skipped startup testing – Failing to test the system after installation leaves room for undetected problems.
Failure to document the installation – Missing records can delay future maintenance and void warranties.

Addressing these issues during or immediately after installation helps maintain reliability and extends battery service life.

Why Professional UPS Battery Installation Matters

Installing UPS batteries may seem like a routine task, but mistakes can lead to equipment failures, shortened battery life, or warranty issues. Professional technicians bring more than just technical skill, they know how to identify potential problems before they cause downtime. They are also trained to follow manufacturer specifications, use the correct tools, and ensure the system is properly tested and documented after installation.

Certified installers also understand the safety risks involved. Improper handling of battery terminals or wiring can result in short circuits or even fire hazards. A specialized technician works quickly and safely, reducing the risk of injury or system damage.

For facility managers, working with professionals means less guesswork, fewer repeat issues, and more reliable long-term performance. It also provides peace of mind, knowing the job was done right the first time.

FGC Provides UPS Installation Services Nationwide

UPS battery installation plays a direct role in system performance, service continuity, and equipment protection. When batteries are installed correctly, systems stay reliable, warranties stay protected, and service becomes easier to manage. But when shortcuts are taken, even a well-built UPS can become a liability.

Facility Gateway Corporation provides UPS battery installation services across the country, backed by experienced technicians who understand both the technical details and the operational demands of high-uptime facilities. From selecting compatible batteries to completing full-function tests, our team handles the work efficiently and in line with industry best practices.

We support a wide range of industries, including healthcare, education, manufacturing, and IT. If you’re planning a battery replacement or need support across multiple locations, our team is ready to help.

Contact FGC today to schedule service or request a quote.

UPS Fire Risk: Ways To Prevent Electrical Fires

Fri, 23 Aug 2024 18:10:22 GMT

UPS systems in commercial and industrial settings power devices to allow for safe shutdowns of equipment. They also provide workers with the time needed to perform troubleshooting of power systems or to activate generators. However, a UPS unit can pose a fire risk when not properly maintained.

Key Takeaways

Overheating and electrical faults are the two main causes of UPS fires.
Periodic maintenance should be done to both the UPS unit and battery system.
Smart monitoring and centralized management of UPS units can prevent future electrical fire dangers.

What Can Cause a UPS to Catch Fire?

Like any other device in your facility, UPS systems experience a build-up of heat that can cause components to catch fire. They can also give off electrical shocks ranging from 100mA up to more than 2,000mA that could lead to electrical burns. While these are two main problems of what could create a UPS fire risk, there are various sources that can lead to these two causes.

Overheating could be the result of dust or lack of airflow. Components generate heat when in operation. For a UPS system, depending on the type, it can be constantly on to help monitor the current flow for systems, charge the batteries, and clean up "dirty power" for equipment. When dust covers the components, the dust creates a thick coating around air ducts and vents. The heat inside the casing has no means to escape, leading to too much heat build-up. This excessive heat can cause components and dust to catch fire.

The location of the UPS system and high room temperatures can also cause the UPS unit to overheat. You may have the UPS situated in a location where other components or even the wall blocks off or impedes air flow from the vents. These obstructions prevent the heat inside the UPS from becoming expelled by the fan. Also, if the room is excessively hot or the room's cooling system fails, the hot temperatures in the room along with the hot temperatures in the UPS can create issues.

Electrical faults happen when there is a problem with the electrical flow. Some common types of electrical faults include arcing, short circuits, or battery overcharging. Arcing, also called an arc flash, occurs when several pieces of equipment become energized. The conductor gives off electrical energy that moves through the air to another conductor to cause an electrical flash. This arcing creates a large amount of heat that can cause objects to explode or combust.

Short circuits are another type of electrical fault that could cause a potential UPS fire risk. A short circuit happens when the electrical current flows in the wrong direction. This issue can cause equipment to overload, which leads to excessive heat and explosions. Battery overcharging occurs when there is an excessive float voltage. If the electronics that control the float charge fail due to damage, it could cause the battery to overcharge and combust.

UPS Fire Risk Management Tips

Preventive maintenance is the top priority when it comes to preventing issues that could create a UPS fire risk. This maintenance should focus on both the UPS system as well as the battery. UPS maintenance consists of inspecting components for possible issues, replacing parts with excessive wear-and-tear or damage, and cleaning out dust.

UPS battery maintenance should look for physical problems with the battery, including swelling and leakage, as well as reduced battery capacity and runtime. Additional fire risk management tips would include checking the vent openings for any obstructions from other equipment or objects.

You also want to monitor the room temperatures to ensure cooling systems reach the UPS unit. You can also obtain a UPS unit that features monitoring functions and alarms that can warn you of potential issues between maintenance inspections.

Another UPS fire risk management tip involves providing additional safety devices. If your operations deal with excessive power surges or voltage spikes, connecting additional surge protection equipment in conjunction with the UPS unit can provide extra protection. Another layer of equipment monitoring can provide timely alerts to potential issues if the UPS system itself experiences a failure.

How UPS Systems Prevent Electrical Fires?

A well-maintained UPS system can also help to prevent electrical fires. Some of these features are included as part of the UPS system, while others are future innovations.

Engineers are looking into technologies to design UPS units with smart tech that can integrate with other smart devices in the facility, such as fire protection systems, smoke alarms, and other connected emergency equipment . This integration also involves constant, real-time monitoring through cloud platforms and mobile applications. You can manage UPS data and reports through remote devices for faster repair responses and system shutdowns to create a safer working environment.

With smart UPS functions and features, the units can detect power anomalies, excessive wear to components, battery issues, and high temperatures. A range of actions can then be taken, such as sending alerts to workers, sounding alarms, cutting power to batteries to prevent overcharging, or safely powering down connected devices.

Bottom Line

A UPS system is designed to provide backup power for your facilities in case of power blackouts, surges, or other anomalies. However, these systems also need to be managed to prevent safety risks such as fire hazards.

Depending on your power needs, you want to size the UPS system to your energy load to ensure it can provide the required emergency power. Then you want to install the unit properly and develop a periodic maintenance plan to inspect and repair the UPS to address the common causes of UPS fire risks, such as overheating and electrical faults. Constant monitoring done by both the UPS unit and by workers can prevent small problems from becoming larger safety issues.

Batteries in Series vs Parallel: Types of Battery Connection for Power and Voltage Optimization

Mon, 15 Apr 2024 16:56:01 GMT

Ever found yourself immersed in a weekend project, like setting up a backup power system for your business or setting up a solar power system, only to hit a roadblock when it comes to connecting batteries? The excitement of creating a reliable and efficient energy source can quickly turn into a maze of decisions when you encounter the dilemma of series versus parallel battery connections. As you strive to optimize your power setup, the need to understand the disparities between these configurations becomes apparent.

When connecting multiple batteries, you may have them placed in a series or parallel depending on the power and voltage needs of the application.

Key Takeaways

Positive-to-positive connections (parallel) offer an increase in the overall output of power.
Positive-to-negative connections (series) provide an increased voltage output.
The number of batteries used for a series vs parallel connection is based on battery capacity, battery voltage, and the application.

Batteries in Series vs Parallel

Batteries serve various purposes, such as powering systems, offering backup during emergencies, or storing renewable energy like solar and wind power for grid use. In many cases, multiple batteries are required for these applications, with the batteries interconnected both among themselves and with the target device. Two common configurations for integrating these batteries are series connections and parallel connections, and the choice between them depends on how the positive and negative terminals are interconnected through the cable harness.

Using multiple batteries is ideal when the battery chemistry cannot be changed to offer higher power or voltage for the application. This configuration is also used when a larger battery cannot be placed in the device.

Batteries in Series: Pros and Cons

With batteries in a series, the voltage increases by double. So two 6-volt batteries will provide 12 volts while two 12-volt batteries will offer 24 volts. For a series configuration, batteries must have the same voltage for a safe connection to prevent damage. A 6-volt battery should never be connected to a 12-volt battery in a series placement. Also, keep in mind that even with the increase in voltage, the amp-hour capacity does not change.

There are various advantages to batteries in a series. Series configurations are necessary for high-voltage applications. The load on the batteries is spread across them equally, helping to reduce stress while providing an increase in overall battery efficiency. For alternative power storage or backup power, a series configuration can store more energy for extended periods of time.

Overcharging and undercharging are two types of disadvantages to a series configuration. If one battery cell is weaker in the series, charging may continue in the attempt to fill the weaker battery while the rest have full capacity. Another instance is when the charge is stopped when batteries with more capacity are fully charged without the weaker battery reaching its top level. So the weaker battery remains undercharged. Battery balancing is usually required to prevent overcharging or undercharging which can degrade the battery pack's performance.

Another disadvantage is that battery cells can discharge at different rates. Batteries can discharge quickly and die before others, as this problem may lead to the system shutdown. Only four batteries can be placed into a series unless the batteries have lead cell chemistries. There is no limit to the number of lead cell batteries in a series configuration.

Batteries in Parallel: Pros and Cons

Batteries arranged in a parallel configuration result in an increased amp-hour capacity. For example, connecting two batteries, each with a capacity of 100 amp-hours (Ah), in parallel yields a combined capacity of 200Ah. Similar to batteries in series, batteries in parallel need to have the same voltage. However, the voltage itself remains unchanged. For instance, if you connect four 12-volt 100Ah batteries in parallel, the configuration provides a total power capacity of 12 volts and 400Ah.

Parallel battery connections are designed to increase the length of time that the battery offers power to the application. There are many advantages to this configuration. With parallel configurations, the chance of overcharging or undercharging for a weak battery decreases.

Devices that have high power needs can get the right amount of battery power for a specified length of time. Also, if a battery fails, the system will keep running off the power offered by the remaining batteries.

Disadvantages to parallel connections are thermal runaway and a decrease in efficiency. Thermal runaway occurs when one cell overheats as this overheating can spread to the rest of the batteries quickly to the point of fire or explosion. Another disadvantage is that the battery's energy storage capacity is not increased. These batteries can also take longer to charge.

How to Connect Batteries in Series

A series battery connection involves the cables connected end-to-end. The cable runs from the positive terminal of one battery to the negative terminal of the second battery. If more than two batteries are used, such as 4 battery cells, one set of batteries will have a positive-negative connection as the other set of batteries will do the same.

There will be two positive terminals open and two negative terminals open. The positive terminal of one battery set will be connected to the positive terminal on the other battery set. The negative terminal will become connected to the other available negative terminal. So all four batteries will now be connected.

How to Connect Batteries in Parallel

A parallel battery configuration involves using a cable to connect the positive terminal of one battery to the positive terminal of the second battery. Then the negative terminals are connected by another cable. This setup continues until the appropriate capacity is reached.

The positive and negative ends of the parallel battery configuration are then connected to the device, inverter, or alternate power source controller. The number of batteries that can be connected in a parallel configuration is not limited by battery chemistry type. Usually, for solar power batteries, 8 cells can be connected. The determining factors for the number of batteries to use in this setup are based on capacity and battery type.

Bottom Line

Connecting batteries series vs parallel configurations can offer an increase in power or voltage that can suit your application. Evaluating the application, space requirements, battery chemistry, and other factors can allow you to decide on which placement will be right for your devices. It is always recommended to never mix battery types or manufacturer brands since manufacturers will develop unique cell chemistries that can differ from other battery cell producers.

Commercial and industrial operations that use main electrical grid power may still rely on UPS batteries to provide backup power in case of power outages, surges, or fluctuations. Here at Facility Gateway Corporation, we provide UPS units for sale as well as provide parts and maintenance services. Contact us today to learn more.

How Do I Calculate What Size UPS I Need?

Thu, 11 Jan 2024 22:36:34 GMT

Uninterruptible power supply (UPS) units play a crucial role in providing backup power for your connected devices during power fluctuations, surges, or failures. This ensures the continuous operation of vital equipment, data protection, and a seamless transition to generators if necessary. To determine the ideal size and type of UPS for your requirements, it's essential to calculate both the load and runtime specific to your equipment. In this guide, we'll walk you through the process.

Key Takeaways

Identify Your Equipment: Begin by listing the equipment that needs UPS protection, excluding non-essential devices to avoid energy wastage.
Calculate Total Energy Usage: Determine the total energy consumption of your connected equipment during peak operational hours.
Factor in a Safety Margin: Allow for additional load capacity to prevent running the UPS at 100% capacity, which can lead to inefficiencies and potential failures.
Regularly Update: Periodically review your energy consumption and adjust your UPS system to accommodate future expansions or equipment upgrades that may alter your total load.

What Size UPS Do I Need?

When sizing a UPS unit, focus on two critical factors: load and runtime. First, figure out the peak load your equipment requires during the day, which refers to the power consumption of a device at any given moment. Simultaneously, calculate runtime , indicating how long the UPS battery can power your devices until the main power returns, or switch to generators.

Ensure that your UPS handles only essential equipment for emergency operations. Avoid including unnecessary devices, as they can drain valuable energy resources.

Select a UPS size that strikes the right balance – neither undersized, risking inadequate power supply, nor oversized, resulting in energy waste and space consumption. Mismanagement of UPS size can also lead to unit failure .

How to Calculate the Total Amount of Power Needed for a UPS System

To determine the total power load of your equipment, consult the technical labels on each device, where power consumption is listed in watts (W) or volt-amperes (VA). If these figures aren't readily available, check technical data sheets or the manufacturer's guide/manual. In case of uncertainty, contact the manufacturer directly for specifications.

Alternatively, consider using a separate meter to measure the power consumption of your essential equipment during peak operations. Avoid using the main utility meter, which accounts for the entire building's power usage, including equipment unrelated to the UPS.

How to Calculate UPS Runtime and Load

Once you have the list of equipment and their power usage figures, you can evaluate the UPS unit that best suits your needs. UPS unit requirements are typically stated in volt-amperes (VA) or kilo-volt amperes (kVA). To convert watts to volt-amperes, use the formula: VoltAmps = Watts / Power Factor.

You can also calculate the Power Factor (efficiency) of your equipment by dividing True Power (measured in Kilowatts) by Apparent Power (measured in VoltAmps).

Sum the VoltAmp values for all equipment listed in watts. To ensure the UPS doesn't run at maximum capacity, increase this base value by 20% to 25%. The resulting number represents the required UPS unit value, helping you choose the appropriate UPS model.

In addition to load calculation, determine how long your UPS needs to keep devices operational.

This involves three steps:

Multiply amp-hour (Ah) battery rating by battery voltage (V) rating: Ah x V = new rating.
Multiply the new rating by battery efficiency and the total number of batteries: new rating x battery efficiency x total batteries = new value.
Divide the new value by the watt load: Watt load / value = battery runtime.

Now you have both runtime and load calculations to guide your UPS selection.

Consider Building Layout

Lastly, keep in mind that the layout of your building can influence UPS unit selection. If space constraints prevent the installation of a larger UPS unit, consider multiple smaller units, segregating equipment to each UPS. This necessitates recalculating power consumption based on the specific devices connected to each unit.

The Bottom Line

Here at Facility Gateway Corporation, we offer UPS equipment for your operations. Obtain the UPS systems you need to keep your operations running efficiently when there is a power failure or when disaster strikes. We also offer UPS maintenance and parts to keep your unit running optimally. Contact us today to learn more.

Types of UPS Batteries and Their Uses

Wed, 11 Oct 2023 20:08:58 GMT

UPS systems rely on storing power inside their battery that can be used as a backup energy source for connected devices. While there are different types of UPS devices for applications, there are also many types of UPS batteries.

When it comes time to replace the UPS battery , you want to get the one that offers the right amount of backup power for your devices. The types of UPS batteries to have will depend on the application, shelf life, and your budget.

Why Are UPS Batteries Critical?

Batteries make up the crucial function of a UPS system. When the main power comes into the facility, some of the electricity flows into the UPS battery as backup power. The rest of the electrical current moves through the UPS to the connected devices.

The moment a power fluctuation or failure occurs, the UPS switches from the main power supply to the battery. The battery will provide enough current to run devices for a short time. This time period may allow you to save necessary files or work on PCs, or finish performing other tasks using the specific device. The battery may also give enough time for you to discover the source of the main electrical failure to make repairs.

What Are the Main Types of UPS Batteries?

The three main types of UPS batteries are VRLA, VLA, and lithium-ion. A UPS will typically have multiple cells of the same battery chemistry lined up as a series or in a series-parallel arrangement to provide a maximum current while optimizing the space inside the UPS unit.

VRLA

Value-regulated lead acid (VRLA) batteries employ the oxygen recombination technology where hydrogen produced during charge/ discharge recombines with oxygen, as the oxygen develops on the positive plate, and becomes diffused onto the negative plate. This battery type is vented to prevent a build up of hydrogen gas which is produced during the discharge/ recharge process. These batteries have lower costs and are sealed so the electrolyte will not leak or drip out if inverted.

VLA

Vented lead acid batteries are also known as flooded or wet cells. They contain acid electrolytes that are flooded over thick lead plates. These batteries require more maintenance but have a longer lifespan and are more reliable than VRLA batteries.

Lithium-Ion

Lithium-ion batteries are the newest battery innovation as they are lightweight, small, and powerful. The batteries are used for heavy-duty applications. Lithium-ion has faster recharging than lead acid batteries and relies on a battery management system (BMS) to monitor temperature, voltage, and current fluctuations.

How Long Do UPS Batteries Last?

VLRA batteries have the shortest lifespan of 5 years. VLA batteries, when well maintained, may last up to 20 years (pro-rated life). Lithium-ion batteries have a lifespan of about 8-10 years.

Keep in mind that the shelf life of the UPS battery may be shortened due to a variety of factors, including poor maintenance, damage, or fluctuating room temperatures.

To learn more about UPS batteries and to get UPS battery replacements , contact Facility Gateway.

Main Components of a UPS System

Mon, 25 Sep 2023 20:43:26 GMT

What is a UPS System?

‍Briefly, a UPS system is an electrical apparatus that provides emergency power to a load when the input power source or main power fails. Businesses use UPS systems to protect their computers, data centers, and other electrotonic equipment in the event of an unforeseen loss of power.

Without the backup a UPS system provides, loss of power can lead to a range of catastrophic outcomes, from data loss and business disruption to injuries and fatalities. UPS systems can be small, protecting a single computer, to large, protecting entire businesses, schools, factories, and hospitals.

Large or small, all UPS systems have four main components. Understanding the basics of how your UPS system works is the first step to providing the best maintenance.

Main Uninterruptible Power Supply (UPS) Components of UPS Systems

There are four main components in a UPS system:

The UPS batteries
The rectifier
The inverter
The static bypass switch.

What are UPS Batteries?

The UPS batteries are the “heart” of any UPS system. UPS batteries are the source of emergency power in the event of a power loss. During a utility power failure, the UPS batteries support the connected load. Either the rectifier or a separate charger ensures that the batteries are always charged.

There are several types of UPS batteries, but the most common are 1) Valve Regulated Lead Acid (VRLA), 2) Flooded Wet Cell (commonly called VLA), and 3) Lithium-Ion.

All UPS systems contain at least one “string” of batteries, or a connected number of required batteries. The number of batteries in a string will depend on the UPS system’s DC (direct current) voltage. In smaller UPS systems, battery strings might be housed inside the UPS unit itself. In larger UPS systems, batteries may look like separate pieces.

Because batteries are connected in strings, and the strings are connected in a series, if one battery goes bad, it could cause the entire UPS system to fail. For this reason, the regular inspection and maintenance of UPS batteries is critical, regardless of their age.

What is a UPS Rectifier?

The rectifier serves a few critical functions. First, the rectifier is the piece of the UPS system that converts input power from AC, or alternating current, to DC, or direct current. DC power routes to the inverter. This is the first half of a double conversion process.

The rectifier is also responsible for re-charging the UPS batteries.

What is a UPS Inverter?

The inverter is another key part of the double conversion process. The double conversion process works as a filter for events like electricity surges or spikes, and electrical noise.

As explained above, the rectifier converts input power from AC to DC power, and DC power routes back to the inverter. The inverter works as part of the double conversion process by converting the DC voltage back to AC output. This AC output is what powers the critical load.

The conversion process basically looks like AC -> DC -> AC again. The output of the process should be a pure sine waveform.

What is a UPS Static Bypass Switch?

The UPS static bypass switch is the superhero in the event of a failure of the UPS system. The status bypass switch works as a safeguard, automatically connecting the load to the main supply.

The static bypass switch gets its name because in the event of a system failure, it bypasses the other three main UPS system components (the rectifier, batteries, and inverter.)

The static bypass switch is a backup. It doesn’t perform the filtering function like the double conversion process described above. However, the existence of the static bypass switch within a UPS system ensures the system can keep working on utility power in the event the batteries, inverter or rectifier fail. Please keep in mind that some components can not safely be worked on while the UPS is in Static Bypass. That is why FCG recommends adding an external maintenance bypass to any critical UPS application

What is an External Maintenance Bypass?

An External Maintenance Bypass is a separate device consisting of breakers (sometimes a rotary switch) and bussing that allows the user to completely isolate the UPS system from power while still providing Utility power to the load. In other words, the allows utility power to wrap around the UPS system and shut power off to the UPS and Batteries without dropping the load.

In some cases, with the use of an External Maintenance Bypass, you can completely remove an older UPS and replace it with a brand new unit without losing power to the load.

Other Parts of UPS Systems

Depending on your specific UPS system, and its size and type, your system may include several other components. Your UPS system might include fans, capacitors, external maintenance bypass, or transient volt surge suppressors, for example.

Scheduling preventative maintenance visits are crucial to preserving the functionality of your UPS system. FGC Service offers a wide variety of maintenance services of Uninterruptible Power Systems, including emergency service, NOC monitoring, site surveys, generator & HVAC service, rental services, and construction management.

We understand the importance of proper UPS battery maintenance and the technical requirements needed to install and recycle any string of batteries.

To speak with one of our product specialists directly, we invite you contact us or start a chat with our team in the chat feature at the bottom right corner of this page!

How To Calculate UPS Runtime and Load

Thu, 20 Apr 2023 20:25:12 GMT

When purchasing a UPS system, you want to ensure that it can handle the load for the connected devices. If the UPS is too small, the connected devices will draw the power from the backup battery too quickly to allow you to fix the main power source. You won't have enough time to run the devices for a proper shutdown. Calculating the UPS runtime and load will allow you to have the right backup battery for your connected devices.

Tips for Calculating UPS Runtime and Load

To figure out the load and runtime, you want to list all the devices that will be connected to the UPS. Then check out the labels that are on the back, underside, or side of the devices that will have the amps and voltage of the devices. Take the number for the amp and multiply it by the voltage rate. This measurement will be your VoltAmps (VA). If the device lists wattage instead of the voltage, you can take the watt measure and divide it by the power factor to convert the measurement into VoltAmps.

Now, you want to multiply the VoltAmps by the number of equipment. This action will give you the VA subtotals as you want to add up the subtotals to get your total power requirement. Lastly, multiply this measurement by 1.2 for a total. This grand total is the VoltAmp requirement.

VoltAmps x amount of connected equipment = VA subtotals.

Add VA subtotals for total power requirement.

Total power requirement x 1.2 for the total when adding on more equipment in the future.

How To Calculate UPS Backup Time

When calculating the amount of backup time the battery in the UPS has to provide to your devices, you want to take the amp hour battery rating (Ah)and multiply the rating by the battery's voltage rating. You also want to multiply the number of batteries as well as the efficiency of the battery to this measurement. Once you get a total, you want to divide the watts by this number. Understanding the backup time allows you to know how much time your devices have to operate once the UPS switches to battery power.

The calculation would be: battery Ah rating x battery voltage (v) rating x the number of batteries x battery efficiency. Then divide this number by watt load.

You can then figure out what you need to do with your equipment when the UPS is in operation. If you don't plan to have any generator connected, you'll have enough time to safely power down equipment. If you must keep equipment running for long hours, you may connect a generator as the UPS battery will be used to give you enough time to power up the generator . If you only need a few hours of backup power to finish tasks before powering down equipment, you may also obtain extra backup batteries to work with the UPS unit.

Things to Consider When Calculating UPS Runtime and Loading

Keep in mind that you can increase the runtime based on the number of batteries that you add on as modules to the UPS unit. However, even when having these extra batteries, you won't be increasing the capacity of the UPS system. You'll just have more time for your devices to run during outages.

Also, once you calculate the VoltAmp requirement, you will want to pick out a UPS unit with a VoltAmp rating that is always above this measurement. You may have to recalculate the runtime and loading measurements for your equipment when upgrading your connected devices or adding on more devices. You then may have to upgrade your UPS unit to provide adequate power for the new equipment.

UPS Sizing Calculator & UPS Selection

There are several ways to calculate the UPS runtime and load. The easiest method is to use the manufacturer's sizing tools and calculators. Many companies post online calculators on their websites. Once you get the calculation, you can then pick out the UPS unit that matches the measurements. Once you know the load, you can place in enough backup batteries to have the right amount of runtime so that the connected devices can operate for a specific amount of time.

Depending on how the manufacturer has set up their website, the calculator may list UPS choices on the same page that meet this requirement, or it may provide a link to a web page that best suits your needs. Otherwise, measure the VoltAmp rating of all your devices and compare it to the Volt/Amp rating of the UPS system.

The UPS ratings on the label can differ in meaning. You may see it say VoltAmps (VA), kilowatts (kH), or kilo-volt-amperes (kVA). The watt of the UPS is the unit's real power, while the VA and kVA ratings are the power limitations. The type of current that the UPS system uses may reduce the watts for the VA rating, which is the case when it comes to using AC power. This aspect is considered the power factor. The power factor is the ratio of these two measurements. So if the UPS has a rating of 100kVa, it may only be able to handle a load of 80kW of real power due to the AC having a power factor of 0.8 that is flowing into the circuit.

When it comes to UPS units, having the right backup power is essential to protect equipment from power fluctuations, surges, blackouts, and other emergencies . Here at Facility Gateway Corporation, we help customers figure out the right UPS system for their devices as well as offer UPS maintenance and repair. Contact us today to learn more.

What Is a TVSS? Transient Voltage Surge Suppressors

Fri, 14 Apr 2023 20:06:59 GMT

What is a TVSS Device?

A TVSS is a device that cuts off the power from the AC line when encountering a power surge or a power spike, which are considered transients. The name TVSS has officially been replaced with the more commonly known phrase surge power device (SPD) yet is still in use today. The devices cut off the flow of power when there is a surge or spike to prevent sensitive and critical-mission equipment from becoming damaged. These devices differ from uninterruptible power supply (UPS) devices as TVSS devices do not store energy in a backup battery pack for later use due to a power outage.

Power system transients occur for a short period of time at very high voltages. A common type of transient would be considered a lightning strike. The surge can happen within a microsecond (1/1000 second) or millisecond (1/1000000 second). A transient voltage surge suppressor is designed to offer some protection from these transients yet cannot always handle large overvoltages such as 50,000v that can come from a lightning strike.

What Does a Transient Voltage Surge Suppressor Do?

A transient voltage surge suppressor monitors the voltage from the AC power line. It takes into account the input and output waveforms and does nothing during normal power operating functions. When detecting an abnormality in the voltage, the TVSS closes its switch. This process prevents the surge or spike from traveling further up the line and into the connected devices. TVSSs are commonly used to protect sensitive electronic equipment from damage caused by voltage spikes and surges, such as those that can occur during lightning strikes or power grid fluctuations.

Types of TVSS

When looking at TVSS and other surge protection equipment , you will notice that there are different types of these devices. Each TVSS device is categorized by type (1, 2, or 3) or by category (A, B, or C) based on where it is installed along the AC line. Understanding where they are installed and what functions are included in the device.

Type 1 (Category C) TVSS:

These devices are installed along the line side of the device yet can be placed in any location in the power distribution system. So you may find a Type 1 TVSS outside the service entrance, inside the building along the branch panel, or up to the point of use for the connected device. The device will have different functions such as overcurrent protection installed. It does not require external overcurrent protection. The Type 1 TVSS has a nominal discharge current of 10kA or 20kA. The Type 1 TVSS is designed to handle high-energy surges and is suitable for use in applications where lightning protection is required.

Type 2 (Category B) TVSS:

You will install a Type 2 TVSS at the load side to the service entrance. The load side is considered the service entrance for the AC power line at the branch panel. Some TVSS have overcurrent protection while others will require external overcurrent protection from other devices such as a CB or fuse). The nominal discharge current for Type 2 TVSS is 3kA, 5kA, 10kA, or 20kA. The Type 2 TVSS is typically used to protect individual devices or equipment within a facility from the effects of smaller, more frequent voltage surges and spikes. These devices are commonly found in commercial and industrial settings, where the cost of equipment damage due to electrical disturbances can be high.

Type 3 (Category A) TVSS:

The Type 3 TVSS are devices such as receptacles, plugs, or power strips, which become installed near the connected electronic device that it is protecting. These devices are very common for both commercial offices and residential homes to protect smaller electronics from surges that may come from wall outlets.

Keep in mind that Type 1 and Type 2 TVSS are hardwired into the AC line while the Type 3 TVSS are considered plug-ins. In addition to certain TVSS identified by category or type, other TVSS may be defined by the design of the switch components and how much voltage they can handle. They are also categorized by their response time. There are three types called clamps, crowbars, and hybrids.

When selecting a TVSS, you want to understand the power surges that may commonly occur in your building or region. You also want to look for a UL listing on the device that says TVSS. If the device does not have this listing or says "TAP" on the label, it may be a current tap device that looks like a TVSS but does not have a protection value. Ensure the hard-wired TVSS that you purchase comes with a component schematic for maintenance and servicing, and that the TVSS comes with a warranty.

When you are in need of surge suppressor devices, surge protection devices, UPS systems, and other backup power supply systems, turn to the experts at Facility Gateway Corporation. Contact us today to learn more.

UPS Alarms: Understanding Lights and Beeps

Tue, 21 Feb 2023 19:39:49 GMT

UPS systems are designed to operate automatically when there is a power fluctuation, power failure, or other abnormality to ensure that connected devices continue to operate until the main power is restored. However, a UPS system still needs to be monitored and maintained. If a problem occurs, the UPS alarms and lights will activate to warn workers that there is an issue with the UPS. These lights and alarms provide a signal so workers who may be in different areas of the facilities, can hear them and instantly know what to do. With regular maintenance , a UPS can last for years to provide power protection to your devices.

Different Types of UPS Alarms and Their Meanings

The UPS system will have different types of alarms based on the present issue . While every manufacturer will have a different type of display, LED warning lights, and alarm sounds that will be unique to their brand, most UPS will have a basic meaning to each light and sound.

If the UPS gives an audible beep, ring, or siren sound, it is a general indication that there is a problem with the system . The noise is to give the first alert to a problem. The sound is designed to be loud enough to be heard and different enough to the regular sounds from the connected devices to catch a worker's attention. The sound is to bring the worker to the UPS device so they can look at the control panel and see which lights are on for the UPS.

A manufacturer may have different alarm sounds based on a specific problem. To understand their meaning, it is advisable to review the UPS manual for that specific system. Otherwise, most UPS will have the basic alarm for both minor and major malfunctions as well as color-coordinated lights that will activate.

Common Causes of UPS Alarm Activation and How to Troubleshoot Them

A minor problem that may activate an alarm could be a component that has reached its end of life. This pre-warning alarm gives a worker a signal that a component may be on the verge of a breakdown and that the worker should take the necessary steps to fix the component before it completely breaks down. During the pre-warning alarm, the UPS may still continue to function normally. The alarm simply gives the worker ample time to order the necessary parts to perform the repairs.

Another common cause could be a power surge or short circuit. These issues could place the UPS in a bypass mode, battery mode only, or standby mode. The system is waiting for further instructions or troubleshooting from the worker to determine the root cause and to perform the necessary actions to get the system back online.

Battery issues could also create an alarm activation. The battery could be damaged, overheating, cannot hold a charge, or some other issue.

There may also be a problem with the wiring within the UPS that draws the power into the system or to the battery. There could be faulty wiring, a faulty connection, an overheated circuit, or other issue.

How to Interpret the Different Lights and Beeps of a UPS Alarm

Green, amber/yellow, and red are the three basic colors that will be lit on the control panel when experiencing a UPS malfunction. The green light will always be lit once the UPS is connected and turned on. This color indicates that the UPS is in good working condition and providing monitoring protection for all your connected devices.

An amber or yellow light is used as a warning signal. It may indicate that the UPS unit is still operating but something may cause it to malfunction soon. The UPS may turn on the amber light when the UPS system has switched into bypass mode, battery mode, or standby mode. It could also mean that a component is not working at an optimal level and needs to be checked.

Red colors on the UPS unit indicate a major issue. Some type of critical error has occurred. The UPS system is still receiving power, but other functions may have failed. If there are no lights on the unit, the UPS display may have malfunctioned. The system can still be online but working.

The Importance of Regular Maintenance and Testing of UPS Alarms

Regular testing and maintenance of UPS alarms ensures that the monitoring system for the unit is in operational order. Like any safety device, testing and maintenance should happen on a periodic basis, such as testing at least once a year and maintenance every few months depending on how often the UPS unit is used and whether it is connected to mission-critical devices. You are able to determine if all components and internal systems are working properly, as well as catch issues while they are small.

When an issue is small, you can perform an immediate fix before the UPS goes into failure. At this stage, you can also lower your repair and maintenance costs while keeping the UPS unit working as expected. During maintenance, you can also ensure all functions and software is updated to the latest versions.

Keeping your UPS unit up and running ensures that your connected devices still have power when there are energy fluctuations or an outage with the main power source. Yet your UPS system also requires monitoring and repairs when it experiences issues. Working with companies such as Facility Gateway allows your UPS units to receive timely maintenance and testing to determine any issues and perform immediate repairs. We also provide maintenance contracts to service the UPS periodically to keep everything in working order. This service can help minimize downtimes for your mission critical devices. For more information, contact us today.

Line Interactive vs Double Conversion UPS - Which is Better?

Tue, 24 Jan 2023 21:45:58 GMT

Uninterruptible power supply (UPS) systems provide backup power to connected devices to ensure safe shutdown and to run equipment for short periods of time until the power can become restored.

UPS systems are also used when there may be power fluctuations that impact operations, as the UPS will regulate the voltage to be more stable to prevent equipment damage. Two types of UPS systems are line interactive and double conversion. Learn more about line interactive vs double conversion UPS units.

What is Line Interactive in UPS?

Line interactive involves the operation of the UPS system , which is referred to topology. It involves how the incoming voltage is treated by the UPS system to the benefit and protection of the devices connected to the UPS that will receive this power. Line interactive UPS have a monitoring system designed to evaluate how power comes in from the main power source. This monitor device located in the UPS will activate when there are spikes or decreases in the power. This function is referred to as voltage regulation to address problems such as surges, brownouts, blackouts, electrical impulses, and other anomalies.

Power anomalies can occur for a variety of reasons, such as a problem with the main power supply coming in, storms impacting power lines that can cause brief outages, or when interior or exterior work is done to power systems. Power fluctuations may also occur when other devices on the power unit pull more energy through the system during peak hours or aggressive operations.

The line interactive UPS system will either boost power or decrease power based on the detected anomaly. When it boosts power, it may allow more energy to pass through the UPS unit and directly to the connected device without undergoing other functions, such as line noise filtering. The device obtains the uninterrupted power in the amount it needs to continue functioning until the energy from the main power line evens out.

In the cases when there is a decrease in power from the main supply, the line interactive UPS will switch from the main power supply to the backup power. The devices can continue operating at full capacity without a slowdown in operations. When the power supply returns to normal operating current levels, the UPS will switch back to the main power supply. Normal transfer time between the main line power and other to the battery may typically take about 2 milliseconds up to 4 milliseconds.

Other functions of a line interactive UPS system include providing pure sine wave output, surge protection, and noise protection. While all line interactive UPS offer surge protection, many but not all units will provide pure sine wave output or noise protection.

What is Double Conversion in UPS?

Double conversion UPS, also called online UPS, provides higher levels of protection from raw paper coming in from a utility line. Similar to line interactive UPS, the double conversion system offers voltage regulation but uses a precise method of power conversion. It takes the incoming AC voltage that may be too high or too low to set parameters and changes it to DC power. Then the DC power is converted back into AC power before being sent out to power connected devices.

This method of power conversion offers a more stable energy supply by isolating equipment completely from the incoming power from the main power supply. It is continuous operation for the UPS unit. In addition, there is no transfer time to switch between backup power and main power because the inverter is automatically supplying the power during the conversion method.

Other functions include having an internal static bypass. This bypass protects connected equipment and ensures they have the power for continued operation in case something occurs to the UPS unit. If the double conversion UPS malfunctions, becomes damaged, or needs maintenance, the connected devices still have the required energy.

Similar to line interactive UPS, a double conversion UPS also offers pure sine wave output, noise protection, and surge protection. All double conversion ups offer these features.

Line-Interactive vs. Double Conversion - What's the Difference?

Line interactive UPS are normally used for main power supplies that offer more clean and stable energy. They provide a reliable backup system at a cheaper price.

In the case of double conversion UPS, they may be used when the main power supply is "dirty." Dirty power is when the delivered power supply is constantly experiencing surges, power fluctuations, voltage variations, and frequency variations. Since the power is experiencing these abnormalities on a daily basis, the double conversion UPS voltage regulation features can clean up the dirty power so it is more stable. They are ideal for mission-critical applications or for operations that will experience poor power quality.

Double conversion UPS are typically more expensive than line interactive UPS but offer more functions and reliability. All double conversion UPS protect devices from abnormalities such as surges, brownouts, blackouts, and electrical impulses. Also, all double conversion UPS offer line noise protection, harmonic distortion protection, and frequency variation protection.

When comparing these types of UPS systems, keep in mind the power needs of the devices. Line interactive UPS is common for applications such as small office environments, home computers, and applications that are not mission critical. Double conversion UPS are suitable for mission-critical equipment and devices that need greater power stability to handle their load draws from the main power supply. Both UPS systems offer the basic protections to manage surges, power fluctuations, and blackouts. However, double conversion provides greater protection at a higher price.

If you need UPS systems, parts, or maintenance service for existing UPS equipment, let Facility Gateway Corporation provide you with the products and services for your operations. We work with companies that have mission-critical power needs and that rely on UPS systems that can provide emergency backup storage power on demand. For more information about line interactive and double conversion UPS systems, and which is suitable for your equipment, contact our company today.

OEMs vs Third-Party UPS Maintenance

Tue, 20 Dec 2022 22:52:26 GMT

Often companies don't have the staff or the experience onsite to perform due diligence and maintenance on their uninterruptible power supply (UPS) systems. Hiring a company to perform maintenance can provide varying benefits such as professional tech who can do the work efficiently as well as warranty guarantees. When deciding on a maintenance company to hire, the two main choices are the original equipment manufacturer (OEM) or third party maintenance specialists.

The Pros and Cons of OEM UPS Maintenance

OEM maintenance for UPS systems often is offered at the point of sale. There may be a specific time frame to receive this maintenance, often for free, with the option to continue with a paid contract. Other OEM's provide a limited lifetime guarantee for parts and labor.

The major advantage of using the OEM for maintenance is that the OEM is familiar with the technical specs of the particular purchased system. They have invested vast sums of money in the research and development of their products. They only have a half dozen or so products in current production and provide technical training to their field teams on only their products.

Overall, the advantage of an OEM is that you will have a company that knows how the UPS system works from the inside out, will typically have the parts available, and will have factory support should their field engineers need it.

However, there are some disadvantages to using an OEM for UPS maintenance. The OEM’s are in business to sell hardware and new equipment. So they have to have a field service team for startup and warranty service of their products. When it comes to post warranty service the OEM’s are not as focused on meeting clients expectations. They tend to manage their field service teams to the highest levels of utilization, oftentimes running them over 100% utilization for weeks on end. The OEM’s field service team is sized for the company's anticipated new unit startup and warranty services rather than post warranty service. This leaves them vastly undermanned to provide service to their post warranty clients.

Another issue is the cost of the post warranty service. As these large publicly traded companies are driven by their stockholders to financially outperform month after month and year after year and as such have labor rates much higher in many cases more than double or even triple that of non-oem service providers. OEM’s also make cuts in their business in areas that are not the main focus such as post warranty service. This leads them to be short staffed not only in the field but in all other areas of the field service business such as their emergency call takers, scheduling, quoting, and parts departments.

Lastly, an OEM may not provide service on your equipment as they have designated it at or beyond their end of service life (EOSL). Once a unit is classified as EOSL by an OEM they no longer will offer or provide contracted services on the equipment. They might still provide service on a time and material basis where you again will pay exorbitant labor rates as well as huge markup on non-proprietary parts that can be purchased on the open market at a fraction of the cost.

The Pros and Cons of Third Party UPS Maintenance

Third party maintenance companies, sometimes referred to as Multi-Vendor Service companies, are in the business to provide service, not sell boxes. They advertise their services to clients who are looking for UPS maintenance with field engineers in their region or community that are capable of servicing different OEM makes and models. Third party UPS maintenance companies perform the same services as an OEM, oftentimes are previous employees of the OEM, and have developed their own training from their OEM factory level experience. The third party company will have a large range of service parts stock available to service most UPS systems and other critical power equipment as well as new product solutions from multiple OEM’s.

A main advantage to hiring a third party UPS company, such as Facility Gateway Corporation (FGC) is that they are in business to provide critical power service. They have aftermarket parts for older UPS systems that are no longer available through the OEM, a vast supplier network for non-proprietary parts, allowing you to prolong the operational life of your UPS system until you are ready to upgrade to a new unit. They can also provide rental units of various sizes and have a swap out program for smaller sizes.

A downside to using a third party UPS maintenance company is they will not have the OEM proprietary software that many OEM’s utilize to lock their clients in to coming back to them for service. FGC successfully works with OEM’s on a regular basis getting these issues addressed for our clients.

Lastly, keep in mind that maintenance and repair programs will differ between an OEM and third party UPS maintenance company, as well as between one third party company from another third party company. You will have to perform research and shop around to learn about what offerings are available and their price ranges to find one that will suit your operations.

FGC Third Party Maintenance Services

At FGC, we are a third party multi-vendor maintenance company offering a wide range of services to companies. We offer both maintenance contracts as well as one-time preventive maintenance to ensure your UPS system is working optimally. If your UPS system suddenly stops working, we can provide emergency service to get the system functioning again.

Flywheel UPS: UPS Energy Storage

Wed, 23 Nov 2022 14:36:33 GMT

When going to purchase an uninterruptible power supply system (UPS) , there is much more to consider than the brand and the price. UPS systems come in different types of configurations based on how the power flows through the system and what functions the system provides.

These functions can include offering surge protection, managing power fluctuations, providing overcharge protection, and many other features. To determine which UPS system to purchase, you need to consider the application's power and function requirements.

What is Flywheel UPS Energy Storage?

A Flywheel UPS energy storage system uses stored kinetic energy that is transformed into DC power. The DC power is sent to the UPS that converts the DC energy into AC power that goes to the connected devices. This kinetic energy is generated by the flywheel, which is a rotary mechanical device that spins as the rotation creates electrical energy that becomes converted into kinetic energy.

When it comes to flywheel UPS, they do not contain batteries such as lead acid, lithium, or nickel that are commonly used in other UPS systems. This setup makes the flywheel safer than other types of battery chemistries that experience thermal runaway, such as lithium batteries.

Thermal runaway occurs when the battery chemistry becomes unstable to the point where the thermal temperatures inside the cells rapidly rise in a short amount of time. Energy is released by the battery that causes the temperatures to rise higher, exceeding safety thresholds. In time, the battery may explode or catch fire.

Many battery systems that experience thermal runaway will have battery management systems (BMS) to monitor the battery's temperature and other functions to ensure they stay within safety parameters. For a flywheel UPS, a BMS system is not required since there are no battery cells present.

How Does Flywheel UPS Technology Work?

A flywheel UPS works by using a rotor made of carbon fiber, steel, or carbon fiber composite. The rotor functions as a generator, motor, and energy storage system. The flywheel will spin at speeds of up to 37,000 revolutions per minute (RPM).

Some flywheels have mechanical bearings, while newer flywheel technologies contain magnetic bearings to create the rotational force. Magnetic bearings create a higher energy density.

The AC power comes into the UPS from the main energy source. A typical flywheel setup will have a rectifier AC/DC and a static bypass. If there is a power fluctuation, over-voltage, or power failure, the DC/AC flywheel turns the kinetic energy into DC power that goes through the DC bus and into the inverter DC/AC. The inverter converts the DC power into AC current that is then sent from the flywheel UPS to the connected devices to run them.

A flywheel UPS offers roughly 10 seconds to 15 seconds of power and can fully recharge within 15 minutes. Some units are capable of a 2-minute recharge.

Who Should Use This Type of UPS Energy Storage?

Flywheel UPS units are usually reserved for specific use applications. A reason for this is because the UPS energy storage only runs for about 10 seconds to 15 seconds, only allowing enough time for a changeover to other backup power sources. Other applications for a flywheel UPS may include handling power sags, dips, or transient over-voltages.

Some industries that may benefit from a flywheel UPS may include oil and gas. In these situations, the flywheel UPS can withstand harsh environments and temperatures where a battery may degrade, lose capacity, or experience damage that leads to thermal runaway. Manufacturing factories may also use the flywheel UPS if the working environment may cause damage to battery-operated UPS units.

The wind turbine industry and power grid companies may also use flywheel UPS systems. Wind turbines can store generated energy during off-peak hours or days when there are high wind speeds. Grid power applications consist of using the flywheel UPS to regulate grid frequency and to balance supply and demand changes.

A range of other industries may use a flywheel UPS if the energy from the main power source fluctuates and is unstable, as this type of UPS energy storage can clean up the incoming power to create a more stable sine wave as output current.

Specs of Flywheel UPS Energy Storage

Flywheel UPS energy storage systems have unique specifications that may create benefits to a company. These specifications include the cycle life, lifespan, temperature requirements, discharge/recharge rates, size, weight, cost, and maintenance requirements.

Cycle Life/Lifespan

A flywheel UPS can last for up to 20 years in operation. It does not have a limit to its cycle life. The energy storage capacity never diminishes from extended use, unlike battery storage UPS systems that will experience cell aging and capacity loss.

Temperature Requirements

These UPS systems can operate in temperatures of up to 104°F for normal environments. For flywheel UPS cabinets that have reduced power ratings (de-rated), the UPS can operate at higher temperatures up to 122°F.

Discharge/Recharge Rates

As discussed earlier, the flywheel UPS will discharge its entire load capacity within 10 seconds to 15 seconds. It is capable of recharging in 2 minutes, but often takes 15 minutes under normal settings.

Size

The size of the flywheel UPS is similar to available sizes offered in battery-type UPS systems. When selecting a size, consider the type of energy capacity needed for applications and the amount of space where the flywheel UPS will be placed.

Weight

A flywheel UPS weighs less than a lead acid UPS and nickel-zinc UPS batteries. The units may have similar weights to lithium-ion battery UPS. For example, a typical 30-inch by 30-inch cabinet could weigh about 1,800 pounds.

Cost

The initial purchase cost for a flywheel UPS is about the same as when purchasing a lead-acid battery. The total cost of ownership is figured out based on continued maintenance and reduced cooling costs, which may lead to savings for the company since you are not constantly replacing batteries.

Maintenance

The maintenance of the flywheel UPS will depend on whether the system operates on mechanical bearings or magnetic bearings. Magnetic bearings offer ease of use and lower maintenance costs. Mechanical bearings have higher maintenance since the bearing must be lubricated and may experience more wear-and-tear during daily use.

UPS Service and Products

Flywheel UPS systems can provide immense benefits for companies that have special applications where short-term backup power or when needing to manage or balance fluctuating power from main power sources. Here at Facility Gateway Critical Systems, we offer UPS maintenance services as well as UPS products to companies. Contact us for more information.

Emergency Lighting Inverters: The Basic Intro

Wed, 26 Oct 2022 20:04:17 GMT

Storms and other natural disasters can cause both power outages and power surges.

It’s at these times -- when power is fluctuating wildly -- that emergency lighting is needed. An emergency lighting inverter can keep the lights on when all other electrical features fail.

What is an Emergency Lighting Inverter?

Emergency lighting inverters act as backup power supplies when the main electrical supply fails. While the same type of inverter can theoretically be used for almost anything, the inverters are usually used for emergency lighting so that people can evacuate during disasters.

How Do Emergency Lighting Inverters Work?

Emergency lighting inverters are so-named because of how they switch between electrical current types.

Almost every electrical fixture in commercial buildings (and homes) runs on alternating current (AC). As long as AC current is running through a building’s electrical system, as long as the power is on, an emergency lighting unit draws small amounts of electricity to keep its batteries charged. The inverter remains in standby mode during this time of normal operation.

The rectifier component of the emergency lighting inverter changes the AC power that it accepts into direct current (DC) electricity, which is used for for charging a battery and storing the power.

When power is lost, the emergency lighting inverter senses the change because it stops receiving AC current. It transitions to the battery supply, and again inverts the electrical current to AC current. This time, the current is switched from DC to AC so that it can be used by the building’s electrical fixtures -- primarily its emergency lighting.

Emergency lighting is often prioritized because it’s so important and draws relatively little electricity. A lighting-specific inverter is practical even for small commercial buildings because it doesn’t have to be overly large.

Why Do Commercial Buildings Need Lighting Inverters

Commercial buildings should be equipped with lighting inverters for one simple reason. In many situations where people have to find exits, an external power source is needed because the main power is down. Storms, floods, fires, and other disasters all can result in loss of power, and require immediate evacuation.

Lighting inverters are a pragmatic, effective, and reliable way to provide the external power for emergency lighting. In many states, buildings over a certain size or used for certain purposes are required by law to have functional emergency lighting inverters in place.

What Maintenance is Required for Emergency Lighting Inverters?

Like all emergency preparedness equipment, emergency lighting inverters should be checked and serviced regularly. Building owners don’t want to find out that their inverter isn’t functional during the midst of a disaster. Regular checkups are the way to prevent mid-disaster failure.

Servicing an emergency lighting inverter involves checking the batteries and connections, and testing the inverter’s operation. This should be done by a knowledgeable and experienced emergency lighting specialist, both so that it’s done right and so a building owner isn’t liable.

If you own a commercial building, contact us at Facility Gateway Critical Services to set up an emergency lighting inverter maintenance program.

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Case Study #6 UPS Battery Emergency Call at a Home Improvement Store

Fri, 21 Oct 2022 19:09:24 GMT

Type of Customer/Facility: Home improvement store

Location: New Hampshire

Product: Cyberex 2200 18 kVA (Date Code: 2010) & backs up the store

Service Level: Full service contract includes scheduled preventative maintenance visits as well as 24/7 emergency service with a guaranteed response time. All parts, labor, and travel are covered under a full service contract.

Summary: Batteries required replacement in February of 2021 for the Cyberex 2200 UPS System.

Preliminary Actions: Customer notified us on 2/1/2021 that the output failed abruptly on their Cyberex 2200 in the computer room and they had to switch the unit into test mode to restore power. Facility Gateway responded to the UPS battery emergency call with in the 4 hour response time and determined the unit had bad batteries. The Field Technician ordered replacement batteries and had them shipped to the site. FGC scheduled a battery replacement for 2/11/2021.

Project Timeline:

· Customer Notification: 2/1/2021

· Batteries ordered: 2/2/2021

· Batteries delivered: 2/9/2021

· Battery replacement performed: 2/11/2021

· Project completed: 2/12/2021

Failed Parts: Yes; (48) HRL1234WF1FR (Provided by FGC)

Findings/Solutions:

1. On 2/1/2021 the customer called into the POST (National Operation Center).

2. The Post dispatched a technician for the site; the FE arrived onsite within the 4 hours guaranteed response time.

3. It was determined the UPS had bad batteries, so FGC Field Technician contacted corporate purchasing to order batteries.

4. Batteries arrived on site on 2/9/2021.

5. Upon technician arrival on 2/11/2021, the site contact stated the replacement batteries associate with the Cyberex 2200 UPS were onsite

6. The technician removed and replaced old batteries with new batteries provided by FGC. All old batteries were properly recycled.

7. Cyberex was placed into global bypass, shut down and restarted.

8. Upon departure, UPS was back online, supporting critical load, with no alarms or faults present.

Case Study #7: UPS Failure From Outdated Parts

Fri, 21 Oct 2022 19:09:11 GMT

Type of Customer/Facility: Casino

Location: New Jersey

Product: Liebert AP610T 500 kVA UPS System (Date Code: 2012). Backs up the data center.

Service Level with description: PM+ contract includes the number of scheduled maintenance visits as well as 24/7 emergency service with a response but does not include the purchase of replacement parts or the labor to install replacement parts.

Summary: UPS system tripped and would not reset, resulting in building running on utility power. A smell was radiating throughout the room, leading the FGC team member who troubleshooted via telephone to believe capacitor or transistor failure. Contract is PM+ and does not include replacement parts or the labor to install the replacement parts.

Preliminary Actions: The UPS unit was offline with an inverter fault and DC fuse open alarm. Initial troubleshooting determined the DC shunt fuse and DC capacitor fuses were open, the AC output capacitors were burnt, and there was inconsistent resistance reading on rectifier SCR’s.

Mean Time to Repair (MTTR): 24 hours to diagnose, 7 days to order, deliver, and install multiple parts

Failed Parts: Yes (Inverter, Shunt and Capacitor Fuses, AC Output Capacitors)

Findings/Solutions: Our NOC received a call from our customer in distress, indicating their UPS unit was no longer functioning and was emitting an odd smell throughout the room. By the next day, our field engineer troubleshooted the unit and determined the inverter, shunt and capacitor fuses, and the AC output capacitors had failed because of the lack of recommended replacement parts previously. All capacitors and fuses were then ordered and replaced within the week. Inverter parts were then ordered to be installed on the customer’s next preventative maintenance visit.

1. NOC received a call from the customer regarding the failed UPS unit.

2. The field engineer inspected and troubleshooted the unit to determine the failed parts.

3. The FGC parts team overnight ordered the parts for the field engineer to replace.

4. The field engineer replaced the ordered parts and scheduled further part installment upon the next preventative maintenance visit.

5. The FGC team called the customer following the successful repair to check in to make sure UPS is running without issues.

6. Customer was very pleased with the response and repair.

Case Study #8: A Case of a UPS in Bypass

Fri, 21 Oct 2022 19:08:59 GMT

Type of Customer/Facility: Casino

Location: Pennsylvania

Product: 2008 UPS System, Eaton 9390. Backs up the south end of the property

Service Level: Full service including parts, labor, and emergency calls

Summary: After phone technical support and a site visit, our field engineers determined the root cause of the UPS bypass were multiple outdated parts. Our field engineer visited the site and determined the UPS unit had outdated capacitors, fans, and batteries, resulting in the UPS’ failure.

Preliminary Actions: The unit was operating in bypass mode upon the emergency notification. The circuit breaker on the UPS unit continuously tripped and would not close. A missing or disabled wire was the suspected culprit from phone technical support. The unit was newly under contract and had not received a preventative maintenance visit prior to the emergency.

Mean Time to Repair (MTTR): 24 Hours to Diagnose and Quote

Failed Parts: Capacitors, Fans, and Batteries

Findings/Solutions:

1. Our field engineer performed phone technical support to determine what was causing the UPS unit to be in bypass.

2. Another of our field engineers visited the site the same day as the emergency call, examined the UPS unit, and determined the capacitors, fans, and batteries were outdated in the UPS unit.

3. The outdated parts were quoted the next business day.

4. After two weeks, the client returned the purchase order. We were able to order the parts from our supplier three days later.

Case Study #9: An Empty Tank Threatened Uptime

Fri, 21 Oct 2022 19:08:47 GMT

Type of Customer/Facility: Retail Store

Location: Kansas

Product: Caterpillar D125-6 Generator, 2009. Unit backs up the store.

Service Level with description: PM Plus. Includes a guaranteed response time with parts and labor billed at T&M rates.

Summary: Our client’s generator, previously sitting at about ½ tank, was low. They had a scheduled power outage with the Utility Company and did not expect the fuel to last at the current level. Our NOC provided assessment and scheduled a fuel delivery for the next day.

Preliminary Actions: Our client had a scheduled power outage at their store. They got in contact with our NOC to calculate runtime with the existing fuel level. After determining low runtime, FGC scheduled a fuel delivery. By the next day, our client received 217 gallons of fuel to meet their runtime needs.

Mean Time to Solution (MTTS): 24 Hours

Failed Parts: None

Findings/Solutions:

1. Our NOC received a call from our client regarding their concerns on their generator’s fuel level. Because they had a scheduled power outage the next week, they wanted to double check runtime.

2. After runtime was determined to be low, our NOC was in contact with our generator fuel delivery team.

3. The fuel delivery was scheduled for the next day. 217 gallons of generator fuel was delivered to the site within 24 hours.

4. The client was very pleased with the response and fueling process for their generator. The prescheduled utility downtime was maintained by the the generator on site thanks to the proper amount of fuel.

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Case Study #10: UPS Batteries on Thermal Runway

Fri, 21 Oct 2022 19:08:34 GMT

Type of Customer/Facility: Utility Services

Location: NJ

Product: Enersys Wet Cell 4DXC-13B External Batteries, Date Code 10/2010

Service Level with description: PM Plus. Includes a guaranteed response time with parts and labor billed at T&M rates.

Summary: The client called our National Operations Center (NOC) because their UPS batteries were overheating. A senior field engineer was immediately dispatched to the site. Within two hours, our field engineer arrived at the site, assessed the situation, and recommended a replacement battery cabinet for the client.

Preliminary Actions: Our client called our NOC, indicating their batteries were overheating. Our field engineer arrived at the site within two hours of the call. They then performed temperature readings of both the ambient room temperature and the temperature adjacent to the batteries. After measuring the ambient temperature to be 92°F and the batteries’ temperature to be around 140°F, our field engineer concluded the batteries were in thermal runway and needed to be taken offline immediately. The field engineer transferred the UPS into bypass and opened the battery breaker to remove it from charge. Our Account Management Team along with our Tech Support Team proposed a rental option to the client as well as a long-term replacement.

Mean Time to Respond (MTTR): Under 2 Hours

Failed Parts: Yes, Enersys Wet Cell 4DXC-13B External Batteries

Findings/Solutions:

1. The Facility Gateway Field Engineer performed temperature checks on both the ambient room temperature and the batteries casing temperature.

2. The Facility Gateway Field Engineer concluded the batteries were in thermal runway.

3. The Facility Gateway Field Engineer placed the UPS unit into bypass and opened the battery circuit breaker to remove the batteries from charge.

4. Facility Gateway recommended a rental option for the client’s immediate needs.

How Long Does A UPS Last?

Fri, 21 Oct 2022 19:07:05 GMT

Understanding When an Upgraded System is Needed

Uninterruptible Power Supplies (UPS) are a lot like cars. There always comes the point when the cost of maintenance outweighs that of simply upgrading to a new device. How long does a UPS last? How can you determine when the time for a new unit has finally come?

While it’s a question we get all the time, determining when it makes sense to replace your UPS system can depend on a wide range of personal factors unique to your site, your needs, and your particular unit. Highly sensitive pieces of equipment in and of themselves, UPS systems include several other delicate components such as batteries, capacitors, circuit boards, and more which can all be repaired or replaced as well. Understanding when to repair these components and when to replace the unit as a whole is critical to guaranteeing complete protection against load failure and utility outages.

Below, we’ll explore a few ways to determine whether your UPS unit still has a few more good years left in it or if you should consider an upgrade.

First, A Few Signs Your UPS System Needs Replacing

Before we consider anything else about your UPS unit and requirements, it is valuable first to review the four key factors listed below. If your UPS unit is experiencing either of these, it is likely time to begin searching for a new unit.

If it’s been 10-12 years since your last UPS purchase:

With the exception of the batteries they rely on, UPS units are generally designed for longevity and can last for many years. However, they will experience wear from usage and other environmental factors just like any other electronic equipment. In our experience, once your UPS ages past its twelfth year, it’s time to start looking for a new unit.

While many systems can be pushed to last more than 15 years, ask yourself if you’re willing to rely on an older unit for your mission critical equipment. One thing to consider is whether or not the parts are still supported by the original equipment manufacturer (OEM). In some cases, the OEM will no longer support older UPS systems by discontinuing parts that are manufactured, causing the parts to become difficult to source. It is best to replace your system before obsolescence to prevent unnecessary extended downtime and situations where the service provider must source parts through other channels. By planning ahead and considering replacement at year 10-12, you will have plenty of time to research the best options and get the best deal without risking your equipment or data.

If your UPS is becoming obsolete:

When you find your UPS’s lack in any of these areas, you are at an increased risk of downtime and it is likely time to consider upgrading to a newer system. Due to how quickly the electronics sector is evolving, your UPS can become outdated in as little as five years. While you likely won’t have to replace the unit that soon, your new needs may quickly outpace your old unit’s capabilities beyond that time frame.

If your facility is growing:

As your business grows and evolves, so too will your critical load needs. Paying attention to these changes in your business will allow you to realize if your UPS system needs replacing quickly. For example, if your needs are increasing, the original UPS unit you selected years ago may no longer be able to meet your new load requirements. Alternatively, if you’ve condensed your offerings or services in some way, the larger UPS you chose maybe too big, and you could be wasting energy.

A good UPS service provider should help you understand where your system has been trending in terms of load and maintenance requirements and offer suggestions to help optimize your system.

If you are experiencing any of the above scenarios or any other reason you feel it’s time to replace your UPS system, here are a few ways to get started on selecting the best replacement option.

If you could save money by upgrading to a more energy efficient UPS:

Today’s UPS systems are much more energy efficient then the UPS(s) built over 10 years ago. Most manufactures are now creating transformer-less systems that can tolerate power anomalies as well as the transformer design UPS(s) of the past. These new UPS systems are in the 97-98% efficiency range, whereas a lightly loaded older transformer designed UPS maybe in the 70-80% efficiency range.

By correctly sizing an older transformer-based UPS, you can save considerably on annual operating costs and reduce your utility bill. In some cases, you can see a 3–5-year return on investment by upgrading to a new UPS.

Also, most new UPS systems will come with a 1–3-year warranty, so the need for a full service maintenance contract is not always necessary. This benefit offers yet another way to help justify the purchase of a new UPS with annual maintenance savings. By relying on the new equipment warranty, you can also cut considerable operation expense dollars by reducing your annual maintenance budget spend.

Choosing a New UPS – Understanding Your Requirements

The most important consideration when selecting a UPS is to choose that which best matches your requirements. How do you determine what those requirements are? A great way to start is to find solid answers to these questions:

· What are the current load requirements of your system?

· How do you expect that load to fluctuate in the next 5-10 years? (increase, decrease, consistent?)

· Where is your system being installed? What sort of environmental factors should be considered? (dryness, humidity, etc.)

· How important is energy efficiency to your facility and industry?

· What are your uptime requirements?

Finding answers to all of these questions should be done before you begin the shopping process. If you need help determining those answers, talk to a UPS consultant. By helping you understand your needs from a critical power perspective, teams like ours can help you better determine the UPS system that will best meet your needs. In the meantime, you can get started answering the first question with the guidance provided below!

How Critical Are Your Loads?

To help you get started, we’ve outlined a process you can use to review your UPS unit's load is currently supporting.

First, you will want to total the load and draw requirements of all the equipment you have connected to your UPS. Typically, you can find those numbers in product manuals or by checking with the manufacturer. Once you’ve added them all up, you’ll want to compare that total to the wattage capabilities of your system.

If your unit is loaded between 25-80% of the total capacity, congratulations – you've likely done a great job implementing your UPS. However, if your load is coming in at greater than 80%, your unit is running low on available capacity and could be overloaded. Running your UPS at this high capacity for extended periods of time can also significantly decrease your equipment's lifespan. If this is the case, you'll likely want to choose a new unit with a higher capacity. Be sure to choose one that gives you room to expand even further.

Conversely, if your load is less than 25% of your UPS's overall capacity, you are likely wasting both energy and money by continuing to run the system. In either case, a new unit would be a much-needed option.

Facility Gateway Critical Services – Your UPS System Advisor

At Facility Gateway Critical Services, understanding your UPS system needs is what we do. From initial purchase to ongoing maintenance and beyond, we have the experience, skill, and knowledge to ensure that your UPS and battery services are covered no matter where you are.

If you’d like to continue discovering your UPS system requirements, want to request a quote, or just want a little more information about who we are, contact our team today. In every case, we look forward to helping you mitigate costly downtime and serving your uninterruptible power supply needs.

4 Common Reasons for UPS Failure & How to Prevent Them

Fri, 21 Oct 2022 19:06:41 GMT

When was the last time you had your Uninterruptible Power Supply serviced? If the answer is any longer than “last year”, improving your UPS management will be absolutely critical to preventing catastrophic downtime.

Regardless of your type of facility, if you’re using a UPS, you should always be aware that UPS failure is a very real possibility and is actually the number one cause of data center downtime. Luckily, there are solutions. Below, we’ll cover a few of the most common reasons uninterruptible power supplies fail and how you can work to prevent them.

Why Do Uninterruptible Power Supplies Fail?

There are a wide range of reason a UPS can fail, which can make it difficult to keep on top of maintenance requirement. For example, mistakes can be unknowingly made that will reduce the lifespan or functionality of your UPS, environmental conditions could be harsher than expected, or more simply, a component could reach the end of its viable lifespan. That being said, here area few of the most common UPS issues we see on our maintenance visits.

#4: Fans

Used to cool the electronic components inside and keep everything functioning properly, fans are an absolutely critical, yet overlooked component of UPS systems. If your UPS is operating at 80 percent of its rated capacity, fans will be even more important to keep an eye on as the systems inside the UPS will be running much hotter than usual.

As one of the few mechanical components of a UPS, fans can degrade over time, resulting in reduced revolutions per minute (RPMs),increased noise, and failure to start entirely. When fans fail, a UPS can overheat, causing the unit to transfer to bypass, leaving your critical loads unprotected.

#3: Filters

Filters are closely associate with fans, as clogged filters can lead to fan failures. Overtime, dust can and will build up on air filters, causing them to clog and your UPS to shut down due to overheating.

Thankfully, replacing air filters is an easy and inexpensive part of most UPS maintenance plans. Be sure your filters are inspected at least once a month and changed as needed to extend the lifetime of your UPS and it’s components.

#2: Capacitors

Relatively simple in design, capacitors are absolutely crucial for storing and releasing electrical energy and are responsible for smoothing out and filtering voltage fluctuations. Typically, capacitors need to be replaced every 5 to 7 years regardless of the size and type. However, a range of factors can influence their lifespan. For example, the chances of a failure increase as the capacitors become older. Other factors include aspects such as the amount of applied voltage, the amount of over-current, environmental temperatures, and more. Unfortunately, it’s not always easy to tell you have a capacitor failure. When one capacitor fails, the others in the system are designed to take up the load themselves. While useful for short periods of time, this setup can damage the other capacitors and shorten the lifespan of all.

To ensure your capacitors are always functioning optimally, be sure to schedule annual inspections where an experienced technician can optimize operation and potentially even extend lifespan. Capacitor replacement is an essential part of UPS maintenance and is the best way to maximize not only the life of the capacitors themselves, but also the performance of your UPS.

#1: Old or Damaged Batteries

Batteries are one of the most delicate components of your UPS and require the most maintenance and care. Unfortunately, functioning batteries are also the most critical component of your UPS, making frequent and regular upkeep an absolute necessity.

Batteries themselves can suffer from a variety of ailments. Improper usage, over-cycling, long durations of storage without recharging, and weather can all significantly decrease the lifespan and capacity of your batteries. Although there’s a lot of variation throughout the industry, most batteries will last you around 3-5 years if taken care of properly. Without that proper care and maintenance however, batteries may only last half that long.

To avoid concerns with batteries, make sure conditions are kept as optimal as possible. Additionally, you should make a point to schedule annual preventive maintenance visits that include battery inspections, impedance/conductance tests, and performance assessments to evaluate any potential weaknesses.

Prevent UPS Failures With Facility Gateway Critical Services

No matter what UPS issues you are facing, a preventive maintenance (PM) plan is the perfect solution to help you avoid unnecessary downtime. At FGC, we appreciate the complexity of managing a comprehensive and effective critical power infrastructure. Accordingly, we customize our UPS service and maintenance contracts to your individual company’s needs. Our primary goal is always to ensure your systems are fully operational or repaired as quickly as possible to keep your facility running. Included with every signed contract is:

· A dedicated service team consisting of a scheduler, a contract manager, & a project manager

· 24/7, 365 National Operation Center for emergency response & technical support

· OEM support for firmware, parts & repair needs available

· Budget planning for OPEX & CAPEX available

· Facility Keys asset management software included with web-based service reports

· Preferred pricing on battery replacement &T&M repairs

Case Study #11: A Pinched Wire is Cause for Alarm

Thu, 06 Oct 2022 21:37:21 GMT

Type of Customer/Facility: Engineering Facility

Location: FL

Product: UPS System, Liebert NPower, 2009

Service Level with description: This unit was not contracted upon our client’s emergency call.

Summary: Our client called our NOC, noting their UPS was experiencing a Battery Overtemperature Warning alarm. A field engineer was dispatched to analyze the unit and determine if the battery cabinet was too warm. Upon determining the battery cabinet was not too warm, the battery interface board was calibrated to no effect. The field engineer ordered a new battery interface board, in hopes the board was faulty and thus causing the alarm. After the new board was installed, the alarm was still present. The field engineer further examined the unit and traced the wiring between the battery cabinet and the UPS system. The field engineer found a wire pinched in the top panel of the unit the fans are mounted to.

Preliminary Actions: Upon examination and installation by our field engineer at the site, the field engineer determined the battery cabinet was not too warm and determined the battery interface board was not causing the alarm. Upon further examination, a pinched wire in the top panel of the UPS unit was found to be the cause for the alarm.

Mean Time to Repair (MTTR): 6 Days

Failed Parts: No, a wire in the top panel with the UPS’ fans mounted was pinched, causing the Battery Overtemperature Warning.

Findings/Solutions:

1. Our client called the NOC to assist in clearing their Battery Overtemperature Alarm.

2. Our NOC dispatched a field engineer to the site to determine if the battery cabinet was too hot.

3. The field engineer determined the battery cabinet was not too hot and thus thought the battery interface board needed to be recalibrated. The field engineer recalibrated the board, but the alarm did not clear.

4. The Facility Gateway Parts Team ordered a new battery interface board for the unit. Once our client received the new board, the field engineer was dispatched again to install the equipment. The newly installed board did not clear the alarm.

5. The field engineer further examined the unit and observed a pinched wire in the top panel of the UPS unit where the fans are mounted. The field engineer determined this was the root cause of the alarm, fixing the wire to disable the alarm.

UPS Systems: What Are the Different Types?

Thu, 15 Sep 2022 20:19:27 GMT

When going to purchase an uninterruptible power supply system (UPS), there is much more to consider than the brand and the price. UPS systems come in different types of configurations based on how the power flows through the system and what functions the system provides.

Online Double Conversion

Online double conversion UPS systems have rectifiers that are designed to take the incoming utility AC power, alternating current, and rectify it to DC power, direct current. AC power comes from the mains is changed into DC power and then inverted back into higher quality AC power. This process addressed voltage fluctuations and distortions as they come in from the power source.

The mains power flows into the AC/DC rectifier/charger to charge the UPS battery and power the DC/ AC inverter. The power from the DC/AC inverter then goes to the connected load. If the incoming mains power does not have any fluctuations or distortions, some online double conversion UPS system have an eco-mode that can suspend the inverter function and allow the mains power to go directly to the connected loads.

Online double conversion UPS systems are normally used for server rooms and data centers that have mission-critical equipment. These systems offer surge protection, battery backup, over-voltage protection, brownout protection, fully online operations, built in redundancy, and pure sine wave output.

Line-Interactive

Line-interactive UPS systems are ideal for desktop computers, network workstations, network server racks, audio/video equipment, and office networks. You can obtain line-interactive UPS systems specifically for desktop computers or for networks.

These systems offer conditioned power by eliminating too high or too low voltages that may come in through the main power supply. The UPS helps to eliminate voltage fluctuations. The line interactive UPS is connected to utility mains power which goes into the surge protector and then into a voltage regulator which provides power to for the battery charger and connected loads. If a power failure is detected, the unit provides power to the connected loads from the battery until line until power is restored.

Both desktop line-interactive UPS and network line-interactive UPS provides functions such as brownout protection, surge protection, and battery backup. Desktop UPS models may also provide pure sine wave output and overvoltage protection. Some brands of network UPS models may offer overcharge protection, pure sine wave output, and higher power availability features.

Offline UPS/Standby UPS

Offline UPS systems are also referred to as standby UPS systems. The main function of these devices is to provide surge protection and battery backup power when there is a power failure from the main power line. During typical operation, the main power travels into the surge suppression as the component helps to filter out voltage spikes and surges. Then the power travels into the connected load.

The main power also goes through a separate line that leads to the AC/DC charger, UPS battery, and DC/AC inverter before going into the connected loads. If there is a power failure, the UPS DC/AC inverter automatically switches to the battery mode. Controlling the power surge that comes in from the mains line prevents the higher voltage from damaging electronic devices.

These devices have fewer functions than line-interactive and online double conversion UPS models. They are often used for residential home offices, emergency lighting, and desktop computers. Tthe main functions of these systems are surge protection and battery backup.

The length of time that a battery backup supplies alternate power will be based on the device and connected loads. Battery backups are simple devices that are used for lower investment equipment, such as home desktops, PCs, and small office settings. UPS systems are battery backup devices but are more advanced and offer higher power protection that can be used for sensitive and high-powered equipment.

Industry Uses for UPS Systems

UPS systems can be used for residential, commercial, and industrial operations. They provide protection and backup power to any technology, electrical, or telecommunication, or data center equipment where data files could be damaged or lost due to a power failure. They also prevent serious business interruptions.

Maintenance on UPS systems should be a regularly scheduled task. This maintenance inspection of the operation of the UPS system and backup battery are performed proactively to determine if there are any issues that may need to be addressed. Maintenance tasks may include changing the air filters to ensure proper ventilation, inspecting for hot spots along internal connections, and replacing UPS capacitors or fans.

Here at Facility Gateway Corporation, we offer UPS equipment, replacement parts, UPS batteries, and UPS maintenance service contracts for companies. We also offer emergency repair services in case your UPS system experiences a problem. For more information regarding our services and products, contact our company today.

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History of The Uninterruptible Power Supply

Mon, 15 Aug 2022 18:43:52 GMT

The uninterruptible power supply (UPS) system provides backup power to applications and equipment. If the main source of power becomes interrupted due to weather, fluctuating power surges, natural disasters, or other issues, the UPS provides power for a range of time from its battery pack.

The uninterruptible power supply has an interesting history and has changed since its first introduction in 1934. Read on to learn more about the history of the uninterruptible power supply.

Who Invented the Uninterruptible Power Supply?

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John J. Hanley was the inventor of the uninterruptible power supply. Back during his time, he was interested in rail passenger trains. These rail systems ran on electricity as he was worried about passenger safety. If the electrical systems in the rail passenger trains failed in some way, this may lead the passenger train to continue traveling without being in control by the train operator.

In 1934, he obtained a patent for the "Apparatus for Maintaining an Unfailing and Uninterrupted Supply of Electrical Energy." The device's function was to allow for automatic switching to the battery in case of a power failure. At the same time, an external electrical source would supply power to the battery in the device during regular operations. The name was later changed to uninterruptible power supply.

The first UPS systems used flywheel rotary designs that only provided backup power for about 20 seconds up to 90 seconds. The high speed flywheel would spin and build up kinetic energy that became stored. If the power fluctuates or fails, the flywheel's kinetic energy would provide DC current to the application. Considered a green technology, the flywheel rotary UPS is still used today for smaller backup functions as they can last for 20 years.

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How Does an Uninterruptible Power Supply Work?

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A UPS system works as a backup power supply as well as a surge protector. It connects to the main power source (wall outlet) and directly to the application or to a power distribution unit that is connected to multiple equipment. If there is a power failure, the UPS automatically switches to its battery pack to begin powering the devices. This solution provides a company enough time to evaluate the power issue, fix equipment problems, and/or save electronic documents and data. The amount of backup power provided by the UPS system depends on the capacity of the battery pack and the power needs of the connected equipment.

In some configurations, two UPS systems may become connected. If the first UPS system battery runs out of power or experiences a failure, the second UPS system kicks in to provide backup power.

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How Many Types of UPS are There?

There are 3 basic topographies to UPS systems: offline/standby, double-conversion, and line-interactive. These are not to be confused with interruptible power supplies (IPS) that are mostly used for emergency lighting. The type of UPS system to use will be based on the desired features, costs, and safety.

Offline/Standby UPS

Offline/Standby UPS systems are the most basic devices that provide surge protection and backup power. The UPS routes AC power from the main AC power source to charge the internal battery and directly to the AC load. It then uses an inverter to convert the DC battery power into AC power to the load when a power outage occurs. It uses an electronic switch to change the source of power, DC battery or main AC power, to allow the electrical current to pass down the output line. This electronic switch is usually subcycle, meaning it happens very fast so the load equipment does not see an interruption. These types of UPS are designed to handle surges, blackouts, brownouts, and are usually the least expensive type.

Double-Conversion UPS

Double-Conversion UPS systems use a rectifier to convert the incoming AC power to DC power which is used to charge the battery and power an inverter. The inverter changes the DC power back into AC power to feed the load. Because of this dual conversion, surges, spikes, distortions, or other anomalies on the incoming AC power are never seen by the critical loads on the output of the unit. The double-conversion UPS is considered the best type of unit while also costing more than the others due to it always running and its power conditioning features. In addition to handling surges, brownouts, and blackouts, the double-conversion UPS also manages over/under voltage as well as harmonic distortion, line noise, and frequency variation.

Line-Interactive UPS

Line-Interactive UPS systems use a ferroresonant transformer to help stabilize the AC power when electrical voltage fluctuations occur. The main difference with this type of UPS system is that when the electrical voltage drops out, it uses the ferroresonant transformer to carry load for a brief moment until the battery begins discharging through the inverter and transformer to the load. While it handles most of the same issues as the double-conversion UPS, it does not offer the same level of protection from the utility line as a dual conversion UPS system does.

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What Are the Uses of UPS Systems?

Throughout the history of the uninterruptible power supply system, its main function has been to provide emergency backup power if there is power loss from a main source. It allows work to continue or enough time to perform orderly shut down of systems to avoid damage and loss of data. As technology advances, UPS systems have evolved to be more efficient, reliable, and more versatile even allowing for automatic shut down of systems and notifications of alarms and events via email or text.

The UPS has become an efficient and reliable piece of equipment to prevent data loss or possible data corruption that can happen when equipment suddenly shuts down due power surges. It can also prevent the hardware and components inside equipment from experiencing damage. Based on the size of the UPS and the runtime, it may offer equipment with enough power to complete tasks until the main power source comes back online.

Here at Facility Gateway, we offer UPS and battery equipment sales and maintenance contract services for companies across the country. Having a dependable source of power available the moment the lights flicker or the electricity shuts down ensures that your equipment will keep running safely for a specific amount of time. For more information regarding our UPS products and services, reach out to our company today.

External Maintenance Bypass for UPS – The What & Why

Mon, 18 Jul 2022 18:52:29 GMT

Many industrial and commercial operations rely on uninterrupted power supplies (UPS) to provide backup power for equipment. If inclement weather or business disaster occurs that causes a power failure or fluctuation, the UPS provides the electrical power needed for connected equipment to continue to operate. However, like with every piece of equipment, the UPS may require maintenance, repairs, or replacement.

A UPS does not last forever and requires regular maintenance, so it runs optimally. Also, problems may occur that cause a failure. When servicing the UPS, the connected equipment has to stay running for operations. You cannot shut down the processes just to service the UPS equipment. In those instances, you may use an external maintenance bypass for the UPS system.

What is an External Maintenance Bypass?

A maintenance bypass allows you to work on the UPS without interrupting power to your equipment. The main purpose of the external maintenance bypass is to isolate the UPS from utility power for service. It is used to redirect power around the UPS when it requires maintenance, repairs, or replacement. The maintenance bypass ensures power is available to the connected load devices or to the power distribution unit(PDU).

An external maintenance bypass unit consists of an NEMA-rated mechanical enclosure that has circuit breakers or rotary switches. This equipment allows for power to pass between it via the UPS and to a power distribution unit or critical loads. It can be mounted onto the wall or be placed in-line within a matching cabinet enclosure as the UPS.

Configurations for External Maintenance Bypasses

External maintenance bypass systems for UPS equipment come in varied sizes, shapes, and ratings. For example the switches utilized could be regular breakers or rotary switches, they could be wall mounted or stand alone, they could have built in distribution, and they could have interlocking circuits to prevent mis-operation, Most importantly is the option of ‘make before break’ and brake before make’ which describes the switching function of the maintenance bypass system.

Make Before Break

A make before break maintenance bypass system is configured in a fashion where the UPS system can be electrically isolated from incoming utility power and the critical loads the system powers. With this system properly configured and installed a UPS & Battery system can be uninstalled and anew replacement system installed without ever taking down power to the critical loads.

Brake Before Make

A brake before make maintenance bypass system is configured in a fashion where the critical load must be de-energized as it disconnects the utility power from the load while isolating the UPS system prior to being able to turn on the maintenance bypass switch to provide utility voltage to the critical load.

Maintenance Bypass Setups

When setting up the maintenance bypass, it will be the first piece of equipment that is directly connected to the available power supply mains. Then the maintenance bypass is connected to both the UPS and to the power distribution unit. There will be an input line and an output line connected between the UPS and maintenance bypass. This setup allows workers to manually control the UPS so it can be de-energized for serviced and repair without impacting the critical load.

Internal Static Bypass Setup

An external maintenance bypass should not be confused with an internal static bypass switch. An internal static bypass switch allows for some maintenance to be performed internal to the UPS. While most of the internal components are de-energized while on internal static bypass, there are still areas within the UPS equipment that are still energized and would not be service able without an outage.

Benefits of External Maintenance Bypass for UPS

The main benefit for external maintenance bypass is to allow the UPS and battery system to be isolated from critical loads for service and trouble shooting. A properly designed and installed UPS system with an external maintenance bypass will provide years of reliable service allowing for battery and aged based component replacements without interruptions to your critical loads.

Facility Gateway Corporation: UPS Maintenance Services

Here at Facility Gateway Corporation, we are a UPS equipment and service supplier. We offer UPS equipment, batteries, capacitor, fans, and part replacement. Our company also provides comprehensive UPS maintenance contracts and emergency services. If you are interested in external maintenance bypass for your backup power systems or want to learn more about our maintenance work, reach out to our company today.

The Leading Causes Of UPS Battery Failure

Mon, 20 Jun 2022 19:07:03 GMT

UPS systems provide emergency backup power to applications during severe weather conditions, unexpected power outages, and during unstable power fluctuations. However, a UPS system may also experience failure at uncertain times, which could create serious problems for facilities when they need to have a backup source of power.

These failures may range from a UPS internal component failure such as a fan or logic board failure to a battery failure. Learn more about the leading causes of UPS battery failures and what to do to prevent them.

Common UPS Battery Issues

Like any other piece of equipment, a UPS battery system should undergo scheduled maintenance, repair, or replacement to ensure the system works as intended. If the UPS system is used outside its recommended parameters or not used for its intended application, certain factors may cause the UPS system to fail. Some common types of UPS battery issues may entail the following.

Overheating

Batteries may overheat from a variety of causes. A UPS battery has a nominal operating temperature of 77°F. If the battery environment is below or above this temperature, it will experience shortened capacity or fail to hold to the load when needed.

Capacity Loss

Batteries within a UPS system have a 100% capacity when first installed in an operating environment of 77°F. This capacity rating means that the battery is able to fully support the load for the designed run time at a specified load. However, over time battery capacity can be impacted based on a number of factors such as temperature, number of discharges, and charge voltage to name a few. When a battery's capacity drops, it means it can no longer provide the amount of power for the length of time the system was designed for.

Thermal Runaway

Thermal runaway is a dangerous condition that can occur within a battery system. This condition can occur when the impedance changes within the battery system (internal battery components/chemistry and/or connections) requiring the charging system working harder (providing more current/ amps) in order to maintain the designed battery system voltage. As the charging system works harder to maintain system voltage the battery system, the extra current is dissipated as heat which results in further impedance changes. This cycle will continue until the charger and battery system is either taken offline or a connection is burned open. When a battery undergoes thermal runaway, it becomes permanently damaged and may result in a fire or explosion.

Sulfation

Sulfation is a chemical reaction that occurs along the battery's positive plates. The sulfate crystals start to accumulate, causing the battery to slowly lose capacity until it is dead over time. Sulfation is a common occurrence with lead acid batteries and it may lead to permanent damage in the way of shorter battery life, higher heat buildup, longer charging times, and shorter run times.

Factors That Cause Premature Battery Failure

There are many factors that may lead to battery overheating problems, sulfation, thermal runaway, and capacity loss. Proper identification of the issues can allow the right types of solutions to be implemented.

Overheating Factors

Abnormal Room Temperatures

Most UPS and battery equipment is designed to be run in a computer room type of environment that is free from dust and debris and has ambient temperatures that are suitable for the electronics. Manufacturers will list the suitable operating temperatures for the system, which may range from 32°F to 102°F. The battery within the UPS system should be operated at an ambient temperature as close to 77°F as possible. Running the battery in temperatures higher than the recommended range may result in overheating, loss capacity, and failures and for every 10°F above 77°F the battery life expectancy is cut in half.

Incorrect Battery Applications

UPS systems utilize batteries specifically designed for this application. Using the wrong type of battery in your UPS may lead to failure, overheating, or shortened lifespan. This is a very common problem today as there are so many battery suppliers providing inexpensive alternatives to the critical power market. Clients may think they are saving a few dollars but in reality the total cost of ownership goes up as these batteries fail prematurely resulting in down time, emergency service visits, and ultimately replacement of the system battery prematurely.

Sulfation Factors

Undercharging

Batteries should be charged to the voltage specified by the battery manufacturer. Undercharging the battery results in sulfation and loss capacity. Undercharging occurs when the system used to maintain the battery system is not properly set or maintained.

Thermal Runaway

Overcharging

When the battery charge voltage is set higher than recommended by the battery manufacturer, the battery life will be impacted and may also lead to heat being generated by the battery. Over charging alone may not lead to thermal runaway but it can play a role in the degradation of the battery to the point the battery impedance begins to be affected which does lead to thermal runaway.

Short Circuits

A short circuit may occur when a battery cell overheats as the separators melt on the battery. The resulting heat damages the separators. Cell separators may also become dislodged for other reasons such as shipping and handling or production defects. When a battery cell has shorted the overall battery voltage will be reduced by 2 volts dc.

Battery Damage

Mishandling of the battery, using the UPS battery in other applications where it is not intended, accidentally dropping the battery, or damage caused while in transport may lead to problems where the battery short circuits or overheats.

Capacity Loss

Poor Storage

When UPS batteries are placed into storage, the battery undergoes self-discharging. The self-discharge rate varies based on the battery chemistry, such as lead acid, lithium-ion, or nickel-based (NiCad/NiMH) chemistries. When a battery self-discharges for long periods of time, it can experience capacity loss if they do not undergo a full periodic recharging.

Additional Factors

Both thermal runaway and overheating impact the capacity of the battery. Damage to the battery, improper handling, improper battery use are additional reasons why a battery cannot charge to its intended capacity rate.

How to Correct UPS Battery Faults

Many UPS battery faults can be corrected with proper handling and usage of the battery. You should also perform the correct charging/recharging cycling processes, use and store batteries at optimal room temperatures, and avoid undercharging the battery. Also, consider having a technician perform preventive maintenance which may involve visual inspections of the batteries to look for sulfation, ventilation and cooling issues, and incorrect wiring problems may prevent short circuits and other issues.

Here at Facility Gateway Corporate, we offer maintenance services and provide the necessary testing and parts to ensure that your UPS battery is working at full capacity. Learn more about our services by contacting us today.

Why Your Industrial Generators Need Consistent Maintenance

Mon, 16 May 2022 19:13:55 GMT

As with all mechanical equipment in industrial and commercial facilities, generators require planned maintenance to ensure that they operate at optimal levels while in operation. Unfortunately, a company may skip the generator’s preventive maintenance schedule. Some facility managers feel that the generator is seldom used, so it doesn't need constant upkeep. A business owner may feel that pulling workers from off the production line to perform maintenance would lead to unnecessary costs.

Learn more about why it's important for generators to undergo planned maintenance and types of maintenance schedules that can be used for both owned and rented generators.

The Importance of Generator Planned Maintenance

Planned maintenance for generators allows you to extend the life of your generator. If you use your generator constantly based on operations, the internal components wear out quickly. Preventive maintenance allows you to fix small issues that may cause the generator to malfunction. This maintenance indicates whether you need to repair or replace components quickly to prevent unnecessary downtime.

Even when sitting idle, a generator may become exposed to environmental factors such as dirt, dust, sawdust, grease, high humidity, and extreme temperatures. All these environmental aspects can impact the generator's operational systems, components, and backup batteries. A generator preventive maintenance schedule provides regular equipment checks to understand how the environment affects components.

You may notice issues that will soon need to be addressed and can update maintenance logs regarding the state of the system. Then, your company may figure out ways to change the environmental factors to lessen the negative impact that the workplace has on the generator and other equipment.

Types of Generator Preventive Maintenance Schedules

Generator preventive maintenance schedules are based on several factors which include the length of operational time, the length of idle time, environmental factors, and whether you rent or own the generator. Rental companies may offer preventive maintenance checks as part of their service plans as they have specific schedules that they follow for specific pieces of generator equipment.

Typical maintenance schedules are divided up as weekly, monthly, semi-annually, and yearly. Your company may increase or decrease the number of performed inspections depending on how frequently the generator is used. There are certain tasks that are performed for each schedule which may be suitable for your generator equipment.

Weekly

Weekly preventive maintenance may consist of powering on the generator for a length of time to listen to how it runs and to visually look at moving components. This task is considered a no-load, automatic transfer switch exercise. It allows the generator to run without any outside power fluctuations that could influence its overall operation.

While running, you may check for any fluid leaks. You also can check that the right fuel is in the system and how quickly the fuel level is being consumed. Other aspects to evaluate include checking the circuit breaker to ensure the circuit path is closed and making sure the generator is primed for automatic startup by having it in Auto mode. Lastly, weekly maintenance should also involve listening for device alarms and that no alarms or warnings sounded during operation.

Monthly

Monthly maintenance typically consists of checking engine coolant levels, the engine oil levels, and the battery. It may also involve searching for any loose wires, signs of damage along fuel pipes, and that proper water drainage is occurring (for diesel fuel generators). You may inspect the battery for corrosion and that its operating system is working properly. Other tasks may include cleaning up the area around the generator and checking for pest infestations.

Semi-Annual

Semi-annual preventive maintenance is a more in-depth inspection and repair task. It includes both the maintenance work performed by your in-house staff as well as the work performed by a service technician. The generator undergoes a full battery diagnostic check as well as an examination of the coolant system, drive belts, exhaust system, air cleaners, fuel system, AC wiring system, and DC electrical system.

Annual

During annual preventive maintenance visits, you may perform replacement of several components that have become damaged or dirty to improve the generator's operating performance. The generator's transfer switch is completely powered off for a full inspection. Parts that undergo replacement may include air filters, fuel filters, oil filters, and spark plugs.

You may also replace old fuel and oil. Other tasks may include flushing out coolant systems, conducting load bank testing, and cleaning the system.

Generator Monthly Maintenance

If a generator is not put into constant use, some companies may be able to forego weekly preventive maintenance visits and could instead combine the tasks associated with weekly visits and monthly visits

So in addition to checking coolant, oil, and fuel levels, you may also check whether the generator is using the right fuel and making any changes or modifications to improve performance. Checking the circuit breaker as well as the battery should always be top priority for monthly generator maintenance.

The battery chemistry may experience aging due to humidity, vibrations, and extreme temperatures. These issues could lead to dangerous short circuits or thermal runaways. Inspecting the battery for corrosion and replacing the battery system when seeing warping, bulges, broken terminals, or leakage is always advisable.

Emergency Generator Maintenance Procedures

Sometimes even with a comprehensive preventive maintenance schedule, generator systems experience a malfunction. Developing emergency generator maintenance procedures allows you to assign specific tasks to workers and outline how to proceed with work to ensure the equipment is repaired quickly and thoroughly. The generator should not be placed online until major repairs are completed and go through a startup checklist to evaluate the performance of all systems.

Emergency generator maintenance may also involve emergency visits with service technicians. In order for the service technician to provide you the best service possible, document the issues that are experienced and any repairs or replacements that your in-house staff performed prior to the technician's arrival. This process ensures that the technician has a full perspective of previous work performed to the generator so they know how to proceed with their work.

A generator preventive maintenance schedule provides enormous benefits to industrial and commercial operations. If you need generator service or emergency service, contact Facility Gateway Corporation. Reach out to us today for a quote.

The Importance of UPS Preventative Maintenance for Your Power Supply

Mon, 18 Apr 2022 19:22:17 GMT

Certain equipment needs to function 24/7 in your facility based on your times of operation. Your uninterruptible power supply (UPS) system is included. If the UPS goes down, your facility's equipment may lose power at critical times. This factor can hamper operations, cause data to be lost, and lead to lost profits.

However, even the components in the UPS system itself may fail. From reaching the end of their shelf life to experiencing a defect or malfunction, the UPS system could go down at the worst possible time without you knowing it. By performing consistent UPS maintenance, you ensure that these industrial generators will remain at top performance throughout the entire year.

The Importance of UPS Maintenance

UPS maintenance allows you to get a snapshot of the current health of your critical power equipment systems. You're able to check the functions of components and perform quick repairs to any worn parts. You also may take note of any anomalies that could impact the future performance of the equipment and order specific spare parts in advance to have them available when required. We call these spare parts kits.

When you perform regular preventive maintenance, your UPS system offers a range of additional benefits. In addition to reducing downtimes by keeping machines running during power outages, an efficient UPS system also prevents power fluctuations and surges from negatively impacting equipment. The UPS system kicks in during these times, ensuring that the right electrical current level is maintained to keep equipment running. It prevents surges that could damage components.

UPS maintenance also improves energy efficiency by ensuring that all components are running at optimal levels. The lifecycle of the system becomes prolonged, which leads to a decrease in operational costs that occur during downtimes. This maintenance also allows engineers to spot potential problems that could cause the UPS to experience a serious malfunction and costly downtime.

Battery Testing for UPS Maintenance

The critical component of the UPS system involves the battery. When there is any power interruption or surge, the battery supplies the power for the facility's equipment. However, batteries have a shelf life. Overcharging, undercharging, extreme temperatures, electrolyte loss, improper venting, and other factors may cause the battery to fail in the UPS system.

Battery testing as part of the UPS maintenance task allows you to know the battery cell's state of health (SoH) and state of charge (SoC). The battery must be able to support the connected load -- the equipment directly attached to the UPS system -- to avoid catastrophic failure.

Battery testing typically involves checking the condition of the terminals, connections, float charges, and open circuits. The service team also performs impedance testing and voltage readings. Our engineers also evaluate the working environment for the UPS system, as well as checking for corrosion damage to inter-cell and inter-cabling systems.

If the battery needs replacement, the service team performs the palletization and string removal of the old battery. Then we install the new UPS battery while following all manufacturer instructions.

Emergency Call Response for UPS Maintenance

Sometimes even with the most comprehensive maintenance schedule, some issues aren't caught until it is too late. When creating a UPS maintenance plan, you need to have emergency call response procedures in place when the UPS system malfunctions or fails unexpectedly.

Emergency call response should involve forming a strong business relationship with the service team. The field engineer should come to the site immediately after the call and remain onsite until the UPS system issue becomes resolved. They will evaluate the entire system to identify the root causes and then provide a report of possible solutions. Before providing any repairs, the field engineer obtains authorization to ensure that you fully understand the issue, the repair services that will be provided, and the costs for the entire emergency call response.

Once obtaining authorization, the service team performs the necessary work efficiently to minimize downtimes. They issue you both a field service report and root cause analysis report for your maintenance records.

Spare Parts for UPS Maintenance Purposes

With consistent maintenance, you come to understand which UPS system parts wear out faster than others or need repairs more often. Then you may order spare parts well in advance and stock the right amounts you need to perform any quick emergency repairs. A UPS maintenance service team should have access to parts for all UPS equipment brands.

We offer part kits stocking for facilities and ensure those kits are up-to-date with the latest UPS models and technologies. In addition, we also offer parts for UPS systems that date back for 20+ years in product age. To do this, we recycle UPS systems no longer used by other facilities. Our teams repair, test, and service these recycled parts to ensure that the equipment operates at optimal levels while providing a 90-day warranty when our engineer performs the installation.

Our Maintenance Contract Types

At Facility Gateway Corporation (FGC), we offer several maintenance contracts for facilities based on their UPS maintenance needs and their budgets. We also offer customized service contracts tailored to your facility's current and future maintenance needs. We fully assess the UPS system and working environment, as well as your standard operating procedure and maintenance operating procedure, to design a contract that meets your requirements.

In addition, we also provide hybrid contracts if you have several UPS systems onsite that require different levels of maintenance. So you can pick out the right contract type for each UPS system. Our standard service contracts provide the following options.

Preventive Maintenance (PM) Only: Emergency call services, quoted parts and labor, technical support, and OEM warranty until exhausted

PM Plus: Emergency call services, technical support, quoted parts and labor, OEM warranty until exhausted, and guaranteed response time

Full Service: Emergency call services, OEM warranty until exhausted, technical support, guaranteed response time, parts and labor covered by FGC

Keeping your UPS system working at full capacity at all times is essential. Let FGC provide you with the maintenance services that best fits into your facility's operations. For more information regarding our services or to select a service contract, get in touch with our service engineers today.

Uninterruptible Power Supply (UPS) Service

Fri, 18 Mar 2022 19:57:50 GMT

Facility Gateway Corporation (FGC) is a Madison, Wisconsin-based UPS Service Company that has been in business since 2008.

We have a staff of 40+ professionals ready to work for you. Looking for Uninterruptible Power Supply (UPS) Service? You’ve come to the right place.

Here are some of our most popular services:

Maintenance Contracts

FGC is happy to customize a UPS service contract to your company’s unique needs. We serve as your single point of contact to manage your critical power, a service that saves our clients valuable time and money.

First, we’ll communicate on-site with your IT and Facility Managers to learn about your goals, objectives, and service requirements. Then, we’ll create a detailed business proposal. Lastly, we’ll oversee your method of procedures (MOPs), standard operating procedures (SOPs),and comprehensive service program to ensure all assets are performing at the highest standards.

Through our extensive post preventative maintenance(PM) technical review, we will examine your field service reports (FSR) and perform an open dialog assessment taking any CAPEX/OPEX requirements and cost-saving opportunities into consideration regarding your UPS maintenance.

We offer three main UPS service coverage options: PM,PM Plus, and Full Service. With all three options, you’ll receive technical support and emergency service dispatched by FGC. With PM Plus and Full-Service plans, you’ll receive a guaranteed response time. And our Full-Service plans cover all electrical components except batteries and no more than 10% of the total capacitors.

Of course, our contracts are customizable, and our service team can design a hybrid maintenance contract for all UPS systems to include different levels of service for each UPS. Our extensive vendor network is nationwide and in parts of Canada. This network includes OEM, third-party service companies, and FGC technicians placed on-site for expert support.

One Time PMs

Don’t need a full maintenance contract, but interested in a professional checkup? FGC has you covered. Whether you’ll looking for a straight answer, a recommendation, or you’re keeping to a tight budget, FGC is available for one-time UPS maintenance visits at any location.

For a full list detailing the comprehensive scope of our preventative maintenance visits, visit our One-Time PM page.

Emergency Service

Our clients love our fast and professional response times. FGC is proud to provide emergency UPS and battery service nationally. FGC supports all OEMs, and we’re able to bring OEM representatives to your location when needed. We have local field engineers stationed across the country, waiting for your dispatch. We’ll stay on-site with you until you’re back online.

Our technicians average 20+ years of experience and work on all UPS makes and models. We always provide FSRs (field service reports) and RCAs (root cause analyses) after every emergency call. When you need it most, you’re in good hands.

Site Survey

Looking for another set of eyes from UPS experts? You might benefit from a site survey. FGC helps perform load calculations, can review your carbon footprint, help determine sizing for growth, and even review levels of redundancy. We’ll meter and take actual power measurements to make sure you have the right data going forward. Our experts will educate you on your options for any changes you might be considering.

A typical executive summary from a site survey includes a review of your physical floor plan, load level and electrical profile, a review of your UPS input and output switchgear, a review of downstream electrical distribution, and much more. Visit our UPS Site Survey page to learn more.

Add Generator & HVAC Service

FGC clients can always add an HVAC, PDU, fire suppression, or any other critical equipment to their existing contract. If you’re working with a preferred vendor, we can add them to our existing FGC Service Network and continue to manage the process on your behalf. FGC is happy to take on the responsibility of serving as your support company, working with vendors to implement the right solutions.

Our Facility Keys™ software platform enables us to hold all vendors to your pre-approved scopes and MOPs. Our Account Management Team can review quotes provided by vendors to ensure the correct scope of service is provided at a reasonable cost. And as always, we double-check scope and workmanship for our clients.

Rental Services

FGC understands the importance of having zero downtime. When you’re in need of a temporary critical power solution, we can help. We provide our clients access to rental equipment solutions nationally and can dispatch at a moment’s notice. Whether you have a pre-planned or emergency need, our 24/7/365U.S.-based National Operations Center is just a phone call away.

We also have an extensive network of qualified electricians available to provide hook-up services if needed. Whether you need equipment for a few hours or a few months, FGC has you covered. And if your project runs over, don’t worry - FGC’s monthly rate will stay consistent, without any 'gotcha' price changes.

Construction Management

FGC partners with clients as their Critical Facility Construction Administrator, allowing us to serve as a single point-of-contact for clients to communicate their project needs. We stay focused on your design and construction needs so that you can stay focused on growing your business.

FGC is a leader in critical facility infrastructure projects from concept & design to data center construction management. Specializing in projects involving critical electrical and mechanical infrastructure of technical facilities, we add to our core services by utilizing local, customer-selected vendors, contractors, and service providers.

Our data center construction management plan includes overseeing the process of procurement, construction, project management, and commissioning and testing those results in a data center standard that exceeds your expectations.

NOC Monitoring

Our National Operations Center (NOC) is based in the United States and is available 24/7, 365 days a year by phone. If you ever have an emergency service need, simply call our NOC at (866)255-6030. Our NOC is always ready to assess, dispatch, and oversee equipment emergencies quickly and accurately. For current clients, FGC actively monitors UPS batteries remotely from our Wisconsin office.

Through active monitoring, we can react quickly to any issue and proactively dispatch a local technician before downtime occurs. We monitor a full range of metrics, such as load levels per phase, operational status, input/output breaker position, UPS and battery temperature alarms, fan failure alarms, battery voltage DC buss and call level, and battery breaker position. Visit our NOC monitoring page to learn more.

Billable Technical Support

FGC knows that not every situation requires a dispatch. Sometimes, a simple nuisance alarm can be reset with the proper uninterruptible power supply technical support over the phone. Is your UPS too old to be supported by the OEM, but not old enough to replace? This is where FGC comes in: call our U.S.-based National Operations Center, and we’ll walk you through any situation with technical support over the phone -24/7, 365 days a year.

Our experienced technicians have an extensive electronic library of manufacturer technical literature and operating manuals at the ready. The first 15 minutes of technical support by phone are free, and anything after that is billed (with our authorization) at a competitive rate.

For all things UPS, Contact FGC Today.

To speak with one of our UPS system experts directly, we invite you to contact us via our online contact form, or start a chat with our team in the chat feature at the bottom right corner of this page!

Replacing Lead-Acid UPS Batteries with Lithium-Ion Batteries

Mon, 28 Feb 2022 21:07:04 GMT

You’ve heard of the impressive new Smart-UPS product line, but did you know that you can use lithium-ion batteries in your UPS too? The use of lithium-ion batteries brings many added features and benefits.

Read on to hear what the UPS battery service and replacement experts at Facility Gateway Corporation have to say about this impressive new technology.

An Overview of Lithium-Ion Smart-UPS Products

If you’re tired of frequent battery replacements, have encountered unexpected battery failures noticed higher temperatures and runtime degradation overtime, or even if you’re just interested in lowering your total cost of UPS ownership, you may have considered lithium-ion Smart-UPS products.

How long do lithium-ion batteries last?

Lithium-ion batteries have a life cycle of up to ten times that of a traditional sealed lead-acid battery. For lead-acid batteries, a typical life cycle is up to 500 cycles while for a lithium-ion battery used in a UPS, the typical life cycle can be up to 5,000 cycles. (For reference, a cycle refers to a full discharge and recharge.) After a battery’s capacity at full charge reaches around 70%, you should replace the battery.

Are lithium-ion batteries lighter?

Yes, lithium-ion batteries are lighter, take up less space than traditional sealed lead-acid batteries, and are typically up to one third smaller overall.

Can you hot-swap a lithium-ion battery pack?

Yes, you can hot-swap a lithium-battery pack in a single-phase UPS. You can even replace internal batteries while your UPS is still running in online mode.

Benefits of Switching to Lithium-Ion Batteries for UPS Systems

Lithium-ion batteries save your company money and time, and lead to fewer risky situations during the Smart-UPS’ lifecycle, all while keeping run-times up. How exactly is this accomplished? Let’s explore the benefits lithium-ion batteries bring and their unique advantages over lead-acid batteries.

1. Lithium-Ion Batteries have a Higher Capacity than Lead-Acid Batteries. In fact, the exact number is almost double. Translation: when you switch from lead-acid to lithium-ion, you receive more power from a smaller, lighter unit.

2. Lithium-Ion Batteries are more Environmentally Friendly than Lead-Acid Batteries. Not only do lithium-ion batteries have an easier and more environmentally conscious disposal method, but they can even be recycled in some circumstances.

3. Lithium-Ion Batteries Cost less than Lead-Acid Batteries Long-Term. In terms of start-up costs or initial investment, it’s true that traditional sealed lead-acid batteries are a cheaper option as compared to lithium-ion. But keep in mind, lead-acid batteries require more frequent maintenance, creating an additional cost for you, and need to be replaced more quickly and more frequently. On the other hand, Lithium-ion batteries last longer, and require less preventative and responsive maintenance.

4. Lithium-Ion Batteries Are More Efficient than Lead-Acid Batteries. Lithium-ion batteries simply store more power than their traditional sealed lead-acid counterparts. Your UPS will be run more efficiently when making the switch to lithium-ion. Lithium-ion batteries can use about 95% of stored energy from a single charge, while a lead-acid battery will only use about 80-85% of stored energy.

5. Lithium-Ion Batteries Charge More Quickly than Lead-Acid Batteries. Lithium-ion batteries charge more quickly, and they can handle a higher charge amperage than a traditional sealed lead-acid battery can. Why is this? Lead-acid batteries are rather limited in terms of handling a charging current. Faster charging lead-acid batteries mean overheating and low efficiency throughout the cycle.

Can You Safely Replace Lead Acid Batteries and Use Lithium-ion Batteries in a UPS?

Yes, you absolutely can safely use lithium-ion batteries in your uninterruptible power system. For example, Schneider Electric has been doing so successfully since 2013. Lithium-ion Smart-UPS products can offer features like a battery monitoring system (BMS). With this BMS, you can monitor and control the energy flow in the battery pack, utilize overvoltage and overtemperature protection at cell level, thermal runaway protection, overload and short circuit protection at pack level, and even harness a dedicated fuse within the battery pack.

How Can Lithium-Ion Smart-UPS Products be Replaced?

You can replace your traditional sealed lead-acid battery with lithium-ion batteries in your Smart-UPS products. For a successful transition, keep the following tips in mind:

1. Make sure you check and replace the voltage on your battery bank. A low charge will not provide the power you need, but a very high charge can lead to damage of your new lithium-ion battery. A happy medium is best!

2. Immediately set your Battery Monitoring System (BMS) to “AH.” This produces the most reliable reading. Most Smart-UPS are designed for a drop-in swap, but you’re better off here. Make sure you check your connections.

Could You use UPS Battery Service and Replacement Help from Trusted Experts?

As the “heart” of any UPS system, batteries are the source of emergency power in the event of a power loss. During a utility power failure, the UPS batteries must support the connected load to prevent catastrophic outcomes, from data loss and business disruption to injuries. That’s why proactive maintenance and replacement of UPS batteries is crucial. We recommend replacement every 3-5 years of all UPS batteries - your UPS may have more than one!

At Facility Gateway, our experts in battery service are here to keep your business running 24/7/365. We offer a wide variety of UPS battery service and replacement options for all uninterruptable power systems. Our experts understand the importance of proper UPS battery maintenance and replacement, not to mention the technical requirements needed to install and recycle any string of batteries.

Contact Facility Gateway Corporation (FGC) at any time at 866-255-6030 for UPS & battery service needs, or call our U.S. based National Operating Center’s emergency line at 866-432-1711 that is staffed 24/7 . Let us be your partner for all mission critical equipment services. To speak with one of our experts directly, we invite you to contact us via our online contact form , or start a chat with our team in the chat feature at the bottom right corner of this page!

A Guide to Commercial Generator Rentals: Types, Rates, Fuel Sources, and Safety

Mon, 24 Jan 2022 21:12:51 GMT

Commercial generator rentals are a great way to save money and get the commercial power you need. However, there are many types of commercial generators on the market with different fuel sources, rates, and sizes. As a result, choosing the best option for your facility and application can be complicated.

In this guide, you will learn about commercial generators as well as how to size them for your needs. You will also find safety tips that can help keep your business running smoothly incase of an emergency!

Read on to get started.

Which Generator Type is Right For You?

Not all commercial generators are created equal, and they vary in size, fuel type, and power output. When it comes to commercial generator rentals there are two primary types:

The first is professional generators, which usually serve construction and light industrial situations. Smaller in size but with high power output (usually between 5,000 to 10,000 watts), these generators are well suited as a backup to existing standby generators or during events where short-term power is required.

The second type is full industrial generators, designed to deliver large amounts of power for industrial applications. An example includes keeping critical components of factories or medical centers operating. Output for industrial generators exceeds 10,000 watts, making them more expensive, but also the preferred option for most industrial applications.

The Different Types of Generator Fuel

There are different sources of commercial fuel, with diesel and propane generators being the most common for large industrial applications.

Diesel

Diesel generators are typically commercial grade, with diesel fuel as the main power source. As the industry standard, these generators are available in the broadest range of sizes and power configurations. They also have lower rental rates typically. They are best suited for short-term rentals with low operating time and minimal loads.

Natural Gas

With nearly zero emissions, natural gas generators are the cleanest available option. Natural gas is relatively inexpensive when compared to other options like diesel and can be stored on-site.

As a result, this type of generator is best suited for long-term rentals with long operating times and high loads. The fuel consumption these applications would require if using a diesel generator makes natural gas a more practical and efficient solution. Examples include schools, hospitals, and other facilities where environmental concerns are important.

A commercial natural gas generator will provide between four to eight hours of power before refueling or switching to another fuel source is necessary, depending upon the size of the unit.

How to Size a Rental Generator

It's important to choose a commercial generator size based on your application's requirements. However, knowing how to select the best option can be confusing. The first things to consider when sizing a commercial generator are:

• What will it power?

• How long do you need it?

• How much voltage is required?

To begin, determine if the generator is going to service the entire facility or only supply power for critical functions. Some of those functions might include:

• Lighting

• Computer Systems

• Emergency Safety Equipment

• Ventilation & Air Conditioning

Then, identify what type of voltage is required and whether you will need a single or three-phase. This can be a complicated and detailed process if you're unfamiliar with the industry, but it is absolutely critical to choosing the correct generator. When in doubt, consult with a generator rental professional about your requirements before renting.

Rental Generator Safety

There are several steps you can and should take with your rental generator to ensure proper operation and safety.

Before using your commercial generator unit for the first time, consult with its owner's manual or the technicians who deliver the generator to learn how it should be started and operated.

It is also important that commercial rentals are stored somewhere safe and dry when not in use. This procedure will help ensure your commercial rental remains durable while providing you with peace of mind. Additional safety precautions worth taking include:

• Avoiding excessive strain which could cause the generator to stop working

• Ensuring all cables, cords, and accessory devices are insulated and grounded

• Verifying the generator is properly ventilated at all times, with plenty of airflow

• Avoiding contact with hot surfaces

• Storing fuel away from the generator at all times

• Making sure the generator is stopped and secured before servicing

If you're ever unsure of what steps to take to ensure the safety of your generator operation and your staff, ask the technician to demonstrate how to operate the rental safely. Not only are we happy to do so, but it could spare you a lot of damage.

Commercial Generator Rates

Ultimately, the cost of your generator rental will be based on the size of the generator, how long it will be rented for, and how many hours it will be used. When renting a generator, rental rates are generally fixed and based mostly on the length of time rented or the generators’ size.

For this reason, and the safety of your load, it's important to ensure you don't choose generators that are too large for your needs.

The Facility Gateway Critical Services Rental Process

Ready to get started on the generator rental process? Tell us about your project.

What generator size is required? What is the location of the generator? How long will you need a rental for? When you work with our commercial generator rentals team, we'll work with you to determine the best rental option for your needs.

Some of our commercial generator rates include:

• Hourly Rates (includes set up time)

• Daily Rates (24 hours)

• Weekly Rates (seven days)

• Monthly Rates (30 days or more)

We list the rental rates upfront, including all fees—no hidden charges or tricks. Once an agreement is signed, we start mobilizing the generator solution and team to your site. We set it up, get power connected, and provide ongoing fueling on some plans.

Contact our team today to get started!

SOP for UPS Preventative Maintenance Procedure

Fri, 07 Jan 2022 21:21:49 GMT

Does your UPS system need a check up ? Even if your UPS seems to be functioning perfectly, it’s important to be on the offense before problems arise. That’s where great preventative maintenance visits come in handy. No matter your UPS system’s manufacturer, your company needs a reliable technician that can be called on site to conduct preventative maintenance check-ins.

In this article, we will outline a few of the standard checklist items our technicians use during a maintenance visit. As an organization that relies on its UPS system in the event of a power outage, you know that fantastic maintenance services are absolutely crucial for proper UPS uptime, and not the area you want to neglect.

SOP (Standard Operating Procedure) for Preventative Maintenance of UPS Systems:

Here are some of the items that are included in a One-Time UPS System Preventative Maintenance Visit:

· Perform a complete visual inspection of all internal sub-assemblies, wiring harnesses, connections, cables, and major components

· Check for proper clearance around the unit

· Perform temperature checks on all breakers, connections, and associated controls and then report all high-temperature areas

· Check for cleanliness; then clean or replace as needed

· Check rectifier and inverter snubber circuit board for discoloration

· Check power capacitors for swelling or leakage

· Check capacitor vent caps extruded more than 1/8fans for proper operation

· Lubricate and check bearings for abnormal condition, where possible

· Record all meter readings and calibrate as necessary, where possible

· Measure and record phase-to-phase input, output, bypass, and battery voltages and currents, where possible

· Review alarm log/history for any irregular activity, where possible

· Verify remote status panel operation

· Measure and record harmonic-trap filter currents, where possible

· Check the inverter and rectifier snubbers for discoloration or damaged wiring

· Check all contacts to ensure secure connections

· Verify that connections show no signs of discoloration

· Check fuses on the DC capacitor deck for continuity, as applicable

· Clean interior and exterior of unit (with your approval)

· Perform operational test of the system including unit transfer and battery discharge

· Measure and calibrate, as necessary, where possible, all electronics to system specifications

· Measure and record all low-voltage power-supply levels

· Review system performance with you, and address any questions you may have, as well as schedule any needed repairs

· Provide a comprehensive inspection report, with recommendations within 7 to 10 business days

When choosing a partner for the preventative maintenance of your UPS System, pay special attention to the qualifications required of their technicians. It is true that not all technicians are created equal – for example, some technicians may have the intellect, but lack the practical hands-on experience to provide adequate maintenance services for your equipment.

At Facility Gateway Corporation, we believe in employing only the most dedicated technicians. Our technicians average twenty or more years of experience. They are factory trained, and work on all UPS makes and models from all manufacturers. Stationed across the nation, FGC technicians are always available at anytime in your local area. And at FGC, our promise to our clients is that our technicians will follow outlined Standard Operating Procedures 100% of the time.

Also included in our One-Time UPS System Preventative Maintenance Visit is a check-up for your UPS Systems’ battery. This includes:

· Measure and record each cell terminal voltage (DC and AC)

· Measure and record overall system DC voltage and current levels

· Measure and record ambient room temperature

· Measure and record temperature of all negative posts

· Measure and record AC ripple voltage and current

· Measure and record VDC and VAC of jar/cell (cell#1 + post to frame ground; frame ground to – post of last cell in string)

· Check jar and cover for signs of leakage

· Check for corrosion on terminal post and connector

· Check general appearance and cleanliness of battery room and batteries

· Review your company’s battery maintenance logs and add maintenance entry

· Safety check: confirm proper warning/hazard labels

· Safety check: confirm proper operational information, placards, and labeling

· Safety check: check safety equipment and supplies for proper amount and location

· Torque battery to manufacturer's specification(if connection resistance measures greater than 20% of average)

· Clean and re-secure all battery terminals and jumper connections, as applicable (up to 20%)

· Clean and neutralize jar and rack/cabinet, as applicable

· Load test each jar or use equivalent device

· Provide inspection report with recommendations to you within 7 to 10 business days

Another important consideration for your UPS System preventative maintenance partner is its battery and stocking capabilities. At Facility Gateway Corporation, we know we could not provide the high level of quality service that we’re able to deliver to our clients if we did not have superior access to great batteries and parts. We also understand that breadth is key, which is why we stock several million dollars of inventory in parts, batteries, and replacement equipment nationally. We carry both OEM certified and third-party parts to ensure your UPS system has the highest possible uptime on our watch.

Facility Gateway Corporation provides emergency responses to our clients twenty-four hours a day, seven days a week, 365 days a year. Our Wisconsin-based National Operations Center is staffed all night and day, with analysts who are experienced, knowledgeable, and connected. Because of our non-stop customer service system, we are always just moments from dispatching a quality technician to your site at any time you call. We have local Field Engineers across the nation at the ready.

If you find you are in need of phone tech support in the middle of the night, you’re completely covered when you choose to partner with FGC. Until your UPS is back online, we will stay on-site to ensure you will have no more additional downtime.

Contact Facility Gateway Corporation (FGC) at any time at 866-255-6030 for emergency UPS & battery service needs, or call our U.S. based National Operating Center at866-432-1711. Let us be your partner for uninterruptible power supply services.

Whether you are looking for a recommendation or simply budget conscience, FGC is willing to conduct a one-time UPS maintenance visit as necessary at any location. Facility Gateway understands the importance of proper UPS maintenance, regardless of its original manufacturer. To speak with one of our UPS system experts directly, we invite you to contact us via our online contact form , or start a chat with our team in the chat feature at the bottom right corner of this page!

DC Power Systems Overview - The Role of the UPS

Wed, 29 Dec 2021 21:33:44 GMT

What is DC Power?

Direct current (DC) is the one-directional flow of electricity. As opposed to alternating current (AC), DC electric current flows in a constant direction. AC power is converted from DC power through rectifiers, which only allow electric currents to flow in one direction. DC power is converted into AC power through an inverter, which uses electronic components like inductors and capacitors or transformers. These tools can’t give out more power than they take in, and during the process of switching AC to DC or DC to AC power, some energy is lost in the process and becomes heat.

DC power is used in a range of applications, from household uses like flashlights and remotes, to charging batteries, to the provision of electric supply for industrial motors and railways. In high-voltage form, DC power is even used to transmit huge amounts of electricity from remote generators and to connect power grids.

Read more for an overview on DC power systems, including the role of DC power UPS plays and the main components of the system.

What is the Role of DC Power in a UPS?

DC Power is very commonly used in emergency power situations, through the use of UPS (uninterruptible power supply) systems. A UPS system is an electrical apparatus that provides emergency power to a load when the input power source or mains power fails. Businesses everywhere rely on UPS systems to power their electronic equipment in the event of an unexpected power outage.

Electricity blackouts, spikes, surges, or over-voltage could typically mean the loss of critical data, and perhaps millions of dollars in damage and lost profits. UPS systems keep the lights on so companies can function as normal until normal power resumes. UPS systems can be small, protecting a single computer, to large, protecting entire companies, data centers, schools, factories, and hospitals.

Though some are mechanical in nature, most UPS systems store electricity in a series of rechargeable batteries. When normal power is on, or in other words-when not experiencing a power outage-the batteries of the UPS system are charged by DC power. In most situations and applications, this DC power is then converted from AC power through the use of a transformer and rectifier circuit.

When an unexpected power outage occurs, the pre-charged batteries of the UPS system are full of DC power. Most equipment requires AC power to run, however. In a “typical” UPS system, the UPS system’s inverter converts the DC power back to AC power again, so your normal functions can resume.

What is a DC Power System?

A DC power system is a UPS system that provides DC output in the same uninterruptible manner any UPS system could. This system provides DC power to equipment and is used in a range of industries. As previously described, most equipment operates using AC power, but when long discharge and low amperage output is required, DC systems are preferred. DC systems typically convert AC to DC power when an electricity blackout occurs. They also keep backup batteries charged and regulate the electricity sent to your equipment, so you use the correct input voltage.

What are the Main Components of a DC Power System?

There are five main components of a DC Power System. Briefly described below, they are:

The rectifier/charger: This is an electrical device converting AC to DC power. Not only does it provide DC power, but it also charges backup batteries. The rectifier/charger is the hero of the system, and it’s what makes sure the system can continue to work when an unexpected electricity blackout occurs.

The controller: The controller is the component of a DC system that sends instructions to the other components within the system using communication protocols.

The batteries: Different DC power systems can use different kinds of batteries. Some of the most common types of batteries a DC system may use are VLRA batteries, wet cell batteries, lithium-ion batteries, or NICAD batteries. What type of battery a DC power system uses will depend on the specific application, and several other considerations, including the temperature within the building where the system is stored, available budget, and environmental concerns, among other things.

The distribution system: The distribution system is the part of the system that provides electricity for ultimate use. The distribution system may be external, or it may not be housed in the same area as the rectifier, but it is a separate component within the DC system.

The enclosure: There are so many different types of DC power system enclosures, and many are environment and/or application specific. Common enclosure designs include shelf mount and rack mount enclosures.

Need DC System / UPS Assistance or Advice?

Facility Gateway Corporation understands the importance of selecting the right UPS to protect your business in the event of an unexpected power outage, and we also know how crucial it is to provide proper UPS maintenance. At FGC, we are happy to provide advice, UPS maintenance, or set your business up with the right UPS system to fit your unique needs.

To speak with one of our UPS system experts directly, contact Facility Gateway Corporation at any time at866-255-6030 for emergency UPS & battery service needs, or call our U.S. based National Operating Center at 866-432-1711. We also invite you to contact us via our online contact form, or start a chat with our team in the chat feature at the bottom right corner of this page! Let us be your partner for uninterruptible power supply services.

Dry Battery vs Wet Battery: Which is Better for Uninterruptible Power Supply?

Fri, 27 Aug 2021 15:40:35 GMT

Batteries are the most important part of your uninterruptible power supply. However, there are a lot of options to choose from, making this difficult decision even more challenging.

When determining which type of battery is best for your power needs, you'll want to consider the differences between wet-cell and dry-cell batteries. The most important difference between a wet-cell and dry-cell battery for uninterruptible power supplies (UPS) is in how they are maintained following installation.

What's the best battery option for you? Find out by reading this blog post about how they work, what the maintenance requirements there are, and a few of their pros and cons!

Wet-Cell Battery Overview

A wet-cell UPS battery uses a liquid electrolyte such as sulfuric acid to generate power. Typically, these batteries have a longer lifespan and can be discharged deeper than a dry-cell alternative. However, they do require more maintenance than dry-cell alternatives.

Below, we outline a few of the wet-cell battery's advantages.

Pros of Wet-Cell Batteries

Longer Lifespan: A wet-cell battery has a much longer life span than of dry cells, so it won't need to be replaced as often. They also don't contain lead-acid.

Deeper Discharges: The discharge rate is also more forgiving with a wet-cell battery, meaning that it can be discharged to 100% without damaging the cells.

Electrolyte Is Nonflammable: The electrolytes in wet-cell batteries are non-flammable and won't produce toxic gases when meeting water or air.

Dry-Cell Battery Overview

A dry-cell UPS battery stores its charge in an enclosed container and uses a special type of valve to regulate the flow of electricity to and from the battery. This design makes the dry-cell battery very safe to use and easy to maintain.

The downside is that these batteries are not as durable nor long-lasting, but they do have more charge cycles before they need replacement.

Pros of Dry-Cell Batteries

Operation in any position: Unlike wet-cell batteries, dry-cell batteries can be operated in any position, useful for a wide range of applications.

Efficient Power Creation: Dry-cell batteries also typically have great energy densities, packing a large amount of power into a small, efficient design. Dry-cell UPS batteries can be a good choice if you're looking for something small enough to fit in tight spaces with little weight.

Longer Storage: Dry-cell batteries are typically used as primary cells and therefore can handle long periods of storage. These maintain their charge for longer than secondary batteries which is why they're still used in UPS systems, even though lithium-ion, lead-acid, and nickel-cadmium are the more popular types of battery currently on the market.

Cost savings: Since the dry-cell batteries require less maintenance over time, they are a less expensive battery to maintain.

Dry vs Wet Battery for Uninterruptible Power Supply: Maintenance and Upkeep Differences

Dry-Cell Battery Maintenance

As one of the most durable battery options available , maintaining your dry-cell batteries is relatively easy and can be accomplished with a few simple, infrequent steps.

Keep the battery clean: Cleaning is essential to prolong dry-cell battery life. This can be done with a damp cloth or dry rag, and you should clean any dirt from around the terminals as well. Avoid using harsh chemicals or anything that might damage the plastic casing of your batteries as this will cause them to wear down more quickly than they would otherwise.

Keep battery temperature stable: Dry-cell batteries should be stored in a cool and dry environment. Most batteries should be kept at the recommended 15 degrees Celsius (or 59 degrees Fahrenheit). Be sure to avoid freezing temperatures and do not store these batteries near sources of heat. Dry-cell batteries are more susceptible to overheating than wet-cell options, so keep them away from closed windows on sunny days or any other source that might create high temperatures around the battery.

Do not short circuit your batteries: If you're handling a battery, it's important to avoid all contact between the terminals of the battery and other metal objects. Make sure that they are insulated from anything that may cause them to contact one another by using electrical tape or some type of insulation material on either side of the terminal.

PM (Preventative Maintenance) Frequency: Depending on the runtime configuration and the string size, we recommend conducting a battery PM visit during every UPS PM, 2 times annually. If this is a mission critical application, we recommend quarterly PMs. Make sure to get voltage and resistance reading for every individual jar during every PM. We recommend a Midtronics meter or something equivalent for proper reporting.

Wet-Cell Battery Maintenance

Wet-cell batteries require regular maintenance to function properly. This maintenance includes:

Periodic top-up of the electrolyte: You'll need to periodically add water and acid to maintain the optimum level for battery performance. Wet-cell or flooded batteries typically need their electrolyte levels checked at least once every three months.

Keep cables clean and dry: This is very important, as even a small amount of corrosion can cause your wet-cell batteries to malfunction or fail to provide power.

Check for leaks: Keep an eye out for any unusual signs of bubbles or gas. Gas is the first warning sign that your battery needs to be recharged and serviced.

PM Frequency: We recommend conducting a battery PM visit quarterly for wet-cell battery plants. If this is a mission critical application, we recommend monthly PMs. Make sure to get voltage and resistance reading for every individual jar during every PM. We recommend a Midtronics meter or something equivalent for proper reporting.

The wet-cell batteries should also have a thorough inspection at least once per year, preferably in spring before summer when temperatures are warmest.

FGC – Your Partner in Battery Maintenance

Facility Gateway Corporation offers a wide variety of replacement UPS batteries for all uninterruptable power systems. We understand the importance of proper maintenance and recycling, so we recommend replacing your dry-cell batteries every 3-5 years and your wet-cell batteries every 15-50 years, depending on the configuration and application to ensure maximum production time in between replacements.

You can learn more about the lifecycle of your UPS and its components by visiting our recent blog on the subject or speak with a member of our team!

Our Account Managers will work with your site contact to ship out any new battery order you need ASAP.

How to Improve Building Management System with a UPS

Fri, 13 Aug 2021 20:50:49 GMT

Building management systems are crucial to the success of many businesses across the world, allowing owners and operators to have complete control over and insight into the inner workings of their facilities. From HVAC systems, mechanical issues, computer networks and more, these high-powered and convenient systems make it possible for one person to manage it all.

But what happens when your facility’s power supply is unstable, or worse, shuts off completely? This is where uninterruptible power supplies (UPS) come into play. A UPS doesn’t just provide power during blackouts or brownouts, it can also help protect your expensive investment in equipment and data by working together with your building management system.

Here, we discuss how implementing a UPS into your facility’s building management system can improve how your company works as well as what important considerations you should make before an integration!

What is a Building Management System (BMS)?

Like a brain in a body, large facilities often rely on a building management system (BMS) to monitor a wide range of processes and functions. From the HVAC and security systems to computer networks and more, the BMS ensures everything is running smoothly, without interruption or damage. Certain BMSs can also deliver reporting and data analysis to help you operate more efficiently.

Typically, the BMS will be a personal or embedded computer that uses software to communicate through an industrial control network to the entire facility.

Pros & Cons of BMS

Building Management Systems and software provide a wide range of benefits business owners and facility managers rely on every day. Primarily, they allow managers to easily access and control any area of your structure and/or property, from any location.

For example, through extensive data monitoring and processing functions, a BMS can manage every system in your structure, including mechanical and electrical. Better yet, these systems can adapt alongside your business as the two continue to evolve and develop over time.

However, when the power supply fails or declines in stability, building management systems are rendered all but useless. All that amazing functionality depends on a steady supply of usable power, which large industrial facilities are not always able to guarantee. This is where a BMS can benefit from an Uninterruptible Power Supply (UPS).

What is a UPS?

A UPS is a battery-powered device you can plug into your building's electrical system to provide a backup source of power. It does this by continuously monitoring the available electricity and routing it around any problems, such as brownouts or blackouts.

How Does a UPS Help Your Building Management System?

The main benefits of integrating a UPS into your building management system all come down to power. Many UPS models are designed to provide both a stable power stream, and enough backup power to ensure all your expensive electrical devices and equipment are shut down properly in the event of an outage.

When critical devices feeding the building management system are also hooked up to a UPS, the benefits start to show themselves quite clearly.

Any servers, computers, and other valuable electronics are protected from power spikes, and will be shut off correctly in the event of an outage. That means all the data, and or health of the devices themselves, is preserved.

A UPS and BMS working together can also result in significantly reduced energy costs. Stable electricity often means reduced strain on HVAC systems and other building processes.

Integration Considerations – How BMS and UPS Communicate

Different standards of communication between UPS systems and Building Management Systems have made integrating such a system somewhat challenging for building managers.

IT infrastructure and devices like servers, storage systems, and networks use Simple Network Management Protocol (SNMP) to communicate with each other (i.e., collecting, organizing, and modifying information). Conversely, building management systems communicate through protocol layers called BACnet/IP.

The discrepancies in communication styles are akin to different languages. They can both talk about the same thing but won’t understand each other without a translator. In some instances, it takes a person or a team of people to be the “translator,” monitoring both data types at the same time. For small and medium enterprises, that can be an extremely impractical set up. However, solutions exist.

Practical Solutions for Connecting a UPS to Your BMS

To reap all the rewards of a fully connected system, be sure to choose a solution that will easily connect to your BMS. Having a fully cohesive system provides building system managers with a complete view of their UPS status and performance all in one location. The result is a new level of oversight, a reduced risk of unplanned downtime, and total peace of mind when it comes to your building management.

When looking for a UPS, make sure to choose one with solid, reliable network management features that are BACnet certified. Efficiency can be further increased by using the latest available software on your connection.

Facility Gateway Corporation–Your UPS Integration Partner

Connecting a UPS to your building management system isn’t an easy task, but with the right team of professionals behind you it can deliver a wide range of benefits. Facility Gateway Critical Services has all the experience and knowledge necessary to help you manage your mission critical UPS and battery maintenance, as well as integration with pre-existing systems, like a BMS.

Learn more about us, or contact us today and tell us about your project!

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How to Tell if UPS Battery Needs Replacing

Thu, 04 Mar 2021 20:07:15 GMT

Old batteries are often the weakest link of any Uninterruptible Power Supply (UPS). Delivering emergency power supply to your electrical load in the case of a power failure, UPS systems allow your devices to keep running long enough for the generator to kick in or until a proper shut down can occur. They also protect your devices from power surges, brownouts, black outs, and power transients.

Most UPS systems rely on batteries as their source of power. However, batteries are often prone to failure, requiring replacement themselves. But how can you tell if a UPS battery needs replacing for sure? Here, we will outline a few of the warning signs, as well as ways to confirm the need for a replacement, and your options for doing so. Ready to get started?

UPS Battery Replacement Warning Signs

The Low Battery Alarm Has Sounded

Most UPS systems come with a low battery alarm . The machine will run a periodic self-test, only giving an alert signal when a battery replacement is required. Usually, this signal takes the form of an indicator light or alarm sound. If you have a monitoring system set up, you may also receive alerts via email or alternative digital communication.

Preventive Maintenance Visits

Your UPS Service Technician will PM the batteries during your annual and semiannual UPS Preventive Maintenance Visit. They can easily compare your battery Midtronics readings to the OEM allowable specifications to ensure the batteries are good operating order. They can also lend expert advice and opinions on your battery's health and well-being based on their Midtronics readings.

Strange Behavior & UPS Battery Failure Symptoms

When near failure, batteries will often begin to demonstrate strange symptoms you can use to judge the remaining life of your battery. Typically, repeating alarms, flashing panel lights, and strange terminal displays are all symptoms of a failing UPS battery.

Old Age

Every battery manufacture puts a date code on their batteries, telling you when your battery was made. In most cases, you should expect your UPS batteries to last a maximum of three to four years. While that lifespan can differ depending on the usage requirements of your system and your load, if batteries are nearing this age, it is likely time to consider a replacement.

When the Battery Begins Shorting its Rated Capacity

When your battery system can no longer supply at least 80percent of its rated capacity in ampere hours, it is a likely indicator that your battery needs to be replaced. Typically, when the battery reaches this percentage, the aging process will accelerate rapidly, ending the useful life of the battery. This can literally happen overnight.

Early Discharge

If your UPS batteries are taking longer to charge, and are self-discharging earlier than usual, it is a definite sign that the battery’s life is nearly over.

How to Check UPS Battery Health and Confirm It Needs Replacement

When your battery begins to display any of the above warning signals, you will want to confirm whether it needs to be replaced or not. There are a few methods you can implement on your own to do so.

First, Inspect the Batteries

In some cases, you may be able to tell whether a battery needs to be replaced simply by looking at it. If you see any of the signs below, it is almost definitely a sign your battery needs immediate replacement:

Visible Signs of a UPS Battery Problem

· Broken terminals

· Bulges in the casing

· Cracks in the plastic

· Excessive leaking

· Or any discoloration

These changes to the battery’s physical appearance can be indicators of a short, overcharging, or simply a lack of proper battery maintenance. If you have inspected the battery and found none of the above, move on to the next step.

Take a Voltage Reading

If you have a voltage reader on hand, or already integrated, hook it up to your battery and compare the voltage reading to the voltage the battery is supposed to be capable of providing. If it is significantly reduced while being charged, it could indicate any of the following scenarios:

· Your battery experienced a short circuit

· Your battery has a dead cell

· Your battery has become sulfated

Sulfated batteries are usually unable to reach a full charge and will self-discharge far more quickly than a healthy battery. Any of the above scenarios will require a battery replacement.

Battery Replacement Options

UPS systems are already equipped with VRLA batteries and are typically replaced with a similar models. If you are looking for added runtime or redundancy, now would be a good time to discuss options with your service provider. In some cases, you can fit larger amp hour batteries into your current cabinet to lengthen your runtime. However, if you have the space, you can also add a second cabinet for redundancy.

In the end, you can have your service company simply replace your UPS batteries with new ones every few years. This will entail new batteries, new interconnects if needed, hardware torqued to the OEM specifications and battery monitoring devices if necessary. Sometimes you may want the replacement to happen during non-peak hours which can include nights or weekends so make sure they are able to accommodate your schedule.

Visit our construction division’s website for more information and an in-depth comparison of UPS Runtime Solutions .

Facility Gateway Critical Services: Your UPS Service Partner

FGC Service offers a wide variety of replacement UPS batteries and assistance for all Uninterruptible Power Systems. We understand the importance of proper UPS battery maintenance and the technical requirements needed to install and recycle any string of batteries.

If you’d like to learn more about our battery replacement and monitoring services, check out our battery replacement guide .

If you’d prefer to speak with one of our product specialists directly, we invite you to contact us via our online contact form, or start a chat with our team in the chat feature at the bottom right corner of this page!

Annual Second Harvest Food Drive

Wed, 20 Jan 2021 20:08:04 GMT

A HUGE thank you to all our employees who donated food for our Second Harvest Food Bank Food Drive this year. We ended up donating 576 pounds of food!

Advances in UPS Technology

Fri, 18 Dec 2020 20:07:50 GMT

Advancements to three-phase uninterruptible power supply bring greater efficiency and modularity, along with a reduced footprint, improved connectivity and a lower total cost of ownership.

Case Study #5 UPS Cooling Fan Replacement

Sun, 06 Dec 2020 20:09:42 GMT

Type of Customer/Facility: Hospital

Location: Wisconsin

Product: Mitsubishi 9833A UPS 100 kVA (Date Code: 2006) & backs up the west wing of the hospital

Service Level: PM + contract includes the number of scheduled maintenance visits as well as 24/7 emergency service with a response, but does not include the purchase of replacement parts or the labor to install replacement parts.

Summary: Received a call from the customer on Saturday, 12/5/2020 that the UPS was in alarm for cooling fan abnormality. Customer requested troubleshooting over the phone to determine if fan needs to be replaced.

Preliminary Actions: Our technician determined the battery breaker was tripped. Our technician was then scheduled to go to the customer’s site the following day.

Mean Time to Repair (MTTR): 1 day (EC call placed on 12/5/2020 at 3:30 PM & fan was replaced on 12/6/2020 at 2:30PM)

Failed Parts: Yes; (1) Cooling Fan

Ordered fan from FGC Madison Inventory

Findings/Solutions:

1. During the emergency dispatch on Sunday, 12/6/2020, our technician found the UPS in bypass with a fan failure alarm on display.

2. Our technician removed the top guard covering cooling fan, found fan locked up.

3. Our technical staff was able to order a fan from our Madison inventory warehouse, and drop it off at the hospital for our technician the same day to replace the fan.

4. Our technician replaced the cooling fan, reset UPS fault, transferred UPS to normal. UPS online, with no alarms. Emergency call completed.

Case Study #4: Emergency Call During a PM Service Visit

Mon, 30 Nov 2020 20:12:37 GMT

Type of Facility: Casino

Location: New Jersey

Product: Liebert AP377 100 kVA, backs up security system - Date Code: 2002

PM Service for UPS Summary:

Down UPS System discovered during a preventive maintenance for ups system visit at 8 AM on November 18, 2020. Contract is full service and the UPS is at its end of life/discontinued from the manufacture. Parts are no longer being manufactured from the OEM.

Service Level: Full Service contract includes all parts and labor covered during the PM visits, including emergency calls that we respond to during the contract term (excluding full capacitor replacement and batteries).

Preliminary Actions: UPS was found in Bypass with an inverter over-current phase A alarm. Our technician conducted further troubleshooting and checked all the capacitors and all were within specifications. FGC field engineer discovered discolored inductors in Phase A. The inductor overheated and was burnt during the normal operation, which caused the inverter leg over current and switched to bypass.

Mean Time to Repair (MTTR): 1 business day

Failed Parts: Yes, discussed possible replacement of the unit, but since the repair was feasible and the part was in stock, we moved forward with the repair. (1) Output inductor PN: 02-768711-00-3 (Since the unit was over 18 years old part purchased from a 3rd party vendor)

Findings/Solutions:

1. FGC parts team sourced & shipped needed parts for next day delivery at 10:51 AM on November 18, 2020.

2. Field engineer returned the next day to install replacement parts and placed the UPS System back into service.

3. Liebert AP377 was placed back online at 3:30 PM on November 19, 2020.

4. FGC called the customer following the successful repair to check in to make sure UPS is running without issues.

5. Customer was very pleased with the response and repair.

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What Does “99% Power Efficiency” Really Mean in Silicon Carbide MOSFETs? April 21, 2020 by John Koon

Thu, 15 Oct 2020 19:07:36 GMT

Whenever we discuss power semiconductors, the feature that takes center stage is power efficiency. But what exactly do we mean by that term?

https://www.allaboutcircuits.com/news/what-does-99-power-efficiency-mean-silicon-carbide-mosfets/

Case Study #3 Parts availability/UPS Bypass

Tue, 01 Sep 2020 19:14:02 GMT

Type of Facility: Casino

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Product: Eaton 9390 - 80 kva

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Summary: Parts availability / UPS bypass

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Preliminary Actions: Customer had a fan fail alarm on there Eaton 9390-80 kva UPS. FGC shipped replacement fans and scheduled technician to do a fan replacement. When the technician got onsite and found failed fan he noticed that one of the wires from the AC capacitor assembly had been sucked up into fan blades causing damage to the fan and compromising the wiring on the capacitors Assembly. The UPS was put offline to ensure no further damage would be done to UPS.

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Solutions: OEM could not provide replacement capacitor assembly in a timely manner as parts had a 3-4 week lead time. FGC was able to fabricate a new wiring assembly from information out technician took while onsite and source replacement capacitors direct from the supplier to get parts shipped in 2 days and our technician was back onsite within 3 days to get the UPS back online and running properly.

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Case Study #2 Power Conditioning UPS System

Mon, 20 Jul 2020 19:15:34 GMT

DEALING WITH LESS THAN IDEAL UTILITY POWER

Type of Facility: Proton Therapy

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Products: UPS GE TLE Series 1000 KVA & UPS Mitsubishi UP9933-A304DU-4 300 KVA

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Summary: ‍

A Maryland based customer is the first center in the region to offer proton therapy – a highly advanced and precise form of radiation. The center is the first and most experienced proton center in the region.

Their treatment of patients is entirely based on the up time of the sensitive medical equipment.Every time they experience a power outage, their equipment must be reset and recalibrated before they may see more patients. This lost time and sometimes damaged power supplies from the utility loss was adding up to a tremendous financial loss.

Solutions:

‍Facility Gateway provided a turnkey UPS solution for the RF amplifier that not only provided a means to ride out a power loss but conditioned the existing utility power to reduce wear and tear on the power supplies. FGC managed electrical installation, permitting, and provided project management and support throughout the process.

Our customer is now able to maximize patients seen and minimize maintenance to the sensitive medical equipment.

Case Study #1 - Discontinued UPS System

Sat, 20 Jun 2020 19:16:23 GMT

Type of Facility: Distribution Center

Product: Liebert AP366 75 kVA (Date Code: 1993)

Summary: Contract is full service and the UPS is at its end of life/discontinued

Preliminary Actions: The customer stated unit was in bypass. An FGC Technician was dispatched to the site to troubleshoot. He found a failed inductor on UPS along with 3 capacitors. FGC was able to source and ship a replacement inductor and capacitors to the site. Our technician returned to the site 11/27 and completed repairs on UPS.

Discontinued UPS System Solutions:

1. FGC is able to service and repair discontinued UPS systems that most vendors are not due to lack of parts being available for these discontinued UPS units.

2. Customer understands the risk they are at with a discontinued UPS system and have placed an order for a replacement system due to be changed out in early 2020.

3. Customer was very pleased with the response and repair.

Keeping UPS and Generators Prepared

Fri, 22 Nov 2019 20:08:17 GMT

"Success involves paying attention to three key issues: understanding standby power systems, implementing a comprehensive preventive maintenance program, and arranging for effective monitoring of system performance."