Battery Rebuilds and Installation

Whether its technical information on your current battery installation, a requirement for a replacement battery quotation or battery autonomy extension options, speak to one of our experts now for advice.

Battery Testing Options

Using the latest technology our advanced battery testing not only measures battery impedance and voltage but also, chemical sulfation and dryout. (see FAQ’s below) This gives a more accurate look at the overall battery health.

The test is non intrusive and can be completed without having to dismantle the battery string saving time and money. Having this advanced battery testing completed as part of ongoing normal maintenance builds a picture and a history for every battery in a string, giving early warnings to failure and anomalies at a fraction of the price compared to an installed monitoring system. Identifying a bad battery in a string early can not only prevent failure at a critical moment but also ensure the entire battery string isn’t put in danger of being damaged by one single bad block. Following each test a report is compiled that identifies each battery tested and its condition, comparing this information with past tests will indicate the current health level of the battery set and help determine when the batteries need budgeting for full replacement.

Battery impedance testing has long been the way for a non intrusive test on UPS batteries. Placing a special tester across each battery takes a measurement of the battery internal resistance, this reading can be compared to the manufacturers specifications or previous readings to give an indication of the battery health.

Sulfation and grid corrosion are main factors for the internal resistance rising. Every time a battery is discharged and recharged there is some sulfation and grid corrosion that takes place, this is quite normal as all batteries have a design life. Impedance testing can provide early identification of any single blocks that are failing prematurely. If a battery blocks’ internal resistance gets so high that it becomes open circuit, this will cause detriment to the remaining batteries and cause the entire battery string to fail. Impedance testing batteries as part of normal ongoing maintenance can build a picture of battery health and give an early warning to possible failures.

Using a thermal imaging camera we can identify any hot spots on a live system. This is ideal for critical systems that cannot be isolated for other types of intrusive testing. A thermal image will show any connection defects causing excess heat on the associated isolators and switchgear in addition to the battery terminals. It also gives an indication of airflow around and between batteries and can serve as an  early warning indicator for insufficient cooling or any high impedance connections.

If there are any issues identified, the report can be used to get permission for a controlled shutdown for further investigation and testing. It is a totally non intrusive test and can be completed with no disruption to business. Adding thermal imaging testing to ongoing UPS maintenance is cost effective and reduces the chance of thermal runanway.

A UPS system load test is the only 100% way of testing a complete system, however, this test although very accurate, carries risks. Ultimately we put the system to work doing the job it was designed to do, protecting the critical load. If there is a failure, the load could be lost and therein lies the risk.  Normally on the commissioning of a system, a load test would be conducted before completion and sign off.  You would be forgiven for thinking why would I ever put my critical load at risk, the system has been running fine for the last year since commissioning I don’t need this test. But you need to consider, have you had any power cuts, has the system ever been switched, will all the elements of the system work together as expected, have you increased the system load.

By having regular non intrusive testing and a good maintenance program, obviously the risk is reduced, having a UPS engineer on site completing the test reduces the risk further. If you have a N+1 system the risk is almost 0% as a test on one system at a time can be completed using an artificial load.

We would recommend a system load test every time the electrical infrastructure is changed, like a battery replacement, new electrical switch gear or every 24 months is possible.

Top Reasons for Battery Failure

  • Environment
  • Age Deteriotaion
  • Never Maintained

UPS Battery Replacements

Leading brand battery replacements

We are a premium distributor of Yuasa batteries and also have partnerships with the most commonly accepted UPS battery suppliers including CSB, Exide, Enersys and Fiamm. Contact us for a competitive proposal.

Full battery or single block replacements

Recent testing may have highlighted a rogue battery block or entire string fault. With correct technical matching of the battery characteristics followed by a careful equalisation charge, we can replace either a single block or full battery string in your current installation.


Batteries supplied for all UPS makes and models

All UPS vendors use a handful of leading battery suppliers in their original equipment. We can provide options for exact replacement of the existing blocks or an option of a technically comparative battery.

Batteries are the Most Important Aspect of an Uninterruptible Power Supply

Why Batteries are so Important

It is the battery that provides the UPS with power to continue running in the event of a mains failure.

An old or badly maintained battery set could affect the autonomy time of your uninterruptible power supply and result costly downtime should you get a mains failure.

All lead acid batteries, wet or gel, are prone to natural decay and have a design life of five, ten or twelve years. This is caused by metals and acid sharing the same plastic container.

How Age Affects Battery Life

Natural degrading is typically about 5% per annum, depending on the type and brand of battery used. It is because of this degradation that you need to check the battery in your UPS to be sure that you will get your required and expected runtime during a mains failure. If the batteries are not in a great condition then the autonomy time will be dramatically reduced and therefore a planned, safe shutdown will not be achieved. Although regular maintenance and ideal environmental conditions can extend the working life of UPS batteries, they will all eventually need replacing.

Get a Battery Health Check

If you have any doubts about the condition of your uninterruptible power supply or stand-by emergency lighting system, we can offer a comprehensive check-up, service and UPS battery replacement service for all leading UPS brands, including AEC, Riello, MGE, APC, Eaton, Powerware, Chloride, Gamatronic, Borri, Huawei, New Wave, and any other make or model.

Our nationwide service is available 24/7 and includes safe licensed disposal of all waste.

Frequently Asked Questions

Its common knowledge that the battery system is the weakest link in a UPS and that battery failure is the leading cause of load loss and associated downtime.

Understanding how to correctly store, install, check and maintain a battery system will help prevent ultimate failure and also extend the service life of your current installation.

Lets take a look at some frequently asked questions when it comes the UPS batteries and battery maintenance.

Can you change batteries on any UPS system?
Yes is the short answer, depending on the size and type of UPS would determine how complex the replacement would be, but the principles are all the same. Our skilled battery engineers have worked on many systems over the years.
Do you only supply Yuasa batteries?
No, Yuasa is our prefered supplier. The level of quality from Yuasa and the warranty is exeptional in our experiance, they can supply almost any block in the UK within a day. We are a Yuasa main dealer, so can supply what we feel are the best batteries at the very best price. However if it is a specifc battery you require we do have accounts with all the leading battery manufacturers.
What does VRLA stand for?
Valve regulated Lead Acid.
VRLA batteries work on the oxygen recombination principle. However, the recombination process is not 100% efficient. So over time, the internal pressure increases, and a certain amount of gases have to be released to maintain the ideal pressure. This is achieved with the help of one-way, pressure-sensitive valves which open when the internal pressure increases above a certain threshold and allow the excess gases to be vented. That is why these batteries are called VRLA or valve regulated lead acid batteries. Excess gases are also produced if these batteries are overcharged or discharged at rates higher than the recommended rate.
What is sulfation and grid corrosion?
Sulfation and grid corrosion are the main killers of lead acid batteries. Sulfation is a thin layer that forms on the negative cell plate if the battery is allowed to dwell in a low state-of-charge. During use, small sulfate crystals form, but these are normal and are not harmful. During prolonged charge deprivation, however, the amorphous lead sulfate converts to a stable crystalline and deposits on the negative plates. This leads to the development of large crystals that reduce the battery’s active material, which is responsible for the performance. If caught in time, an equalising charge can reverse the condition. Grid corrosion can be reduced with careful charging and optimisation of the float charge.
Why do batteries need to be cooled?
Heat is a killer of all batteries, but high temperatures cannot always be avoided. As a guideline, each 5°C rise in temperature cuts the life of a sealed lead acid battery in half. This means that a VRLA battery for stationary applications specified to last for 10 years at 25°C would only live 5 years if continuously exposed to 30°C and 30 months if kept at a constant temperature of 35°C. Once the battery is damaged by heat, the capacity cannot be restored.
What is the "end of useful life" for a UPS battery?
The IEEE defines “end of useful life” for a UPS battery as being the point when it can no longer supply 80% of its rated capacity in ampere-hours. When your battery reaches 80% of its rated capacity, the aging process accelerates, and you should replace it.
How long can I store my batteries?
When batteries are stored disconnected from a charger, their life will decrease. Due to the self-discharge characteristics of lead-acid batteries, it is recommended you charge them every three to four months of storage. After 12 months, permanent loss of capacity will start to occur. To prolong shelf life without charging, store batteries in a cooler environment.

Battery Testing and Replacement Quotes

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