Technical manual section 06

BCI Battery Technical Manual BCIS-06 REV DEC02 Issued Current Revision: 1997-01 2002-12 BCI SPECIFICATIONS FOR CONSTANT CURRENT CYCLE LIFE TESTING OF DEEP CYCLE BATTERIES SCOPE AND CLASSIFICATION The purpose of this specification is to provide methodology ad test conditions for constant current life cycle testing of batteries used in Marine, Golf, RV, Utility Vehicle, and other similar deep cycle applications The test procedure is designed to provide a standard basis for comparison of products and for evaluation of performance in the production and development of batteries While it is not possible to duplicate the wide variety of field use conditions in the laboratory, this procedure is intended to simulate average field usage and failure modes as closely as practical The measurement of life cycle performance of a battery is defined as the number of charge and discharge cycles the battery will deliver per the following procedure until the capacity has fallen to 50% of the manufacturers rated capacity in ampere hours at the two hour rate of discharge (C2) BCIS-06 Rev DEC02 PRETEST CONDITIONING AND PROCEDURES 2.1 Product Selection All cells and/or batteries selected for life cycle testing shall be representative samples of the product being manufactured and shall be new (60 days or less from date of manufacture), charged, and undamaged 2.2 Boost Charge Prior to commencing initial capacity tests (Step 5.3), cells and/or batteries of the test circuit shall be given a boost charge in accordance with manufacturer’s instructions BCIS-06 Rev DEC02 INITIAL CAPACITY TESTS It is permitted (but not required) to conduct initial capacity tests of the cells and/or batteries in accordance with BCIS-05 of the BCI Technical Manual prior to the initiation of life cycle testing Capacity tests (not to exceed 10 in number) may be conducted in accordance with manufacturer’s instructions The life cycle test shall be commenced immediately following the completion of the initial capacity testing BCIS-06 Rev DEC02 TEST EQUIPMENT All equipment shall be clean, in good working order, and calibrated in accordance with the requirements of the National Bureau of Standards 4.1 Thermometers Shall be graduated so that each scale division will not represent more than 2°F (1°C) and shall have an accuracy of ± 2°F (1°C) 4.2 Hydrometers Shall be graduated so that each scale division will not represent more than 0.005 units of specific gravity and shall be accurate to at least 0.005 units 4.3 Instrumentation Voltage and current readings shall be made with instruments capable of an accuracy of ±0.1% Timers shall have an accuracy of 0.5% or better BCIS-06 Rev DEC02 CYCLE TEST PROCEDURE 5.1 Temperature The electrolyte temperature of the cells and/or batteries of the test circuit shall be maintained at 80°F ± 5°F (26.7°C ± 3°C) Where electrolyte temperature cannot be measured directly (VRLA) the battery temperature shall be maintained by appropriate means at 80°F ± 2°F (26.7°C ± 1°C) 5.2 Circuit Voltage The test circuit may be configured to any voltage desirable or convenient; consistent with the capability of the test equipment 5.3 Discharge Cycle Cells and/or batteries of the test circuit shall be discharged at a constant current equal to I2 (the hour current rate in amperes as specified by the manufacturer) until the terminal voltage reaches 1.75 volts per cell The run time to 1.75 volts per cell in minutes shall be recorded The capacity of the battery as a percentage of full rating shall be calculated as the actual run time of the discharge in minutes x 100%, divided by 120 minutes 5.4 Charge Cycle Cells and/or batteries of the test circuit shall be recharged in accordance with the manufacturer’s instructions, or by other means such as constant current or current limited constant voltage such that not less than 5% and not more than 30% overcharge is delivered to the battery 5.5 Rest Periods Following the charge cycle as above, an optional rest period not to exceed eight hours may be provided in order to allow the cells and/or batteries of the test circuit to cool such that the temperature requirements of Section 5.1 are maintained 5.6 Equalizing Charge For flooded batteries, additional charging, over and above the normal charge cycle per Section 5.4, but not to exceed 30% of the rated hour capacity, may be administered as required to assure that all test cells and/or batteries are in a fully charged and balanced condition For VRLA batteries, the manufacturer’s equalizing instructions shall be followed 5.7 Electrolyte Level & Specific Gravity In those products with electrolyte access, the electrolyte levels shall be maintained by periodic water additions in accordance with manufacturer’s instructions or such that the level of electrolyte is maintained at a minimum of 6mm (0.25 in.) above the top of the separator Water addition frequency and quantity shall be recorded throughout the period of the life cycle test 5.8 Defects Defective cells and/or batteries may be removed from the test string during the course of life cycle testing, not exceed 50% of the total cells in the circuit It is not permitted to add replacement cells to the circuit during the life cycle test regime BCIS-06 Rev DEC02 END OF LIFE At the number of charge and discharge cycles when the battery fails to deliver 50% of the manufacturers rated hour ampere hour capacity on the discharge cycle per Section 5.3, the cells and/or batteries of the test circuit shall be considered to have failed A final discharge test in accordance with BCI Recommended Specifications for Rating and Testing Electric Vehicle and Deep Cycle Batteries (BCIS-05 of the BCI Technical Manual), may be conducted to determine precise capacity of the test cells and/or batteries at their end of life condition ... BCIS -06 Rev DEC02 INITIAL CAPACITY TESTS It is permitted (but not required) to conduct initial capacity tests of the cells and/or batteries in accordance with BCIS-05 of the BCI Technical Manual. .. temperature requirements of Section 5.1 are maintained 5.6 Equalizing Charge For flooded batteries, additional charging, over and above the normal charge cycle per Section 5.4, but not to exceed... BCIS -06 Rev DEC02 END OF LIFE At the number of charge and discharge cycles when the battery fails to deliver 50% of the manufacturers rated hour ampere hour capacity on the discharge cycle per Section