BCI Battery TechnicalManual BCIS-15 REV DEC02 Issued Current Revision: 1993-04 2002-12 LIFE CYCLE TESTING OF LEAD-ACID INDUSTRIAL STORAGE BATTERIES FOR MOTIVE POWER SERVICE TABLE OF CONTENTS SCOPE AND DEFINITIONS 2 TEST CONDITIONS 2.1 Cell Selection 2.2 Initial Capacity Test 2.3 Life Cycle Test 2.4 Temperature 2.5 Equalizing Charge 2.6 Electrolyte Level (Flooded Batteries) 3 TEST METHODS 3.1 Test Cycle – Regime A 3.2 Additional Charging 3.3 Measured Capacity Test 3.4 Alternate Measured Capacity Test 3.5 End of Life Test EVALUATION BCIs-15 Rev DEC02 SCOPE AND DEFINITIONS 1.1 Scope 1.1.1 This standard covers life cycle test conditions and procedures for lead-acid industrial storage batteries for motive power service 1.2 Definitions 1.2.1 Battery – A battery shall consist of one or more cells 1.2.2 Flooded Cell – A cell with excess acid in which the products of electrolysis and evaporation are freely allowed to escape into the atmosphere as they are generated These cells can be classified as “vented” 1.2.3 Valve Regulated Cell – A cell that is sealed with the exception of a valve which opens to the atmosphere when the internal gas pressure of the cell exceeds atmospheric pressure by a predetermined amount A VRLA (valve regulated lead-acid) cell provides means for recombination of internally generated oxygen and suppression of hydrogen gas evolution to limit water consumption 1.2.4 Cell Temperature – The average temperature of the electrolyte contained in a cell For a vented cell, the cell temperature shall be based on direct measurement of the electrolyte temperature For a VRLA cell, the cell temperature shall be equated to the temperature measured at the negative terminal 1.2.5 Equalizing Charge – An equalizing charge of a storage battery is a prolonged charge, usually at the finishing rate or less, to correct any inequalities of voltage and specific gravity which may have developed between the cells during service TEST CONDITIONS 2.1 Cell Selection 2.1.1 The cell or cells selected for life cycle testing shall be representative samples of the product being tested Samples representative of a battery manufacturer’s production product shall be randomly selected from the production process and shall not be specially built 2.2 Initial Capacity Test 2.2.1 A test for determining initial capacity, as specified in BCI Standards Publication BCI-I-2, Determination of Capacity of Lead-Acid Industrial Storage Batteries for Motive Power Service, shall be started within 90 days after the cell or cells have been filled with electrolyte and charged 2.3 Life Cycle Test 2.3.1 The life cycle test shall be started within 60 days after completing the initial capacity test 2.4 Temperature 2.4.1 The ambient temperature during storage of the cells before testing is started shall not exceed 100°F (37.8°C) BCIs-15 Rev DEC02 2.4.2 The cell temperature throughout the life cycle test shall be within a range of 70°F (21.1°C) through 115°F (46.1°C) 2.5 Equalizing Charge 2.5.1 Cells shall be given an equalizing charge, in accordance with the manufacturer’s instructions, prior to the start of the life test 2.6 Electrolyte Level (Flooded Batteries) 2.6.1 The electrolyte level and specific gravity of all cells shall be maintained in accordance with the manufacturer’s published instructions TEST METHODS 3.1 Test Cycle – Regime A 3.1.1 The total time for one complete cycle shall equal 12 hours The test shall consist of a series of cycles as follows: 3.1.2 A charge in accordance with the manufacturer’s published instructions but not to exceed 115 percent of the ampere-hours removed on the previous discharge The charge, including any open circuit stand, shall not exceed hours 3.1.3 An alternate Regime B of 16 hours for a complete cycle may be used where the charge period may be extended, not to exceed 12 hours 3.2 Additional Charging 3.2.1 Additional charging, not exceeding the rated 6-hour ampere-hour capacity, may be given monthly to assure the test units are in a fully charged state 3.3 Measured Capacity Test 3.3.1 At intervals of not more than 100 cycles, the test unit shall be discharged at the hour rate to a final voltage equal to 1.70 volts per cell to demonstrate that at least 80 per cent of the rated 6-hour ampere-hour capacity can be obtained This discharge shall be in accordance with BCI Standard Publication BCI-I-2, Determination of Capacity of Lead-Acid Industrial Storage Batteries for Motive Power Service 3.4 Alternate Measured Capacity Test 3.4.1 In place of the measured capacity test of Paragraph 3.3, the test unit may be tested, at intervals of not more than 100 cycles, as specified in Paragraph 3.1 The voltage of the test units at the end of the test discharge shall not be less than 1.70 volts per cell 3.5 End of Life Test 3.5.1 If the final voltage of the test unit is less than 1.70 volts per cell when tested in accordance with Paragraphs 3.3 or 3.4, the test unit may be retested in accordance with 3.3 3.5.2 If the test unit fails to meet the requirements of the second capacity test, the life test shall be considered complete and the cycle number of the first failing discharge shall be considered the number of life cycles obtained BCIs-15 Rev DEC02 3.5.3 If the test unit meets the capacity requirements on the second discharge, the test unit may be returned to life cycle testing EVALUATION 4.1 If the cells are damaged as a result of malfunction of test equipment, the life test shall be considered void ... shall not exceed 100°F (37.8°C) BCIs -15 Rev DEC02 2.4.2 The cell temperature throughout the life cycle test shall be within a range of 70°F (21.1°C) through 115 F (46.1°C) 2.5 Equalizing Charge...BCIs -15 Rev DEC02 SCOPE AND DEFINITIONS 1.1 Scope 1.1.1 This standard covers life cycle test conditions... 3.1.2 A charge in accordance with the manufacturer’s published instructions but not to exceed 115 percent of the ampere-hours removed on the previous discharge The charge, including any open