Technical manual section 18

BCI Battery Technical Manual BCIS-18 NEW APRIL 06 Issued 2006 Current Revision: 2006-04 Approval Submission: 2005-10 STANDARD FOR DEEP CYCLE FAST/BATTERY CHARGERS FOREWORD This standards publication has been prepared by the Industrial Battery Charger Subcommittee of the Industrial Battery & Charger Committee, Battery Council International It is based on Battery Council International Standard BCIS-16, Standard for Deep Cycle Battery Chargers It incorporates updated material for deep cycle fast battery chargers TABLE OF CONTENTS Scope Purpose Definitions Classification Performance Safety Test Methods: 10 BCIS-18 Rev APRIL 06 SCOPE The Deep Cycle Fast Battery Charger Standard covers battery chargers used to fast charge lead acid deep cycle batteries that are used in battery-powered equipment such as, but not limited to, industrial forklifts, tuggers, personnel carriers, electrical vehicles, golf carts, mine vehicles, etc This document is not intended to supercede or replace any charger, battery or truck manufacturer’s recommended practices PURPOSE The Deep Cycle Fast Battery Charger Standard is a performance standard designed to be general enough to cover any present or future technologies; yet specific enough, so that the consumer will know the recharge capabilities, methods of recharging, and the criteria under which specific data is obtained and calculated DEFINITIONS 3.1 AMBIENT TEMPERATURE Ambient temperature is the environmental temperature surrounding the object under consideration 3.2 AMPERE-HOUR CAPACITY Ampere-hour capacity is the number of ampere-hours that a storage battery can deliver under specified conditions such as temperature, specific gravity, rate of discharge, and final voltage 3.3 AUDIBLE NOISE Audible noise is the sound level produced by the charger equipment, measured in decibels 3.4 AUTOMATIC CHARGE TERMINATION Automatic charge termination is the ability to automatically terminate a charge when predetermined conditions are met 3.5 BATTERY CAPACITY Battery capacity is the ability of a fully charged battery to deliver a specified quantity of amperes over a specified period of time 3.6 BATTERY CHARGER A battery charger is a device used to charge a storage battery 3.7 CHARGE* Charge is the conversion of electrical energy to chemical energy within the cell or battery 3.8 CHARGING RATE* Charging rate is the current, expressed in amperes, at which a battery is charged BCIS-18 Rev APRIL 06 3.9 CHARGER EFFICIENCY Charger efficiency is the DC output volt-amperes divided by the AC input watts 3.10 CHARGER POWER FACTOR Charger power factor is the AC input in watts divided by the AC input in volt-amperes 3.11 CONSTANT CURRENT CHARGE A constant current charge is a charge in which the value of the current to the battery is maintained at a constant value 3.12 CONSTANT VOLTAGE CHARGE A constant voltage charge is a charge in which the DC voltage potential of the charger is maintained at a constant value at the output terminals 3.13 DISCHARGE RATE The discharge rate is the current, in amperes, at which the battery is discharged 3.14 DISCHARGE* Discharge of a storage battery is the conversion of the chemical energy of the battery into electrical energy 3.15 EQUALIZING CHARGE An equalizing charge is an extended charge that is delivered to a charged storage battery for the purpose of minimizing voltage and specific gravity variations between the cells that may develop over time Where specific gravity can not be measured (VRLA) the equalizing charge is intended to ensure complete restoration of the active material within a cell 3.16 FAST CHARGE *Fast Charge Class has recharge time from 40% to 80% of 1.0 hour or less *Fast Charge Class has recharge time from 40% to 80% of 1.1 to 2.0 hours * Battery at room ambient (770F +/- 50F) at start of charge Note: This is a figure of merit based only on the charger output capability The end user should keep in mind that battery temperature significantly influences fast charge recharge time 3.17 FINISHING RATE* Finishing rate is the rate of charge, expressed in amperes, to which the charging current is reduced near the end of a charge 3.18 FULLY CHARGED BATTERY A battery or cell is considered fully charged when the battery electrolyte is within specific gravity nameplate range Where specific gravity can not be measured (VRLA) it is the state of charge wherein all available active material is in its charged state such that charging under selected conditions produces no significant change BCIS-18 Rev APRIL 06 3.19 LIVE PART A live part is a part consisting of electrically conductive material which has a potential greater than zero during normal use of the equipment 3.20 NOMINAL VALUE Nominal value is a value assigned for the purpose of convenient designation 3.21 OPPORTUNITY CHARGE A period of charging initiated by an operator during a period of non use such as break time, lunch period, shift change, etc and ended either by the operator or automatically terminated by the charger 3.22 OUTPUT VOLTAGE RATING The output voltage rating of a battery charger is the nominal voltage of the battery it is designed to charge, or the voltage range of the batteries it is designed to charge 3.23 RMS (ROOT MEAN SQUARE) VALUE 3.23.1 The root mean square value of an alternating voltage or current is the square root of the mean value of the square of the voltage or current values during a complete cycle 3.23.2 RMS is the effective value of an alternating current that corresponds to the direct current value that produces the same heating effect 3.24 SPECIFIC GRAVITY Specific gravity is the ratio of the weight of the solution (electrolyte) to the weight of an equal volume of water at a specific temperature 3.25 START RATE Start rate is the initial rate of current, expressed in amperes, delivered to a discharged storage battery 3.26 SWITCHING POINT The switching point is a point at which the charge or discharge rate is abruptly switched to another rate, or to a pause condition 3.27 TAPER CHARGE A taper charge is where the value of charging current reduces as the battery voltage increases 3.28 TEMPERATURE COMPENSATION The adjustment of the charging source voltage as a function of battery temperature BCIS-18 Rev APRIL 06 3.29 TEMPERATURE TERMINATED CHARGING Termination of the charge cycle if the battery electrolyte temperature exceeds a preset maximum temperature 3.30 VOLT-AMPERES* The unit of apparent power in the International System of Units (SI) The volt-ampere is the apparent power at the points of entry of a single-phase, two-wire system when the product of the root-mean-square value in amperes of the current by the root-mean-square value in volts of the voltage is equal to one 3.31 WATTS* The unit of power in the International System of Units (SI) The watt is the power required to work at the rate of joule per second CLASSIFICATION There are many types of chargers used internationally; this section is designed to standardize the specifications used in describing a specific charger or charging requirement 4.1 RECHARGE CODES The charger “recharge code” is used to describe the capability of a charger to recharge a battery from 40-80% within a given number of hours after the fully charged battery has been discharged at the hour rate to 40 percent of its rated ampere-hour capacity Temperatures shall be as specified in BCI-I-2 Section 3.5 XXXXAH XXXV X.XHR Hours to recharge from 40-80% Nominal Battery Volts Battery Capacity (AH, at hr rate) e.g 1000AH 048V 1.0HR One hour (HR) to recharge a 1000-ampere hour (AH) 48-volt (V) battery discharged to 40% of nameplate capacity back to 80% *ANSI/IEEE Standard 100 - 1988 BCIS-18 Rev APRIL 06 PERFORMANCE 5.1 USUAL SERVICE CONDITIONS Following are usual service conditions: 5.2 5.1.1 Ambient air temperature between 00C (320F) and 400C (1040F) 5.1.2 Altitudes not exceeding 1000 meters (3300 feet) above sea level 5.1.3 AC supply voltage and frequency given in section 5.3 5.1.4 Battery size (voltage and ampere-hour rating) within the charger's nameplate rating 5.1.5 A battery maintained within the manufacturer's operating parameters UNUSUAL SERVICE CONDITIONS The following unusual service conditions may require specific design considerations and should be brought to the attention of the manufacturer: 5.2.1 Exposure to damaging fumes (corrosive air contaminants) 5.2.2 Exposure to excessive moisture 5.2.3 Exposure to excessive dust 5.2.4 Exposure to abrasive or conductive dust 5.2.5 Exposure to steam 5.2.6 Exposure to oil vapor 5.2.7 Exposure to explosive mixtures of dust or gases 5.2.8 Exposure to salt air 5.2.9 Exposure to outdoor use 5.2.10 Exposure to abnormal vibration, shocks, or tilting 5.2.11 Exposure to dripping water 5.2.12 Exposure to unusual transportation or storage 5.2.13 Unbalanced AC voltages 5.2.14 Departure of AC system voltages from a substantially sinusoidal waveform 5.2.15 Input supply voltage and frequency outside ranges given in 5.3 5.2.16 Operation in ambient temperatures more than 400C (1040F) or less than 00C (320F) BCIS-18 Rev APRIL 06 5.2.17 Batteries with electrolyte temperatures outside of the manufacturers recommended range 5.2.18 Operation at altitudes more than 1000 meters (3300 feet) above sea level 5.2.19 Battery size (voltage and ampere-hour rating) not within the charger's nameplate rating 5.2.20 A battery not maintained within the manufacturer's operating parameters 5.3 INPUT VOLTAGE AND FREQUECY The charger shall be able to deliver its rated output when supplied at the rated input voltage It shall, however, be capable of operating under the following conditions of input voltage and frequency in such a way that the safety of persons is not reduced and that neither the charger nor battery sustain any damage *AC Line variations: *AC Line frequency variations + 6%, - 10% +/- 0.2% *of nameplate rating 5.4 CHARGING RATE The following criteria are based on: A The charger is being operated within its nameplate rating B The battery is performing within its design criteria 5.4.1 For lead-acid batteries The charger output current shall not exceed a value that will cause an increase in battery temperature outside of the manufacturers recommended range 5.5 MINIMUM RECHARGE REQUIREMENTS Batteries must be fully charged (3.17) and given an equalizing charge (3.15) a minimum of once per week or per battery manufacturer’s requirements Whenever returning battery to nameplate specific gravity, maximum overcharge shall be 15% Equalize overcharge shall be per battery manufacturer’s recommendation 5.6 EFFICIENCY The charger efficiency shall be determined by measuring the input watts at the AC input terminals by means of wattmeter and by measuring the average values of the direct voltage and current at the output terminals From the values thus measured, the charger efficiency shall be calculated in accordance with the following: Nominal Charger Efficiency = average DC volt-ampere output x 100 Input watts Conditions: Nominal input voltage and frequency Maximum output power BCIS-18 Rev APRIL 06 5.7 POWER FACTOR The power factor for single-phase and three-phase battery chargers shall be calculated as follows: Percent Power Factor = ∑ watts per phase x 100 ∑ rms volt-amperes per phase Conditions: Nominal input voltage and frequency Maximum output power 5.8 NAMEPLATE MARKING The following minimum information shall be given on the nameplate if applicable: 5.8.1 Model number 5.8.2 Serial number 5.8.3 Type of battery for which the charger was designed, e.g., LA (lead-acid); PB (lead-acid); VRLA (valve regulated lead-acid); all types 5.8.4 Number(s) of cells in series 5.8.5 Nominal output voltage 5.8.6 Ampere-hour capacity 5.8.7 Rated output in amperes 5.8.8 Nominal AC supply voltage(s) 5.8.9 Supply frequency 5.8.10 Phase 5.8.11 Rated AC line amperes 5.8.12 Number of charging circuits (if more than one) 5.8.13 Date code 5.8.14 Classification code 5.8.15 Max Output DC Power (kW) SAFETY 6.1 GENERAL SAFETY REQUIREMENT All BCI labeled products shall perform and be tested in accordance with the Underwriters' Laboratories Standard for Industrial Battery Chargers #1564, or the safety standard(s) applicable at the location of use, (if known) BCIS-18 Rev APRIL 06 6.2 COMPONENTS The battery charger shall contain at least the following components: 6.2.1 A transformer or other device to electrically isolate the battery being charged from the AC source 6.2.2 Means for manually terminating the charging current 6.2.3 A device indicating charger operation 6.2.4 Output overcurrent protective devices 6.2.5 Means to prevent connector arcing on battery disconnect If not done mechanically then the requirement must be met when the separation velocity between connectors is 30 inches/sec 6.2.6 6.3 Means to compensate for, or terminate due to changes in battery temperature OPERATING INSTRUCTIONS A label with clear and precise operating instructions shall be provided 6.4 INSTRUCTION MANUAL An instruction manual shall be provided with each charger and shall include at least the following information: 6.5 6.4.1 Safety instructions 6.4.2 Installation instructions 6.4.3 Operating instructions 6.4.4 Schematic or wiring diagrams, or both 6.4.5 Trouble shooting instructions 6.4.6 Maintenance procedures ENCLOSURE SERVICE GROUNDING A separate, clearly identified grounding terminal shall be provided for the connection of the AC input grounding conductor All dead metal parts of the unit shall be conductively connected to this grounding terminal 6.6 AC INPUT CABLE ENTRY The charger cabinet shall be provided with an entry hole or knockout located as near as possible to the input connection terminals If the charger is supplied with AC input cable, a strain relief shall be provided BCIS-18 Rev APRIL 06 6.7 DC OUTPUT CABLE EXIT The charger cabinet shall be provided with an exit hole(s) or knockout(s) to accommodate the required strain relief located as near as possible to the output connection terminals If the charger is supplied with DC output cable(s), a strain relief(s) shall be included 6.8 DC OUTPUT CABLE(s) When battery charger DC cable set(s) are supplied, they shall be of a size and rating that will safely carry the output current The polarity of the output shall be plainly identified 6.9 AC CIRCUIT PROTECTION The charger must be provided with protection against overload or short circuit in all ungrounded AC input power conductors, unless cord-connected with an attachment plug for connection to the supply circuit TEST METHODS 7.1 GENERAL This section is intended to provide test methods to evaluate the performance and safety characteristics of battery chargers Tests shall be divided into three categories: 7.2 7.1.1 Performance tests 7.1.2 Safety tests 7.1.3 Production tests INSTRUMENTATION Measuring apparatus shall have sufficient resolution, stability, and accuracy so as to ensure a limit of error not exceeding 1% of the measured quantity For each test, sufficient metering and monitoring shall be provided so as to ensure conformance with the test conditions 7.3 PERFORMANCE TESTS Performance tests are those that must be made on a representative sample of every battery charger model(s) that represents the worst set of operating conditions (usually the maximum kilowatt output in a particular enclosure) and that are repeated whenever a change is made that modifies the performance of the charger The battery charger shall be operated for a complete charge cycle to establish its performance in accordance with Sec Performance tests shall include the following: 7.3.1 Charge Time (40% to 80%) 7.3.2 Charger efficiency 7.3.3 Power factor 10 BCIS-18 Rev APRIL 06 7.4 SAFETY TEST Safety tests are those that must be made on a representative sample of every battery charger model(s) that represent the worst set of operating conditions (usually the maximum kilowatt output in a particular enclosure) and that are repeated whenever a change is made that affects the safety characteristics of the charger The substitution of a higher rated direct replacement component does not necessitate retesting the representative charger model Safety tests shall include the following: 7.5 7.4.1 Dielectric 7.4.2 Fire hazard 7.4.3 Mechanical integrity 7.4.4 Audible sound level limit 7.4.5 Component temperature test 7.4.6 Anti-arc testing PRODUCTION TESTS Production tests shall be made on all production units for the purpose of maintaining safety, quality, and performance Production tests for battery chargers shall include the following: Dielectric Cabinet ground integrity Circuit operation 7.5.1 DIELECTRIC TESTS A battery charger shall be capable of withstanding for minute, without breakdown, the application of a 50 or 60 Hertz essentially sinusoidal test voltage with the battery charger at the maximum operating temperature that it reaches in normal use As an alternative, 120 percent of the specified test voltage shall be applied for second Primary circuits to dead-metal parts and primary circuits to secondary circuits shall be capable of withstanding the application of 1000 volts plus twice the rated primary voltage Secondary circuits operating at 50 volts or less shall be capable of withstanding 500 volts between these circuits and dead-metal parts Secondary circuits operating at more than 50 volts shall withstand 1000 volts plus twice the maximum rated secondary circuit voltage between the circuits and dead-metal parts 11 BCIS-18 Rev APRIL 06 The leakage current for these test voltages shall not exceed 0.75 milliampere on cord connected chargers and 5.0 milliamperes on conduit-connected chargers, under all rated operating conditions The charger shall be tested with one of the following types of test equipment or equivalent: 7.5.1.1 A 500 volt-ampere or larger transformer with voltmeter 7.5.1.2 A less than 500 volt-ampere transformer having output voltmeter, audible and visual indication of breakdown and reset button The test voltage as specified above shall be applied between the following points: 7.5.1.3 Alternating current input terminals to dead-metal parts 7.5.1.4 Alternating current input terminals to direct-current output terminals 7.5.1.5 Direct-current terminals to dead-metal parts For these tests, all semiconductors, capacitors and sensitive control components shall be short-circuited; printed circuit control boards shall be removed Contactors and relays shall be in their operating mode 7.5.2 CABINET GROUND INTEGRITY TEST The resistance of the ground connections in the charger cabinet shall be checked with a continuity tester that has a current source of 1mA or greater One lead from the tester shall be connected to the cabinet grounding terminal and the other lead used to probe the cabinet grounding terminals and exposed dead metal parts 7.5.3 CIRCUIT OPERATION TEST The battery charger shall be tested to ensure that all of its components are properly interconnected and adjusted to function according to the typical voltampere curve designated for that charger 12 ... 400C (1040F) or less than 00C (320F) BCIS -18 Rev APRIL 06 5.2.17 Batteries with electrolyte temperatures outside of the manufacturers recommended range 5.2 .18 Operation at altitudes more than 1000... label with clear and precise operating instructions shall be provided 6.4 INSTRUCTION MANUAL An instruction manual shall be provided with each charger and shall include at least the following information:... charge, expressed in amperes, to which the charging current is reduced near the end of a charge 3 .18 FULLY CHARGED BATTERY A battery or cell is considered fully charged when the battery electrolyte