Technical manual section 16

BCI Battery Technical Manual Current Revision: 2007-12 STANDARD FOR DEEP CYCLE BATTERY CHARGERS FOREWORD The Deep Cycle Battery Charger Standard is a performance standard which is des

BCI Battery Technical Manual

Current Revision: 2007-12

STANDARD FOR DEEP CYCLE BATTERY CHARGERS

FOREWORD

The Deep Cycle Battery Charger Standard is a performance standard which is 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

TABLE OF CONTENTS

1 SCOPE AND DEFINITIONS 3

2 CLASSIFICATION 5

2.1 Recharge Codes 5

2.2 Charging Methods, List Of Symbols 6

3 PERFORMANCE 13

3.1 Usual Service Conditions 13

3.2 Unusual Service Conditions 13

3.3 Input voltage 14

3.4 Charging Rate 14

3.5 Charger Characteristic Curve 14

3.6 Recharge requirement for lead-acid batteries: 15

3.7 Efficiency 16

3.8 Power Factor 16

3.9 Nameplate Markings 16

4 SAFETY 17

4.1 General Safety Requirement 17

4.2 Components 17

4.3 Operating Instructions 17

4.4 Instruction Manual 17

4.5 Enclosure Service Grounding 18

4.6 AC Input Cable Entry 18

4.7 DC Output Cable Exit 18

4.8 DC Output Cable 18

4.9 AC Circuit Protection 18

5 TEST METHODS 18

5.1 General 18

5.2 Instrumentation 19

5.3 Performance Test .19

5.4 Safety Test 19

5.5 Production Test 19

5.5.3 Dielectric Test 20

5.5.4 Cabinet Ground Integrity Test 20

5.5.5 Circuit Operation Test 20

1 SCOPE AND DEFINITIONS

1.1.1 The Deep Cycle Battery Charger Standard covers battery chargers used to recharge deep

cycle batteries that are used in battery-powered equipment including, but not limited to, industrial forklifts, tuggers, personnel carriers, electrical vehicles, golf carts, mine vehicles, etc

1.2 Definitions

1.2.1 AMBIENT TEMPERATURE

Ambient temperature is the environmental temperature surrounding the object under consideration

1.2.2 AMPERE-HOUR CAPACITY

Ampere-hour capacity is the number of ampere-hours which a storage battery can deliver under specified conditions such as temperature, specific gravity, rate of discharge, and final voltage

1.2.3 AUDIBLE NOISE

Audible noise is the sound level produced by the charger equipment, measured in decibels 1.2.4 AUTOMATIC CHARGE TERMINATION ( a )

Automatic charge termination is the ability to automatically terminate a charge when

predetermined conditions are met

1.2.5 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

A battery charger is a device used to charge a storage battery

1.2.7 CHARGE (per ANSI/IEEE Standard 100 – 1988)

Charge is the conversion of electrical energy to chemical energy within the cell or battery 1.2.8 CHARGING RATE (per ANSI/IEEE Standard 100 – 1988)

Charging rate is the current, expressed in amperes, at which a battery is charged

1.2.9 CHARGER EFFICIENCY

Charger efficiency is the DC output voltamperes divided by the AC input watts

1.2.10 CHARGER POWER FACTOR

Charger power factor is the AC input in watts divided by the AC input in voltamperes

1.2.11 CONSTANT CURRENT CHARGE ( I )

A constant current charge is a charge in which the value of the current to the battery is maintained at a constant value

1.2.12 CONSTANT VOLTAGE CHARGE ( U )

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

1.2.13 DISCHARGE RATE

The discharge rate is the current, in amperes, at which the battery is discharged

1.2.14 DISCHARGE (per ANSI/IEEE Standard 100 – 1988)

Discharge of a storage battery is the conversion of the chemical energy of the battery into electrical energy

1.2.15 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

1.2.16 FINISHING RATE (per ANSI/IEEE Standard 100 – 1988)

Finishing rate is the rate of charge, expressed in amperes, to which the charging current is reduced near the end of a charge

1.2.17 FULLY CHARGED BATTERY

A battery or cell is considered fully charged when additional charging with sufficient

amperage will not result in additional stored capacity

1.2.18 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

1.2.19 NOMINAL VALUE

Nominal value is a value assigned for the purpose of convenient designation

1.2.20 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

1.2.22 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

1.2.23 START RATE

Start rate is the initial rate of current, expressed in amperes, delivered to a discharged

storage battery

1.2.24 SWITCHING POINT ( o or O )

The switching point is a point at which the charge or discharge rate is abruptly switched to another rate, or to a pause condition

1.2.25 TAPER CHARGE ( W )

A taper charge is where the value of charging current reduces as the battery voltage

increases

1.2.26 VOLTAMPERES (per ANSI/IEEE Standard 100 – 1988)

The unit of apparent power in the International System of Units (SI) The voltampere 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

1.2.27 WATTS (per ANSI/IEEE Standard 100 – 1988)

The unit of power in the International System of Units (SI) The watt is the power required to

do work at the rate of 1 joule per second

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

2.1 RECHARGE CODES - The charger “recharge code” is used to describe the capability of a

charger to recharge a battery within a given number of hours after the battery has been discharged for a specified number of hours or minutes to a specified percent of its rated ampere-hour capacity

2.1.1 XXX D YY C ZZ: Where XXX = Percent of Discharge

YY = Dishcarge Rate in Hours

ZZ = Hours to Recharge e.g 80D6C8: 80% discharge (D) at the 6 hour rate with charge (C) time of 8 hours 80D5C14: 80% discharge (D) at the 5 hour rate with charge (C) time of 14 hours

OR

2.1.2 XXX DM YYY C ZZ: Where XXX = Percent of Discharge

YYY = Discharge Rate in Minutes

ZZ = Hours to Recharge

2.2 CHARGING METHODS, LIST OF SYMBOLS

I - Constant current charging: Charging during which the value of current is maintained at a constant value

U - Constant voltage charging: Charging during which the charger potential is maintained at

a constant value

W - Tapering charge characteristic: Charging where the value of charging current reduces as battery voltage increases

t - Time

D - Discharge: Discharge when used as part of a charging regime

V - Voltage

E - Equalize

O or 0 - Switch point

a - Automatic Termination

2.2.1 CHARGING METHODS AND CURVES

The following examples do not exclude the possibility of other acceptable charging

characteristics

2.2.1.1 CURVE

- symbol: W

- operation: charge with decreasing current, manual termination

Characteristic Charge Cycle

V I

2.2.1.2 CURVE

- symbol: W a

- operation: charge with decreasing current, automatic charge termination

Characteristic Charge Cycle

V I

2.2.1.3 CURVE

- symbol: W o W a

- operation: automatic charge termination

I

V

2.2.1.4 CURVE

- symbol: WU

- operation: automatic charge with limitation of voltage

Characteristic Charge Cycle

I

V

2.2.1.5 CURVE

- symbol: WUW a

- operation: automatic charge with limitation of voltage and automatic termination

Characteristic Charge Cycle

I

V

2.2.1.6 CURVE

- symbol: U

- operation: fast charge with constant voltage

Characteristic Charge Cycle

I V

2.2.1.7 CURVE

- symbol: U a

- operation: as Example 2.2.1.6 with automatic charge termination

Characteristic Charge Cycle

V

I

2.2.1.8 CURVE

- symbol: I

- operation: charge with constant current

Characteristic Charge Cycle

V I

2.2.1.9 CURVE

- symbol: I a

- operation: as Example 2.2.1.8 with automatic charge termination

Characteristic Charge Cycle

V I

2.2.1.10 CURVE

- symbol: I o I a

- operation: high current at start of charge, then reduced current with automatic charge

termination

Characteristic Charge Cycle

V I

2.2.1.11 CURVE

- symbol: I U

- operation: charge with constant current, then constant voltage

Characteristic Charge Cycle

V I

2.2.1.12 CURVE

- symbol: I U I a

- operation: as example 2.2.1.11 but completion of charging with low constant current and automatic termination

Characteristic Charge Cycle

V I

2.2.1.13 CURVE

- symbol: W U Wa E

- operation: automatic charge with limitation of voltage and automatic termination and

equalize

I

V

CURRENT

Characteristic

TIME Charge Cycle

2.2.1.14 CURVE

- symbol I1 I2 I3 I4 a

- operation: step constant current

Characteristic Charge Cycle

I

V

3.1 USUAL SERVICE CONDITIONS – Following are usual service conditions:

3.1.1 Ambient air temperature between 32°F (0°C) and 104°F (40°C)

3.1.2 Altitudes not exceeding 1000 meters (3300 feet) above sea level

3.1.3 AC supply voltage and frequency given in section 3.3

3.1.4 Battery size (voltage and ampere hour rating) within the charger's nameplate rating

3.1.5 A battery maintained within the manufacturer's operating parameters

3.2 UNUSUAL SERVICE CONDITIONS – The following unusual service conditions may require

specific design considerations and should be brought to the attention of the manufacturer: 3.2.1 Exposure to damaging fumes (corrosive air contaminants);

3.2.2 Exposure to excessive moisture

3.2.3 Exposure to excessive dust;

3.2.4 Exposure to abrasive or conductive dust;

3.2.5 Exposure to steam;

3.2.6 Exposure to oil vapor;

3.2.7 Exposure to explosive mixtures of dust or gases;

3.2.8 Exposure to salt air;

3.2.9 Exposure to outdoor use;

3.2.10 Exposure to abnormal vibration, shocks, or tilting;

3.2.11 Exposure to dripping water;

3.2.12 Exposure to unusual transportation or storage;

3.2.13 Unbalanced AC voltages;

3.2.14 Departure of AC system voltages from a substantially sinusoidal waveform;

3.2.15 Input supply voltage and frequency outside ranges given in 3.3

3.2.16 Operation in ambient temperatures more than 104°F (40°C) or less than 32°F (0°C)

3.2.17 Operation at altitudes more than 1000 meters (3300 feet) above sea level

3.2.18 Batteries with electrolyte temperatures at the start of charge less than 50°F (10°C) or more

than 104°F (40°C)

3.2.19 Battery size (voltage and ampere hour rating) not within the charger's nameplate rating 3.2.20 A battery not maintained within the manufacturer's operating parameters

3.3 Input voltage and frequency – 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 neither does the charger or battery sustain any damage

*AC Line variations: + 6%, - 10% of nameplate rating

*AC Line frequency variations: +/- 0.2% of nameplate rating

3.4 Charging Rate

The following criteria are based on:

The charger is being operated within its nameplate rating

The battery is performing within its design criteria

3.4.1 For lead-acid batteries

The charger output current shall not exceed a value that will cause an increase in battery temperature of more than 40°F (22.2°C) during the charge

3.5.1.3 The initial battery temperature shall be 77° F (25°C)

3.5.1.4 The battery charger shall be run at nominal input voltage

3.5.1.5 The charger used shall be typical of the product being represented

3.5.1.6 Data shall be recorded and plotted at intervals of 30 minutes or less

3.5.2 The following must be plotted:

3.5.2.1 DC output current (in percent of battery capacity) versus time;

3.5.2.2 DC voltage (in volts per cell at battery terminal) versus time;

3.5.2.3 Percent of Ampere-Hours returned, versus time

3.6 Recharge requirement for lead-acid batteries:

3.6.1 Charger with automatic controls

3.6.1.1 MINIMUM RECHARGE: The charger shall be capable of returning a minimum of 2%

overcharge,( based on 100% rating of the battery), after the battery has satisfied the

maximum discharge per the charger classification code, with the charger set for its normal mode

3.6.1.2 MAXIMUM OVERCHARGE: The charger shall return a maximum of 15% overcharge (based

on the 100% rating of the battery), after a discharge of 50% or more with the charger set for its normal mode

3.6.1.3 The table and graph below show recharge requirements for various depths of discharge

RECHARGE REQUIREMENT CHART AND GRAPH IN % OF BATTERY 100% RATING

% DISCHARGE

% RECHARGE

RECHARGE REQUIREMENT

MINIMU RECHARGE

50 60 70 80 90 100 110 120

MAXIMUM OVERCHARGE

Percent Discharge Percent Recharge

3.6.2 Charger with manual controls

3.6.2.1 Instruction shall be provided that would enable the user to properly set the charger to meet

the limits in 3.6.1

3.7.1 The charger efficiency shall be determined by measuring the input watts at the AC input

terminals by means of wattmeters 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:

Percent Charger Efficiency = (average DC voltampere output x 100) / (input watts)

3.7.2 The charger efficiency over the complete charge cycle shall be calculated as follows:

Percent Charge Cycle Efficiency = (kilowatt-hours output x 100) / (kilowatt-hours input)

3.8.1 The power factor for single-phase and three-phase battery chargers shall be calculated as

follows:

Percent Power Factor = (Σ watts per phase x 100) / (Σ rms voltamperes per phase)

3.8.2 For single-phase rectifiers, the input watts can be measured with a wattmeter and the

voltamperes can be calculated from measurements of the true rms input voltage and true rms input current, using true rms responding meters For a balanced three-phase source and load, the input power factor shall be calculated as follows:

Percent Power Factor = (input watts x 100) / (1.732(line volts)(line current))

where the line volts and line current are rms values measured with rms responding meters 3.8.3 The charger power factor over the complete charge cycle shall be calculated as follows:

Percent Charge Cycle Power Factor = (kilowatt-hours input x 100) / (kilovoltampere-hours input)