Technical Manual Section_13 BCI-I-4_2002

8/8/2019 Technical Manual Section_13 BCI-I-4_2002

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BCI BatteryTechnical

Manual

BCIS-I-4REV.

DEC02

Issued 1996-08Current Revision: 2002-12

STANDARD FOR DEEP CYCLE BATTERY CHARGERS

FOREWORD

The Deep Cycle Battery Charger Standard is a performance standard which is designed to be generalenough to cover any present or future technologies; yet specific enough, so that the consumer will knowthe recharge capabilities, methods of recharging, and the criteria under which specific data is obtainedand calculated.

TABLE OF CONTENTS

1. Scope and Definitions..............................................................................................................................71.1. Scope 71.1.1. 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.............................................71.2. Definitions.............................................................................................................................................71.2.1. AMBIENT TEMPERATURE

Ambient temperature is the environmental temperature surrounding the object under consideration.........71.2.2. AMPERE-HOUR CAPACITY

Ampere-hour capacity is the number of ampere-hours which a storage battery can deliver under specifiedconditions such as temperature, specific gravity, rate of discharge, and final voltage.................................71.2.3. AUDIBLE NOISE

Audible noise is the sound level produced by the charger equipment, measured in decibels......................71.2.4. AUTOMATIC CHARGE TERMINATION ( a )

Automatic charge termination is the ability to automatically terminate a charge when predeterminedconditions are met........................................................................................................................................71.2.5. BATTERY CAPACITY

Battery capacity is the ability of a fully charged battery to deliver a specified quantity of amperes over aspecified period of time................................................................................................................................7


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1.2.6. BATTERY CHARGER

A battery charger is a device used to charge a storage battery.................................................................. .71.2.7. CHARGE (per ANSI/IEEE Standard 100 1988)

Charge is the conversion of electrical energy to chemical energy within the cell or battery........................71.2.8. CHARGING RATE (per ANSI/IEEE Standard 100 1988)

Charging rate is the current, expressed in amperes, at which a battery is charged.....................................71.2.9. CHARGER EFFICIENCY

Charger efficiency is the DC output voltamperes divided by the AC input watts..........................................71.2.10. CHARGER POWER FACTOR

Charger power factor is the AC input in watts divided by the AC input in voltamperes................................71.2.11. CONSTANT CURRENT CHARGE ( I )

A constant current charge is a charge in which the value of the current to the battery is maintained at aconstant value..............................................................................................................................................81.2.12. CONSTANT VOLTAGE CHARGE ( U )

A constant voltage charge is a charge in which the DC voltage potential of the charger is maintained at aconstant value at the output terminals........................................................................................................ .81.2.13. DISCHARGE RATE

The discharge rate is the current, in amperes, at which the battery is discharged.......................................81.2.14. DISCHARGE (per ANSI/IEEE Standard 100 1988)

Discharge of a storage battery is the conversion of the chemical energy of the battery into electricalenergy..........................................................................................................................................................81.2.15. 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........ ...81.2.16. 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 nearthe end of a charge......................................................................................................................................81.2.17. FULLY CHARGED BATTERY

A battery or cell is considered fully charged when additional charging with sufficient amperage will notresult in additional stored capacity...............................................................................................................81.2.18. LIVE PART

A live part is a part consisting of electrically conductive material which has a potential greater than zeroduring normal use of the equipment.............................................................................................................8

1.2.19. NOMINAL VALUE

Nominal value is a value assigned for the purpose of convenient designation........................................ ....81.2.20. OUTPUT VOLTAGE RATING

The output voltage rating of a battery charger is the nominal voltage of the battery it is designed tocharge, or the voltage range of the batteries it is designed to charge..........................................................81.2.21. RMS (ROOT MEAN SQUARE) VALUE...........................................................................................81.2.22. SPECIFIC GRAVITY

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Specific gravity is the ratio of the weight of the solution (electrolyte) to the weight of an equal volume ofwater at a specific temperature....................................................................................................................91.2.23. START RATE

Start rate is the initial rate of current, expressed in amperes, delivered to a discharged storage battery... .91.2.24. SWITCHING POINT ( o or O )

The switching point is a point at which the charge or discharge rate is abruptly switched to another rate, orto a pause condition.....................................................................................................................................91.2.25. TAPER CHARGE ( W )

A taper charge is where the value of charging current reduces as the battery voltage increases................91.2.26. VOLTAMPERES (per ANSI/IEEE Standard 100 1988)

The unit of apparent power in the International System of Units (SI). The voltampere is the apparentpower 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 toone...............................................................................................................................................................91.2.27. 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 atthe rate of 1 joule per second......................................................................................................................92. CLASSIFICATION...................................................................................................................................92.1. RECHARGE CODES - The charger recharge code is used to describe the capability of a charger torecharge a battery within a given number of hours after the battery has been discharged for a specifiednumber of hours or minutes to a specified percent of its rated ampere-hour capacity.................................92.1.1. XXX D YY C ZZ: Where XXX = Percent of Discharge.....................................................................92.1.2. XXX DM YYY C ZZ: Where XXX = Percent of Discharge.................................................................92.2. CHARGING METHODS, LIST OF SYMBOLS....................................................................................102.2.1. CHARGING METHODS AND CURVES.................................................................................... ......103. PERFORMANCE...................................................................................................................................173.1. USUAL SERVICE CONDITIONS Following are usual service conditions:................................ ......17

3.1.1. Ambient air temperature between 32F (0C) and 104F (40C).......................................................17

3.1.2. Altitudes not exceeding 1000 meters (3300 feet) above sea level...................................................173.1.3. AC supply voltage and frequency given in section 3.3.....................................................................173.1.4. Battery size (voltage and ampere hour rating) within the charger's nameplate rating......................173.1.5. A battery maintained within the manufacturer's operating parameters.............................................173.2. UNUSUAL SERVICE CONDITIONS The following unusual service conditions may require specificdesign considerations and should be brought to the attention of the manufacturer:..................................173.2.1. Exposure to damaging fumes (corrosive air contaminants);............................................................173.2.2. Exposure to excessive moisture................................................................................................ ......173.2.3. Exposure to excessive dust;.......................................................................................................... ..173.2.4. Exposure to abrasive or conductive dust;................................................................................ ........173.2.5. Exposure to steam;..........................................................................................................................173.2.6. Exposure to oil vapor;................................................................................................................. .....173.2.7. Exposure to explosive mixtures of dust or gases;............................................................................17

3.2.8. Exposure to salt air;.........................................................................................................................183.2.9. Exposure to outdoor use;.................................................................................................................183.2.10. Exposure to abnormal vibration, shocks, or tilting;.........................................................................183.2.11. Exposure to dripping water;...........................................................................................................183.2.12. Exposure to unusual transportation or storage; ................................................................... .........183.2.13. Unbalanced AC voltages;...................................................................................................... ........183.2.14. Departure of AC system voltages from a substantially sinusoidal waveform;................................183.2.15. Input supply voltage and frequency outside ranges given in 3.3....................................................18

3.2.16. Operation in ambient temperatures more than 104F (40C) or less than 32F (0C).....................183.2.17. Operation at altitudes more than 1000 meters (3300 feet) above sea level...................................18

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

104F (40C)...............................................................................................................................................183.2.19. Battery size (voltage and ampere hour rating) not within the charger's nameplate rating..............183.2.20. A battery not maintained within the manufacturer's operating parameters.....................................183.3. Input voltage and frequency The charger shall be able to deliver its rated output when supplied atthe 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 thecharger or battery sustain any damage.

*AC Line variations: + 6%, - 10% of nameplate rating*AC Line frequency variations: +/- 0.2% of nameplate rating.....................................................................183.4. 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.....................................................................................183.4.1. For lead-acid batteries

The charger output current shall not exceed a value that will cause an increase in battery temperature of

more than 40F (22.2C) during the charge................................................................................................183.5. Charger Characteristic Curve.............................................................................................................183.5.1. The following conditions must be met:.............................................................................................183.5.2. The following must be plotted:.........................................................................................................193.6. Recharge requirement for lead-acid batteries:....................................................................................193.6.1. Charger with automatic controls.......................................................................................................193.6.2. Charger with manual controls..........................................................................................................203.7. EFFICIENCY.................................................................................................................................. ....203.7.1. The charger efficiency shall be determined by measuring the input watts at the AC input terminalsby means of wattmeters and by measuring the average values of the direct voltage and current at theoutput terminals. From the values thus measured, the charger efficiency shall be calculated inaccordance with the following:

Percent Charger Efficiency = (average DC voltampere output x 100) / (input watts)...............................203.7.2. 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)..........................203.8. POWER FACTOR..................................................................................................................... .........203.8.1. 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 voltamperes per phase).............................203.8.2. For single-phase rectifiers, the input watts can be measured with a wattmeter and the voltamperescan be calculated from measurements of the true rms input voltage and true rms input current, using truerms responding meters. For a balanced three-phase source and load, the input power factor shall becalculated 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. ..................203.8.3. 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)....... ....203.9. NAMEPLATE MARKING....................................................................................................................203.9.1. Model number .................................................................................................................................203.9.2. Serial number...................................................................................................................................20

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3.9.3. Type of battery for which the charger was designed, e.g., LA(lead-acid); PB(lead-acid); VRLA(valve regulated lead-acid); NC(nickel-cadmium); NCVR(nickel-cadmium valve-regulated); all types.......213.9.4. Number(s) of cells in series..............................................................................................................213.9.5. Nominal output voltage............................................................................................................... .....213.9.6. Ampere-hour capacity......................................................................................................................213.9.7. Rated output in amperes..................................................................................................................213.9.8. Nominal AC supply voltage(s)..........................................................................................................213.9.9. Supply frequency.............................................................................................................................213.9.10. Phase.............................................................................................................................................213.9.11. Rated AC line amperes..................................................................................................................213.9.12. Number of charging circuits (if more than one)..............................................................................213.9.13. Date code ......................................................................................................................................213.9.14. Classification code.........................................................................................................................213.10. NAMEPLATE MARKING..................................................................................................................213.10.1. Model number ...............................................................................................................................21.................................................................................................................................................................21

3.10.2. Serial number.................................................................................................................................213.10.3. Type of battery for which the charger was designed, e.g., LA(lead-acid); PB(lead acid); VRLA(valve regulated lead-acid); NC(nickel-cadmium); NCVR(nickel-cadmium valve-regulated); all types.......213.10.4. Number(s) of cells in series............................................................................................................21

3.10.5. Nominal output voltage............................................................................................................ ......213.10.6. Ampere-hour capacity....................................................................................................................213.10.7. Rated output in amperes................................................................................................................213.10.8. Nominal AC supply voltage(s)........................................................................................................213.10.9. Supply frequency...........................................................................................................................213.10.10. Phase...........................................................................................................................................213.10.11. Rated AC line amperes................................................................................................................213.10.12. Number of charging circuits (if more than one).......................................................................... ..213.10.13. Date code ....................................................................................................................................223.10.14. Classification code.......................................................................................................................224. SAFETY 224.1. GENERAL SAFETY REQUIREMENT.......................................................................................... ......224.1.1. All BCI labelled 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 thelocation of use, (if known)..........................................................................................................................224.2. COMPONENTS The battery charger shall contain at least the following components:................. ..224.2.1. A transformer or other device to electrically isolate the battery being charged from the AC source 224.2.2. Means for manually terminating the charging current......................................................................224.2.3. A device indicating charger operation..............................................................................................224.2.4. Output overcurrent protective devices....................................................................................... ......224.3. OPERATING INSTRUCTIONS...........................................................................................................224.3.1. A label with clear and precise operating instructions shall be provided................................... ........224.4. INSTRUCTION MANUAL An instruction manual shall be provided with each charger and shallinclude at least the following information:..................................................................................................224.4.1. Safety instructions............................................................................................................................224.4.2. Installation instructions.....................................................................................................................22

4.4.3. Operating instructions......................................................................................................................224.4.4. Schematic or wiring diagrams, or both.............................................................................................224.4.5. Trouble shooting instructions...........................................................................................................224.4.6. Maintenance procedures.............................................................................................................. ...224.5. ENCLOSURE SERVICE GROUNDING.................................................................................... .........224.5.1. A separate, clearly identified grounding terminal shall be provided for the connection of the ACinput grounding conductor. All dead metal parts of the unit shall be conductively connected to thisgrounding terminal.....................................................................................................................................224.6. AC INPUT CABLE ENTRY.................................................................................................................22

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4.6.1. The charger cabinet shall be provided with an entry hole or knockout located as near as possible tothe input connection terminals. If the charger is supplied with AC input cable, a strain relief shall beprovided.....................................................................................................................................................224.7. DC OUTPUT CABLE EXIT.................................................................................................................234.7.1. The charger cabinet shall be provided with an exit hole(s) or knockout(s) to accommodate therequired strain relief located as near as possible to the output connection terminals. If the charger issupplied with DC output cable(s), a strain relief(s) shall be included...................................................... ...234.8. DC OUTPUT CABLE..........................................................................................................................234.8.1. When battery charger DC cables are supplied, they shall be of a size and rating that will safelycarry the output current. The polarity of the output shall be plainly identified. ..........................................234.9. AC CIRCUIT PROTECTION...............................................................................................................234.9.1. The charger must be provided with protection against overload or short circuit in all ungrounded ACinput power conductors, unless cord-connected with an attachment plug for connection to the supplycircuit...................................................................................................................................................... ...235. TEST METHODS...................................................................................................................................235.1. GENERAL....................................................................................................................................... ...235.1.1. Performance tests............................................................................................................................235.1.2. Safety tests......................................................................................................................................235.1.3. Production tests.......................................................................................................................... .....235.2. INSTRUMENTATION...................................................................................................................... ...23

5.2.1. Measuring apparatus shall have sufficient resolution, stability, and accuracy so as to ensure a limitof error not exceeding 1% of the measured quantity. For each test, sufficient metering and monitoringshall be provided so as to ensure conformance with the test conditions....................................................235.3. PERFORMANCE TESTS Performance tests are those that must be made on a representativesample of every battery charger model(s) that represents the worst set of operating conditions (usuallythe maximum kilowatt output in a particular enclosure) and that are repeated whenever a change is madethat modifies the performance of the charger. The battery charger shall be operated for a completecharge cycle to establish its performance in accordance with Sec. 3.......................................................235.3.1. Battery temperature rise............................................................................................................... ...235.3.2. Charging curve ................................................................................................................................235.3.3. Charger efficiency ...........................................................................................................................235.3.4. Power factor ....................................................................................................................................235.4. SAFETY TEST....................................................................................................................................24

5.4.1. Safety tests are those that must be made on a representative sample of every battery chargermodel(s) that represent the worst set of operating conditions (usually the maximum kilowatt output in aparticular enclosure) and that are repeated whenever a change is made that affects the safetycharacteristics of the charger.....................................................................................................................245.4.2. The substitution of a higher rated direct replacement component does not necessitate retesting therepresentative charger model.............................................................................................................. ......245.4.3. Safety tests shall include the following:............................................................................................245.5. PRODUCTION TESTS...................................................................................................................... .245.5.1. Production tests shall be made on all production units for the purpose of maintaining safety, quality,and performance........................................................................................................................................245.5.2. Production tests for battery chargers shall include the following:.....................................................245.5.3. DIELECTRIC TESTS.......................................................................................................................245.5.4. CABINET GROUND INTEGRITY TEST..........................................................................................25

5.5.5. CIRCUIT OPERATION TEST....................................................................................................... ...25

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1. SCOPE AND DEFINITIONS

1.1. Scope

1.1.1. The Deep Cycle Battery Charger Standard covers battery chargers used to recharge deepcycle 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 underconsideration.

1.2.2. AMPERE-HOUR CAPACITY

Ampere-hour capacity is the number of ampere-hours which a storage battery can deliverunder 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 whenpredetermined conditions are met.

1.2.5. BATTERY CAPACITY

Battery capacity is the ability of a fully charged battery to deliver a specified quantity ofamperes over a specified period of time.

1.2.6. BATTERY CHARGER

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.

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1.2.11. CONSTANT CURRENT CHARGE ( I )

A constant current charge is a charge in which the value of the current to the battery ismaintained 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 ismaintained 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 intoelectrical energy.

1.2.15. EQUALIZING CHARGE

An equalizing charge is an extended charge that is delivered to a charged storage battery forthe purpose of minimizing voltage and specific gravity variations between the cells that maydevelop 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 isreduced 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 greaterthan 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 isdesigned to charge, or the voltage range of the batteries it is designed to charge.

1.2.21. RMS (ROOT MEAN SQUARE) VALUE

1.2.21.1. The root mean square value of an alternating voltage or current is the square root of themean value of the square of the voltage or current values during a complete cycle.

1.2.21.2. RMS is the effective value of an alternating current that corresponds to the direct currentvalue that produces the same heating effect.

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1.2.22. SPECIFIC GRAVITY

Specific gravity is the ratio of the weight of the solution (electrolyte) to the weight of an equalvolume 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 dischargedstorage 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 toanother 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 voltageincreases.

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 theapparent power at the points of entry of a single-phase, two-wire system when the product ofthe root-mean-square value in amperes of the current by the root-mean-square value in voltsof 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 todo work at the rate of 1 joule per second.

2. CLASSIFICATION

There are many types of chargers used internationally; this section is designed to standardizethe 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 acharger to recharge a battery within a given number of hours after the battery has beendischarged for a specified number of hours or minutes to a specified percent of its ratedampere-hour capacity.

2.1.1. XXX D YY C ZZ: Where XXX = Percent of DischargeYY = Dishcarge Rate in HoursZZ = Hours to Recharge

e.g.80D6C8: 80% discharge (D) at the 6 hour rate with charge (C) time of 8 hours80D5C14: 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 DischargeYY = Dishcarge Rate in HoursZZ = Hours to Recharge

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2.2. CHARGING METHODS, LIST OF SYMBOLS

I - Constant current charging: Charging during which the value of current is maintained at aconstant 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 asbattery voltage increases.

t - Time

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

V - Voltage

E - Equalize

O or0 - Switch point

a - Automatic Termination

2.2.1. CHARGING METHODS AND CURVES

The following examples do not exclude the possibility of other acceptable chargingcharacteristics.

2.2.1.1. CURVE

- symbol: W- operation: charge with decreasing current, manual termination

VOLTAGE

CURRENT TIME

Characteristic Charge Cycle

VOLTAGE

CURRENT

V

I

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2.2.1.2. CURVE

- symbol: Wa- operation: charge with decreasing current, automatic charge termination

VOLTAGE

CURRENT TIME


VOLTAGE

CURRENT

V

I

2.2.1.3. CURVE

- symbol: Wo Wa- operation: automatic charge termination

VOLTAGE

CURRENT TIME


VOLTAGE

CURREN

T

I

V

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2.2.1.4. CURVE

- symbol: WU- operation: automatic charge with limitation of voltage

VOLTAGE


VOLTAGE

CURRENT

I

V

CURRENT

TIME

2.2.1.5. CURVE

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

VOLTAG

E

CURRENT TIME


VOLTA

GE

CURRENT

I

V

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2.2.1.6. CURVE

- symbol: U- operation: fast charge with constant voltage

VOLTAGE

CURRENT TIME


VOLTAGE

CURRENT

I

V

2.2.1.7. CURVE

- symbol: Ua- operation: as Example 2.2.1.6 with automatic charge termination

VOLTAGE

CURRENT TIME


VOLTAGE

CURRENT

V

I

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2.2.1.8. CURVE

- symbol: I- operation: charge with constant current

VOLTAGE

CURRENT TIME


VOLTAGE

CURRENT

V

I

2.2.1.9. CURVE

- symbol: Ia- operation: as Example 2.2.1.8 with automatic charge termination

VOLTA

GE

CURRENT TIME


VOLTAGE

CURRENT

V

I

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2.2.1.10. CURVE

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

termination

VOLTAGE

CURRENT TIME


VOLTAGE

CURRENT

V

I

2.2.1.11. CURVE

- symbol: I U- operation: charge with constant current, then constant voltage

VOLTAGE

CURRENT TIME


VOLTAG

E

CURRENT

V

I

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2.2.1.12. CURVE

- symbol: I U Ia- operation: as example 2.2.1.11 but completion of charging with low constant current and

automatic termination

VOLTAGE

CURRENT TIME


VOLTAGE

CURRENT

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

VOLTAGE

Characteristic

VOLTAGE

CURRENT

TIME

Charge Cycle

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2.2.1.14. CURVE

- symbol I10I20I

30I

40...a

- operation: step constant current

VOLTAGE

CURRENT TIME


I

VOLTAGE

CURRENT

V

3. PERFORMANCE

3.1. USUAL SERVICE CONDITIONS Following are usual service conditions:

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

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 requirespecific 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;

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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 104F (40C) or less than 32F (0C)

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 50F (10C) or more

than 104F (40C).

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 whensupplied at the rated input voltage. It shall, however, be capable of operating under thefollowing conditions of input voltage and frequency in such a way that the safety of persons isnot 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 40F (22.2C) during the charge.

3.5. Charger Characteristic Curve

3.5.1. The following conditions must be met:

3.5.1.1. The battery used shall have the same ampere-hour capacity as the charger.

3.5.1.2. The discharge shall be in accordance with the charger classification.

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

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 themaximum discharge per the charger classification code, with the charger set for its normalmode.

3.6.1.2. MAXIMUM OVERCHARGE: The charger shall return a maximum of 15% overcharge (basedon the 100% rating of the battery), after a discharge of 50% or more with the charger set forits 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

50 55 65 7060 75 80 85 90 8595 100

% DISCHARGE

% RECHARG

RECHARGE REQUIRE

MINIMU

RECHAR

50

60

70

80

90

100

110

120

MAXIMU

OVERCHARG

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Percent Discharge Percent RechargeMin. Max.

100 102 11590 92 10580 82 9570 72 8560 62 7550 52 65

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 meetthe limits in 3.6.1.

3.7. EFFICIENCY

3.7.1. The charger efficiency shall be determined by measuring the input watts at the AC inputterminals by means of wattmeters and by measuring the average values of the direct voltageand 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. POWER FACTOR

3.8.1. The power factor for single-phase and three-phase battery chargers shall be calculated asfollows:

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

3.8.2. For single-phase rectifiers, the input watts can be measured with a wattmeter and thevoltamperes can be calculated from measurements of the true rms input voltage and true rmsinput current, using true rms responding meters. For a balanced three-phase source andload, 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-hoursinput)

3.9. NAMEPLATE MARKING

The following minimum information shall be given on the nameplate if applicable:

3.9.1. Model number

3.9.2. Serial number

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3.9.3. Type of battery for which the charger was designed, e.g., LA(lead-acid); PB(lead-acid); VRLA(valve regulated lead-acid); NC(nickel-cadmium); NCVR(nickel-cadmium valve-regulated); alltypes.

3.9.4. Number(s) of cells in series

3.9.5. Nominal output voltage

3.9.6. Ampere-hour capacity

3.9.7. Rated output in amperes

3.9.8. Nominal AC supply voltage(s)

3.9.9. Supply frequency

3.9.10. Phase

3.9.11. Rated AC line amperes

3.9.12. Number of charging circuits (if more than one)

3.9.13. Date code

3.9.14. Classification code

3.10. NAMEPLATE MARKING

The following minimum information shall be given on the nameplate if applicable:

3.10.1. Model number

3.10.2. Serial number

3.10.3. Type of battery for which the charger was designed, e.g., LA(lead-acid); PB(lead acid); VRLA(valve regulated lead-acid); NC(nickel-cadmium); NCVR(nickel-cadmium valve-regulated); alltypes.

3.10.4. Number(s) of cells in series

3.10.5. Nominal output voltage

3.10.6. Ampere-hour capacity

3.10.7. Rated output in amperes

3.10.8. Nominal AC supply voltage(s)

3.10.9. Supply frequency

3.10.10. Phase

3.10.11. Rated AC line amperes

3.10.12. Number of charging circuits (if more than one)

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3.10.13. Date code

3.10.14. Classification code

4. SAFETY

4.1. GENERAL SAFETY REQUIREMENT

4.1.1. All BCI labelled 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).

4.2. COMPONENTS The battery charger shall contain at least the following components:

4.2.1. A transformer or other device to electrically isolate the battery being charged from the ACsource

4.2.2. Means for manually terminating the charging current

4.2.3. A device indicating charger operation

4.2.4. Output overcurrent protective devices

4.3. OPERATING INSTRUCTIONS

4.3.1. A label with clear and precise operating instructions shall be provided.

4.4. INSTRUCTION MANUAL An instruction manual shall be provided with each charger andshall include at least the following information:

4.4.1. Safety instructions

4.4.2. Installation instructions

4.4.3. Operating instructions

4.4.4. Schematic or wiring diagrams, or both

4.4.5. Trouble shooting instructions

4.4.6. Maintenance procedures

4.5. ENCLOSURE SERVICE GROUNDING

4.5.1. A separate, clearly identified grounding terminal shall be provided for the connection of theAC input grounding conductor. All dead metal parts of the unit shall be conductivelyconnected to this grounding terminal.

4.6. AC INPUT CABLE ENTRY

4.6.1. The charger cabinet shall be provided with an entry hole or knockout located as near aspossible to the input connection terminals. If the charger is supplied with AC input cable, astrain relief shall be provided.

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4.7. DC OUTPUT CABLE EXIT

4.7.1. The charger cabinet shall be provided with an exit hole(s) or knockout(s) to accommodatethe required strain relief located as near as possible to the output connection terminals. If thecharger is supplied with DC output cable(s), a strain relief(s) shall be included.

4.8. DC OUTPUT CABLE

4.8.1. When battery charger DC cables are supplied, they shall be of a size and rating that willsafely carry the output current. The polarity of the output shall be plainly identified.

4.9. AC CIRCUIT PROTECTION

4.9.1. The charger must be provided with protection against overload or short circuit in allungrounded AC input power conductors, unless cord-connected with an attachment plug forconnection to the supply circuit.

5. TEST METHODS

5.1. GENERAL

This section is intended to provide test methods to evaluate the performance and safetycharacteristics of battery chargers.

Tests shall be divided into three categories:

5.1.1. Performance tests

5.1.2. Safety tests

5.1.3. Production tests

5.2. INSTRUMENTATION

5.2.1. Measuring apparatus shall have sufficient resolution, stability, and accuracy so as to ensure alimit of error not exceeding 1% of the measured quantity. For each test, sufficient meteringand monitoring shall be provided so as to ensure conformance with the test conditions.

5.3. PERFORMANCE TESTS Performance tests are those that must be made on arepresentative sample of every battery charger model(s) that represents the worst set ofoperating conditions (usually the maximum kilowatt output in a particular enclosure) and thatare repeated whenever a change is made that modifies the performance of the charger. Thebattery charger shall be operated for a complete charge cycle to establish its performance inaccordance with Sec. 3.

Performance tests shall include the following:

5.3.1. Battery temperature rise

5.3.2. Charging curve

5.3.3. Charger efficiency

5.3.4. Power factor

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5.4. SAFETY TEST

5.4.1. Safety tests are those that must be made on a representative sample of every battery chargermodel(s) that represent the worst set of operating conditions (usually the maximum kilowattoutput in a particular enclosure) and that are repeated whenever a change is made thataffects the safety characteristics of the charger.

5.4.2. The substitution of a higher rated direct replacement component does not necessitateretesting the representative charger model.

5.4.3. Safety tests shall include the following:

5.4.3.1. Dielectric

5.4.3.2. Fire hazard

5.4.3.3. Mechanical integrity

5.4.3.4. Audible sound level limit

5.4.3.5. Component temperature test

5.5. PRODUCTION TESTS

5.5.1. Production tests shall be made on all production units for the purpose of maintaining safety,quality, and performance.

5.5.2. Production tests for battery chargers shall include the following:

5.5.2.1. Dielectric

5.5.2.2. Cabinet ground integrity

5.5.2.3. Circuit operation

5.5.3. DIELECTRIC TESTS

5.5.3.1. A battery charger shall be capable of withstanding for 1 minute, without breakdown, theapplication of a 50 or 60 Hertz essentially sinusoidal test voltage with the battery charger atthe maximum operating temperature which it reaches in normal use. As an alternative, 120percent of the specified test voltage shall be applied for 1 second.

5.5.3.2. Primary circuits to dead-metal parts and primary circuits to secondary circuits shall becapable 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 voltsbetween 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 voltagebetween the circuits and dead-metal parts.

5.5.3.3. The leakage current for these test voltages shall not exceed 0.75 milliampere on cordconnected chargers and 5.0 milliamperes on conduit-connected chargers, under all ratedoperating conditions.

5.5.3.4. The charger shall be tested with one of the following types of test equipment or equivalent:

5.5.3.4.1. A 500 volt-ampere or larger transformer with voltmeter.

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5.5.3.4.2. A less than 500 volt-ampere transformer having output voltmeter, audible and visualindication of breakdown and reset button.

The test voltage as specified above shall be applied between the following points:

5.5.3.4.2.1. Alternating-current input terminals to dead-metal parts.

5.5.3.4.2.2. Alternating-current input terminals to direct-current output terminals.

5.5.3.4.2.3. Direct-current terminals to dead-metal parts.

5.5.3.4.3. For these tests, all semiconductors, capacitors and sensitive control components shall beshort-circuited; printed circuit control boards shall be removed. Contactors and relaysshall be in their operating mode.

5.5.4. CABINET GROUND INTEGRITY TEST

5.5.4.1. The resistance of the ground connections in the charger cabinet shall be checked with acontinuity 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 cabinetgrounding terminals and exposed dead metal parts.

5.5.5. CIRCUIT OPERATION TEST

5.5.5.1. The battery charger shall be tested to ensure that all of its components are properlyinterconnected and adjusted to function according to the typical voltampere curve designatedfor that charger.

Documents

Technical Manual Section_13 BCI-I-4_2002