Standard

February 2000

Process Industry PracticesElectrical

PIP ELSAP01Battery Chargers for Station Batteries

PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice hasbeen prepared from the technical requirements in the existing standards of majorindustrial users, contractors, or standards organizations. By harmonizing thesetechnical requirements into a single set of Practices, administrative, application, andengineering costs to both the purchaser and the manufacturer should be reduced. Whilethis Practice is expected to incorporate the majority of requirements of most users,individual applications may involve requirements that will be appended to and takeprecedence over this Practice. Determinations concerning fitness for purpose andparticular matters or application of the Practice to particular project or engineeringsituations should not be made solely on information contained in these materials. Theuse of trade names from time to time should not be viewed as an expression ofpreference but rather recognized as normal usage in the trade. Other brands having thesame specifications are equally correct and may be substituted for those named. AllPractices or guidelines are intended to be consistent with applicable laws andregulations including OSHA requirements. To the extent these Practices or guidelinesshould conflict with OSHA or other applicable laws or regulations, such laws orregulations must be followed. Consult an appropriate professional before applying oracting on any material contained in or suggested by the Practice.

Process Industry Practices (PIP), Construction Industry Institute, TheUniversity of Texas at Austin, 3208 Red River Street, Suite 300, Austin,Texas 78705. PIP member companies and subscribers may copy this Practicefor their internal use.

Not printed with State funds

February 2000

Process Industry Practices Page 1 of 9

Process Industry PracticesElectrical

PIP ELSAP01Battery Chargers for Station Batteries

Table of Contents

1. Introduction..................................21.1 Purpose ............................................. 21.2 Scope................................................. 2

2. References ...................................22.1 Process Industry Practices ................ 22.2 Industry Codes and Standards .......... 22.3 Conflict Resolution............................. 2

3. Definitions ....................................3

4. Design and Fabrication ...............34.1 General .............................................. 34.2 Operating Environment...................... 34.3 Input and Output Requirements......... 44.4 Controls ............................................. 64.5 Control Indications ............................. 64.6 Alarm Indications - Local ................... 64.7 Alarm Indications - Remote ............... 74.8 Panel Meters...................................... 74.9 Wiring, Cables, and Devices ............. 74.10 Grounding .......................................... 84.11 Enclosure........................................... 84.12 Painting.............................................. 84.13 Nameplate ......................................... 8

5. Testing.......................................... 9

6. Shipping ....................................... 9

7. Documentation ............................ 9

PIP ELSAP01Battery Chargers for Station Batteries February 2000

Page 2 of 9 Process Industry Practices

1. Introduction

1.1 PurposeThis Practice provides the requirements including design, installation, inspection,testing, shipment, and documentation for the purchase of battery chargers forapplication in process industries.

1.2 ScopeThis Practice and Data Sheet define the minimum requirements for an electronicallycontrolled indoor battery charger used for charging batteries for station applications.These include requirements for design, inspection, testing, shipment, anddocumentation for indoor non-classified areas.

2. References

Applicable requirements in the latest edition (or the edition indicated) of the followingindustry standards and Process Industry Practices shall be considered an integral part of thisPractice. Short titles will be used herein when appropriate.

2.1 Process Industry Practices (PIP) PIP ELSAP01D - Data Sheet for Battery Chargers for Station Batteries PIP ELSAP11 - Design and Fabrication of Flooded-Cell Lead-Acid Batteries

for Electrical Stations2.2 Industry Codes and Standards

National Electrical Manufacturers Association (NEMA) NEMA PE 5-1996 - Utility Type Battery Chargers

National Fire Protection Association (NFPA) NFPA 70 - National Electrical Code (NEC)

Underwriters Laboratory, Inc. (UL) UL 489 - Molded-Case Circuit Breakers, and Circuit-Breaker Enclosures

2.3 Conflict ResolutionAny conflicts between the referenced documents shall be identified to the buyer inwriting for resolution. When resolving conflicts, the following order of precedenceshall apply:

Purchase Order

Data Sheet(s) This Practice

Referenced documents

PIP ELSAP01February 2000 Battery Chargers for Station Batteries


3. Definitions

For the purposes of this Practice, the following definitions apply:

Equalizing charge: An extended charge to a measured end point that is given to a storagebattery to ensure the complete restoration of the active materials in all the plates of all thecells

Floating charge: A method of operation for storage batteries in which a constant voltage isapplied to the battery terminals sufficient to maintain an approximately constant state ofcharge

Full float operation: Operation of a DC system with the battery charger and load cellconnected in parallel and with the battery charger supplying the normal DC load, plus anyself discharge or charging current or both required by the battery. (The battery will delivercurrent only when the load exceeds the charger output.)Percent ripple voltage: The ratio of the root mean square value of the ripple voltage to theabsolute value of the total voltage expressed as a percentage

Ripple: The alternating current component from a direct current power supply arising fromsources within the power supply

4. Design and Fabrication

4.1 General4.1.1 The battery charger shall be designed, constructed, and tested in accordance

with NEMA PE 5-1996.4.1.2 The charger shall provide constant voltage float and equalize charging of the

battery bank and, at the same time, deliver 0%100%-rated current output toa varying on-line load.

4.1.3 The charger shall maintain the preset output DC voltage regulation to theconnected load with the battery connected to the charger.

4.1.4 The charger shall be sized to provide a battery recharge time as specified onthe Data Sheet.

4.2 Operating Environment4.2.1 The battery charger shall be designed for indoor operation at an ambient

temperature between 0 and 50C or as specified on the Data Sheet and at arelative humidity between 0% and 95%, non-condensing.

4.2.2 The battery charger will be located in an indoor non-classified area.



4.3 Input and Output Requirements4.3.1 Input Overcurrent Protection

An input circuit breaker shall be provided for overcurrent and short-circuitprotection, as well as to provide a means of isolating the input power to thecharger. The circuit breaker shall have an interrupting capacity equal to orgreater than the available short-circuit current listed on the Data Sheet.Molded-case circuit breakers shall be designed and tested in accordance withUL 489.

4.3.2 Input Power SupplyThe input power supply shall be as specified on the Data Sheet.

4.3.3 AC Line CompensationThe charger shall maintain the specified performance by providing automaticcompensation for up to 10% variation in the AC line voltage.

4.3.4 Input SurgeThe input circuits of the charger shall withstand the surge test specified inNEMA PE 5-1996, Section 9.1.9.

4.3.5 Output Voltage RegulationDC output voltage shall be regulated to 0.5% in the float mode and shallbe regulated to 1% in the equalize mode for any combination of AC linevoltage variation of 10% of nominal, AC line frequency variation of 5%of normal, load variations of 0% to 100%, and ambient temperaturevariations of 0 to 50C.

4.3.6 Operation without BatteryWhen a battery eliminator is specified on the Data Sheet, the charger shallmeet all the performance criteria of this Practice with the batterydisconnected.

4.3.7 DC Output RippleWith the battery connected, the root mean square (RMS) ripple voltage shallnot exceed the limits specified in NEMA PE 5-1996, Table 6.

4.3.8 DC Output Current LimitA current limit circuit shall be provided. The circuit shall be factory-set at105% of the rated DC output current.

4.3.9 Float VoltageThe float voltage setting shall be adjustable as follows:

a. Lead-acid battery - 2.15 to 2.35 volts per cellb. Nickel-cadmium battery - 1.35 to 1.45 volts per cell



4.3.10 Equalize VoltageThe equalize voltage setting shall be adjustable as follows:

a. Lead-acid battery - 2.20 to 2.45 volts per cellb. Nickel-cadmium battery - 1.50 to 1.60 volts per cell

4.3.11 Temperature Compensated ChargingWhen specified on the Data Sheet, a battery temperature-sensing probe shallbe provided for sensing the temperature of a pilot cell. The output voltage ofthe charger shall be automatically adjusted to provide a negative temperaturecompensation of 5 mV per degree C for changes in battery temperatureabove or below the standard temperature of 25C.

4.3.12 Dynamic ResponseWith the battery connected, dynamic response shall be as specified inNEMA PE 5-1996, Section 5.10.

4.3.13 Start-up BehaviorThe charger shall have soft-start characteristics. The start-up walk-infeature shall increase the output current from 20% to 100% of the rated loadwithin 15 seconds.

4.3.14 Abnormal Load ConditionsFor nickel-cadmium battery applications, the charger shall operate into azero battery voltage without activating protective devices.

4.3.15 Output Surge ProtectionThe output circuits of the charger shall withstand the surge test as specifiedin NEMA PE 5-1996, Section 9.1.9.

4.3.16 Output Overcurrent ProtectionUnless specified otherwise on the Data Sheet, a two-pole output circuitbreaker shall be provided for overcurrent and short circuit protection, as wellas a means of disconnecting the charger from the load.

4.3.17 Parallel Operation of Two ChargersWhen specified on the Data Sheet, the battery charger shall be designed toallow parallel operation and load sharing between two chargers connected toa common battery and load. Failure of one charger shall not affect theoperation of the other charger or battery.

4.3.18 InterlocksThe enclosure shall be interlocked to prevent opening or closing of the doorunless both input and output protective devices are in the open position.Provisions shall be provided inside the enclosure to allow the input device tobe closed for diagnostic purposes with the door open.



4.4 Controls4.4.1 Float/Equalize Timer

An equalizing timer shall be provided for manually placing the battery onequalize charge. The timer shall have a manually adjustable timing range of0 to 72 hours.

4.4.2 Output Voltage AdjustmentsSeparate controls shall be provided for independently adjusting the float andequalizing voltage levels.

4.4.3 Automatic Equalize Charge ControlWhen specified on the Data Sheet, the charger shall be equipped withautomatic controls to automatically switch to equalizing charge after an ACpower interruption of more than 5 minutes. The charger shall automaticallyreturn to float charge mode 8 hours (field adjustable from 0 to 24 hours)after an automatic start of the equalize charge mode.

4.4.4 High-Voltage ShutdownThe charger shall automatically shutdown if the output DC voltage reaches110% of the output voltage setting.

4.4.5 Alarm Reset ButtonA momentary pushbutton to reset the remote alarm relay shall be provided.

4.5 Control IndicationsThe following control indications shall be provided by LED or LCD on the frontpanel of the charger enclosure:

a. Charger onb. Float chargec. Equalize charge

4.6 Alarm Indications - Local4.6.1 The following alarm indications shall be provided by LED or LCD on the

front panel of the charger cabinet:a. Positive ground faultb. Negative ground faultc. Charger failured. Low-output voltagee. Cooling fan failure (for force ventilated units)

4.6.2 When indicated on the Data Sheet, the following alarm indications shall beprovided by LED or LCD on the front panel of the charger cabinet:

a. AC input failure



b. Charger overtemperaturec. Overload shutdownd. High output voltagee. Equalize charge modef. Battery end of dischargeg. Output breaker open

4.6.3 All alarms shall remain latched until manually reset after the alarm conditionhas been cleared.

4.7 Alarm Indications - RemoteA form C alarm contact, rated 120 VAC, 5 amps, shall be provided forannunciating all the alarms of Section 4.6 as a common alarm to Buyers centralalarm-monitoring system.

4.8 Panel Meters4.8.1 Output Voltage and Current

A digital (LED or LCD) panel meter shall be provided to display the outputcurrent and voltage readings. Meters shall have 1% full-scale accuracy.

4.8.2 Ground Fault IndicationWhen specified on the Data Sheet, positive and negative ground faults shallbe displayed on a common meter via a switch to show the magnitude of theleakage current.

4.9 Wiring, Cables, and Devices4.9.1 Wiring shall comply with NFPA 70 (NEC).4.9.2 Wiring brought out to terminal blocks shall be permanently identified with

heat-shrinkable wire markers. Wire numbers and color codes shallcorrespond to the numbers and colors shown on the schematic/wiringdiagram(s).

4.9.3 Terminal blocks shall be provided for connection of external control andalarm wiring. A maximum of two wires per point is permitted.

4.9.4 All energy-isolating devices that are required to perform safe maintenanceshall be capable of accepting a lockout device in the OFF or disconnectedposition only.

Note: An energy-isolating device is a mechanical device that physicallyprevents the transmission or the release of energy.

4.9.5 Each energy-isolating device shall be clearly identified to indicate itspurpose. Devices that receive external power shall have the source of powerincluded in their labeling.



4.9.6 Provide permanent wire supports. Adhesive backing wire supports are notacceptable.

4.10 Grounding4.10.1 Grounding provisions shall meet the requirements of NFPA 70 (NEC).4.10.2 The enclosure shall be provided with a copper equipment grounding

connection.

4.10.3 The positive and negative DC buses shall be isolated from the earth ground.

4.11 Enclosure4.11.1 Enclosures shall be manufacturers standard unless indicated otherwise on

the Data Sheet.4.11.2 Enclosure preference shall be for natural convection cooling. When forced

ventilation is used, the enclosures shall be equipped with removable, easilycleanable inlet air filters.

4.11.3 Enclosures shall be designed for front access to all components and testpoints.

4.11.4 Handles, screws, and hinges shall be corrosion resistant.4.11.5 Where provided, the enclosure door handle shall have provision to be

padlocked.

4.11.6 Cable entry shall be as specified on the Data Sheet.4.11.7 Enclosure shall be designed and constructed so that all normal controls are

operable with the doors closed.

4.12 PaintingFinish shall be manufacturers standard (i.e., method, type, color, etc.), unlessotherwise specified on the Data Sheet.

4.13 Nameplate4.13.1 The following information shall be permanently marked on each enclosure:

a. Manufacturers name and addressb. Equipment model and serial numberc. Input AC voltage and number of phasesd. Nominal output DC voltagee. Rated output current

4.13.2 All major devices and components of the battery charger shall be providedwith engraved, laminated plastic nameplates identifying the devices orcomponents and their function.



5. Testing

5.1 The battery charger shall be factory-tested to demonstrate the performance and thefunctionality required by this specification.

5.2 When specified on the Data Sheet, additional tests shall be performed. Certified testreports shall be furnished.

6. Shipping

Seller shall identify the following on each shipping group:

a. Purchase Order numberb. Requisition numberc. Equipment numberd. Project number

7. Documentation

AWithBid

BFor

Review

CFinal

Certified

DAs

Built

DESCRIPTION

X X X X General layout of equipment, showing all dimensions,weights, location, and outline drawings showing the finalassembled configuration

X Copies of certified test reports

X X X One-line diagram, three-line diagram, control schematicsand connection wiring diagrams

X(1) Installation, operation, maintenance manual and requiredmaintenance schedules

X X X Safety instructions clearly identifying proper and improperoperation that might injure personnel and cause damageto operating equipment

A. Bidder shall furnish these documents with proposal.B. Seller shall furnish these documents for Buyer's review and authorization to proceed before

fabrication.C. Seller shall furnish these documents as part of the final certified document submittal.

(1) Equipment shall be shipped with one (1) set of installation, operation, and maintenancemanuals.

D. As-built within 2 weeks following shipment.

Note: Seller shall provide one (1) reproducible set of drawings plus the specified number of copies ofall documentation and operating manuals as indicated on the Data Sheet. Format forreproducible drawings shall be CAD convertible .dxf electronic format unless the Seller specifiesotherwise in the proposal.

1. Introduction1.1 Purpose1.2 Scope

2. References2.1 Process Industry Practices (PIP)2.2 Industry Codes and Standards2.3 Conflict Resolution

3. Definitions4. Design and Fabrication4.1 General4.2 Operating Environment4.3 Input and Output Requirements4.3.1 Input Overcurrent Protection4.3.2 Input Power Supply4.3.3 AC Line Compensation4.3.4 Input Surge4.3.5 Output Voltage Regulation4.3.6 Operation without Battery4.3.7 DC Output Ripple4.3.8 DC Output Current Limit4.3.9 Float Voltage4.3.10 Equalize Voltage4.3.11 Temperature Compensated Charging4.3.12 Dynamic Response4.3.13 Start-up Behavior4.3.14 Abnormal Load Conditions4.3.15 Output Surge Protection4.3.16 Output Overcurrent Protection4.3.17 Parallel Operation of Two Chargers4.3.18 Interlocks

4.4 Controls4.4.1 Float/Equalize Timer4.4.2 Output Voltage Adjustments4.4.3 Automatic Equalize Charge Control4.4.4 High-Voltage Shutdown4.4.5 Alarm Reset Button

4.5 Control Indications4.6 Alarm Indications - Local4.7 Alarm Indications - Remote4.8 Panel Meters4.8.1 Output Voltage and Current4.8.2 Ground Fault Indication

4.9 Wiring, Cables, and Devices4.10 Grounding4.11 Enclosure4.12 Painting4.13 Nameplate

5. Testing6. Shipping7. Documentation

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