World Class Charging Systems. TEBETRON Puls. Charging Systems for Traction Batteries

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1 World Class Charging Systems TEBETRON Puls Charging Systems for Traction Batteries

2 the gentle way of charging TEBETRON Puls Charging Systems for Traction Batteries Reliable and efficient charging equipment correctly matched to battery capacity and required recharge times, are a basic necessity for operational effectiveness and optimised battery life and performance. In Order to further enhance battery life and maximise battery utility the TEBETRON range has been equipped with Puls charging technology. TEBETRON Puls Systems The TEBETRON System is comprised of the following types: TEBETRON Puls Digital ammeter and voltmeter TEBETRON Puls NI Without instrument Saving energy and costs TEBETRON Puls technology replaces the conventional prolonged gassing period with a series of full current Pulses which create uniform electrolyte density, and equalises cell voltages whilst saving energy and reducing battery temperature. This not only reduces charge times but leads to a significant reduction in water loss which minimises battery maintenance and also allows the charged battery to be placed in to service without the need for a cooling off period normally associated with conventional charging technology. Special Features of the TEBETRON Puls Series Modern charging system for lead acid batteries with Puls-Wa-characteristic (12-14 h / h) Reduction of charging time by Puls-Wa-characteristic Lower water consumption of the battery and thus reduced maintenance (Low Maintenance) Automatic equalising Energy saving and battery protection by variable recharge time (increased life of the battery) Automatic charging Simple operation, charging starts automatically, "switch on" cannot be forgotten Additional facilities available: - Digital indication of current (%) and voltage (V/E) with fault reports - Aquamatic Event storage for the number of charging cycles and other historical data (see operating manual) programming and read-out of the event memory by means of the service software B_Term 32

3 Aquamatic By means of an integrated relay contact inside the charger, it is possible to control an automatic water refill system. The switch-on time is controlled automatically by the charger electronics. Microprocessor-Controlled Charging Electronics The TEBETRON electronics incorporate all control and monitoring functions to ensure accurate charging charcteristics. Light-emitting diodes on the front panel indicate the following operational conditions. - Charge - Gassing charge/equalizing charge - Charge complete - Fault Digital current display The TEBETRON charger in version E is additionally provided with a digital display. The following data are displayed: charging current in (%) battery voltage in volt per cell (V/E) error alarms: current (I), voltage (U), time (t), EEPROM error (EEP)

4 Service software B_Term 32 All chargers of the TEBETRON series are provided with an I 2 C interface on the charger electronics. Via this interface and by means of the service software B_Term 32, all system and event information from the TEBETRON charger can be displayed and modified. System requirements: - PC, laptop or notebook with 486 or Pentium processor - Windows 95/98/NT - 8 MB RAM, at least 10 MB free hard disk capacity - serial interface (RS 232) - interface converter with connection and adapter cable File Units Settings Window Help The event memory contains the following information: - number of started charging processes - number of correctly completed charges - number of executed forced switch-overs - number of max. charge times exceeded - number of current/voltage errors - number of EUW errors Charger address Console System data Tebetron Puls Software version No. of started charging cycles No. of correctly finished charges No. of forced switch-overs No. of charging time overrange No. of I/V errors Display of events. File Units Settings Window Help Console System data Level 1 Level 2/1 Level 2/2 Charger address On On On WoWa-charger Aquamatic EC Maintenance charge Maintenance charge (alternating) Gassing charge time (4h=off / 5h=on) Contactor interconnection (old=off / new=on) Display of charging parameters Divider without EC (1-255) Divider with EC (1-255) Time constant without EC ( min) Time constant with EC ( min) File Units Settings Window Help Console System data Level 1 Level 2/1 Level 2/2 Charger address Calibration point (2,00-2,55 V/C) Changeover point WoWa (2,00-2,55 V/C) max. charging time (0-18,0 h) Sulphatation time ( min) max. bulk charge time (0-18,0 h) Switch on time Aquamatic ( min) First turn-on time EC ( min) Turn-on time EC ( min) Idle time EC ( min) Time-delay relay contact monitoring (0-255 s) Turn-on time maintenance charge ( min) Turn-off time maintenance charge (0-18,0 h)

5 Puls-Wa-characteristic The TEBETRON range features Puls charging technology. Using this technology, the electrolyte is mixed through the use of current pulses during the gassing phase of the charge cycle. This mixing is necessary to avoid layering (stratification) of the electrolyte which can lower the efficiency of the battery and reduce available capacity. NEW! V/C 2,7 I/% 100 Benefits of Puls technology: Smaller transformer sizes = reduced input fusing/lower comparative purchase cost Reduced Supply requirements = lower installation costs/more efficient use of available mains supply Energy saving = reduced electricity cost Lower Battery Maintenance = Lower labor cost Reduced gassing phase/temperature rise = Higher battery utilisation through quicker return to service. Increased Overall efficiency Reduced maintenance These current pulses generate gassing phases which mix the electrolyte and prevent the formation of acid layers. By the use of the Puls characteristic the charging factor is reduced (approx ) this leads to an actual reduction in transformer output required to charge a specific capacity within a given time. This offers a commercial advantage of using a smaller charger output, as well as the operational benefits of offering reduced cabling/fusing requirements for any given voltage- output combination. The reduction in the overcharge factor against conventional charge characteristics results in a reduction in water loss and therefore allows potentially costly battery maintenance to be significantly reduced. 2,4 2,1 50 2, : h Fig.1: Characteristic U Puls I Puls I Wa U Wa Comparison between the TEBETRON Puls-Wa characteristic and a DIN-Wa characteristic with equal charging times. In this case, a TEBETRON Puls charger will be selected which is two power levels smaller than a conventional Wa charger. Charging Characteristics and Charging Times The charging process corresponds to a Puls-Wa-characteristic i.e. the charging current falls with rising battery voltage (see Fig. 1). The charging time is dependent on matching the equipment's nominal current to the battery capacity. For an available charging time of hours an initial charging current of 9 A to 11 A per 100 Ah battery capacity should be selected. By means of the pulse-wa characteristic, it is possible to reduce the charging time to 7.5 to 8 hours. In this case, for a desired charging time of 7.5 to 8.5 hours an initial charging current of 16 A to 18.5 A per 100 Ah battery capacity has to be chosen. Conservation Charging Part of the energy stored in the traction battery is lost in the course of time by self-discharge. The equalisation or conservation charging process, which is automatically performed following the end of the charging process, restores this lost energy. In this way the battery capacity remains fully available even after long idle periods, e.g. during operational holidays. Equalisation or conservation charge also protects against sulphating of the plates, thus increasing the lifetime of the battery.

6 Typetable TEBETRON Puls Output current [V] Battery capacity in Ah Puls-Wa-characteristic charging time 7,5-8,5h Battery capacity in Ah Puls-Wa-characteristic charging time 12 14h Charger current allocation per 100 Ah battery capacity TEBETRON Puls 16 A-18,5A 9 A-11 A Charging charact.: Puls-Wa Puls-Wa Charging time 7,5 8,5h 12 14h Nom. output current [A] Cabinet dimensions [mm] Cabinet type Height Width Depth FLP FTP FSP FSP Charging time: Charging time is dependent on the state of discharge of the battery and the ability of the charging equipment to deliver the current for the capacity of the battery. Charging output currents shown in the type table relate to 80 % battery discharge. Type: without digital current display with digital current display -FTP NI -FTP Nom. input voltage [V] Mains fluses [A] Cabinet V 16 FLP E 230 G 24 / 16 B-FTP V 16 FLP E 230 G 24 / 20 B-FTP V 16 FLP E 230 G 24 / 25 B-FTP V 16 FLP E 230 G 24 / 30 B-FTP V 16 FTP E 230 G 24 / 40 B-FTP V 16 FTP E 230 G 24 / 50 B-FTP V 16 FTP E 230 G 24 / 60 B-FTP V 16 FTP E 230 G 24 / 70 B-FTP V 16 FTP E 230 G 24 / 80 B-FTP V 16 FTP E 230 G 24 / 90 B-FTP V 16 FTP D 400 G 24 / 100 B-FTP V 16 FSP D 400 G 24 / 125 B-FTP V 20 FSP D 400 G 24 / 150 B-FTP V 16 FSP D 400 G 24 / 170 B-FTP V 16 FSP D 400 G 24 / 190 B-FTP V 16 FLP E 230 G 36 / 16 B-FTP V 16 FLP E 230 G 36 / 20 B-FTP V 16 FLP E 230 G 36 / 25 B-FTP V 16 FTP E 230 G 36 / 30 B-FTP V 16 FTP E 230 G 36 / 40 B-FTP V 16 FTP E 230 G 36 / 50 B-FTP V 16 FTP E 230 G 36 / 60 B-FTP V 16 FTP D 400 G 36 / 70 B-FTP V 16 FSP D 400 G 36 / 80 B-FTP V 16 FSP D 400 G 36 / 90 B-FTP V 20 FSP D 400 G 36 / 100 B-FTP V 16 FSP D 400 G 36 / 125 B-FTP V 16 FSP D 400 G 36 / 150 B-FTP V 20 FSP D 400 G 36 / 170 B-FTP V 16 FLP E 230 G 48 / 16 B-FTP V 16 FTP E 230 G 48 / 20 B-FTP V 16 FTP E 230 G 48 / 25 B-FTP V 16 FTP E 230 G 48 / 30 B-FTP V 16 FTP E 230 G 48 / 40 B-FTP V 16 FTP D 400 G 48 / 50 B-FTP V 16 FSP D 400 G 48 / 60 B-FTP V 16 FSP D 400 G 48 / 70 B-FTP V 16 FSP D 400 G 48 / 80 B-FTP V 16 FSP D 400 G 48 / 90 B-FTP V 16 FSP D 400 G 48 / 100 B-FTP V 20 FSP D 400 G 48 / 125 B-FTP V 20 FSP D 400 G 48 / 150 B-FTP V 25 FSP D 400 G 48 / 170 B-FTP V 16 FTP E 230 G 80 / 20 B-FTP V 16 FTP E 230 G 80 / 25 B-FTP V 16 FTP D 400 G 80 / 30 B-FTP V 16 FSP D 400 G 80 / 40 B-FTP V 16 FSP D 400 G 80 / 50 B-FTP V 16 FSP D 400 G 80 / 60 B-FTP V 16 FSP D 400 G 80 / 70 B-FTP V 20 FSP D 400 G 80 / 80 B-FTP V 20 FSP D 400 G 80 / 90 B-FTP V 20 FSP D 400 G 80 / 100 B-FTP V 25 FSP D 400 G 80 / 125 B-FTP V 35 FSP D 400 G 80 / 150 B-FTP V 50 FSP D 400 G 80 / 170 B-FTP Weight [kg] Type* *Please complete type by additional letters Subjet to technical change without notice Benning Power Electronics (UK) Ltd. Oakley House Hogwood Lane Finchampstead Berkshire RG40 4QW GB Tel / Fax: / info@benninguk.com /2003 paus Design & Medien, Bocholt Subject to alterations. Printed on chlorine free paper.