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Battery Charger System Test Procedure_V2.0_2008_06_17

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Energy Efficiency Battery Charger System Test Procedure

Version
2.0</b>1.<b>2

June 17April 22
, 2008

Suzanne Foster Porter and Paul Bendt, Ph.D., Ecos Consulting
Haresh Kamath and Tom Geist, EPRI Solutions
Jordan Smith, Loïc Gaillac, and José Salazar, SCE

Development funded by: Pacific Gas and Electric
and

California Energy Commission-Public Interest Energy Research (PIER) Program
and Southern California Edison


Scope

A. General Scope
The purpose of the test procedure is to measure the energy efficiency of battery chargers
coupled with their batteries, which together are referred to as battery charger systems.
This term covers all rechargeable batteries or devices incorporating a rechargeable
battery and the chargers used with them. Battery charger systems include, but are not
limited to:

electronic devices with a battery that are normally charged from ac line voltage or dc
input voltage through an internal or external power supply and a
dedicated
battery
charger;
the battery and battery charger components of devices that are designed to run on
battery power during part or all of their duty cycle (such as many portable appliances
and commercial material handling equipment);
dedicated battery systems primarily designed for electrical or emergency backup
(such as emergency egress lighting and uninterruptible power supply (UPS)
systems);
devices whose primary function is to charge batteries, along with the batteries they
are designed to charge. These units include chargers for power tool batteries and
chargers for automotive, AA, AAA, C, D, or 9 V rechargeable batteries
, as well as
chargers for batteries used in larger industrial battery chargers for motive
equipment, such as electric material handling equipment and vehicles,
including lift trucks (forklifts); airport electric ground support equipment
(EGSE); port cargo handling equipment; tow tractors; personnel carriers;
sweepers and scrubbers are examples of these types of motive equipment.


B. Limitations
1) The scope
of Part 1
is limited to those battery charger systems that operate on
single-phase ac input power or dc input power and that have a nameplate input
power rating of 2 kW or less. The
procedures described by the
scope
of Part 1

isare
also limited to battery charger systems whose
battery

complement of
installed batteries
has a
total
rated energy capacity of 50 kWh or less.
Battery
chargers capable of charging batteries both less than and greater than 50 kWh
shall be tested using Part 1 of this test procedure only with suitable batteries of

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50 kWh or less. See Section I.B.4., below, for criteria used to determine
whether to test a battery charger system under Part 1 or Part 2.


Laboratory testing equipment used to test and analyze batteries is specifically
excluded from the scope of this test procedure. However, battery charger
systems that provide power for portable laboratory testing equipment are
included.

The scope includes a battery charger that is packaged or sold without batteries.
Part 1,
Section V.C herein specifies the selection of suitable batteries for test
using the procedures contained in Part 1. Part 2, Section II.A., herein,
specifies the selection of suitable batteries for test using the procedures
contained in Part 2
.

Some examples of battery charger systems included in
this

the
scope
of Part 1
are: cellular and cordless telephones, cordless power tools, laptop computers,
cordless shavers, uninterruptible power supplies emergency egress lighting,
golf
carts,
portable lawn tools,
and
rechargeable toys
, and marine and RV chargers,
.

Note: The charging circuitry of battery charger systems may or may not be located within the
housing of the end-use device itself. In many cases, the battery may be charged with a dedicated
external charger and power supply combination that is separate from the device that runs on power
from the battery.

Note: This test procedure is not intended to test batteries in the absence of a corresponding
charger.

2) The scope of Part 2 of this procedure includes test and analysis methods to
evaluate the energy usage and impact of battery chargers for batteries
powering motive equipment.

Some examples of battery charger systems included in the scope of Part 2
are those used for batteries used for larger battery chargers for motive
equipment, such as electric material handling equipment and vehicles,
including lift trucks (forklifts); airport electric ground support equipment
(EGSE); port cargo handling equipment; tow tractors; personnel carriers;
sweepers and scrubbers. See Section I.B.4., below, for criteria used to
determine whether to test a battery charger system under Part 1 or Part 2.


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3) The chargers covered by Part 2 of this procedure are rated for 600 volts or
less and connect to the utility grid with a plug or are permanently
connected. Part 2 of this procedure does not cover the following:
a) Consumer electronics products and/or household devices, with either
internal or external charger.
b) Battery chargers for on-road full-function electric or plug-in hybrid-
electric vehicles.
c) Battery chargers for automotive, marine and/or RV starter batteries, or
batteries used in conjunction with starting or running internal
combustion engines and their accessories.
d) Battery chargers for signaling devices.
If they meet the criteria in Section I.B.2, above, these excluded devices may be
covered by the scope of Part 1.

4) Criteria for determining whether to test under Part 1 or Part 2:
a) Battery charger systems specifically excluded from Part 2, which
meet the criteria listed under Scope in Section B.1., above, are to be
tested using the procedures listed in Part 1.
b) Battery charger systems designed to charge flooded, deep-cycle,
lead-acid batteries used to power motive equipment such as those
listed under Scope in Section B.2., above, are to be tested using the
procedures listed in Part 2.


References

The following list includes documents used and/or referenced in the development of this
test method:

BCIS-05: Battery Council International, BCI Specifications for Electric Vehicle Batteries,
BCIS-05 Rev. DEC02.
BCIS-14: Battery Council International, Determination of Capacity of Lead-Acid Industrial
Storage Batteries for Motive Power Service, BCIS-14 Rev. DEC02.
BCIS-16: Battery Council International, Standard for Deep Cycle Battery Chargers, BCIS-
16 Rev. DEC02.
Buchmann, Isidor, Batteries in a Portable World: A Handbook on Rechargeable Batteries
for Non-Engineers, Cadex Electronics Inc., 2001.
IEC 60050-300: International Electrotechnical Commission, International Electrotechnical
Vocabulary- Electrical and Electronic Measurements and Measuring Instruments, I</i>EC
60050-300, Edition 1.0, 2005.
IEC 60051: International Electrotechnical Commission, Direct Acting Indicating Analogue
Electrical Measuring Instruments and their Accessories, IEC 60051, parts 1-9, Edition
5.0, 1997.
IEC 60254-1: International Electrotechnical Commission, Lead-acid traction batteries
Part 1: General requirements and methods of tests, IEC 60254-1, Edition 4.0, 2005.
IEC 61056-1: International Electrotechnical Commission, General Purpose Lead-Acid
Batteries (Valve Regulated Types) Part 1: General Requirements, Functional
Characteristics Methods of Test, IEC 61056-1, Edition 2.0, 2002.
IEC 61951-1: International Electrotechnical Commission, Secondary cells and batteries
containing alkaline or other non-acid electrolytes Portable sealed rechargeable single
cells Part 1: Nickel-cadmium, IEC 61951-1. Edition 2.0, 2003-2004.

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IEC 61951-2: International Electrotechnical Commission, Secondary cells and batteries
containing alkaline or other non-acid electrolytes Portable sealed rechargeable single
cells Part 2: Nickel-metal hydride, IEC 61951-2, Edition 2.0, 2003.
IEC 61960: International Electrotechnical Commission, Secondary cells and batteries
containing alkaline or other non-acid electrolytes Secondary lithium cells and batteries
for portable applications, IEC 61960, Edition 1.0, 2003.
IEC 62133: International Electrotechnical Commission, Secondary cells and batteries
containing alkaline or other non-acid electrolytes Safety requirements for portable
sealed secondary cells, and for batteries made from them, for use in portable
applications, IEC 62133, Edition 1.0, 2002.
IEC 62301: International Electrotechnical Commission, Household Electrical Appliances -
Measurement of Standby Power, IEC 62301, Edition 1.0, 2005.
IEEE 100: Institute of Electrical and Electronics Engineers, The Authoritative Dictionary
of IEEE Standards Terms, IEEE 100,