Battery Charger and Rectifier Test Procedure

This procedure describes the methods and requirements in the start-up and commissioning of the Rectifier / Charger System of UPS. The main keywords for this article are battery charger, rectifier, Battery charger test procedure,  Load Test Rectifier, Load Test charger.

GENERAL REQUIREMENTS

✓ Each item should be checked in accordance with the requirements in specification, drawings and manufacturer’s instruction and technical data as required to verify completeness of installation.
✓ All necessary verification activities for the equipment should be completed before implementation of start-up and commissioning.

SAFETY PRECAUTIONS

✓ Start-up and commissioning must be carried out by a qualified engineer, trained by the manufacturer or one of its agents. Failure to observe this will invalidate any future claims.
✓ The rectifier/ charger will contain potentially lethal voltages at all times once power is applied from the main distribution panel. Safety tagging and clearance procedure should be utilized in the start-up and commissioning.
✓ Clear the area of all unauthorized personnel and install barricades if possible to restrict entry of unauthorized persons.
✓ Tag the power disconnect switches on the distribution panel board which supplies power to the rectifier/ charger before working on the equipment.

Test Equipment & Tools Rectifier / Charger System

✓ Digital Multimeter.
✓ Phase Sequence Meter.
✓ Temperature Measuring Equipment.
✓ Load bank.

What Inspection need to be done.

✓ Inspect all wires and conductor insulation for damage.
✓ Inspect all wiring connections to the capacitor banks. Re-tighten if necessary.
✓ Check all terminal and breaker connections for tightness. Re-tighten if necessary.
✓ Remove and foreign objects from the components or the interior area of the unit. Make sure air passages are clear and free of debris. Re-tighten if necessary.
WARNING:
HAZARDOUS VOLTAGES ARE PRESENT IN THE EQUIPMENT THROUGHOUT THE MAJORITY OF THE START-UP PROCEDUR.
PROCEED WITH CAUTION.
✓ Carry out a thorough visual inspection of the equipment. Check the security of all cable terminations and ensure that all electrical connectors, plugs and sockets are correctly located and firmly fitted.

START- UP:  CAUTION!!!!
It is assumed that the installation is complete, the system has been personalized and set-up accordingly.

The main keywords for this article are battery charger, rectifier, Battery charger test procedure,  Load Test Rectifier, Load Test charger. 

RECTIFIFER / CHARGER:

✓ Ensure that the external Rectifier / Charger input supply circuit breaker is switched to ON position.
✓ Measure input line to line voltages of all three phases and ensure values are within +10%, -10% of nominal rating.
✓ Nominal Voltage: Check the nominal input voltage Vac (L-L)
Volts, phase R to phase Y
Volts, phase Y to phase B
Volts, phase B to phase R
✓ Measure the input frequency and ensure value is within +/-5% of nominal rating.
Nominal Frequency: 60 Hz
Hertz, input Frequency
Phase Rotation

WARNING: THE FOLLOWING PROCEDURE WILL APPLY POWER TO LOAD, ENSURE THAT IT IS SAFE TO DO

battery charger rectifier

FOLLOW THE START -UP PROCEDURE

b- Switch on the main MCB input.
c- Switch on the charger using charger on/off switch.
d- The charger will start and ramp to its set voltage.
e- Close output circuit breaker of the charger.
f- Select float mode. Measure and record the float voltage.
g- Select boost mode. M·easure and record the boost voltage.
h- Select Equalize mode. Measure and record the equalize voltage.
i- Select float mode.
j- Measure and record the battery voltage.
k- Check and verify correct polarity at the battery fuse.
I- Close the battery fuse.
m-lf there are no alarms present, charger is in normal Operation.
n- Simulate and verify various alarms (Floating, Boost, Pre commissioning, Mains Fault, Charger Fault, High DC Voltage, Low DC Voltage, AC MCB OPEN/TRIPPED, DC MCB OPEN/TRIPPED, COOLING FAN FAULT)
o- Check the remote relay contacts for the alarms where applicable.

Load Test Rectifier / Charger System

✓ After the charger START -UP and there is no alarm present, this means that the charger is healthy and we can proceed for the load test by increasing the load gradually as follow and check the stability of the output voltage from the charger.
✓ At the time of Load test the percentage of load will increase according to the following table and their respected parameters must be recorded.

rectifier load test

The above value must be tolerable with the limits given by Manufacturer

Battery Charger Test Procedure

Standard: Tests according to IEC Standard 61951-1
1- Mandatory Condition: The battery set should have been properly charged as per the commissioning instructions of the battery manufacturer for the duration specified.
2- Visual Inspection: Cleanliness of battery is checked and the electrolyte level checked as specified on the individual cells. The tightness of cell connections on individual terminals should be ensured.
3- The load current, minimum voltage of battery system, ampere-hour, duration etc., is preset in the test equipment using the keypad. For (e.g.) a 400 AH battery set, 8Hr. duration specification 40 A and 10 Hr.  duration are set. Minimum voltage setting is = No. of cells x end cell voltage of cells as per
manufacturer specification.
4- It is to be ensured that the set value of the current and duration is within the discharge capacity of the type of cell used. Also the total power to be dissipated in the load unit should be within the power rating of the battery load kit.
5- Individual cell voltages and specific gravity of the each cell to be recorded before the start of the test.
6- Battery chargers to be switched off/load MCB in charger to be switched off.
7- Loading of the battery to be started at the specified current value. It is preferred to select constant current method to discharge the battery load. Individual cell voltages of the battery and specific gravity of each cell with temperature set are to be recorded every one hour .Also check the current drain by battery at every 1 hour intervals.
8- It is to be ensured that all the cell voltages are above the end-cell voltage specified by the manufacturer.
If any of the cell voltages falls below the threshold level specified by the manufacturer, this cell number is to be noted and the cell needs to be replaced.
9- Test set automatically stops loading after set duration (or) when minimum voltage reached for the battery set.
10- Test to be continued until the battery delivers the total AH capacity it is designed for. Value of AH and individual cell voltages to be recorded every half an hour.
11 – Acceptance Limits: This test establishes the AH capacity of battery set at required voltage.
The acceptance limit for the test is to ensure the battery set is capable of supplying the required current at specified DC voltage without breakdown for the required duration.

125 V BATTERY CHARGER TEST PROTOCOL

(Battery Charger Standard Reference IEC 60623, Clause 4, and relevant SEC Transmission Specification 46-TMSS-02 Rev.a, TES-P-103).

The main keywords for this article are battery charger, rectifier, Battery charger test procedure,  Load Test Rectifier, Load Test charger.

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