This specification describes a solid-state battery charger. The Charger shall operate in conjunction with the existing building/plant electrical systems to provide high quality power to the load.

Unless noted otherwise, the design, fabrication, testing, and performance of the system shall be in accordance with the standards and codes, where applicable, of the following agencies:

National Electrical Manufacturers Association (NEMA)

American National Standards Institute (ANSI)

National Electric Code (ANSI/NFPA 70-1993)

Institute of Electrical and Electronic Engineers (IEEE)

International Electrotechnical Commission (IEC)

The system shall operate at rated output without any adverse affects in an ambient temperature of 0 C to 40 C (32 F to 104 F), except batteries.

The system shall operate at a relative humidity of 5% to 95% non-condensing for a temperature range of 10 C to 40 C.

The system shall operate at any altitude from sea level up to 2500m Meters (8,200ft) above sea level without derating.

Each Charger system shall consist of the following major components:

Input/Output Circuit Breakers

Isolation Transformer

Rectifier Bridge

Control Board

Upon pressing the equalize push-button, the charger shall automatically initiate the equalize voltage for the pre-set time on the equalize timer.

Pressing the float push-button any time during the equalize mode shall return the charger to the float voltage.

Incoming AC power shall be converted to regulated DC output by the rectifier/charger. The rectifier/charger shall be a constant potential, phase-controlled, solid-state type with constant voltage and current control circuitry.

The rectifier/charger shall have sufficient capacity to support the total connected load and to recharge the battery at the equalize condition to 90% of full capacity within the specified recharge time.

The primary AC input voltage and frequency shall be as specified on the System Data Sheet.

The input power factor shall be a minimum power factor of 0.75 at nominal input voltage, frequency, and at full-rated load.

Nominal Float Voltage: 130 VDC, adjustable +/-5%

Nominal Equalize Voltage: 140 VDC, adjustable +/-5%

The charger output steady state voltage shall not change more than +/-1% (worst case) at the battery bank, for a cable length less than 10 ft., from no load to full-rated load, with input voltage variation of +10% to-10% and input frequency variation of +/-5%. (+10%-15% without discharging the batteries).

The output ripple shall be less than 2% RMS when connected to a battery bank having an eight hour, ampere hour rating of at least four (4) times the full load ampere rating of the battery charger..

The charger shall be capable of supplying 125% rated full load current at float voltage and -10% input. This shall not cause damage to the charger/rectifier, tripping of circuit breakers, or blown fuses. The current limit shall be adjustable from 50% to 125% of rated output.

An internal screw-type adjustment shall be provided to adjust the float voltage +/-5%.

An internal screw-type adjustment shall be provided to adjust the equalize voltage +/-5%.

An internal 0-100 Hour electronic timer shall be provided to manually place the charger into a high voltage equalize mode for a specific amount of time and then automatically return it to its normal float mode when the time has elapsed.

A dry type isolation transformer shall be supplied on the input to the rectifier with surge/transient protection on the secondary side.

The delta-wye three phase transformer shall be wound with copper wire and use a UL recognized 200` C insulation system.

An epoxy based insulating varnish shall be applied with a V P I

(Vacuum Pressure Impregnation) system to insure a low temperature rise over the 30 year design life of the transformer.

The AC input to the Rectifier/Charger shall be insensitive to phase rotation. The AC input shall be completely isolated from the static bypass circuit.

The Rectifier/Charger shall be capable of supplying 66% of its rated load with the loss of one of its three phase inputs.

The Rectifier/Charger shall be capable of having its DC output terminals paralleled with other chargers and maintain control stability and voltage regulation.

All controls specified below shall be accessible on the front panel unless specified.

Float - A momentary push button shall be provided to manually select the float mode on the charger.

Equalize - A momentary push button shall be provided to manually select the float mode on the charger.

At a minimum the front panel shall be equipped with the following 3.5 inch scale analog meters (2% accuracy) for the following functions:

DC Output Voltmeter

DC Output Ammeter

The charger shall be equipped with the following equipment:

Indicators shall be long life Neon, A form "C" contact (SPDT) rated 3 amps@120VAC/28VDC shall be furnished for each specified alarm.

Fan Failure (if applicable) - An indicator (Red) and alarm contact shall be provided when any fan has failed. The relay shall be normally deenergized.

Low DC Voltage - An indicator (Red) and alarm contact shall be provided when the charger DC output voltage is less than 120 VDC. The relay shall be normally energized.

AC Power Failure - An indicator (RED) and alarm contact shall be provided when the input voltage fails. The relay shall be normally energized.

Provisions shall be made to accomodate the addition of a factory supplied optional 0.1% output ripple filter.

The overall AC to DC efficiency shall be greater than 90% with the Charger at full rated load and nominal input voltage.

The overload devices shall not be activated when the system is started under any normal operating conditions.

AC Input Circuit Breaker - A three pole, molded- case breaker shall be provided for charger/rectifier disconnection and overload protection. The A.I.C. rating of the breaker shall be 10KA minimum.

DC Output Circuit Breaker - A molded case breaker shall be provided for charger output disconnection and overload protection. The A.I.C. rating of the breaker shall be 10KA minimum.

The audible noise generated by the unit under rated operating conditions shall not exceed 60dBA at 5 feet away from any side of the enclosure and 3 feet above ground. The sound levels shall be measured with the unit operating at rated load, voltage and frequency.

Forced-air cooling shall be provided when necessary to ensure that all components are operating at below their specified operating temperature.

Wiring materials and practices shall be at a minimum in accordance to UL 1015, 105 C. All wiring and buswork shall be copper throughout the system. PVC insulation shall be used on control wiring only. Power wiring shall use SIS insulation.

Electromagnetic effects shall be minimized to ensure that computer systems, or other similar electronic systems, shall neither adversely affect nor be adversely affected by the system.

All power transformers or chokes shall be designed using copper windings for reliability and efficiency. The insulation type shall have a temperature rating of at least 200 C

(UL 1446, Class N).

An epoxy based insulating varnish shall be applied with a V P I (Vacuum Pressure Impregnation) system to insure a low temperature rise over the 30 year design life of the transformer.

The nameplate shall be located on the front inside display door and the following minimum information shall be provided on the nameplate:

a. Solidstate Controls, Inc., Model # and Serial #

b. AC Input Voltage, Phase and Frequency

c. Rated AC Input Current

d. Rated DC Output Voltage and Current

The enclosure shall be a NEMA-1(IP-20), free standing, with minimum 12GA framework. Door panels shall be a minimum of 14GA steel and side panels shall be a minimum of 18GA.

The enclosure shall be mounted on channels with a 3 inch lifting base open at the front and back to facilitate moving with a fork lift and to provide an entrance area for air movement through the enclosure.

The enclosure shall be designed with blank plates on the sides and rear for installation against a wall. The equipment shall be designed to allow replacement or maintenance of all components from the front.

One or more hinged doors shall be provided in the front with door locks on each. Hinged panels, 36" and larger, shall be provided with a 2 point latching system for holding the panels securely. Removable covers shall be attached with machine screws.

Air inlets and outlets shall be protected by screens or perforated metal guards to prevent the entrance of a rod having a diameter of 0.5 inches or longer.

Cable entry shall be through the top or bottom of the cabinet. On UL units, bottom cable entry is recommended.

The connections to the AC output or DC input shall be of the stud type and shall be sized for full load service.

Alarm connections shall be sized to allow connection of 14AWG wire maximum. The alarm terminal boards shall be rated for 600 VAC.

The system shall be designed to permit front access to modules, fuses, and assemblies. Parts, test points, and terminals shall be placed so they are accessible for circuit checking, adjustment, and maintenance without removal of any adjacent assembly or component or pose a shock hazard.

Permanent wire supports shall be used, no adhesive backed wire supports shall be used.

All point-to-point wires shall be marked with a permanent marking system on both ends of each wire.

All PCB's, indicator lights, meters, controls, semiconductors, and fuses shall be clearly marked with the component designation for ease of serviceability.

The cabinet shall be constructed so that all controls, except float/equalize, are operable with the doors closed, preventing exposure to high voltage terminals. High voltage warning labels shall be visible when any of the cabinet doors are opened.

All external painted surfaces shall be ANSI 61 Gray enamel with a minimum of 2.0 mil thickness and shall be smooth with no runs, sags, or graininess. All internal mounting plates shall be painted white.

The system testing shall be in conformance with IEEE 944-1986 section 7.0, and IEC-146-4. Certified test data shall be supplied to verify test results.

The manufacturer shall have type-test data available to demonstrate system performance with switch-mode type power supplies.

Cabinet outline and interconnect drawings shall be dimensioned and scaled, and include the following information:

Location of any removable plates for Owner's conduit entry.

Location and size of all terminal blocks for Owner's connections.

Location and size of ventilation openings.

Location of cabinet grounds.

Block diagram including currents for customer cable sizing, breaker locations and sizes, and meter locations.

Size and weight of equipment.

Front panel identification chart.

Nominal heat loss for the specified equipment.

Schematic type drawings shall include the following information:

System schematics shall include item designations for all electrical components.

Relay contacts diagrams shall be shown in the deenergized position.

Wire sizes and numbers shall have the same designations that appear in the equipment.

Preparation for shipment shall be in accordance with the manufacturer's standard shipping procedure.

One complete set of instruction books and "as-built" drawings shall be included with the equipment when shipped.

To facilitate site access, shipment of individual cabinets, rather than complete lineups, may be necessary.

Input Voltage : 480

Frequency : 60

DC Output Amps : 100

DC Output Volts: 130