Upload
others
View
2
Download
0
Embed Size (px)
Citation preview
Battery Chargers
Accessories
Tracker(BHM)
www.stanburyee.com
Australia Taiwan
New Zealand America
Complete Presentation
Bringing YOU
INNOVATIVE Technology in the
Battery Charging Industry
Stanbury Electrical Engineering
Began building conventional charger technology in 1960
Began HF (high frequency) charger development in 1988
First Stanbury HF charger to market in 1996 after 8 years R&D
Reached ~ 80% market share in Australia and New Zealand
Established first USA distribution in 2003
High Frequency Advantages Over Conventional Charger Technology
Improved Energy Efficiency
Less Battery Heating
Lower Supply Current
Greater Versatility
Lighter Weight
Different Charger Technologies Ferro SCR Stanbury
Battery Temp Very Hot Very Hot Cool
Efficiency Low (~85%) Very Low (~80%) High (>91%)
AC Current High Very High Low (~40% lower)
Weight Heavy Heavy Light (~75% lighter)
Profile Fixed Flexible Flexible
dv/dt Control Yes Yes Yes
Supply Voltage Sensitive Can be sensitive Standard units accept 390-530V input range without effect on charging
* Because the “at rest” consumption is 100-200W, the SCR overall efficiency is worse.
Charger Weight
25 to 35% the weight of conventional chargers
Does the work of the heavyweights
Is gentle with your batteries and is inexpensive to feed.
Charger Product Line NG Utility Rapid SHO CV e-Series
PROFILE Taper PEI Accelerated PEI Super High Output PEI Constant Voltage Taper/Constant Voltage
POWER 0.9 - 10kW 1 - 22kW and up 1 – 22kW and up 3.5 - 22.0kW and up 0.25 – 22kW and up 250 – 600W
CELLS 6 - 40 6 - 40 6 - 40 6 - 40 6 - 40 6 - 24
COOLING Convection Convection & Fan Convection & Fan Convection & Fan Convection Convection
Battery Temperature Rise Test Condition
Depth of Discharge Conventional Charger Test Results Stanbury Comparable
% AH Charger Type Hours Trise Hours Trise
93.3 700 SCR Charger #1 (U) 7.5 13.3oC 7.3 9.4oC
79.5 600 SCR Charger #1 (U) 7 12.8oC 6.5 7.8oC
86.2 650 Ferroresonant 7.8 13.9oC 7 8.3oC
…the enemy of battery life
A new battery, controlled lab setting, temperature
measured with thermocouple and data logger.
Three varieties of conventional charger. Several depths of discharge.
The conventional charger took longer to recharge & heated the battery 40 - 65% more. (3.9 to 5.6oC)
Battery Temperature Rise …what causes it?
Primarily: Chemical charging reaction - acid into
water is exothermic (i.e., it gets hot) Current flow through a resistance
Battery Temperature Rise …why does Stanbury get the best result?
Stanbury’s charger technology & PEI charging profile
Superior Charger Technology
Less energy lost Efficient use of energy
Superior Charging Profile
Charging profile that understands your battery
Efficient use of energy
Efficiency in Battery Charging
Charger Efficiency efficiency of a charger in converting the true power going into the charger from the mains,
compared to the power coming out of the charger.
Charge Return Factor the ratio of energy stored in the battery compared to the energy out of the charger.
Overall Efficiency what ultimately determines how much you have to pay towards charging your batteries on
your power bills.
Charger Efficiency
Charge Return Factor
Overall Efficiency
Superior Charger Technology
STANBURY
12.5A Ferro
20A SCR
10.5A
From 3ф 480V they take to provide the same nourishment
The Difference
Superior Charging Profile
EPI-158.38 Stanbury Electrical Engineering PEI Test#3, 750 AH Discharged
Achieving superior charging profile through in-depth understanding of the physics and chemistry behind charging a battery
Exothermic chemical reaction: PbSO4 + 2H2O + 2e- PbO2 + Pb + 2H2SO4 Current through internal battery resistance: Q = i²r
Gassing
Bulk Charging
Over Discharged
State of charge
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
Lower Supply Current
15% lower than Ferro 45% lower than SCR Reduce wiring losses Fit more chargers on a circuit Avoid costly building wiring upgrades AC current (A) / DC power (kW)
(smaller = better)
HF = 1.35 Ferro = 1.6 SCR = 2.5
Test Results
After about 2 weeks the chargers were replaced with similarly-rated Stanbury PEI chargers. The graphs show the dramatic reduction in kVA and Amps on the circuit after the changeover.
Normal operation of a circuit serving 8 battery chargers, a baler, and a 45kVA step-down transformer. Data captured at 5 minute intervals.
Other Chargers do an inferior job of charging your battery and require 50% more AC current and 10% more kWH than Stanbury Chargers!
Energy Cost Savings TARIFF 2 SHIFT
OP COST ANNUAL
STANBURY SAVINGS
El Paso TX Sch 25 (>600kW) $4,523 $815
El Paso TX Sch 24 (15-600kW) $4,183 $754
El Paso TX Sch 29 (>5MW) $3,485 $554
El Paso NM Rate 04 (50-299 kW) $3,003 $533
El Paso NM Rate 09 (>299 kW) $3,094 $494
Wisconsin P&L Sch Cp – 1 $2,582 $460
PG&E Sch 19 (>500 kW) FTA $5,423 $749
PG&E Sch 19 (>500 kW) non FTA $5,759 $800
PG&E Sch 20 (>1000 kW) $5,606 $762
PG&E Sch A-1 (<500 kW) $6,036 $635
PG&E Sch A-10 TOU (<500 kW) $5,619 $625
PG&E Sch A-10 FTA (< 500kW) $5,513 $611
SCE&G Rate 20 > 75 kVA $3,057 $983
Southern Cal Edison TOU-8 $4,598 $673
G- Series
Charge your batteries from a generator in addition to the standard ability to charging from the power grid.
Ideal for the rural working environment where gird power is unreliable or non-existent and also operation in sensitive environments where backup batteries need to be charged up during long power outages.
Suitable for operation with your solar power systems that use backup generators.
Most Stanbury chargers can be upgraded into G-Series chargers.
ConvecCool
Rugged and durable
Capable of handling some of the most hostile operating environments.
Extremely reliable with no moving parts.
FanCool Ideal chargers for facilities that are
constrained by physical space.
Delivers much higher kW power output to physical space ratio.
Extensive safety features such as: high ambient fold back and override shutdown
Opportunity Charging Why Opportunity Charge?
Eliminate battery change
downtime
Reduce the number of batteries on hand
Eliminate the battery room
Reduce recharge time with increased start rate
STANBURY Rapid Chargers uses STOpp‘N’Charge©
technology
STOpp‘N’Charge©
What is STOpp‘N’Charge? STOpp’N’Charge refers to Stanbury’s Technology for Opportunity Charging that delivers efficient
rapid charging
What are the advantages of adopting STOpp‘N’Charge in my company? allow operations to reduce/eliminate battery changing
Eliminate battery room Eliminate battery changer Eliminate spare batteries Reduce safety risks (from changing batteries)
Is Opportunity Charging good for my batteries?
Depends on type of charger and the charging technology. Can be detrimental if old technology chargers are used Stanbury chargers uses STOpp‘N’Charge technology engineered specifically for opportunity charging. Not only is STOpp‘N’Charge safe for your batteries, it also enables you to effectively restore
significant charge to your batteries within a matter of minutes.
…not your ordinary opportunity charging
How do we achieve no battery change?
By charging the batteries at any significant equipment idle time.
Such opportunities can come in the form of operator work breaks, meal breaks and other operational down time.
Average Cost of Changing Batteries in One Forklift
Loss of production for each battery change Cost of labour and forklift
-$ 30
Add time lost queuing Cost of owning an servicing 2nd battery Cost of owing battery charging equipment Cost of housing spare battery and equipment
-$ 30 -$ 60
Not taken into account – cost of accidents
Total cost of 1 change per day Total cost of 2 changes per day Total cost of 3 changes per day
-$ 60 -$ 90
-$120
1 change 250 days per year 1 change 300 days per year 1 change 350 days per year
-$15,000 -$18,000 -$21,000
2 change 250 days per year 2 change 300 days per year 2 change 350 days per year
-$22,500 -$27,000 -$31,000
3 change 250 days per year 3 change 300 days per year 3 change 350 days per year
-$30,000 -$36,000 -$42,000
Changing batteries is like “The Black Hole of Money”!
THANK YOU STANBURY ELECTRICAL ENGINEERING
For more innovative products visit
www.stranburyco.com
Some STANBURY charger users:
COSTCO - BOEING - Disney - Cold Storage - Sysco - FedEx - Stater Brothers
TECHNICAL SLIDES
The following slides are for
technical presentation.
“What’s the frequency Kenneth?”
Key Difference 20,000 Hz Transformer Control
Provides the Advantages
Low Weight High Frequency Less Utility Current Less Battery Heating High (leading) Power Factor Flexibility Reduced Utility Bills Longer Battery Life
or… What’s all this high frequency stuff, anyhow?
AC Input
60 Hz Transformer
LV Rectifier &/or SCR
Battery
AC Input & HV Rectifier
20 kHz Switch &
Transformer
LV Rectifier
Battery
Stanbury Charger Block Diagram
Conventional Charger Block Diagram
Cont
rol
Ferr
ores
onan
t “Co
ntro
l”
SCR
“Con
trol
”
Charger Operation Comparison (AUS/NZ)
Conventional Charger High Frequency Charger 415 V 3 phase 50 Hz AC
48 V 3 phase 50 Hz AC
48 V DC
415 V 3 phase 50 Hz AC
585 V DC
585 V 1 phase high Hz AC
48 V 1 phase high Hz AC
48 V DC
Charger Operation Comparison (USA)
Conventional Charger High Frequency Charger 480 V 3 phase 60 Hz AC
36 V 3 phase 60 Hz AC
36 V DC
480 V 3 phase 60 Hz AC
690 V DC
690 V 1 phase high Hz AC
36 V 1 phase high Hz AC
36 V DC
Test Results - Efficiency
The Stanbury Charger requires less input power for any given output to battery
Note the power consumed “at rest” by the SCR charger
The efficiency of the SCR charger is even worse because more energy that passes through it ends up heating the battery and cables – rather than charging the battery
Electricity costs the same regardless of whether it does useful work or simply heats the battery
The Stanbury Charger is 91-93% efficient
Battery Temperature Rise Wave SCR charger “DC” output varies from 0 amps to several times the average charge current 360
times each second. [Imagine maintaining an average speed of 50 mph by travelling 150 mph for 1 second and 0 mph for 2 seconds out of every 3 seconds].
Ferroresonant charger “DC” output goes from near zero to about 2 times the average charge current 360 times each second.
Stanbury charger maintains a value close to the average charge current continuously. A clip-on ammeter on the DC leads shows a small AC current flows from the Stanbury to the battery - the same measurement on a conventional charger will show 20 to 40 times the AC current flowing.
Physics Energy loss (i.e., heating) is proportional to the square of the instantaneous current, summed over time. The ferro wave causes about 2x & the SCR wave about 3x the battery heating compared with the Stanbury. This also effects the charger external wiring (the battery plug and cables run far cooler with the Stanbury).
Profile The SCR has an IEI profile. The power into the battery is 15% higher at 80% charge than when fully discharged. This level of power input at 80%SOC accelerates the temperature rise.
The ferro has a taper profile. This starts with a high power input, and relies on rising on-charge battery voltage to control the current into the battery. Old batteries and hot batteries experience less rise in on-charge voltage, leading to higher current at charge completion and possible thermal run-away.
The Stanbury has a PEI profile. The power into the battery does not peak at the gassing point as the IEI does, and the finish current required for proper mixing of the acid will be provided to both old and new batteries alike.
Causes of Battery Heat
Exothermic chemical reaction PbSO4 + 2H2O + 2e- PbO2 + Pb + 2H2SO4 Current through internal battery resistance Q = i²r
Profile Options Multiple profiles support
Cold storage operation Opportunity charging Sealed batteries
A charger for every application
Tape
r Pro
file
STO
pp‘n
’Cha
rge
Prof
ile
PEI P
rofil
e