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Battery Chargers Accessories Tracker(BHM) www.stanburyee.com Australia Taiwan New Zealand America Complete Presentation Bringing YOU INNOVATIVE Technology in the Battery Charging Industry

Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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Page 1: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

Battery Chargers

Accessories

Tracker(BHM)

www.stanburyee.com

Australia Taiwan

New Zealand America

Complete Presentation

Bringing YOU

INNOVATIVE Technology in the

Battery Charging Industry

Page 2: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 3: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

High Frequency Advantages Over Conventional Charger Technology

Improved Energy Efficiency

Less Battery Heating

Lower Supply Current

Greater Versatility

Lighter Weight

Page 4: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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.

Page 5: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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.

Page 6: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 7: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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)

Page 8: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 9: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 10: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 11: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

Superior Charger Technology

STANBURY

12.5A Ferro

20A SCR

10.5A

From 3ф 480V they take to provide the same nourishment

The Difference

Page 12: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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%

Page 13: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 14: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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!

Page 15: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 16: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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.

Page 17: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

ConvecCool

Rugged and durable

Capable of handling some of the most hostile operating environments.

Extremely reliable with no moving parts.

Page 18: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 19: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 20: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 21: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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.

Page 22: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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”!

Page 23: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 24: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction
Page 25: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

TECHNICAL SLIDES

The following slides are for

technical presentation.

Page 26: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

“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

Page 27: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 28: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 29: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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

Page 30: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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.

Page 31: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

Causes of Battery Heat

Exothermic chemical reaction PbSO4 + 2H2O + 2e- PbO2 + Pb + 2H2SO4 Current through internal battery resistance Q = i²r

Page 32: Accessories Battery Chargers - SCLAA · Test Results After about 2 weeks the chargers were replaced with similarly -rated Stanbury PEI chargers. The graphs show the dramatic reduction

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