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TEBETRON PulsCharging Systems for Traction Batteries

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TEBETRON Puls Systems

The TEBETRON System is comprised of the following types:

TEBETRON PulsDigital ammeter and voltmeter

TEBETRON Puls NIWithout instrument

TEBETRON Puls ChargingSystems for Traction Batteries

Reliable and efficient charging equip-ment correctly matched to batterycapacity and required recharge times,are a basic necessity for operationaleffectiveness and optimised batterylife and performance.

In Order to further enhance battery life and maximise battery utility theTEBETRON range has been equippedwith Puls charging technology.

TEBETRON Puls technology replaces theconventional prolonged gassing periodwith a series of full current Pulseswhich create uniform electrolyte den-sity, and equalises cell voltages whilstsaving energy and reducing batterytemperature. This not only reducescharge times but leads to a significantreduction in water loss which minimi-ses battery maintenance and also allo-ws the charged battery to be placed into service without the need for a “coo-ling off” period normally associatedwith conventional charging technology.

the gentle way of

charging

Saving energyand costs

Special Features of the TEBETRON Puls Series

• Modern charging system for lead acid batteries with Puls-Wa-characteristic (12-14 h / 7.5 - 8.5 h)• Reduction of charging time by Puls-Wa-characteristic• Lower water consumption of the battery and thus reduced maintenance (Low Maintenance)• Automatic equalising • Energy saving and battery protection by variable recharge time (increased life of the battery)• Automatic charging• Simple operation, charging starts automatically, "switch on" cannot be forgotten• Additional facilities available:

- Digital indication of current (%) and voltage (V/E) with fault reports- Aquamatic

• Event storage for the number of charging cycles and other historical data (see operating manual)• programming and read-out of the event memory by means of the service software B_Term 32

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Aquamatic

By means of an integrated relay contact inside the charger, it is possi-ble to control an automatic water refill system. The switch-on time iscontrolled automatically by the charger electronics.

Microprocessor-ControlledCharging Electronics

The TEBETRON electronics incorporateall control and monitoring functions toensure accurate charging charcteris-tics. Light-emitting diodes on the front panel indicate the following operational conditions.

- Charge

- Gassing charge/Equalizing charge

- Charge complete

- Fault

Digital current display

The TEBETRON charger in version “E”is additionally provided with a digitaldisplay. The following data are dis-played:

• charging current in (%)• battery voltage in volt per cell (V/E)• error alarms: current (I), voltage (U),

time (t), EEPROM error (EEP)

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Service software B_Term 32

All chargers of the TEBETRON series are provided with an I2C interface on the charger electronics. Via this interface and by means of the service software B_Term 32, all system and event informationfrom the TEBETRON charger can be displayed and modified.

System requirements:

- PC, laptop or notebook with 486 or Pentium® processor- Windows® 95/98/NT- 8 MB RAM, at least 10 MB free hard disk capacity- serial interface (RS 232)- interface converter with connection and adapter cable

The event memory contains the following information:

- number of started charging processes- number of correctly completed charges- number of executed forced switch-overs- number of max. charge times exceeded- number of current/voltage errors- number of EUW errors

Display ofcharging parameters

Display of events.

File Units Settings Window Help

Console System data

Charger address

Software version

No. of started charging cycles

No. of correctly finished charges

No. of forced switch-overs

No. of charging time overrange

No. of I/V errors

Tebetron Puls

File Units Settings Window Help

Console System data

Charger address

Level 1 Level 2/1 Level 2/2

Calibration point (2,00 - 2,55 V/C)

Changeover point WoWa (2,00 - 2,55 V/C)

max. charging time (0 - 18,0 h)

Sulphatation time (0 - 1092 min)

max. bulk charge time (0 - 18,0 h)

Switch on time Aquamatic (0 - 1092 min)

First turn-on time EC (0 - 1092 min)

Turn-on time EC (0 - 1092 min)

Idle time EC (0 - 1092 min)

Time-delay relay contact monitoring (0 - 255 s)

Turn-on time maintenance charge (0 - 1092 min)

Turn-off time maintenance charge (0 - 18,0 h)

File Units Settings Window Help

Console System data

Charger address

Level 1 Level 2/1 Level 2/2

Off WoWa-charger

On Aquamatic

Off EC

On Maintenance charge

On Maintenance charge (alternating)

Off Gassing charge time (4h = off / 5h = on)

Off Contactor interconnection (old= off / new= on)

Off

Divider without EC (1 -255)

Divider with EC (1 -255)

Time constant without EC (0 -1092 min)

Time constant with EC (0 -1092 min)

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100

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Reduced maintenance

Puls-Wa-characteristic

The TEBETRON range features Pulscharging technology. Using this tech-nology, the electrolyte is mixedthrough the use of current pulses dur-ing the gassing phase of the chargecycle. This mixing is necessary toavoid layering (stratification) of theelectrolyte which can lower the effi-ciency of the battery and reduce avail-able capacity.

These current pulses generategassing phases which mix the elec-trolyte and prevent the formation ofacid layers.

By the use of the Puls characteristicthe charging factor is reduced (approx1.08-1.10) this leads to an actualreduction in transformer outputrequired to charge a specific capacitywithin a given time. This offers a com-mercial advantage of using a smallercharger output, as well as the opera-tional benefits of offering reducedcabling/fusing requirements for anygiven voltage- output combination.

The reduction in the overcharge factoragainst conventional charge characte-ristics results in a reduction in waterloss and therefore allows potentiallycostly battery maintenance to be sig-nificantly reduced.

Conservation Charging

Part of the energy stored in the trac-tion battery is lost in the course oftime by self-discharge. The equalisa-tion or conservation charging process,which is automatically performedfollowing the end of the chargingprocess, restores this lost energy.

In this way the battery capacityremains fully available even after longidle periods, e.g. during operationalholidays.

Equalisation or conservation chargealso protects against sulphating of theplates, thus increasing the lifetime ofthe battery.

Charging Characteristicsand Charging Times

The charging process corresponds to a Puls-Wa-characteristic i.e. thecharging current falls with rising bat-tery voltage (see Fig. 1).

The charging time is dependent onmatching the equipment's nominalcurrent to the battery capacity. Foran available charging time of 12 - 14hours an initial charging current of 9A to 11 A per 100 Ah battery capaci-ty should be selected.

By means of the pulse-Wa charac-teristic, it is possible to reduce thecharging time to 7.5 to 8 hours. Inthis case, for a desired chargingtime of 7.5 to 8.5 hours an initialcharging current of 16 A to 18.5 Aper 100 Ah battery capacity has tobe chosen.

Fig.1: Characteristic UPuls IPuls IWa UWaComparison between the TEBETRON Puls-Wa characteristic and a DIN-Wa cha-racteristic with equal charging times. In this case, a TEBETRON Puls chargerwill be selected which is two power levels smaller than a conventional Wacharger.

Benefits of Puls technology:• Smaller transformer sizes = reduced input fusing/lower

comparative purchase cost• Reduced Supply requirements = lower installation

costs/More efficient use of available mains supply• Energy saving = reduced electricity cost• Lower Battery Maintenance = Lower labor cost• Reduced gassing phase/temperature rise = Higher

battery utilisation through quicker return to service.• Increased Overall efficiency

N E W !

I/%

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Benning Power Electronics (UK) Ltd. · Oakley HouseHogwood Lane · FinchampsteadBerkshire RG40 4QW · GB Tel. 0 11 89 / 73 15 06 · Fax: 0 11 89 / 73 15 08http://www.benninguk.com · E-Mail: info@benninguk.com

Typetable TEBETRON Puls

Outputcurrent

[V]

Battery capacity in AhPuls-Wa-characteristic

charging time7,5-8,5h

Battery capacity in AhPuls-Wa-characteristic

charging time12–14h

Nom.outputcurrent

[A]

Nom.input

voltage[V]

Mainsfluses

[A]

Cabinet Weight

[kg]

Type*

12

24

36

72

80

Charger current allocation per 100 Ah battery capacity

TEBETRON Puls 16 A-18,5A 9 A-11 ACharging charact.: Puls-Wa Puls-WaCharging time 7,5–8,5h 12–14h

Cabinet dimensions [mm]

Cabinet type Height Width DepthFLP 365 230 360 240FTP 523 245 503 300FSP 654 553 583 490FSP 565 690 553 525

Charging time:Charging time is dependent on the state of discharge of the bat-tery and the ability of the charging equipment to deliver the cur-rent for the capacity of the battery. Charging output currentsshown in the type table relate to 80 % battery discharge.

Type:without digital current display …-FTP NIwith digital current display …-FTP

*Please complete type by additional lettersSubjet to technical change without notice

48

- 120 - 180 16 230 V 16 FLP 365 12 E 230 G 24 / 16 B-FTP- 130 - 220 20 230 V 16 FLP 365 13 E 230 G 24 / 20 B-FTP

140 -150 220 - 270 25 230 V 16 FLP 365 14 E 230 G 24 / 25 B-FTP160 - 180 280 - 330 30 230 V 16 FLP 365 20 E 230 G 24 / 30 B-FTP220 - 250 330 - 440 40 230 V 16 FTP 523 24 E 230 G 24 / 40 B-FTP270 - 300 440 - 550 50 230 V 16 FTP 523 30 E 230 G 24 / 50 B-FTP320 - 360 550 - 660 60 230 V 16 FTP 523 30 E 230 G 24 / 60 B-FTP380 - 430 600 - 770 70 230 V 16 FTP 523 31 E 230 G 24 / 70 B-FTP440 - 500 700 - 880 80 230 V 16 FTP 523 36 E 230 G 24 / 80 B-FTP500 - 560 770 - 990 90 230 V 16 FTP 523 38 E 230 G 24 / 90 B-FTP560 - 620 870 - 1100 100 400 V 16 FTP 523 40 D 400 G 24 / 100 B-FTP630 - 770 1100 - 1350 125 400 V 16 FSP 654 55 D 400 G 24 / 125 B-FTP800 - 930 1360 - 1600 150 400 V 20 FSP 654 70 D 400 G 24 / 150 B-FTP940 - 1000 1400 - 1880 170 400 V 16 FSP 654 85 D 400 G 24 / 170 B-FTP

1050 - 1180 - 190 400 V 16 FSP 654 105 D 400 G 24 / 190 B-FTP- 120 - 180 16 230 V 16 FLP 365 21 E 230 G 36 / 16 B-FTP- 130 - 220 20 230 V 16 FLP 365 22 E 230 G 36 / 20 B-FTP

140 - 150 220 - 270 25 230 V 16 FLP 365 25 E 230 G 36 / 25 B-FTP160 - 180 280 - 330 30 230 V 16 FTP 523 30 E 230 G 36 / 30 B-FTP220 - 250 330 - 440 40 230 V 16 FTP 523 31 E 230 G 36 / 40 B-FTP270 - 300 440 - 550 50 230 V 16 FTP 523 36 E 230 G 36 / 50 B-FTP320 - 360 550 - 660 60 230 V 16 FTP 523 55 E 230 G 36 / 60 B-FTP380 - 430 600 - 770 70 400 V 16 FTP 523 57 D 400 G 36 / 70 B-FTP440 - 500 700 - 880 80 400 V 16 FSP 654 75 D 400 G 36 / 80 B-FTP500 - 560 770 - 990 90 400 V 16 FSP 654 80 D 400 G 36 / 90 B-FTP560 - 620 870 - 1100 100 400 V 20 FSP 654 85 D 400 G 36 / 100 B-FTP630 - 770 1100 - 1350 125 400 V 16 FSP 654 105 D 400 G 36 / 125 B-FTP800 - 930 1360 - 1600 150 400 V 16 FSP 654 115 D 400 G 36 / 150 B-FTP940 - 1000 1400 - 1880 170 400 V 20 FSP 654 125 D 400 G 36 / 170 B-FTP

- 120 - 180 16 230 V 16 FLP 365 21 E 230 G 48 / 16 B-FTP- 130 - 220 20 230 V 16 FTP 523 24 E 230 G 48 / 20 B-FTP

140 - 150 220 - 270 25 230 V 16 FTP 523 30 E 230 G 48 / 25 B-FTP160 - 180 280 - 330 30 230 V 16 FTP 523 31 E 230 G 48 / 30 B-FTP220 - 250 330 - 440 40 230 V 16 FTP 523 37 E 230 G 48 / 40 B-FTP270 - 300 440 -550 50 400 V 16 FTP 523 40 D 400 G 48 / 50 B-FTP320 - 360 550 - 660 60 400 V 16 FSP 654 55 D 400 G 48 / 60 B-FTP380 - 430 600 - 770 70 400 V 16 FSP 654 60 D 400 G 48 / 70 B-FTP440 - 500 700 - 880 80 400 V 16 FSP 654 75 D 400 G 48 / 80 B-FTP500 - 560 770 - 990 90 400 V 16 FSP 654 85 D 400 G 48 / 90 B-FTP560 - 620 870 - 1100 100 400 V 16 FSP 654 95 D 400 G 48 / 100 B-FTP630 - 770 1100 - 1350 125 400 V 20 FSP 654 105 D 400 G 48 / 125 B-FTP800 - 930 1360 - 1600 150 400 V 20 FSP 654 115 D 400 G 48 / 150 B-FTP940 - 1000 1400 - 1880 170 400 V 25 FSP 654 135 D 400 G 48 / 170 B-FTP

- 130 - 220 20 230 V 16 FTP 523 31 E 230 G 80 / 20 B-FTP140 - 150 220 - 270 25 230 V 16 FTP 523 37 E 230 G 80 / 25 B-FTP160 - 180 280 - 330 30 400 V 16 FTP 523 40 D 400 G 80 / 30 B-FTP220 - 250 330 - 440 40 400 V 16 FSP 654 55 D 400 G 80 / 40 B-FTP270 - 300 440 - 550 50 400 V 16 FSP 654 75 D 400 G 80 / 50 B-FTP320 - 360 550 - 660 60 400 V 16 FSP 654 85 D 400 G 80 / 60 B-FTP380 - 430 600 - 770 70 400 V 16 FSP 654 95 D 400 G 80 / 70 B-FTP440 - 500 700 - 880 80 400 V 20 FSP 654 105 D 400 G 80 / 80 B-FTP500 - 560 770 - 990 90 400 V 20 FSP 654 115 D 400 G 80 / 90 B-FTP560 - 620 870 - 1100 100 400 V 20 FSP 654 125 D 400 G 80 / 100 B-FTP630 - 770 1100 - 1350 125 400 V 25 FSP 654 145 D 400 G 80 / 125 B-FTP800 - 930 1360 - 1600 150 400 V 35 FSP 565 155 D 400 G 80 / 150 B-FTP940 - 1000 1400 - 1880 170 400 V 50 FSP 565 165 D 400 G 80 / 170 B-FTP

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