Standard Test Procedure

for
CHARGERS & RECTIFIERS

Revision Date Approval

12 6/01/06 JVS
_________ __________ __________

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 Test Procedure for Rectifiers & Battery Chargers

PURPOSE AND SCOPE:

This procedure describes the standard tests performed on SCR regulated battery chargers. The procedure
describes performance tests and testing of standard functions and alarms that are normally supplied with these
Battery Chargers. Descriptions of testing of specialized options which may be supplied to meet client needs are
not included. Some parts of this procedure may apply to Battery Chargers and Rectifiers that are contained
within a UPS System. All circuits are functionally tested and other features and options checked for correctness.
This procedure is intended for use with Battery Chargers and Rectifiers utilizing 80-2140xx-90 series Control
Boards and, if included, the 80-2253xx-90 series Alarm/Mimic Control Boards.
Reference is made to the Battery Charger / Rectifier Final Test Report forms (Doc.# 02-190383), which are
used to document these tests. A 'check mark ','ok' or 'pass' indicates compliance when specific data is not
required by the Test Form and a 'dash’, 'n/a', or blank space indicates that the test is not applicable to this unit.
When customized features and / or testing are specified, additional forms may be required.
The sequence of tests in the procedure may differ from actual testing, which is completed in a logical
manner determined by the Test Technician or Test Supervisor.

EQUIPMENT REQUIRED: (Equivalent may be used)

1. AC POWER SUPPLIES with proper ratings to supply the unit being tested. Variable supplies are required
for initial startup, regulation and some alarm /option tests.
2. A LOAD BANK sufficient to load the unit to its current-limit rating.
3. An AUXILIARY LOAD BANK for fine adjustment of loads during testing which may contain a bank of
capacitors to be used as a simulated battery.
4. At least two MULTIMETERS and a CLAMP-ON CT.
5. TEMPERATURE PROBES compatible with the above MULTIMETERS.
6. An OSCILLOSCOPE "isolated" from ground.
7. CABLES for connecting the unit to power supplies and loads.
8. A copy of the BATTERY CHARGER/RECTIFIER FINAL TEST REPORT and TEST FORMS.
9. DOCUMENTATION (MASTER PRINT PACKAGE), including access to online systems for
updated information.

SECTION 1 - INITIAL STARTUP & CHECKOUT

1. Visually check the unit for compliance with documentation and possible problems.
2. Connect the unit to the test station ground cable. Close all circuit breakers and disconnect internal
grounding as necessary. Perform ohmmeter checks to determine whether the unit’s input and output
wiring is correctly isolated from chassis ground and that the input is isolated from the output. A reading
of >200kOhms is required.
3. After successful completion of the ohmmeter checks, a Hipot Test (See Attachment A) can be
performed if applicable.
4. Restore internal grounding connections, open circuit breakers and connect input and output cables to
the unit.
5. Disconnect the AC Input control wires at the Charger Control Board. Connect a variable AC supply to
the Charger Input. Close the AC Input circuit breaker. Raise the AC Input slowly and observe that AC
Input Currents are within nominal limits as the voltage is increased to the Charger’s Nominal Input
Voltage. Check to see that fans, meters and accessories (if present) are operating properly.
6. Measure the voltages (See Attachment B) at the AC Input control wires with respect to neutral and
confirm they are within the allowable range.
7. Remove the AC Input Voltage and reconnect the control wiring to the Charger Control board.
8. Set the Float and Equalize potentiometers approximately 1¼ turns CCW from full CW. Confirm that the
Charger Output is safely connected to an open circuit or a minimal load such as a light bulb. Raise the
AC Input Voltage to the Charger’s Nominal Input Voltage and observe that the Charger Output Voltage
rises smoothly to the correct value. Correct any problems found at this point.
9. Connect an oscilloscope across the output of the Charger Bridge, upstream of any filtering components
such as Chokes or Capacitors, and confirm that the output waveform indicates that all Charger Bridge
Semiconductors and Control Circuits are operating properly. Correct any problems found at this point.

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 Test Procedure for Rectifiers & Battery Chargers

10. Connect the Charger to a Power Supply capable of providing power at the rated capacity of the
Charger, and to a Load Bank / Auxiliary Load Bank capable of providing load to the Current Limit
capacity of the Charger.
11. Load the Charger to Full Load and confirm that AC Input Currents are balanced and at the correct levels
for the Charger’s capacity. Confirm that Metering supplied with the Charger is indicating correctly.
Correct any problems found at this point.
12. The Charger is now ready to be tested further or placed on a Full Load Heat Run or Burn-In.

SECTION 2 - PERFORMANCE TESTS AND ADJUSTMENTS

A. HEAT RUN / BURN IN AND TEMPERATURE MEASUREMENT

All Chargers are operated at their Full Load rating for a minimum of 8 hours, but normally overnight (16
hours) at the Ambient Temperature of the Test Department and as near as practical to the Nominal Input
R Voltage of the Charger. Time period for heat run/burn in can be longer if specified by the client. At the end of
the time period, the Surface or Internal Temperatures of Semiconductor Devices, Transformers, Chokes, Filters
and other devices are measured and recorded in the TEMP. section of the Test Form.

1. Using an insertion type temperature probe, measure and record the highest internal temperatures of the
Charger’s AC Input Transformer and DC Output Choke(s). Normal Temperatures should not exceed 170C.
2. Using a surface temperature probe, measure and record the highest surface temperature of all
Semiconductors. Normal Temperatures should not exceed 100C.
3. Using a surface temperature probe, measure and record the temperatures of other applicable devices,
such as Capacitors. Normal Temperatures should not exceed the Manufacturer’s ratings.
4. Check Control Boards, Circuit Breakers, Fuses, Power Connections and other components for abnormal
hotspots.

B. VOLTAGE REGULATION

The Voltage Regulation Test shall demonstrate that the Battery Charger Output Voltage, measured at the
Output Terminals of the Charger, remains within specified limits (usually 1% of the Nominal Setting) under the
specified conditions of Input Line variation and at Output Load variations of No Load to Full Load. These tests
can be performed following initial startup or after heat run / burn in. The following data is recorded in the
Regulation Test section of the Test Form.

1. At Nominal Input Line, with a minimal load applied, adjust the Float and Equalize Voltages to their
specified values. These values are normally specified in the Order Service Specification (OSS) for the job, but
the Equalize Voltage for this test should be the highest voltage that the Charger is designed for and may be
higher than the Equalize Voltage specified.
2. Adjust the Input Voltage of the charger to its Low Line level (normally 10% below Nominal). Ensure that
the Voltage level remains as close as possible to the specified level for both No Load and Full Load conditions.
3. No load (Float): With a minimal load applied and the charger set to Float mode, read and record the input
voltage, input currents and output voltage.
4. No load (Equalize): With a minimal load applied and the charger set to Equalize mode, read and record
the input voltage, input currents and output voltage.
5. Full load (Float): With full load applied and the charger set to Float mode, read and record the input
voltage, input currents, output voltage and output current.
6. Full load (Equalize): With full load applied and the charger set to Equalize mode, read and record the
input voltage, input currents, output voltage and output current.
7. Adjust the Input Voltage of the charger to its High Line level (normally 10% above Nominal). Ensure that
the Voltage level remains as close as possible to the specified level for both No Load and Full Load conditions.
8. Repeat the tests outlined in steps 3 to 6 above.

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 Test Procedure for Rectifiers & Battery Chargers

C. RIPPLE VOLTAGE MEASUREMENT

The Ripple Voltage Test shall demonstrate that the AC Component of the Output DC Voltage of the
Charger is in compliance with stated values for the type of Charger being tested, or with the specific Ripple
Voltage requirements of the unit being tested. The test is performed with the Charger operating at Full Load and
Nominal AC Input Line, and measured at the Output Terminals of the Charger or at the terminals of a connected
Battery or Simulated Battery.

1. Load the Charger to Full Rated Load and adjust the AC Input Voltage to the Nominal value.
2. Using a True RMS AC Voltmeter, measure and record the AC Component of the DC Output Voltage at
the Output Terminals of the Charger.
3. Specific Charger Ripple requirements shall be measured at the terminals of a connected Battery Bank of
four (4) times the Charger Full Load rating. If a 4x Battery is not available, a direct ratio may be used to calculate
the expected Ripple Voltage:
Calculated Ripple = ((Test Battery Ah) / (Charger Rating x 4 )) x (measured ripple E)
R 4. Specific Test Data requirements and conditions for each Charger under test should be recorded in the
appropriate Ripple section of the test form. Standard Chargers require only basic Ripple Voltage measurement.

D. CURRENT LIMIT

The Current Limit setting is defined by the type of charger being tested and / or specified in the Order
Service Specification (OSS). Typical settings are 125%, 115% or 100% of Full Load.

1. Overload the Charger to a level slightly higher than the specified Current Limit.
2. Adjust the Current Limit potentiometer on the Charger Control Board to the specified level.
3. Adjust the Load Bank / Auxiliary Load Bank to reduce the Output Voltage of the Charger to a level equal
to a Battery Voltage of 2.0 VPC (Volts per Cell) or the appropriate level for the system under test.
4. Measure the Currents at the three phase AC Input of the Charger.
5. Record the Current Limit setting and the Maximum AC Input Current in the Current Limit section of the
Test Form.
6. Confirm that Full Load voltage regulation is not affected by the Current Limit setting (Chargers specifying
100% F.L. Current Limit settings).

E. CONTROL VOLTAGE

1. At Nominal Input Line, measure the Line to Neutral Voltages at the Charger Control Board AC Inputs. The
readings should comply with those in Attachment B.
2. Record the Voltages in the Control Voltage section of the Test Form.

F. OVERVOLTAGE

1. Adjust the Float or Equalize Charger Voltage to a level higher than the Maximum Voltage setting (see
Attachment C).
2. After a delay, the Output Voltage should fall to the Max. Voltage level. Adjust the Max Volts potentiometer
on the Charger Control Bd. if necessary.
3. Compliance with the standard settings should be indicated by a check mark on the Test Form.

SECTION 3 – DISPLAYS, ALARMS AND OPTIONS

A. EQUALIZE TIMER

1. Set the Equalize Timer to the correct operating mode (usually D) and program it for a minimal period of
time.
2. Set the Charger to Equalize mode and observe that it returns to Float mode operation after the
programmed time. This test can also be performed during an overnight heat run, with Float and Equalize
voltages set at the same level.
3. Set the Equalize Timer to the standard duration (usually 24 hrs.) for shipment.

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 Test Procedure for Rectifiers & Battery Chargers

B. METERING

1. All Metering shall be checked against a calibrated instrument for compliance with standard or required
accuracy specifications (usually 2% of the full scale of the meter).

C. DISPLAYS AND ALARMS

The front panel displays utilize the 80-2253xx-90 series Alarm Control Board along with 80-2254xx-90
series Alarm Relay boards. Other Charger models may use any combination of Control Boards and discrete
devices for Indication and Annunciation. The Charger Alarm Test Report (Doc.# 02-190383 - Pg. 3) is formatted
for use with the above Alarm Control and Relay boards, but may be used to document the functionality of
Displays, Alarms and Options on other Charger types. For additional Alarms and Options a generic Alarm Test
Report may be used.

1. Check correct operation of all Alarm Indicators and Relay Contacts to established operational standards
or to specific requirements for the Job. Especially on Custom Design units, the Master Schematic, Outline
Drawings, Order Service Specification and associated Job Documentation must be referred to for specific
information about the configuration and operation of features included. All circuits, sensors, devices and their
associated external connections will be operationally tested.
2. Document Function, Contacts, Lamps and Settings on the Alarm Test Report. “Function” will be used only
if the device produces an action other than alarm indication and annunciation.

D. MISCELLANEOUS DATA AND INFORMATION

1. MIMIC OVERLAYS, STARTUP / SHUTDOWN PROCEDURES, SERIAL FOIL TAGS, TAGGING and
CUSTOMER EQUIPMENT TAGGING should be checked against documentation for correctness.
2. Printed Circuit Board PART NUMBERS, SERIAL NUMBERS and REVISION LEVELS will be noted on
the Test Forms.
3. During and after testing, DRAWINGS and DOCUMENTATION will be checked for accuracy and corrected
using RED INK. Any changes made should be discussed with the DESIGNER or appropriate ENGINEERING
PERSONNEL..
4. Manufacturing Errors, Anomalies and all other discrepancies found during the course of testing shall be
documented in the UNIT HISTORY LOG (“Redbook”) by the Technician. Any errors which affect actual
operation of the Charger shall be repaired or resolved and re-tested before the unit leaves the Test Department.
5. All Test Form sheets will contain the Job / S/N , the Name of the Test Technician, Date and space for the
Test Supervisor’s signature.
6. The “as shipped” Float and Equalize Voltages (usually found on the Order Service Specification) of the
Charger will be documented on the YELLOW BATTERY TAG and shipped with the unit.

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 Test Procedure for Rectifiers & Battery Chargers

Attachment A

UL Dielectric Withstand Test Procedure (Hipot)

The test is intended to be conducted at room temperature and with the unit’s electrical circuitry
fully assembled. This procedure is derived from the procedure for UPS Systems.

Procedure:

1. Connect the AC Input terminals (A, B & C) with jumpers.

2. Connect the DC Output terminals (DC+, DC-) with a jumper.
3. Disconnect all Internal Grounding and components susceptible to damage as applicable.
4. Close all Input and Output Circuit Breakers.
5. Apply the voltage in Table 1 between Cabinet Ground and the terminal location. Gradually increase
the test voltage until the desired value is reached and apply for 60 Seconds.
6. Test passes if there is no electrical break down.

Table 1 (typical values for a 480 VAC Input / 130 VDC Output Battery Charger -
use 2 X line + 1000V for other voltage configurations)

Location Test Voltage

AC Input 1960VAC
DC Output 1400VDC

7. Remove all jumpers, reconnect Internal Grounding, reconnect any disconnected components and
open Circuit Breakers.
8. Test Complete.

Note: High voltage may still be present on terminals. Wait at least 5 minutes or discharge terminals to ground
with a bleeder resistor.

Attachment B

Control Voltage Range

+10 / -10% AC Input Range Max. Min.

40C Ambient Temp. 26.1 19.6
50C “ “ 25.1 19.6

+10 / -15% AC Input Range Max. Min.

40C Ambient Temp. 26.1 20.7
50C “ “ 25.1 20.7

(All Voltages are L-N, measured at the Control Board AC Inputs, at Nominal AC Input)

Attachment C

Maximum Voltage Settings

13 VDC “nominal” Voltage - 14.3VDC

R 26 VDC “nominal” Voltage - 28.6VDC
52 VDC “nominal” Voltage - 57.2 VDC
130 VDC “nominal” Voltage - 143VDC
260 VDC “nominal” Voltage - 286 VDC

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