BELATRON compact charging systems switch mode technology ...

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BENNING World Class Charging Systems BELATRON compact charging systems switch mode technology from BENNING World class switch-mode charging systems for charging traction batteries Charger systems, which utilises switch-mode technology have developed a strong market position during the recent years due to their technological advantages. The chargers are smaller, lighter and in particular more efficient than conventional 50 Hz chargers. With this new generation BENNING can respond to the increasing customer requirements with latest high frequency charging technology. Extended product range up to 24 V/120 A and 48 V/60 A The range has been extended to include the highest power single-phase unit in its class, whilst maintaining the existing casework dimensions. Additional features such, as electrolyte circulation is an option with these models. As a result the essential range of trucks in warehouse application are covered by just one modern and compact switch-mode charger range. mains Ua control Principle of primary switch-mode technology feedback Principle operation of a primary switch-mode charger and technological advantages In using switch-mode technology, the rectified input voltage is converted into a high frequency of up to 90 kHz using a chopper power circuit. By using this high frequency, volume and weight of the capacitive and inductive components are reduced substantially. Moreover the sinusoidal current input ensures a power factor close to 1. This means the charger takes only real power from the mains. With this technology an efficiency of about 90 % is achieved. As a consequence a BELATRON compact 24 V/120 A is still a single-phase unit and the nominal input current is lower than 16 A. This reduces the cost of the AC infrastructure for the end user. Features: • Fully automatic charging process including equalisation charge • Energy saving and battery protection charging characteristic • Increased efficiency of about 20% • Pulse characteristics providing • Short recharge times of 7.5 - 8 hours • Energy savings due to a reduced overcharge (charging factor of 1.1) • Therefore reduced battery maintenance intervals due to lower temperature development and lower water consumption • Air electrolyte mixing as option • Lower temperature development due to a ripple free charging current • Suitable for flooded and maintenance free batteries • Reduced volume and weight by a factor of 5 • Available as On-board charger including • Drive off protection incl. Cable • Short-circuit-proof by PCB coating • Shock- and vibration proof design
BENNING World Class Charging Systems BELATRON compact charging systems switch mode technology from BENNING Charging characteristics BELATRON compact The BELATRON compact charging curve is a WUIa characteristics (see picture 1), i.e. when the gassing voltage is reached, the recharge is driven with a falling current. This takes advantage of the fact, that the battery can accept a very high amount of energy until the gassing voltage is reached. When the gassing voltage is reached, the charge is driven by a constant voltage phase. The voltage is kept constant until the charging current equals the limited end of charge current. During this phase again the current is kept constant until shut-off. After the recharge, an equalisation charge is provided automatically. This ensures in case of insufficient recharge or deep discharges the maximum capacity and life expectancy of the battery. For On-board applications and parallel operation the BELATRON compact range provides a WUoU characteristics. BELATRON compact chargers offer innovate pulse characteristics providing reduced recharge times. High current pulses induce the mixing of the electrolyte at the end of the final charging phase (see picture 2). The reduced charging factor contributes not only to a shorter recharge time, but reduces the energy consumption as well. U V/C I [%] U V/C I [%] U I Fig. 1: Voltage - current curves for WUIa characteristic Fig. 2: Pulse characteristic IPuls UPuls dBuV 70 60 50 40 30 20 10 0 Electromagnetic compatibility (EMC) – a standard for product quality Due to the high technical demands on the BELATRON compact, the power electronics meet all relevant European norms for EMC and mains pollution. A measure for the compatibility is the power factor cos ϕ. A typical value for compatible single-phase systems is 0.99. Therefore the efficiency of the unit results in a value of about 90 %. 0.15 1 10 30 MHz Examination of limits according to EN 55014 The mains input meets the limits of the EN 61000-3-2 (see lower curve). This EN standard limits the allowed values of undesired harmonics fed back to the public network. This could lead to malfunction of devices connected to the same network. BELATRON compact charging systems provide a ripple free charging current which leads to a more modest temperature raise during the recharge of about 30 % compared to conventional chargers. According to the considerations of the ZVEI this results in a prolongation of the battery life expectancy of 10 %. On-board version The BELATRON compact range is suitable for On-board applications due to the low volume and weight. For this application a separate range is available. These chargers are shock and vibration proof. Short circuits and malfunction possibly caused by moisture condensation on the PCB’s are avoided by PCB coating. A drive off protection is installed in all On-board versions. This relay contact could easily be connected into the truck control system. Features of the On-board versions: • Shock- and vibration proof design • PCB coating • Drive off protection • Easy installation in the truck
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