February 2000

Process Industry Practices

Electrical

PIP ELSAP01
Battery Chargers for Station Batteries
 PURPOSE AND USE OF PROCESS INDUSTRY PRACTICES

In an effort to minimize the cost of process industry facilities, this Practice has
been prepared from the technical requirements in the existing standards of major
industrial users, contractors, or standards organizations. By harmonizing these
technical requirements into a single set of Practices, administrative, application, and
engineering costs to both the purchaser and the manufacturer should be reduced. While
this Practice is expected to incorporate the majority of requirements of most users,
individual applications may involve requirements that will be appended to and take
precedence over this Practice. Determinations concerning fitness for purpose and
particular matters or application of the Practice to particular project or engineering
situations should not be made solely on information contained in these materials. The
use of trade names from time to time should not be viewed as an expression of
preference but rather recognized as normal usage in the trade. Other brands having the
same specifications are equally correct and may be substituted for those named. All
Practices or guidelines are intended to be consistent with applicable laws and
regulations including OSHA requirements. To the extent these Practices or guidelines
should conflict with OSHA or other applicable laws or regulations, such laws or
regulations must be followed. Consult an appropriate professional before applying or
acting on any material contained in or suggested by the Practice.

© Process Industry Practices (PIP), Construction Industry Institute, The

University of Texas at Austin, 3208 Red River Street, Suite 300, Austin,
Texas 78705. PIP member companies and subscribers may copy this Practice
for their internal use.

Not printed with State funds

 February 2000

Process Industry Practices

Electrical

PIP ELSAP01
Battery Chargers for Station Batteries
Table of Contents

1. Introduction .................................. 2 5. Testing.......................................... 9

1.1 Purpose ............................................. 2
1.2 Scope................................................. 2 6. Shipping ....................................... 9
2. References ................................... 2 7. Documentation ............................ 9
2.1 Process Industry Practices ................ 2
2.2 Industry Codes and Standards .......... 2
2.3 Conflict Resolution............................. 2

3. Definitions .................................... 3

4. Design and Fabrication ............... 3

4.1 General .............................................. 3
4.2 Operating Environment...................... 3
4.3 Input and Output Requirements......... 4
4.4 Controls ............................................. 6
4.5 Control Indications ............................. 6
4.6 Alarm Indications - Local ................... 6
4.7 Alarm Indications - Remote ............... 7
4.8 Panel Meters...................................... 7
4.9 Wiring, Cables, and Devices ............. 7
4.10 Grounding .......................................... 8
4.11 Enclosure........................................... 8
4.12 Painting .............................................. 8
4.13 Nameplate ......................................... 8

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PIP ELSAP01
Battery Chargers for Station Batteries February 2000

1. Introduction

1.1 Purpose
This Practice provides the requirements including design, installation, inspection,
testing, shipment, and documentation for the purchase of battery chargers for
application in process industries.

1.2 Scope
This Practice and Data Sheet define the minimum requirements for an electronically
controlled indoor battery charger used for charging batteries for station applications.
These include requirements for design, inspection, testing, shipment, and
documentation for indoor non-classified areas.

2. References
Applicable requirements in the latest edition (or the edition indicated) of the following
industry standards and Process Industry Practices shall be considered an integral part of this
Practice. Short titles will be used herein when appropriate.

2.1 Process Industry Practices (PIP)

– PIP ELSAP01D - Data Sheet for Battery Chargers for Station Batteries
– PIP ELSAP11 - Design and Fabrication of Flooded-Cell Lead-Acid Batteries
for Electrical Stations

2.2 Industry Codes and Standards

• National Electrical Manufacturers Association (NEMA)

– NEMA PE 5-1996 - Utility Type Battery Chargers
• National Fire Protection Association (NFPA)
– NFPA 70 - National Electrical Code (NEC)
• Underwriters Laboratory, Inc. (UL)
– UL 489 - Molded-Case Circuit Breakers, and Circuit-Breaker Enclosures

2.3 Conflict Resolution

Any conflicts between the referenced documents shall be identified to the buyer in
writing for resolution. When resolving conflicts, the following order of precedence
shall apply:

• Purchase Order
• Data Sheet(s)
• This Practice
• Referenced documents

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 PIP ELSAP01
February 2000 Battery Chargers for Station Batteries

3. Definitions
For the purposes of this Practice, the following definitions apply:

Equalizing charge: An extended charge to a measured end point that is given to a storage
battery to ensure the complete restoration of the active materials in all the plates of all the
cells

Floating charge: A method of operation for storage batteries in which a constant voltage is
applied to the battery terminals sufficient to maintain an approximately constant state of
charge

Full float operation: Operation of a DC system with the battery charger and load cell
connected in parallel and with the battery charger supplying the normal DC load, plus any
self discharge or charging current or both required by the battery. (The battery will deliver
current only when the load exceeds the charger output.)

Percent ripple voltage: The ratio of the root mean square value of the ripple voltage to the
absolute value of the total voltage expressed as a percentage

Ripple: The alternating current component from a direct current power supply arising from
sources within the power supply

4. Design and Fabrication

4.1 General
4.1.1 The battery charger shall be designed, constructed, and tested in accordance
with NEMA PE 5-1996.
4.1.2 The charger shall provide constant voltage float and equalize charging of the
battery bank and, at the same time, deliver 0%−100%-rated current output to
a varying on-line load.
4.1.3 The charger shall maintain the preset output DC voltage regulation to the
connected load with the battery connected to the charger.
4.1.4 The charger shall be sized to provide a battery recharge time as specified on
the Data Sheet.

4.2 Operating Environment

4.2.1 The battery charger shall be designed for indoor operation at an ambient
temperature between 0° and 50°C or as specified on the Data Sheet and at a
relative humidity between 0% and 95%, non-condensing.
4.2.2 The battery charger will be located in an indoor non-classified area.

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PIP ELSAP01
Battery Chargers for Station Batteries February 2000

4.3 Input and Output Requirements

4.3.1 Input Overcurrent Protection
An input circuit breaker shall be provided for overcurrent and short-circuit
protection, as well as to provide a means of isolating the input power to the
charger. The circuit breaker shall have an interrupting capacity equal to or
greater than the available short-circuit current listed on the Data Sheet.
Molded-case circuit breakers shall be designed and tested in accordance with
UL 489.
4.3.2 Input Power Supply
The input power supply shall be as specified on the Data Sheet.
4.3.3 AC Line Compensation
The charger shall maintain the specified performance by providing automatic
compensation for up to ± 10% variation in the AC line voltage.
4.3.4 Input Surge
The input circuits of the charger shall withstand the surge test specified in
NEMA PE 5-1996, Section 9.1.9.
4.3.5 Output Voltage Regulation
DC output voltage shall be regulated to ± 0.5% in the “float” mode and shall
be regulated to ±1% in the “equalize” mode for any combination of AC line
voltage variation of ±10% of nominal, AC line frequency variation of ±5%
of normal, load variations of 0% to 100%, and ambient temperature
variations of 0° to 50°C.
4.3.6 Operation without Battery
When a “battery eliminator” is specified on the Data Sheet, the charger shall
meet all the performance criteria of this Practice with the battery
disconnected.
4.3.7 DC Output Ripple
With the battery connected, the root mean square (RMS) ripple voltage shall
not exceed the limits specified in NEMA PE 5-1996, Table 6.
4.3.8 DC Output Current Limit
A current limit circuit shall be provided. The circuit shall be factory-set at
105% of the rated DC output current.
4.3.9 Float Voltage
The float voltage setting shall be adjustable as follows:
a. Lead-acid battery - 2.15 to 2.35 volts per cell
b. Nickel-cadmium battery - 1.35 to 1.45 volts per cell

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 PIP ELSAP01
February 2000 Battery Chargers for Station Batteries

4.3.10 Equalize Voltage

The equalize voltage setting shall be adjustable as follows:
a. Lead-acid battery - 2.20 to 2.45 volts per cell
b. Nickel-cadmium battery - 1.50 to 1.60 volts per cell
4.3.11 Temperature Compensated Charging
When specified on the Data Sheet, a battery temperature-sensing probe shall
be provided for sensing the temperature of a pilot cell. The output voltage of
the charger shall be automatically adjusted to provide a negative temperature
compensation of 5 mV per degree C for changes in battery temperature
above or below the standard temperature of 25°C.
4.3.12 Dynamic Response
With the battery connected, dynamic response shall be as specified in
NEMA PE 5-1996, Section 5.10.
4.3.13 Start-up Behavior
The charger shall have “soft-start” characteristics. The start-up walk-in
feature shall increase the output current from 20% to 100% of the rated load
within 15 seconds.
4.3.14 Abnormal Load Conditions
For nickel-cadmium battery applications, the charger shall operate into a
zero battery voltage without activating protective devices.
4.3.15 Output Surge Protection
The output circuits of the charger shall withstand the surge test as specified
in NEMA PE 5-1996, Section 9.1.9.
4.3.16 Output Overcurrent Protection
Unless specified otherwise on the Data Sheet, a two-pole output circuit
breaker shall be provided for overcurrent and short circuit protection, as well
as a means of disconnecting the charger from the load.
4.3.17 Parallel Operation of Two Chargers
When specified on the Data Sheet, the battery charger shall be designed to
allow parallel operation and load sharing between two chargers connected to
a common battery and load. Failure of one charger shall not affect the
operation of the other charger or battery.
4.3.18 Interlocks
The enclosure shall be interlocked to prevent opening or closing of the door
unless both input and output protective devices are in the “open” position.
Provisions shall be provided inside the enclosure to allow the input device to
be closed for diagnostic purposes with the door open.

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PIP ELSAP01
Battery Chargers for Station Batteries February 2000

4.4 Controls
4.4.1 Float/Equalize Timer
An equalizing timer shall be provided for manually placing the battery on
equalize charge. The timer shall have a manually adjustable timing range of
0 to 72 hours.
4.4.2 Output Voltage Adjustments
Separate controls shall be provided for independently adjusting the float and
equalizing voltage levels.
4.4.3 Automatic Equalize Charge Control
When specified on the Data Sheet, the charger shall be equipped with
automatic controls to automatically switch to equalizing charge after an AC
power interruption of more than 5 minutes. The charger shall automatically
return to float charge mode 8 hours (field adjustable from 0 to 24 hours)
after an automatic start of the equalize charge mode.
4.4.4 High-Voltage Shutdown
The charger shall automatically shutdown if the output DC voltage reaches
110% of the output voltage setting.
4.4.5 Alarm Reset Button
A momentary pushbutton to reset the remote alarm relay shall be provided.

4.5 Control Indications

The following control indications shall be provided by LED or LCD on the front
panel of the charger enclosure:
a. Charger on
b. Float charge
c. Equalize charge

4.6 Alarm Indications - Local

4.6.1 The following alarm indications shall be provided by LED or LCD on the
front panel of the charger cabinet:
a. Positive ground fault
b. Negative ground fault
c. Charger failure
d. Low-output voltage
e. Cooling fan failure (for force ventilated units)
4.6.2 When indicated on the Data Sheet, the following alarm indications shall be
provided by LED or LCD on the front panel of the charger cabinet:
a. AC input failure

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 PIP ELSAP01
February 2000 Battery Chargers for Station Batteries

b. Charger overtemperature
c. Overload shutdown
d. High output voltage
e. Equalize charge mode
f. Battery end of discharge
g. Output breaker open
4.6.3 All alarms shall remain latched until manually reset after the alarm condition
has been cleared.

4.7 Alarm Indications - Remote

A form “C” alarm contact, rated 120 VAC, 5 amps, shall be provided for
annunciating all the alarms of Section 4.6 as a common alarm to Buyer’s central
alarm-monitoring system.

4.8 Panel Meters

4.8.1 Output Voltage and Current
A digital (LED or LCD) panel meter shall be provided to display the output
current and voltage readings. Meters shall have ± 1% full-scale accuracy.
4.8.2 Ground Fault Indication
When specified on the Data Sheet, positive and negative ground faults shall
be displayed on a common meter via a switch to show the magnitude of the
leakage current.

4.9 Wiring, Cables, and Devices

4.9.1 Wiring shall comply with NFPA 70 (NEC).
4.9.2 Wiring brought out to terminal blocks shall be permanently identified with
heat-shrinkable wire markers. Wire numbers and color codes shall
correspond to the numbers and colors shown on the schematic/wiring
diagram(s).
4.9.3 Terminal blocks shall be provided for connection of external control and
alarm wiring. A maximum of two wires per point is permitted.
4.9.4 All energy-isolating devices that are required to perform safe maintenance
shall be capable of accepting a lockout device in the “OFF” or disconnected
position only.
Note: An energy-isolating device is a mechanical device that physically
prevents the transmission or the release of energy.
4.9.5 Each energy-isolating device shall be clearly identified to indicate its
purpose. Devices that receive external power shall have the source of power
included in their labeling.

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PIP ELSAP01
Battery Chargers for Station Batteries February 2000

4.9.6 Provide permanent wire supports. Adhesive backing wire supports are not
acceptable.

4.10 Grounding
4.10.1 Grounding provisions shall meet the requirements of NFPA 70 (NEC).
4.10.2 The enclosure shall be provided with a copper equipment grounding
connection.
4.10.3 The positive and negative DC buses shall be isolated from the earth ground.

4.11 Enclosure
4.11.1 Enclosures shall be manufacturer’s standard unless indicated otherwise on
the Data Sheet.
4.11.2 Enclosure preference shall be for natural convection cooling. When forced
ventilation is used, the enclosures shall be equipped with removable, easily
cleanable inlet air filters.
4.11.3 Enclosures shall be designed for front access to all components and test
points.
4.11.4 Handles, screws, and hinges shall be corrosion resistant.
4.11.5 Where provided, the enclosure door handle shall have provision to be
padlocked.
4.11.6 Cable entry shall be as specified on the Data Sheet.
4.11.7 Enclosure shall be designed and constructed so that all normal controls are
operable with the doors closed.

4.12 Painting
Finish shall be manufacturer’s standard (i.e., method, type, color, etc.), unless
otherwise specified on the Data Sheet.

4.13 Nameplate
4.13.1 The following information shall be permanently marked on each enclosure:
a. Manufacturer’s name and address
b. Equipment model and serial number
c. Input AC voltage and number of phases
d. Nominal output DC voltage
e. Rated output current
4.13.2 All major devices and components of the battery charger shall be provided
with engraved, laminated plastic nameplates identifying the devices or
components and their function.

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 PIP ELSAP01
February 2000 Battery Chargers for Station Batteries

5. Testing
5.1 The battery charger shall be factory-tested to demonstrate the performance and the
functionality required by this specification.
5.2 When specified on the Data Sheet, additional tests shall be performed. Certified test
reports shall be furnished.

6. Shipping
Seller shall identify the following on each shipping group:

a. Purchase Order number

b. Requisition number
c. Equipment number
d. Project number

7. Documentation

A B C D DESCRIPTION
With For Final As
Bid Review Certified Built

X X X X General layout of equipment, showing all dimensions,

weights, location, and outline drawings showing the final
assembled configuration
X Copies of certified test reports

X X X One-line diagram, three-line diagram, control schematics

and connection wiring diagrams

X(1) Installation, operation, maintenance manual and required

maintenance schedules

X X X Safety instructions clearly identifying proper and improper

operation that might injure personnel and cause damage
to operating equipment

A. Bidder shall furnish these documents with proposal.

B. Seller shall furnish these documents for Buyer's review and authorization to proceed before
fabrication.
C. Seller shall furnish these documents as part of the final certified document submittal.
(1) Equipment shall be shipped with one (1) set of installation, operation, and maintenance
manuals.
D. As-built within 2 weeks following shipment.

Note: Seller shall provide one (1) reproducible set of drawings plus the specified number of copies of
all documentation and operating manuals as indicated on the Data Sheet. Format for
reproducible drawings shall be CAD convertible .dxf electronic format unless the Seller specifies
otherwise in the proposal.

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