BCIS-05 REV.

BCI Battery
Technical DEC02
Manual

Issued 1993-05
Current Revision: 2002-12

BCI SPECIFICATIONS FOR ELECTRIC VEHICLE BATTERIES

1. SCOPE AND CLASSIFICATION

1.1. The purpose of this specification is to provide a method for rating and capacity testing
Electrical Vehicle and Cycling batteries, covering time-rates commonly required for these
applications. A method is outlined for testing a battery; it follows that the method is intended
both for the battery manufacturer to 1) use to establish ratings and newly designed batteries;
and 2) monitor performance of such batteries in production. It also provides a test method for
the user.

1.2. These batteries include lead-acid types and are used in the following applications: floor
scrubbers, golf cars, personnel carriers, trolling, small mine tractors, over the road vehicles,
and other deep cycling applications. Not included are traction (industrial) batteries, defined
as those intended for installation in mechanical handling equipment.

1.3. Performance at all times rates – from 1 though 6 hours shall be established by testing
batteries at rates which will obtain discharge times from 1 through 6 hours at 27°C to a final
voltage of 1.75 times the number of cells. Performance is to be expressed in the form of a
log-log scale, plotting rate of discharge vs. time of discharge. Average voltages are also
recorded as an option in order that watt hour capacity may be readily calculated.

1.4. Performance may then be used to determine rating, or to confirm an established rating. An
example of log-log performance curve is shown in Figure 1.
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Figure 1. Performance of Tested Group GC2 Battery

2. CAPACITY TEST CONDITIONS

2.1. Pretest Conditioning Procedure

All industry sanctioned and approved standards are established on new (60 days or less
since date of manufacture), fully charged batteries. The following conditioning procedure has
been established as requirement prior to laboratory testing.

The batteries shall be charged at a rate in amperes equal to 3% of rated or expected 6 hour
capacity in ampere hours, until all cells are gassing freely, and charge voltage and specific
gravity of electrolyte are constant over three successive readings taken at one hour intervals.
Alternately, batteries may be charged at a tapered rate, starting at a current not to exceed
20% of the 6-hour capacity, finishing at 3% miximum, or as specified by the manufacturer.

2.2. Final Discharge Voltage

The final voltage, when discharge is terminated, shall be 1.75 times the number of cells, for
all tests in the 1-6 hour time range.

2.3. Temperature

Electrolyte temperature shall be 26.7°C ± 3°C (80.6°F ± 5.4°F) at start test, except when
performance at other temperature is to be determined. Ambient shall be a water bath at
26.7°C ± 3°C (80°F ± 5.4°F). Temperature correction may be required; this is to be
determined. When performance at other temperatures is to be measured, electrolyte
temperatures shall be subject to the same range.

2.4. Specific Gravity

Electrolyte shall have a specific gravity of 1.265 ± .005, fully charged at 26.7°C (80°F) unless
otherwise specified.

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2.5. Readings

All voltage, specific gravity and temperature readings shall be taken from the positive terminal
cell to the negative terminal cell, recorded in series and numbered.

2.6. Test Equipment

All equipment shall be clean, in good working order and calibrated.

2.6.1. Thermometers. Shall be graduated so that each scale division will not represent more than
1°C (1.8°F) and shall have an accuracy of ± 1°C (1.8°F).

2.6.2. Hydrometers. Shall be graduated so that each scale division will not represent more than
0.005 units of specific gravity and shall be accurate to at least 0.005 units.

2.6.3. Instrumentation. Voltage and current readings shall be made with instruments capable of an
accuracy of 0.1 ampere and 1% of voltage reading or better. Timers shall be graduated so
that each division will represent not more than one minute and during a 360 minute period
shall have an accuracy within ± 2 minutes.

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3. TEST METHODS

3.1. The following shall be recorded at the completion of the charge: On-charge voltage, charging
rate, temperature and specific gravity.

3.2. Discharge rate of the first test shall be the 3 hour rate, either from an existing rating or from a
calculated 3 hour rate. If none of this information is available, use 75 amperes or other
reasonable approximation depending on battery size. From results of this test, an
approximate 3 hour test rate can be determined. See footnote (5.1).

3.3. When all requirements of Test Conditions have been met, the test discharge shall be
initiated, within 24 hours after preconditioning.

3.4. The constant discharge current shall be maintained within ± 1%of the rate in amperes for the
rated discharge being performed, and is to continue until battery voltage at the terminals
equals 1.75 times the number of cells.

3.5. The elapsed time to final voltage shall be recorded.

3.6. If watt hours are to be measured, then voltage of the battery shall be recorded continuously.
From this record an arithmetic average voltage can be computed from at least 10 equally
time spaced voltage measurements which include beginning and end discharge points.

3.7. Within 5 minutes after completion of the test discharge, temperature and specific gravity of
electrolyte of all cells shall be recorded. Temperature correction of capacity is not yet
established.

3.8. Ampere hourscapacity shall be the product of discharge rate in amperes multiplied by time in
decimal hours required to reach final voltage.

3.9. Watt-hour capacity shall be the product of ampere-hours capacity multiplied by average
voltage computed in Step 3.6.

3.10. Battery shall be recharged as specified under Pretest Conditioning Procedure.

3.11. Characterization testing sequence.

3.11.1.1. A series of three tests are to be performed and plotted to establish the battery performance.
These tests are nominal one, three and six hour discharge tests.

3.11.1.2. The battery to be measured will be given a three hour capacity test. Further conditioning
three hour capacity tests up to 15 cycles may be given if desired.

3.11.1.3. After the three hour performance level has been achieved, a six hour capacity test will be
performed, followed by the one hour capacity test. The six hour and one hour tests may be
repeated twice if necessary.

3.11.1.4. For specific applications, the desired rate only may be run.

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4. PERFORMANCE LINE

4.1. The highest value obtained from each of the one, three and six hour capacity tests will be
plotted on a log-log scale to establish the battery performance. Units are amperes discharge
rate vs. time. Times must not necessarily be exactly one, three and six hours, but shall be
plotted for their actual yield in time.

4.2. The plotted performance line is then considered the measured performance of the tested
battery at 26.7°C or at the temperature at which the test was conducted. This line may be
used to determine minutes run vs. discharge rate in the 1-6 hour range.

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5. COMPLIANCE STANDARDS

When evaluated in accordance with accepted statistical sampling procedures, 90% of the
batteries produced should meet their 1-6 hour ratings.

5.1. Footnote: Ampere Hour Capacity Relationships

For guidance in establishing rates, ampere hour capacity relationships are approximately:

20 hour 125% 3 hour 82%