BPC Technical Information BS 6290

8/10/2019 BPC Technical Information BS 6290

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BPC EMEA Limited, BPC House, Romsey Industrial EstateGreatbridge Road, Romsey, Hampshire, SO51 0HR, UK

Tel: +44 1794 521200 Fax: +44 1794 521400www.bpc-ups.com

Technical Information

British Standard 6290 Part 4


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CONTENTS

Title BS Section Page No.

Separators 3.1 3Terminal Pillars 3.2 6Containers and Lids 3.3 8Pillar seal Assembly 3.4 9Internal Intercell Connectors 3.5 10

Valve 3.6 11Rated Capacity 4.1 12Charge / Discharge 4.2 14

Constant Voltage 4.3.1 16Mechanical Stress 4.4 17Short Circuit 4.5 18Conservation of Charge 4.6 19Short Circuit Current 4.7 21Flammability of Non- Metallic Parts 4.8 22Identification Marks 7.0 23


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British Standards 6290 Part 4, Section 3.1

Separators

Batteries under consideration 2 Volt Bloc Gel & AGM6&12 Volt Monobloc Gel & AGM

Requirements:

The separa tors sha ll be por ous to e lec t ro ly t e bu t e lec t r ica l ly insu la t ing .Suff ic ien t separa tor ov er lap to t he edges of t he p la tes sha l l be provided to

prevent shor t c i rcu i t s forming be t w een the edges of ad jacent p la tes.

BPC specifications: 2 Volt bloc Gel & 6&12 Volt Monobloc Gel

BPC Gel utilizes the best separator technology available in the world today; materials aremanufactured in Germany under strict production control and test procedures. Seefollowing page for Gel separator specifications and characteristics.Separator overlap is approximately 4mm at the sides and the top of the group toprevent the formation of shorts.

During production all dry batteries are short circuit tested and all finished batteries areHigh Rate tested.

BPC specifications: 2 Volt bloc AGM & 6&12 Volt Monobloc AGM

BPC AGM utilizes a random woven glass mat to retain the electrolyte and prevent shortcircuits between the plates. Separator overlap is approximately 4 mm at the sides andthe top. The S wrapping technique is utilized resulting in the bottom of every platehaving a layer of separator to protect against shorting and mossing.


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Terminal Pillars


Requirements:

The te rm ina l p i l l a r s sha l l be cast in lead a l loy and cont a in a th readed inser t(m ale or fem ale) t o w hich m echanical connect ions can be made . The inser t

shal l be prepared so that a sound electr ical and m echanical bond is m adew i th t he p i l l ar. The pr imary cur ren t pa th sha l l be be tw een a f la t sur face onth e p i l l a r assembly and any connec tor and not v ia any t hreaded par t s .

BPC specifications: 2 Volt bloc Gel & AGM

BPC Gel and AGM pillars are manufactured as in the diagrams shown.2V - Insert diameter is 18mm.

6&12 Insert diameter varies from 12mm to 18mm depending on the size of thebattery.


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Containers and Lids


Requirements:

The conta iners and l ids sha l l be made in a f lame re ta rdant p las t ics mat er ia land be so designed as to m in imize f lex ing of t he sur faces under norm aloperat in g pressures.Not e: The preferr ed plast ics m aterial is ABS, a range of copoly m ers based on

th e acry loni t r i l e bu tad iene s tyrene .The l id sha ll be w elded to t he conta iner, and the com ple te des ign sha l l beable to w i ths tand w i thout f rac ture for 5 hours at 20C an in te rna l p ressure of5x the nor m al operat ing pressure decla red by th e m anufac turer. Thecom plete design includes a pi l lar t o l id seal , w hich shal l be designed t oremain gas and e lec t ro ly t e t igh t dur ing t he design l i fe o f the un i t s .


The containers, lids and valve assemblies are constructed from Flame retardant ABSconforming to the flammability classif ication of UL94 V0 or IEC707-FV0.The case to cover assembly is effected by the use of specially formulated ABS two-partepoxy, which gives excellent mechanical and chemical bonding. The epoxy is completelyresistant to attack from Sulphuric acid.The 2 Volt terminal seal is a combination of a mechanical crimp of a lead insert, which ismoulded in to the case, and the use of epoxy and extended mechanical paths. The 6&12

Volt seal is effected by extended mechanical paths and application of two-part epoxy.Under test the sealed units easily withstand a pressure of 20 PSI or 140Kpa for 5 hours.The double sealing of the terminal pillar is impervious to acid penetration. A section isshown below.


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Pillar Seal Assembly


Requirements:

The p il la r to l id seal sha ll be designed to r emain gas t igh t and e lect r o ly te t igh tdur ing t he design l i fe o f the un i t s . When t ested in accordance w i th Appendix5 of t he s tandard . The sea l assem bly sha l l , a f te r 2 00 days on t est , show nos igns of ac id pene t ra t ion .

BPC specifications: 2 Volt bloc Gel & AGM6&12 Volt Monobloc Gel & AGM

The test method of Appendix 5 of the standard is based on inverting the terminal area inacid and applying a current for a given period to test for acid penetration, unfortunatelythis test can not be performed on modern designs as the terminal insert is made fromcopper, nickel and silver plated brass which shows excellent resistance to environmentalcorrosion and reasonable resistance to sulphuric acid, but would corrode during the testif immersed in 1250 SG sulphuric acid.

A section of the terminal assembly is shown in the previous section.


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Internal Intercell Connectors


Requirements:

The int ernal intercel l connectors shal l prevent acid creepage thr ough t hein t e r c el l pa r t i t i on . The y sh al l w i th s t a nd a shor t c ir c u it w i thou t de t r ime n t t oth e sa fe ty of th e un i t .


BPC 2 Volt bloc are mono cells and therefore do not have intercell connectors.

BPC specifications: 6&12 Volt Monobloc Gel & AGM

BPC 6&12 Volt Monobloc batteries are constructed with internal intercell connectors,which extend above and across the top of the battery case. The electrical connection ismade by welding the top of the two intercell connectors together to a depth ofapproximately 5 mm. When the cover is assembled all the intercell welds are submergedin epoxy.


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Valve

Batteries under consideration 2 Volt Bloc Gel & AGM6 & 12 Volt Monobloc Gel & AGM

Requirements:

The va lve sha l l opera te a t the p ressure and to le rance limi t s sta t ed by t hem anufac turer. The va lve sha l l no t a l low th e ingress of a i r.

All BPC 2 Volt Bloc and 6&12 Volt Monobloc batteries utilize an EPDM safety valve ofinternal diameter 11.4mm, the valve stem diameter is 11.6mm.The tested release pressure to date for all incoming SQC testing is 2 PSI +/- 0.5 PSI (14KPa +/- 3.5 KPa) which is within the quoted spread of 1 to 3 PSI.

Valves are tested on valve stems of known size submerged in water, the release andreseal pressure is recorded. Typical reseal pressure is 1 PSI (7 KPa).


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Rated Capacity


Requirements:

For t he purpose of th i s s tandard , the ra ted capaci ty i s the t h ree hour ra te ( C 3 )and shal l be sta t ed by th e manuf actur er.Wh en m easured in accordance wi t h A.1 of BS 6290 the s ta t ed ra ted capac i ty

shal l be achieved on t he f i rs t discharge.


It is industry recognised that Gel cells require cycling to achieve their quotedperformance usually 15 cycles, however the BPC 2V Gel cell will normally achievequoted capacity after 3 cycles. Cells experience two discharge cycles in the factory aspart of the final charging sequence. Below are the average results of 5 batteries testedstraight from finished goods for three cycles. The batteries under test were 2V 300 AhGel. (PSLIFR 300-2) Discharged at 78A for 3 hours to 1.80 vpc.

First Cycle 224 AhSecond Cycle 229 AhThird Cycle 234 Ah

BPC specifications: 2 Volt bloc AGM

BPC 2 Volt AGM cells also undergo a charge discharge cycle as part of the final charging

process and due to the nature of AGM will meet the quoted 3 hour capacity on the firstdischarge. See diagram of the test data for 5 pieces of 2V 500Ah AGM. (PSLIFR 500-2)


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The resulting Ah for 3 hours of 400Ah was easily achieved without reaching the quotedcut off voltage of 1.8V.

AGM batteries also receive two discharge cycles as part of the final charging sequenceand will achieve full capacity when they are packaged for delivery. Below are the resultsof 5 batteries taken at random from the finishing line. The batteries under test were 2V500AH (PSLIFR 500-2) Discharged at 133A for 3 hours to 1.8 vpc.


GelThree pieces of 12V 100Ah Gel (PSLGel 100-12) were taken at random from thefinishing line and tested at 23.1A to 1.75 vpc.

Battery Test 1 Test 2 Test 31 2hrs 54 2hrs 59 3hrs 062 2hrs 52 2hrs 58 3hrs 043 2hrs 56 3hrs 01 3hrs 08

AGMFive pieces of 12V 150Ah AGM (PSLIFR 150-12) were taken at random from the finishingline and tested at 35.5.1A to 1.75 vpc.Battery 1 3hrs 8 mins Battery 2 3hrs 6 mins Battery 3 3hrs 10 minsBattery 4 3hrs 9 mins Battery 5 3hrs 10mins

PSLIFR 2V 500Ah 133A Discharge

1.75

1.8

1.85

1.9

1.95

2

2.05

2.1

2.15

00:00:00 01:00:00 02:00:00 03:00:00

Time

V o

l t s

Battery 1

Battery 2

Battery 3

Battery 4

Battery 5


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BPC specifications: Bloc and Monobloc AGM

The AGM battery is not so resilient to cycling as shown in the graph below.

After 150 cycles of 10% DOD the capacity would be 95% of the quoted C 3 capacity

Battery Cycle Life Vs. Depth of Discharge (DOD)

0

20

40

60

80

100

0 200 400 600 800 1000 1200 1400No. of Cycles

% D

. O . D .


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Endurance at Constant Voltage


Requirements:

Wh en measured in accordance w i th Appendix 2 of t h i s standard no uni tvo l t a ge sha l l f al l b e lo w th e a ve r ag e o f t he u n i t vo l t a ges by m or e t ha n 2 .5%dur ing each 90 day per iod and t he am p hour equiva len t o f gas released sha ll

be less th an 5% of the t o ta l ampere hours passed through th e bat t e ry.

The m anufac turer sha ll sta t e the recom m ended f loat vo l t age in th e type tes tcer t i f ica te .


2 Volt cells on a float voltage of 2.23 Volts per cell (VPC), gave the following resultsafter the 90 day period.

Average voltage 2.23 VPCTotal Deviation 0.26%

Both AGM and Gel cells gave the same result well within the requirement set by thisstandard.

BPC specifications: 6&12 Volt bloc Gel & AGM

Two 6 Volt and two 12 2 Volt cells were connected in series and parallel on a floatvoltage of 2.23 Volts per cell (VPC), gave the following results after the 90 day period.

Average voltage 2.23 VPCTotal Deviation 0.63%

Both AGM and Gel cells gave the same result well within the requirement set by thisstandard.

The volume of gas evolved from all the test batteries over this period was less than thelower limits of detection of the test apparatus. The loss of liquid was not detectable byweighing the cells either. According to the standard 1Ah passed through the cell isequivalent to 449 ml of Hydrogen at 20C. Due to the very low internal resistance of the2 Volt cells is concluded that the gas released over this period is a fraction of therequirement of the standard, which is more biased towards 12V units.


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Endurance under Mechanical Stress

Batteries under consideration 2 Volt Bloc Gel & ASM6&12 Volt Monobloc Gel & AGM

Requirements:

When m easured in accordance w i th Appendix 3 of t h i s s tandard s ix un i t s sha l lrem ain gas- t igh t and any change of per form ance a t th e 5 min ra t e ofd i sc harge shal l no t b e g r e at e r t ha n 10% .


Cells were tested at the quoted 5 minute discharge rate (Note cells were connected inseries to give a 12 Volt system) the units showed no sign of any mechanical stressesinduced by the discharge and the duration of test variation was less than 1%.

BPC specifications: 6&12 Volt bloc Gel & AGM

Cells were tested at the quoted 5 minute discharge rate (Note cells were connected inseries to give a 48 Volt system) the units showed no sign of any mechanical stressesinduced by the discharge and the duration of test variation was less than 3%.


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Conservation of Charge

Batteries under consideration 2 Volt Bloc Gel & AGM6&12 Volt Monobloc AGM

Requirements:

Wh en m easured in accordance w i th Appendix 5 of BS 6290 Par t 1 , 1983 , asm odi f ied by appendix 1 of t h i s standard , t he percentage loss of capaci ty sha ll

no t exceed 28%


Twenty four units of PSLGel 200-2 and PSLIFR 200-2 were fully charged and floated at2.23 VPOC for 24 hours. The units were then placed on open circuit. The standardrequires the test duration be 360 days, the batteries were open circuit for 180 days afterwhich a discharge test was performed the % remaining capacity of the Gel cells was93% and the AGM cells 78%. The graphs below show the expected capacity loss atvarious temperatures.

Self-discharge Characteristics

0

20

40

60

80

100

0 2 4 6 8 10 12 14 16 18Storage Time (Months)

R e s

i d u a l

C a p a c

i t y

40 C

30 C

20 C

10 C


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Four units of PSLGel 100-12 and PSLIFR 100-12 were fully charged and floated at 2.23 VPOC for 24 hours. The units were then placed on open circuit. The standard requiresthe test duration be 360 days, the batteries were open circuit for 180 days after which adischarge test was performed the % remaining capacity of the Gel cells was 91.5% andthe AGM cells 79%. The graphs above show the approximate expected capacity loss atvarious temperatures.


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Flammability of Non- Metallic parts


Requirements:

The f lamm abi l i ty of non-m eta l l i c par t s shal l be sta t ed by th e manuf ac turer.

w hen tested in accor dance w i th m ethod FV of BS6334, i t sha l l comply w i ththa t s ta ted by the manufac turer.

BPC specifications: 2, 6&12 Volt Bloc and Monobloc Gel & AGM

See also section 3.3 Containers and lids.The flammability of all Non-metallic parts as classified by UL9 4 is V0. In addition each2V valve assembly contains an integral FRIT (flame arrestor) above the safety valve.


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BPC Technical Information BS 6290

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