SNI 04-6391-2000 Standar Nasional Indonesia English version Battery Charge Regulator (BCR) – Electrical Requirements and Test Procedures i Badan Standardisasi Nasional ii Contents Foreword. …………………………………………………………………………………………….ii Introduction..…….…………………………………………………………………………… ….iii 1. Scope …………………………………………………………………………………………... 1 2. Reference. 1 3. Term and Definition. …………………………………………………………………………. 1 4. Documentation. ………………………………………………………………………………. 3 5. Marking/Labeling ……………………………………………………………………………… 4 6. Sampling ……………………………………………………………………………………….. 4 7. Pass Criteria and BCR Certification. 4 8. BCR Qualification …………………………………………………………………………….. 5 iii Prakata Foreword Penerapan dan pemanfaatan berbagai Sistem Fotovoltaik di Indonesia telah berlangsung sejak awal tahun 1980-an. Pengkajian kelayakan penerapan sistem fotovoltaik dimulai dari Pilot Proyek Solar Village (bekerjasama dengan TÜV Rheinland, Jerman) pada awal tahun 1980an, kemudian dilanjutkan dengan Pilot Proyek Village Electrification & Pumping System (Kerjasama NEDO, Jepang) di Kenteng, Yogyakarta pada tahun 1987. Pada tahun 1990 setelah sukses dalam penerapan Solar Home System (SHS) di desa Sukatani, Jawa Barat, dimulailah penyebarluasan sistem Fotovoltaik untuk penerangan pedesaan melalui Proyek Banpres dengan memasang 3445 unit SHS di 15 Propinsi Indonesia. Sejak saat itu sistem Fotovoltaik sudah dikenal luas dalam masyarakat. Pada tahun 1998 dengan dicanangkannya Proyek Sejuta Rumah: 50 MWp Photovoltaic Rural Electrification, maka dimulailah era komersialisasi sistem-sistem Fotovoltaik. Untuk mengantisipasi makin berkembangnya bisnis dalam bidang fotovoltaik, maka diperlukan standar spesifikasi teknis, pedoman dan metoda uji komponen serta prosedur penentuan kualifikasi rancangan dan klasifikasi peringkat sistem fotovoltaik termasuk Sistem Fotovoltaik Individual (SFI) atau SHS. Standarisasi ini mempunyai maksud ganda: guna melindungi konsumen dari ketidaksesuaian spesifikasi komponen/sistem yang dijual di pasaran, dan melindungi produsen dari akibat kesalahan persepsi dari masyarakat dalam pemanfaatan sistem fotovoltaik. Dengan adanya standar diharapkan para produsen dan agen juga dapat mempunyai satu dasar perhitungan yang sama untuk mengklasifikasikan sistem fotovoltaik yang dijualnya ke dalam satu sistem peringkat. Dalam bidang standarisasi, Indonesia telah cukup lama terlibat dalam penyusunan dan pengusulan standarisasi khususnya SHS ke forum internasional. Pada saat Proyek Banpres dimulai, spesifikasi teknis SHS yang digunakan untuk proyek ini juga dimanfaatkan oleh World Bank dan AusAID sebagai standar SHS untuk dipasarkan di beberapa negara berkembang. Spesifikasi teknis ini kemudian diusulkan oleh TÜV Rheinland sebagai anggota tetap IEC/TC-82 ke forum IEC/TC-82 (International Electrotechnic Commission/Technical Committee 82: Solar Photovoltaic) sebagai masukan untuk Draft Standar SHS. Dengan demikian Rancangan Standar Nasional Indonesia (RSNI) yang dibuat ini mengacu pada Draft SHS dari standar IEC/TC-82 yang didalamnya memasukkan spesifikasi teknis yang dibuat oleh Indonesia. iv Pendahuluan Introduction Standar BCR (Battery Charge Regulator) untuk pemakaian pada SHS (Solar Home System) ini disusun berdasarkan beberapa referensi standar BCR yang ada, katalog komponen yang berhubungan dengan komponen di BCR , teori (“text book”) yang berhubungan dengan disain rangkaian BCR seperti teori “switching”, komparator, dan dioda, serta pengalaman pengujian BCR dari produksi yang ada sampai saat ini. Dalam perkembangannya, SHS lebih banyak digunakan dinegara berkembang dan/ atau negara tropis seperti misalnya di Indonesia, Philipina, Thailand, Meksiko, negara-negara Afrika, negara-negara Arab dll. Sedangkan negara maju seperti negara-negara Eropa, Jepang dan Amerika Serikat belum siap dalam menyusun standar BCR khusus untuk SHS. Oleh karena standarisasi di Indonesia ini, khusus untuk sistem Fotovoltaik, menggunakan referensi standar Eropa yaitu IEC TC-82, maka dalam penyusunan standar SNI untuk BCR inipun tetap merujuk pada “draft” standar IEC yang pernah disusun. Standar SNI untuk BCR yang disusun sekarang ini ditekankan pada pengujian kualitas unjuk kerja elektris. Adapun kualitas yang lain seperti pengujian mekanikal dan “safety” akan disusun pada tahap berikutnya sesuai dengan perkembangan BCR dan standar Internasional. Kualifikasi unjuk kerja elektrikal BCR ini, khusus diterapkan untuk pemakaian SHS di Indonesia, baik BCR produksi Lokal (Indonesia) maupun produksi Luar Negeri (Import), dengan tidak menutup kemungkinan BCR hasil pengujian ini dapat diekspor. . v Battery Charge Regulator (BCR) – Electrical Requirements and Test Procedures 1. Scope The scope of this standard comprises BCR for lead acid battery with liquid electrolyte (Vented or sealed) The tests describe in this standard are valid for BCR which use the battery terminal voltage as criterion for operation. As well as modern control procedure (for example: state of charge algorithm). The following standard govern the requirement of BCR, which is installed permanently in photovoltaic system, especially for small domestic power supply (Solar Home Systems, SHS). with system voltage is limited up to 50 Vdc and photovoltaic generator with maximum of 500 Wp, to which the BCR intended for examination have been adapted. Mechanical examination is not discussed in this standard and will be elaborate in other standard. 2. Reference pR EN 50314- 3, 1999, Photovoltaic system- Charge Regulators Part 3 performance- Test requirement and Procedures. xxx @ IEC 1997 Draft IEC standard: Charge regulator part 1: Safety- Test requirement and procedure. 3. Term and definition BCR in PV stand alone systems served to match the supply of PV electricity as delivered by the PV module to characteristic of lead acid batteries by limiting excess gassing and water loss by: - Reducing the charge current of PV module such as that a certain voltage (high voltage disconnect) is not exceeded. Limiting deep discharge of the battery is accomplish by automatic disconnect of the load circuit when the battery voltage decreases below a certain voltage (low voltage disconnect) Limiting both voltages is intended to increase the cyclic lifetime of the battery. High voltage disconnect (end of charge voltage)/ final charge voltage High voltage reconnection Low voltage disconnect/final discharge voltage Low voltage reconnection Activated gassing voltage Charge equalization voltage Depth of discharge State of Charge BCR with two point controlled regulation (on-off BCR) Pulse with modulation BCR Series BCR Shunt/Parallel BCR Vnom: Nominal voltage Vgas: Gassing voltage Vmaks: BCR maximum voltage Vpv: PV voltage at PV terminal in BCR Vb: Battery voltage at battery terminal in BCR : Load voltage at load terminal in BCR VL : BCR maximum current input Chalks ILmaks: BCR maximum current output : Load current IL IPV: PV simulator current Ib: Battery simulator current : Digital multimeter for voltage measurement V I : Digital multimeter for current measurement 4. Documentation Documentation in Indonesian should content of the following: − − − − − − − − Installation instruction Operation instruction BCR technical data Trouble shooting Safety precaution Part list Warranty period Block diagram BCR technical documentation should mention following: 4.1 Environment condition: − Range of operational temperature − Maximum relative humidity − Range of storage temperature 4.2 − − − − − − BCR Physical properties: Case dimension Weight Case material Fastener Connector terminal Cables (inlet/cross section) 4.3 − − − − − − − − − − − − − − − Technical specification: Nominal voltage Maximum module current (A) Maximum load current (A) Type of regulator (series or shunt) Working principal (PWM, two-point-regulation; SOC algorithm; etc.) Switching threshold (V) Range of voltage threshold Power consumption (no load) Losses Overload protection Reverse polarity protection Capability of switching to accommodate different nominal voltage Warning sign when load will be disconnected Load disconnect with time delay Display (color LED, accuracy and compatibility) 5. Marking/ Labeling BCR should be labeled/ marked and contents the following: − − − − − − − Name of manufacture (trade mark; manufacture or responsible dealer) Model or BCR type Serial number Nominal voltage Maximum PV module input current Maximum load current Terminal should be labeled confirm with the connection (PV, battery and load). All display should be labeled and confirm with all its function (indicating full battery, empty battery, PV On; etc). Type and capacity of fuse should also mention 6. Sampling Four BCR for qualification testing shall be taken at random from a production batch, in accordance with the procedure given in IEC 60410. BCR shall have been manufactured from specified material and components in accordance with the relevant drawing and process sheets and have been subjected to the manufacture’s normal inspection, quality control and production acceptance procedures. When the BCR to be tested is a prototype of a new design and not from production, this fact shall be noted in the test report. 7. Pass criteria and BCR certification The four BCR from the same production lot are required, and then one sample is taken for inspection of completeness documentation and marking. The four samples are observed visually and tested functionally. When they are passed function test, two samples are selected to undergo the detail test, which are electrical performance test according to drawing no 1.while the other two samples served as replacement. Should one BCR fail any test; another two BCR shall be subjected to the whole of the relevant test from the beginning. If one or both of these BCR also failed, the design shall be deemed not to have met the qualification requirement. If however both BCR pass the test sequence the design shall be judge to have met the qualification requirement. All testing result should be documented in a report, if the samples obtain the pass criteria then it is awarded a BCR qualification test pass certificate according to the type / model related production. 8. BCR qualification BCR qualification test consist of 3 steps, 8.1 Visual observation Visual observation is stressed on the possibility of any defect/damage, inconformity and/or any deviation of BCR physical construction. Generally, the physical observation should include, − − − − − BCR Casing Terminal and connector Display indicator Electronic component, PCB (printed circuit board) Cabling and soldering The practical aspect in repairmen ( assemble/re assemble when it is necessary to repair the BCR). Any peculiarities observed must be conscientiously documented, if necessary by means of photography. 8.2 Functional test 8.2.1 Purpose This functional test is intended to test whether BCR can be functional as it should be. Such as following, − Circuit disconnection between PV module and battery at high voltage disconnect level and reconnect again at predetermined voltage level which is stated in technical specification. − Circuit disconnection between load and battery at low voltage level and reconnect again at predetermined voltage level which is stated in technical specification. − This functional test is conducted accordance with the type or working principle of BCR stated in technical specification. 8.2.2 Test equipment The test equipment use should be calibrated, and the calibration status still valid at the time of qualification. ( see figure 2.) 8.2.3 Qualification procedures Connect BCR that will be qualify as the configuration in figure 2. All the equipment should be in off position prior to the connection. 8.2.3.1 End of charge voltage test a) b) c) d) Set battery simulator voltage 1,05 x Vnom. Set the load (RL) until IL = 0,5 x ILmaks Set IPV until 0,5 x Ichmax.obtained Increase battery simulator voltage gradually with the increment of 0.2 volt, wait for 30 second while observing any alteration on IPV and VPV e) Repeat step d) until PV simulator and battery simulator circuit disconnected. This will be shown by both equipment in the following condition, Series BCR Type: − With two point control: PV simulator will be in open circuit condition, while voltage limiter will be activated (Active display) − PWM: Open circuit voltage pulse initiated at PV input terminal in BCR (switching between system voltage and PV simulator open circuit voltage). To observe this condition, use oscilloscope. Shunt BCR Type : − With two point control. : PV simulator will be in short circuited condition. − PWM: Short circuit voltage pulse initiated at PV input terminal in BCR (switching between system voltage and PV simulator short circuit voltage.). To observe this condition, use oscilloscope. NOTE: approaching end of charge voltage, the voltage addition is 0.05 volt. Record the value of upper limit voltage at the terminal Vb.. For the measuring the upper limit reconnection battery simulator voltage should be decreased gradually by increment of 0.2 volt. 8.2.3.2 Testing of upper limit voltage of BCR with equalization voltage. This procedure is implemented when the BCR equipped with equalization voltage. (Charge equalization voltage). a) Execute step 8.2.3.1, point-to-point e) until upper limit voltage is reached. Set PV simulator current at 0,2 x Ichmaks. b) Decrease battery simulator voltage gradually (by 0,2 Volt) and observed for about 30 seconds until reconnection of upper limit voltage is reached. c) Continue step 8.2.3.2 b) until just a little bit under activated voltage Vgas d) Increase battery simulator voltage as procedures in step 8.2.3.1 point d) and e). If the battery simulator voltage has approach equalization voltage then increases battery simulator voltage as mention in step 8.2.3.1 point e). Record activation voltage Vgas and equalization voltage. If several equalization voltage are obtained, repeat 8.2.3.2 a) to d) according to voltage values given by related BCR technical data in documentation. Record activation voltage Vgas and equalization voltage. 8.2.3.3 Testing of lower limit voltage a) Execute 8.2.3.2 a), b), and c) until load disconector alarm is triggered (if available), Record load disconector alarm voltage. b) Execute 8.2.3.2 b), and c) until lower limit voltage is reached, Record this voltage. c) Execute 8.2.3.2 d) until lower limit reconnection voltage is reached, Record this voltage. 8.2.3.4 Functional test pass criteria BCR under qualification has characteristic as mention in the documentation. Allowable deviation of voltage is ± 0,1 Volt. Recommended BCR operating voltage for SHS implementation is as follow: − − − − Upper limit voltage: (13,8 to 14,5) Volt Upper limit reconnection voltage: has hysterisis with ∆ < 0,5 Volt. Lower limit voltage: (11, 2 to 11,7) Volt Lower limit reconnection has hysterisis with ∆ > 1,0 Volt. If BCR using PWM with equalization voltage, it is recommended that the following values is fulfilled: − Equalization voltage: (14,5 to 15,1) Volt − Upper limit voltage: (13,8 ± 0,1) Volt − Activation voltage Vgas: (11,2 to 12,6) Volt NOTE: These values are for 12-volt battery nominal voltage, other nominal voltage should be adjusted according with related cell voltage. 8.3 Detail test 8.3.1 Power consumption test without load 8.3.1.1 Purpose To test losses in BCR while there is no additional energy input from PV module and load disconnected. 8.3.1.2 Procedure a) Use circuitry mention in figure 2, with PV simulator and load at off condition b) Set battery simulator voltage at lower limit position; c) Measure Ib starting from lower limit voltage to upper limit voltage with increment of 0,5 Volt. Record Ib and observe LED indicator; d) Repeat the measurement, by decreasing battery simulator voltage, starting from upper limit voltage to lower limit voltage. (Opposite of point c). 8.3.1.3 Power consumption test without load pass criteria Sample is stated as passing the test, if current consumption <10 mA for all BCR operation voltage range. 8.3.2 Switching test at upper limit voltage This test also called as current compensation test. 8.3.2.1 Purpose To test BCR’s upper limit voltage connection and disconnection capability and threshold stability for all Ipv.values 8.3.2.2 Procedures Execute 8.2.3.1 for BCR with two-pint control and 8.2.3.2 for BCR with equalization voltage. Both procedures implemented for Ipv at 0,5 A. Repeat procedures above with Ipv at 10%, 50% and 100% from Ichmaks. 8.3.2.3 Switching test at upper limit voltage pass criteria Sample is stated as passing the test, if switching capability of upper limit voltage confirm with its function and has threshold value with tolerance of ± 0,1 Volt for all Ipv.values. 8.3.3 Switching test at lower limit voltage 8.3.3.1 Purpose To test the switching capability at lower limit voltage and the stability of threshold at all IL values. 8.3.3.2 Procedures Execute 8.2.3.3 for IL at 0,5 A. Repeat the test with IL at 10%, 50% and 100% from ILmaks. 8.3.3.3 Switching test at lower limit voltage pass criteria Sample is stated as passing the test, if switching capability of lower limit voltage confirm with its function and has threshold value with tolerance of ± 0,1 Volt for all IL..values. 8.3.4 Voltage drop and efficiency test at PV – Battery terminal in BCR 8.3.4.1 Purpose To test voltage drop and power losses at PV – Battery terminal in BCR 8.3.4.2 Procedure a) Use the circuitry in figure 2. Without load. PV simulator and Battery simulator at on condition. b) Set PV simulator voltage at PV open circuit condition voltage in accordance with BCR utilization, and set Ipv at 10% from Ichmaks c) Set battery simulator voltage at 1,05 Vnom d) Record Vpv, Ipv, Ib and Vb e) Repeat a) to d) for Ipv , at 50% and 100% from Ichmaks 8.3.4.3 Voltage drop and efficiency test at PV – Battery terminal pass criteria Sample is stated as passing the test if value of voltage drop at PV – battery terminal < 5% I Vnom for Ichmaks. 8.3.5 Voltage drop and efficiency test at Battery – Load terminal in BCR 8.3.5.1 Purpose To test the voltage drop and the power losses measure at the battery-load terminal in BCR. 8.3.5.2 Procedure a) b) c) d) e) Use the circuitry in figure 2. Without PV simulator. Battery simulator at On condition Set IL at 10% ILmaks Set battery simulator voltage at 1,05 Vnom Record Vb, Ib, IL and VL Repeat b) to d) for IL at 50% and 100% ILmaks 8.3.5.3 Voltage drop and efficiency test at Battery – Load terminal pass criteria Sample is stated as passing the test if the voltage drop value at Battery-Load terminal < 5% I Vnom for ILmaks. 8.3.6 BCR endurance test at maximum capacity 8.3.6.1 Purpose To test BCR capability at maximum capacity for 1 hour (continuously) 8.3.6.2 Procedure a) Use circuitry diagram in fig 2. b) Set Vb = 1,05 Vnom and Ib at 110% Ichmaks; c) Set Ipv voltage equal to PV module open circuit voltage, according to BCR utilization and set Ipv = Ichmaks; d) Put temperature sensor on one of the following components, blocking diode, FET or heat sink of related component e) Set IL = ILmaks. Record Ipv, Vpv, Ib, Vb, IL, VL and temperature every 15 minute; f) If the temperature of blocking diode or FET show the tendency of increasing drastically along the testing period, then the time should be extend for another 1 hour 8.3.6.3 BCR endurance test at maximum capacity passing criteria Sample is stated as passing this test if following test 8.2 the sample still operate functionally 8.3.7 over load protection test 8.3.7.1 Purpose To test overload protection function in accordance with given technical specification. 8.3.7.2 Precondition Overload protection function should work properly whenever load current reaching 125% ILmaks. This function may be realized by using mechanical fuse or electronically. 8.3.7.3 Procedures a) Use figure 2 with following condition: − PV Simulator at Off condition − Set battery simulator voltage at 1,05 Vnom, and battery simulator current at 150% ILmaks − Set IL = ILmaks b) Increase the value of IL gradually until 125% ILmaks c) Observe whether there is any load disconnection during the increase of IL up to 125% ILmaks d) Record IL as a point of protection. If protection in the form of electronic circuit (automatic) observed the way the protection working for about 10 minute and measure IL (use Oscilloscope when it is necessary). If overload protection is while IL reach 125%, repeat b), c) and d) for IL starting from 100% up to 150% with current increase at 5%. Observe increase of IL every 5 minutes, if there is no disconnection, stop the test 8.3.7.4 Overload protection test pass criteria Sample is stated as passing the test if the overload protection works properly 8.3.8 Reverse polarity protection test 8.3.8.1 Purpose To test BCR’s reverse polarity protection function 8.3.8.2 Procedure a) Use figure 2 without load, Connect load to BCR by reversing the polarity; b) Set battery simulator voltage at Vnom, and increase PV Simulator voltage starting from 0 Volt up to open circuit voltage c) Observe both BCR and the test equipment. Record VL, Ipv and Ib; d) Use figure 2 without load. Connect battery simulator to BCR by reversing the polarity e) Set PV simulator at PV open circuit, increase battery simulator voltage starting from 0 Volt up to Vgas. f) Observe both BCR and the test equipment. Record VL, Ipv and Ib g) Use figure 2. Without load. Connect battery simulator to BCR, connect BCR to PV simulator, both connection is set in the reverse polarity condition h) Set battery simulator voltage at 1,05 Vnom, and increase Vpv starting from 0 Volt up to PV open circuit voltage; i) Observe both BCR and test equipment. Record VL, Ipv and Ib 8.3.8.3 Reverse polarity protection test pass criteria Sample is stated as passing the test if it is not damage during the test 8.3.9 Voltage sensor cable (if available) test 8.3.9.1 Purpose To test the safety of BCR, when the sensor cable in the open circuit or short circuit condition. 8.3.9.2 Procedure Observe the stability of BCR threshold voltage, in both open circuit and short circuit condition. 8.3.9.3 Voltage sensor cable test pass criteria BCR is in safety condition 8.3.10 Temperature sensor cable (if available) test 8.3.10.1 Purpose Observe whether BCR is in safety condition, if sensor cable at open circuit and short circuit condition. 8.3.10.2 Procedure Observe the stability of BCR threshold if sensor cable is in open circuit or short circuit condition. 8.3.10.3 Temperature sensor cable test pass criteria BCR is in safety condition 8.3.11 Temperature compensation at threshold voltage (if available) test 8.3.11.1 Purpose To inspect the possibility of alteration in threshold voltage caused by temperature alteration and inspects temperature compensation, which is caused by battery temperature. 8.3.11.2 Equipment Use the equipments in accordance with figure 2. And climate chamber where temperature could be condisionized in the range +20 0C to +55 0C. 8.3.11.3 Precondition Lower limit voltage should be stable in the temperature range. On the contrary upper limit voltage and Vgas need temperature compensation so that battery-charging characteristic can adjust to environment temperature. Compensation is functioning on upper limit voltage and upper limit reconnection voltage for two-point control BCR with constant hysterisis voltage. Lower limit voltage should keep stable with tolerance of ± 0,3 Volt and threshold of overload protection and reconnection voltage should have temperature coefficient (– 3) up to (– 5) mV/ K per cell. 8.3.11.4 Procedure a) Threshold voltage is tested accordance with functional test 8.2 with test temperature as following 20 0C, 25 0C, 55 0C and 20 0C; b) BCR or temperature sensor should keep at each temperature for at least 15 minute; c) If temperature sensor of BCR mounted externally, then only this sensor conditionized at each above temperature. while the BCR itself operating in ambient temperature.. If BCR does not has external temperature sensor, then the whole BCR should conditionized at each above temperature. 8.3.11.5 Temperature compensation at threshold voltage test pass criteria Sample is stated as passing the test if it is confirm with 8.3.11.3. 8.3.12 Threshold voltage regulation (if available) range test 8.3.12.1 Purpose To identify whether the regulation could be done at threshold voltage which is suit to recommendation in accordance with point 8.2.3.4. 8.3.12.2 Procedure a) Regulation is executed for each existing threshold voltage. which are regulate upper limit voltage, lower limit voltage, temperature compensation, and current compensation.; b) Put threshold regulator at minimum position and measured the threshold voltage. c) Put threshold regulator at maximum position and measure threshold voltage d) Put the threshold regulator back to the initial position 8.3.12.3 Threshold voltage regulation (if available) range test pass criteria Sample is stated as pass test criteria if threshold regulator still in the recommended limits accordance with point 8.2.3.4. Figure 1. Flowchart 4 Specimens 1 Specimen Documentation Visual Inspection Marking/Labeling Function Test 2 Specimens 2 Specimens Self-Consumtion Test at No Load High Voltage Disconect and Reconect Test Low Voltage Disconect and Reconect Test Voltage Drop Test PV-Battery Volateg Drop Test Battery-Load Endurance Test Function Test Overload Protection Test Function Test Reverse Polarity Test Funtion Test Voltage Sensor Cable Test Temperature Sensor Cable Test Temperature Compensation Test Threshold Voltage Range Test Uji Fungsi Report If needed Ipv PV Simulator IL Vpv VL BCR Vb Ib Battery Simulator Figure 2. Test Configuration Dummy Load ( RL )