BELATRON compact charging systems switch mode technology ...

World Class Charging Systems
BELATRON compact
World class switch-mode charging
systems for traction batteries

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

BENNING World Class Charging Systems
Type table
BELATRON compact
Battery capacity [Ah]*
Out- flooded flooded sealed Nominal Nominal Mains
put- battery battery battery current Input fuses cabinet Weight Type
voltage charging time** charging time charging time voltage Standard On-board
[V] 7,5 – 8 h 11 – 14 h 11 – 14 h [A] [V] [A] [kg]
12 45 – 50 50 – 80 40 – 50 8 230 0.8 WT 300 – 2 E 230 G 12 / 8 B-FBC
55 – 70 70 – 100 50 – 60 10 230 1.0 WT 300 – 2.5 E 230 G 12 / 10 B-FBC
70 – 80 80 – 120 60 – 75 12 230 1.25 WT 300 EG 600 2.5 E 230 G 12 / 12 B-FBC
90 – 110 110 – 160 80 – 100 16 230 1.4 WT 600 EG 600 3.5 E 230 G 12 / 16 B-FBC
110 – 130 130 – 200 100 – 125 20 230 1.7 WT 600 EG 600 3.5 E 230 G 12 / 20 B-FBC
140 – 180 180 – 250 125 – 160 25 230 2.1 WT 600 EG 600 3.5 E 230 G 12 / 25 B-FBC
170 – 200 200 – 300 150 – 185 30 230 1.9 WT 900 EG 900 5.5 E 230 G 12 / 30 B-FBC
190 – 250 250 – 350 175 – 220 35 230 2.2 WT 900 EG 900 5.5 E 230 G 12 / 35 B-FBC
24 45 – 50 50 – 80 40 – 50 8 230 1.45 WT 300 – 2 E 230 G 24 / 8 B-FBC
55 – 70 70 – 100 50 – 60 10 230 2.0 WT 300 – 2.5 E 230 G 24 / 10 B-FBC
70 – 80 80 – 120 60 – 75 12 230 2.4 WT 300 EG 600 2.5 E 230 G 24 / 12 B-FBC
90 – 110 110 – 160 80 – 100 16 230 2.7 WT 600 EG 600 3.5 E 230 G 24 / 16 B-FBC
110 – 130 130 – 200 100 – 125 20 230 3.4 WT 600 EG 600 3.5 E 230 G 24 / 20 B-FBC
140 – 180 180 – 250 125 – 160 25 230 4.2 WT 600 EG 600 3.5 E 230 G 24 / 25 B-FBC
170 – 200 200 – 300 150 – 185 30 230 3.8 WT 900 EG 900 5.5 E 230 G 24 / 30 B-FBC
190 – 250 250 – 350 175 – 220 35 230 4.5 WT 900 EG 900 5.5 E 230 G 24 / 35 B-FBC
270 – 350 350 – 500 240 – 320 50 230 6.2 WT 900 EG 900 7.5 E 230 G 24 / 50 B-FBC
360 – 465 460 – 640 330 – 500 65 230 8 WT 900 EG 1800 8.5 E 230 G 24 / 65 B-FBC
470 – 625 600 – 850 425 – 650 85 230 10.1 WT 3000 – 12 E 230 G 24 / 85 B-FBC
560 – 710 710 – 1000 500 – 770 100 230 11.9 WT 3000 – 12 E 230 G 24 / 100 B-FBC
670 – 850 850 – 1200 600 – 920 120 230 14.4 WT 3000 – 12 E 230 G 24 / 120 B-FBC
36 45 – 50 50 – 80 40 – 50 8 230 2.1 WT 600 EG 600 3.5 E 230 G 36 / 8 B-FBC
70 – 80 80 – 120 60 – 75 12 230 3.1 WT 600 EG 600 3.5 E 230 G 36 / 12 B-FBC
90 – 110 110 – 160 80 – 100 16 230 4.1 WT 600 EG 600 3.5 E 230 G 36 / 16 B-FBC
110 – 130 130 – 200 100 – 125 20 230 3.8 WT 900 EG 900 5.5 E 230 G 36 / 20 B-FBC
140 – 180 180 – 250 125 – 160 25 230 4.7 WT 900 EG 900 5.5 E 230 G 36 / 25 B-FBC
190 – 250 250 – 350 175 – 220 35 230 6.4 WT 900 EG 900 7.5 E 230 G 36 / 35 B-FBC
270 – 350 350 – 500 240 – 320 50 230 9.1 WT 900 EG 1800 8.5 E 230 G 36 / 50 B-FBC
48 70 – 80 80 – 120 60 – 75 12 230 4.1 WT 600 EG 600 3.5 E 230 G 48 / 12 B-FBC
90 – 110 110 – 160 80 – 100 16 230 4.1 WT 900 EG 900 5.5 E 230 G 48 / 16 B-FBC
110 – 130 130 – 200 100 – 125 20 230 4.8 WT 900 EG 900 7.5 E 230 G 48 / 20 B-FBC
140 – 180 180 – 250 125 – 160 25 230 6 WT 900 EG 900 7.5 E 230 G 48 / 25 B-FBC
190 – 250 250 – 350 175 – 220 35 230 8.6 WT 900 EG 1800 8.5 E 230 G 48 / 35 B-FBC
270 – 350 350 – 500 240 – 320 50 230 11.6 WT 3000 – 12 E 230 G 48 / 50 B-FBC
330 – 420 420 – 625 330 – 400 60 230 13.8 WT 3000 – 12 E 230 G 48 / 60 B-FBC
*Generally, the current sizes of the battery manufacturers are valid, **Pulse characteristic
Technical details are subject to change without notice.
Dimensions [mm]
Type Hight Width Depth
Standard:
WT 300 88 212 166
WT 600 130 286 225
WT 900 152 365 269
WT 3000 152 365 290
On-board:
EG 600 83 318 178
EG 900 116 386 217
EG 1800 116 436 217
BENNING Power Electronics (UK) Ltd. · Oaklay House
Hogwood Lane · Fincampstead · GB-Berkshire RG 40 4QW
Tel. 0118 / 9731506
Fax 0118 / 9731508
http://www.benninguk.com
E-Mail: info@benninguk.com
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784119.01 GB 07/2004 paus Design & Medien, Bocholt Subject to alterations. Printed on chlorine free paper.