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1、AS 2402.2.12005 Australian Standard Traction batteriesLead-acid Part 2.1: Valve-regulated cells Requirements AS 2402.2.12005 This Australian Standard was prepared by Committee EL-005, Secondary Batteries. It was approved on behalf of the Council of Standards Australia on 26 November 2004. This Stand
2、ard was published on 14 January 2005. The following are represented on Committee EL-005: Australian Automobile Association Australian Automotive Aftermarket Association Australian Chamber of Commerce and Industry Australian Electrical and Electronic Manufacturers Association Energy Supply Associatio
3、n of Australia Engineers Australia Keeping Standards up-to-date Standards are living documents which reflect progress in science, technology and systems. To maintain their currency, all Standards are periodically reviewed, and new editions are published. Between editions, amendments may be issued. S
4、tandards may also be withdrawn. It is important that readers assure themselves they are using a current Standard, which should include any amendments which may have been published since the Standard was purchased. Detailed information about Standards can be found by visiting the Standards Web Shop a
5、t .au and looking up the relevant Standard in the on-line catalogue. Alternatively, the printed Catalogue provides information current at 1 January each year, and the monthly magazine, The Global Standard, has a full listing of revisions and amendments published each month. Australian StandardsTM an
6、d other products and services developed by Standards Australia are published and distributed under contract by SAI Global, which operates the Standards Web Shop. We also welcome suggestions for improvement in our Standards, and especially encourage readers to notify us immediately of any apparent in
7、accuracies or ambiguities. Contact us via email at mailstandards.org.au, or write to the Chief Executive, Standards Australia, GPO Box 5420, Sydney, NSW 2001. This Standard was issued in draft form for comment as DR 04254. AS 2402.2.12005 Australian Standard Traction batteriesLead-acid Part 2.1: Val
8、ve-regulated cells Requirements Originated as AS 24021980. Previous edition 1994. Revised and redesignated in part as AS 2402.2.12005. COPYRIGHT Standards Australia All rights are reserved. No part of this work may be reproduced or copied in any form or by any means, electronic or mechanical, includ
9、ing photocopying, without the written permission of the publisher. Published by Standards Australia GPO Box 5420, Sydney, NSW 2001, Australia ISBN 0 7337 6447 9 AS 2402.2.12005 2 PREFACE This Standard was prepared by the Standards Australia Committee EL-005 on Secondary Batteries to supersede (in pa
10、rt) AS 24021994, Lead-acid traction batteries. AS 24021994 has been split into four parts as follows: Traction batteriesLead-acid, Part 1.1 Vented cellsRequirements Traction batteriesLead-acid, Part 1.2 Vented cellsInstallation and usage Traction batteriesLead-acid, Part 2.1 Valve-regulated cellsReq
11、uirements Traction batteriesLead-acid, Part 2.2 Valve-regulated cells Installation and usage It is intended that parts 1.2 and 2.2 will replace the relevant requirements in AS 2359, Powered industrial trucks. In this Standard, the dimensions of traction battery cells, requirements for measuring inst
12、ruments, rated capacity and the battery test life are based on IEC 60254-1, Lead-acid traction batteries, Part 1: General requirements and methods of test, and IEC 60254-2, Lead-acid traction batteries, Part 2: Dimensions of cells and terminals and marking of polarity on cells. Additional requiremen
13、ts not covered by these IEC publications have been included to cover Australian conditions. Acknowledgment is made of the assistance received from BS 2550, Specification for lead-acid traction batteries. The useful life obtained from a battery is also dependent on the performance of the battery char
14、ger. Performance requirements for battery chargers for lead-acid batteries are specified in AS 2548.1, Battery chargers for lead-acid traction batteriesBattery chargers for vented cells. The terms normative and informative have been used in this Standard to define the application of the appendix to
15、which they apply. A normative appendix is an integral part of a Standard, whereas an informative appendix is only for information and guidance. 3 AS 2402.2.12005 CONTENTS Page SECTION 1 SCOPE AND GENERAL 1.1 SCOPE 4 1.2 REFERENCED DOCUMENTS 4 1.3 DEFINITIONS 4 SECTION 2 DESIGN AND CONSTRUCTION 2.1 C
16、ELL DIMENSIONS8 2.2 CONNECTIONS.8 2.3 CONNECTION TO BATTERY 8 2.4 VALVES.9 2.5 FLAME ARRESTERS 9 2.6 SEALING9 SECTION 3 PERFORMANCE REQUIREMENTS 3.1 GENERAL 12 3.2 RATED CAPACITY. 12 3.3 LIFE 12 3.4 LEAKAGE 12 3.5 CHARGE RETENTION 12 SECTION 4 MARKING 4.1 GENERAL 13 4.2 BATTERIES FOR INDUSTRIAL TRUC
17、KS. 13 4.3 BATTERIES FOR OTHER THAN INDUSTRIAL TRUCKS. 14 APPENDICES A RECOMMENDATIONS FOR THE DESIGN OF BATTERY TRAYS AND LAYOUTS 15 B MILLIVOLT DROP TEST FOR FLEXIBLE INTERCELL CONNECTORS. 17 C VERIFICATION OF RATED CAPACITY. 21 D DETERMINATION OF LIFE . 24 E LEAKAGE TEST FOR VALVE-REGULATED BATTE
18、RY CELLS. 26 F CHARGE RETENTION TEST 27 AS 2402.2.12005 4 Standards Australia .au STANDARDS AUSTRALIA Australian Standard Traction batteriesLead-acid Part 2.1: Valve-regulated cellsRequirements S E C T I O N 1 S C O P E A N D G E N E R A L 1.1 SCOPE This Standard specifies requirements for lead-acid
19、 batteries of the valve-regulated type intended for installation in electric traction vehicles, industrial trucks, mechanical handling equipment, semi-traction applications (e.g. golf buggies and wheelchairs) and other applications where deep cycling is required. A complete battery consists of one o
20、r more self-contained units connected in series or parallel. Each unit consists of individual cells or monoblocs assembled into a battery tray. NOTE: Recommendations for the design of battery trays are given in Appendix A. 1.2 REFERENCED DOCUMENTS The following documents are referred to in this Stan
21、dard. AS 1349 Bourdon tube pressure and vacuum gauges 1915 Electrical equipment for explosive atmospheresBattery-operated vehicles 2359 Powered industrial trucks 2359.1 Part 1: General requirements 2402 Traction batteriesLead-acid 2402.1.1 Part 1.1: Vented cellsRequirements AS/NZS 5000 Electric cabl
22、esPolymeric insulated 5000.1 Part 1: For working voltages up to and including 0.6/1(1.2)kV IEC 60051 Direct acting indicating analogue electrical measuring instruments and their accessories 60051-2 Part 2: Special requirements for ammeters and voltmeters 1.3 DEFINITIONS For the purpose of this Stand
23、ard, the following definitions apply. 1.3.1 Actual capacity The quantity of electricity, usually expressed in ampere hours (A.h), that a fully charged battery can deliver for a specific set of operating conditions, including discharge rate, temperature, initial state of charge, age and final voltage
24、. 5 AS 2402.2.12005 .au Standards Australia 1.3.2 Authorized person The person in charge of the premises, or other person appointed or selected by the person in charge of the premises, to perform certain duties associated with the traction batteries on the premises. 1.3.3 Breakaway current The curre
25、nt required by an engine starting battery to overcome the inertial force of an engine. 1.3.4 Capacity The quantity of electricity, usually expressed in ampere hours (A.h), that a fully charged battery can deliver under specified conditions. 1.3.5 Cell jar A container of high impact, acid resisting,
26、insulating material (usually a thermoplastic material, e.g. polypropylene) into which the plates and other internal components are fitted. 1.3.6 Cell lid A component of high-impact, acid-resisting, insulating material which is sealed to the walls of the container near the top and is provided with ho
27、les for terminals and vent plugs. 1.3.7 Charge-discharge cycle A cycle which starts with the flow of a discharge current from a battery of cells, and which ends when a charging current has returned the battery to a fully charged condition. 1.3.8 Charge retention The capability of a fully charged bat
28、tery to hold its capacity after it has been stored on open circuit at a specified temperature for a specified time. 1.3.9 Charging An operation during which a battery receives electric energy, which is converted to chemical energy, from an external circuit. The quantity of electric energy is known a
29、s the charge and is usually measured in ampere hours (A.h). 1.3.10 Cover A removable covering of suitable material enclosing the top of the battery. 1.3.11 Cranking current The current required by an engine starting battery to keep the engine turning until it fires. 1.3.12 Discharging An operation d
30、uring which a battery delivers current to an external circuit by conversion of chemical energy to electric energy. 1.3.13 Electrolyte A solution which will react with the electrodes and carry an electric current between them when the cell terminals are connected to form a closed circuit. 1.3.14 End
31、terminal post A lead post projecting through the lid of the end cell of a battery from which connection is made to an external circuit or to an end terminal post of another battery. AS 2402.2.12005 6 Standards Australia .au 1.3.15 Fully charged battery A battery is considered to be fully charged if
32、the charging current does not vary over three consecutive hourly readings taken at the end of the charging period, account being taken of temperature variations and the charging voltage is that recommended by the battery manufacturer or supplier. 1.3.16 Industrial truck A powered industrial truck as
33、 defined in AS 2359.1. 1.3.17 Lead-acid cell A cell in which the active materials are as follows: (a) Positive electrodes or plates: lead dioxide. (b) Negative electrodes or plates: spongy lead. (c) Electrolyte: dilute sulphuric acid. 1.3.18 Life The number of charge-discharge cycles before the capa
34、city of a battery falls to 80% of the rated capacity. 1.3.19 Monobloc battery A battery in which a number of cells are fitted in a multi-compartment container. 1.3.20 Opportunity charging The use of periods of inactivity of a partially discharged battery (i.e. state of charge less than 80% of the no
35、minal capacity) to increase its state of charge. 1.3.21 Rated capacity The quantity of electricity in ampere hours (A.h), declared by the battery manufacturer or supplier that a battery can deliver after a full charge under specified conditions. NOTE: The specified conditions are the rate of dischar
36、ge, final voltage and temperature. The capacity of a cell or battery is denoted by the symbol C. Because the capacity varies with rate of discharge, the symbol C is followed by a numerical subscript giving the rate of discharge. Thus C5 is the capacity in ampere hours (A.h) at the 5 h rate of discha
37、rge. The specified temperature is usually 30C. The final voltage depends on battery type and conditions of service. 1.3.22 Repeat starting test A test performed to determine the number of effective starting cycles an engine starting battery can achieve. 1.3.23 Separator A sheet of porous, non-conduc
38、ting acid-resisting material fitted between adjacent plates. 1.3.24 Service weight The service weight of a battery, which includes cells, trays, relevant covers and ballast weights used to compensate for lack of battery mass. 1.3.25 Shall Indicates that a statement is mandatory. 1.3.26 Should Indica
39、tes a recommendation. 7 AS 2402.2.12005 .au Standards Australia 1.3.27 Tapered cable thimble A device fitted to the end of a flexible cable to form the connection between the cable and the battery or battery unit. 1.3.28 Thimble socket A fitting which forms the connection between the end terminal po
40、st and the tapered cable thimble. 1.3.29 Tightening screw A screw used for securing the tapered cable thimble to the thimble socket. 1.3.30 Traction battery More than one traction cell permanently and electrically connected in one circuit, intended for use as the power supply of an electric vehicle
41、or an industrial truck. 1.3.31 Traction cell A cell specifically designed to form part of a traction battery. 1.3.32 Tray (basket) An outer container enclosing a battery or battery unit and treated to resist corrosion by sulphuric acid. 1.3.33 Valve-regulated cell A cell which is closed under normal
42、 conditions but which has an arrangement which allows the escape of gas if the internal pressure exceeds a predetermined value. The cell cannot normally receive any addition to the electrolyte. 1.3.34 Vehicle A mobile, battery-powered machine intended for use on public roads. 1.3.35 Vented cell A ba
43、ttery that has its plates immersed in liquid electrolyte. The volume of electrolyte is sufficient to allow for a reasonable loss of water by evaporation or electrolysis during charging. The batterys cells have a vent in their cover that allows a free exchange of the gases inside the cell with the at
44、mosphere. Water is normally added to vented batteries. AS 2402.2.12005 8 Standards Australia .au S E C T I O N 2 D E S I G N A N D C O N S T R U C T I O N 2.1 CELL DIMENSIONS The most common heights and widths of cells are given in Table 2.1. TABLE 2.1 MAIN DIMENSIONS OF TRACTION BATTERY CELLS Width
45、 (nom mm) Height (nom mm) 295 375 440 500 555 160 750 370 440 500 555 605 198 750 NOTE: Cell lengths are dependent on the number of plates in the cell. 2.2 CONNECTIONS Connections between cell terminal posts should be made by burning on or by a suitable method to minimize joint resistance. Intercell
46、 connections shall not obstruct the filling apertures, and shall be designed and arranged so that they do not cause any damage to the post seal. 2.3 CONNECTION TO BATTERY 2.3.1 Means of connection 2.3.1.1 General A battery shall be provided with (a) permanently connected leads; or (b) terminals desi
47、gned to accept a thimble (see Clause 2.3.2); or (c) bolted take-offs; or (d) other suitable means of connection. 2.3.1.2 Sizing of battery leads A battery lead shall be of a size and amp capacity acceptable for the application. It shall be (a) of the same or greater conductor cross-sectional area as
48、 the input cables of the industrial truck; (b) cross-linked polychloroprene insulated and sheathed flexible cable to AS/NZS 5000.1; 9 AS 2402.2.12005 .au Standards Australia (c) resistant to acids or alkalies; and (d) able to withstand flexing, handling, and impact at temperatures between 54C and mi
49、nus 29C. NOTE: Some purchasers may require a millivolt drop test. Details of a suitable test are given in Appendix B. 2.3.2 Thimbles Thimbles shall conform to the dimensions given in Figure 2.1 or Figure 2.2, as follows: (a) Rated capacity 800 A.h: Figure 2.1. (b) Rated capacity 800 A.h: Figure 2.2. NOTE: Battery connections should be tightened in accordance w