Source: https://www.law.cornell.edu/cfr/text/10/part-430/subpart-B/appendix-Y
Timestamp: 2015-11-29 01:42:36
Document Index: 427184696

Matched Legal Cases: ['art 430', 'art 430', 'art 430', 'art 430', 'art 430', '§ 430']

10 CFR Part 430, Subpart B, Appendix Y to Subpart B of Part 430 - Uniform Test Method for Measuring the Energy Consumption of Battery Chargers | US Law | LII / Legal Information Institute
CFR › Title 10 › Chapter II › Subchapter D › Part 430 › Subpart B › Appendix Y 10 CFR Part 430, Subpart B, Appendix Y to Subpart B of Part 430 - Uniform Test Method for Measuring the Energy Consumption of Battery Chargers
View PDF at GPOPt. 430, Subpt. B, App. Y
The provisions of this appendix are effective on the compliance date of any energy conservation standard for battery chargers.
This appendix covers the test requirements used to measure battery charger energy consumption for battery chargers operating at either DC or United States AC line voltage (115V at 60Hz).
The following definitions are for the purposes of explaining the terminology associated with the test method for measuring battery charger energy consumption.1
2.10. C-rate is the rate of charge or discharge, calculated by dividing the charge or discharge current by the rated charge capacity of the battery.
2.12. Equalization is a process whereby a battery is overcharged, beyond what would be considered “normal” charge return, so that cells can be balanced, electrolyte mixed, and plate sulfation removed.
2.13. Instructions or manufacturer's instructions means the documentation packaged with a product in printed or electronic form and any information about the product listed on a Web site maintained by the manufacturer and accessible by the general public at the time of the test. It also includes any information on the packaging or on the product itself. “Instructions” also includes any service manuals or data sheets that the manufacturer offers to independent service technicians, whether printed or in electronic form.
2.14. Measured charge capacity of a battery is the product of the discharge current in amperes and the time in decimal hours required to reach the specified end-of-discharge voltage.
2.15. Manual on-off switch is a switch activated by the user to control power reaching the battery charger. This term does not apply to any mechanical, optical, or electronic switches that automatically disconnect mains power from the battery charger when a battery is removed from a cradle or charging base, or for products with non-detachable batteries that control power to the product itself.
2.16. Multi-port charger means a battery charger that charges two or more batteries (which may be identical or different) simultaneously. The batteries are not connected in series or in parallel but with each port having separate voltage and/or current regulation. If the charger has status indicators, each port has its own indicator(s). A charger can be both a batch charger and a multi-port charger if it is capable of charging two or more batches of batteries simultaneously and each batch has separate regulation and/or indicator(s).
2.17. Multi-voltage charger is a battery charger that, by design, can charge a variety of batteries (or batches of batteries, if also a batch charger) that are of different rated battery voltages. A multi-voltage charger can also be a multi-port charger if it can charge two or more batteries simultaneously with independent voltage and/or current regulation.
2.18. Off mode is the condition, applicable only to units with manual on-off switches, in which the battery charger:
2.19. Rated battery voltage is specified by the manufacturer and typically printed on the label of the battery itself. If there are multiple batteries that are connected in series, the rated battery voltage of the batteries is the total voltage of the series configuration—that is, the rated voltage of each battery multiplied by the number of batteries connected in series. Connecting multiple batteries in parallel does not affect the rated battery voltage.
2.20. Rated charge capacity is the capacity claimed by a manufacturer, on a label or in instructions, the battery can store under specified test conditions, usually given in ampere-hours (Ah) or milliampere-hours (mAh) and typically printed on the label of the battery itself. If there are multiple batteries that are connected in parallel, the rated charge capacity of the batteries is the total charge capacity of the parallel configuration, that is, the rated charge capacity of each battery multiplied by the number of batteries connected in parallel. Connecting multiple batteries in series does not affect the rated charge capacity.
2.21. Rated energy capacity means the product (in watt-hours) of the rated battery voltage and the rated charge capacity.
2.22. Standby mode or no-battery mode means the condition in which:
2.23. Total harmonic distortion (THD), expressed as a percent, is the root mean square (RMS) value of an AC signal after the fundamental component is removed and interharmonic components are ignored, divided by the RMS value of the fundamental component.
2.24. Unit under test (UUT) in this appendix refers to the combination of the battery charger and battery being tested.
3. Standard Test Conditions
The values that may be measured or calculated during the conduct of this test procedure have been summarized for easy reference in Table 3.1.
Table 3.1— List of Measured or Calculated Values
Name of measured or calculated value
a. Measurements of active power of 0.5 W or greater shall be made with an uncertainty of ≤2 percent at the 95 percent confidence level. Measurements of active power of less than 0.5 W shall be made with an uncertainty of ≤0.01 W at the 95 percent confidence level. The power measurement instrument shall, as applicable, have a resolution of:
b. Measurements of energy (Wh) shall be made with an uncertainty of ≤2 percent at the 95 percent confidence level. Measurements of voltage and current shall be made with an uncertainty of ≤1 percent at the 95 percent confidence level. Measurements of temperature shall be made with an uncertainty of ≤2 °C at the 95 percent confidence level.
c. All equipment used to conduct the tests must be selected and calibrated to ensure that measurements will meet the above uncertainty requirements. For suggestions on measuring low power levels, see IEC 62301, (Reference for guidance only, see § 430.4) especially Section 5.3.2 and Annexes B and D.
3.3. Setting Up the Test Room
All tests, battery conditioning, and battery rest periods shall be carried out in a room with an air speed immediately surrounding the UUT of ≤0.5 m/s. The ambient temperature shall be maintained at 20 °C ±5 °C throughout the test. There shall be no intentional cooling of the UUT such as by use of separately powered fans, air conditioners, or heat sinks. The UUT shall be conditioned, rested, and tested on a thermally non-conductive surface. When not undergoing active testing, batteries shall be stored at 20 °C ±5 °C.
3.4. Verifying the UUT's Input Voltage and Input Frequency
a. If the UUT is intended for operation on AC line-voltage input in the United States, it shall be tested at 115 V at 60 Hz. If the UUT is intended for operation on AC line-voltage input but cannot be operated at 115 V at 60 Hz, it shall not be tested.
b. If a charger is powered by a low-voltage DC or AC input, and the manufacturer packages the charger with a wall adapter, sells, or recommends an optional wall adapter capable of providing that low voltage input, then the charger shall be tested using that wall adapter and the input reference source shall be 115 V at 60 Hz. If the wall adapter cannot be operated with AC input voltage at 115 V at 60 Hz, the charger shall not be tested.
c. If the UUT is designed for operation only on DC input voltage and the provisions of paragraph 3.4 (b) above do not apply, it shall be tested with one of the following input voltages: 5.0 V DC for products drawing power from a computer USB port or the midpoint of the rated input voltage range for all other products. The input voltage shall be within ±1 percent of the above specified voltage.
d. If the input voltage is AC, the input frequency shall be within ±1 percent of the specified frequency. The THD of the input voltage shall be ≤2 percent, up to and including the 13th harmonic. The crest factor of the input voltage shall be between 1.34 and 1.49.
e. If the input voltage is DC, the AC ripple voltage (RMS) shall be:
Unit Under Test Setup Requirements
a. The battery charger system shall be prepared and set up in accordance with the manufacturer's instructions, except where those instructions conflict with the requirements of this test procedure. If no instructions are given, then factory or “default” settings shall be used, or where there are no indications of such settings, the UUT shall be tested in the condition as it would be supplied to an end user.
b. If the battery charger has user controls to select from two or more charge rates (such as regular or fast charge) or different charge currents, the test shall be conducted at the fastest charge rate that is recommended by the manufacturer for everyday use, or, failing any explicit recommendation, the factory-default charge rate. If the charger has user controls for selecting special charge cycles that are recommended only for occasional use to preserve battery health, such as equalization charge, removing memory, or battery conditioning, these modes are not required to be tested. The settings of the controls shall be listed in the report for each test.
4.2. Selection and Treatment of the Battery Charger
4.3. Selection of Batteries To Use for Testing
a. For chargers with integral batteries, the battery packaged with the charger shall be used for testing. For chargers with detachable batteries, the battery or batteries to be used for testing will vary depending on whether there are any batteries packaged with the battery charger.
(1) If batteries are packaged with the charger, batteries for testing shall be selected from the batteries packaged with the battery charger, according to the procedure in section 4.3.b.
(2) If no batteries are packaged with the charger, but the instructions specify or recommend batteries for use with the charger, batteries for testing shall be selected from those recommended or specified in the instructions, according to the procedure in section 4.3.b.
(3) If no batteries are packaged with the charger and the instructions do not specify or recommend batteries for use with the charger, batteries for testing shall be selected from any that are suitable for use with the charger, according to the procedure in section 4.3.b.
b. From the detachable batteries specified above, the technician shall use Table 4.1 to select the batteries to be used for testing depending on the type of charger being tested. Each row in the table represents a mutually exclusive charger type. The technician shall find the single applicable row for the UUT, and test according to those requirements.
(1) Single-capacity if all associated batteries have the same rated charge capacity (see definition) and, if it is a batch charger, all configurations of the batteries have the same rated charge capacity.
(2) Multi-capacity if there are associated batteries or configurations of batteries that have different rated charge capacities.
d. The selected battery or batteries will be referred to as the “test battery” and will be used through the remainder of this test procedure.
Table 4.1—Battery Selection for Testing
Battery selection (from all configurations of all associated batteries)
Lowest charge capacity battery.Highest charge capacity battery.
Use only one port and use the minimum number of batteries with the lowest rated charge capacity that the charger can charge.Use all ports and use the maximum number of identical batteries of the highest rated charge capacity the charger can accommodate.
Lowest voltage battery.Highest voltage battery.
Of the batteries with the lowest voltage, use the one with the lowest charge capacity. Use only one port.Of the batteries with the highest voltage, use the one with the lowest charge capacity. Use only one port.Use all ports and use the battery or the configuration of batteries with the highest total rated energy capacity.
4.4. Limiting Other Non-Battery-Charger Functions
a. If the battery charger or product containing the battery charger does not have any additional functions unrelated to battery charging, this subsection may be skipped.
b. Any optional functions controlled by the user and not associated with the battery charging process (e.g., the answering machine in a cordless telephone charging base) shall be switched off. If it is not possible to switch such functions off, they shall be set to their lowest power-consuming mode during the test.
c. If the battery charger takes any physically separate connectors or cables not required for battery charging but associated with its other functionality (such as phone lines, serial or USB connections, Ethernet, cable TV lines, etc.), these connectors or cables shall be left disconnected during the testing.
d. Any manual on-off switches specifically associated with the battery charging process shall be switched on for the duration of the charge, maintenance, and no-battery mode tests, and switched off for the off mode test.
4.5. Accessing the Battery for the Test
a. The technician may need to disassemble the end-use product or battery charger to gain access to the battery terminals for the Battery Discharge Energy Test in section 5.6. If the battery terminals are not clearly labeled, the technician shall use a voltmeter to identify the positive and negative terminals. These terminals will be the ones that give the largest voltage difference and are able to deliver significant current (0.2 C or 1/hr) into a load.
b. All conductors used for contacting the battery must be cleaned and burnished prior to connecting in order to decrease voltage drops and achieve consistent results.
c. Manufacturer's instructions for disassembly shall be followed, except those instructions that:
d. Care shall be taken by the technician during disassembly to follow appropriate safety precautions. If the functionality of the device or its safety features is compromised, the product shall be discarded after testing.
e. Some products may include protective circuitry between the battery cells and the remainder of the device. If the manufacturer provides a description for accessing the connections at the output of the protective circuitry, these connections shall be used to discharge the battery and measure the discharge energy. The energy consumed by the protective circuitry during discharge shall not be measured or credited as battery energy.
f. If the technician, despite diligent effort and use of the manufacturer's instructions, encounters any of the following conditions noted immediately below, the Battery Discharge Energy and the Charging and Maintenance Mode Energy shall be reported as “Not Applicable”:
4.6. Determining Charge Capacity for Batteries With No Rating
If there is no rating for the battery charge capacity on the battery or in the instructions, then the technician shall determine a discharge current that meets the following requirements. The battery shall be fully charged and then discharged at this constant-current rate until it reaches the end-of-discharge voltage specified in Table 5.2. The discharge time must be not less than 4.5 hours nor more than 5 hours. In addition, the discharge test (Section 5.6) (which may not be starting with a fully-charged battery) shall reach the end-of-discharge voltage within 5 hours. The same discharge current shall be used for both the preparations step (Section 5.4) and the discharge test (Section 5.6). The test report shall include the discharge current used and the resulting discharge times for both a fully-charged battery and for the discharge test.
For this section, the battery is considered as “fully charged” when either (a) it has been charged by the UUT until an indicator on the UUT shows that the charge is complete, or (b) it has been charged by a battery analyzer at a current not greater than the discharge current until the battery analyzer indicates that the battery is fully charged.
When there is no capacity rating, a suitable discharge current must generally be determined by trial and error. Since the conditioning step does not require constant-current discharges, the trials themselves may also be counted as part of battery conditioning.
5. Test Measurement
The test sequence to measure the battery charger energy consumption is summarized in Table 5.1, and explained in detail below. Measurements shall be made under test conditions and with the equipment specified in Sections 3 and 4.
Table 5.1—Test Sequence
Datataken?
Testbattery
Batteryanalyzer or constant-current load
AC powermeter
Thermometer(for floodedlead-acidbatterychargers only)
Record general data on UUT; Section 5.1
Determine test duration; Section 5.2
Battery conditioning; Section 5.3
Prepare battery for charge test; Section 5.4
Battery rest period; Section 5.5
Conduct Charge Mode and Battery Maintenance Mode Test; Section 5.6
Battery Rest Period; Section 5.7
Battery Discharge Energy Test; Section 5.8
Determining the Maintenance Mode Power; Section 5.9
Calculating the 24-Hour Energy Consumption; Section 5.10
Standby Mode Test; Section 5.11
Off Mode Test; Section 5.12
(4) The rated battery voltage of the test battery;
(5) The rated charge capacity of the test battery; and
(6) The rated charge energy of the test battery.
(7) The settings of the controls, if battery charger has user controls to select from two or more charge rates
5.2. Determining the Duration of the Charge and Maintenance Mode Test
a. The charging and maintenance mode test, described in detail in section 5.8, shall be 24 hours in length or longer, as determined by the items below. Proceed in order until a test duration is determined.
b. If none of the above applies, the duration of the test shall be 24 hours.
5.3. Battery Conditioning
a. No conditioning is to be done on lead-acid or lithium-ion batteries. The test technician shall proceed directly to battery preparation, section 5.4, when testing chargers for these batteries.
b. Products with integral batteries will have to be disassembled per the instructions in section 4.5, and the battery disconnected from the charger for discharging.
c. Batteries of other chemistries that have not been previously cycled are to be conditioned by performing two charges and two discharges, followed by a charge, as below. No data need be recorded during battery conditioning.
(1) The test battery shall be fully charged for the duration specified in section 5.2 or longer using the UUT.
(i) A battery analyzer at a rate not to exceed 1 C, until its average cell voltage under load reaches the end-of-discharge voltage specified in Table 5.2 for the relevant battery chemistry; or
(3) The test battery shall again be fully charged as in step c.(1) of this section.
(4) The test battery shall again be fully discharged as per step c.(2) of this section.
(5) The test battery shall be again fully charged as in step c.(1) of this section.
d. Batteries of chemistries other than lead-acid or lithium-ion that are known to have been through at least two previous full charge/discharge cycles shall only be charged once per step c.(5), of this section.
5.4. Preparing the Battery for Charge Testing
Following any conditioning prior to beginning the battery charge test (section 5.6), the test battery shall be fully discharged for the duration specified in section 5.2 or longer using a battery analyzer.
5.5. Resting the Battery
5.6. Testing Charge Mode and Battery Maintenance Mode
a. The Charge and Battery Maintenance Mode test measures the energy consumed during charge mode and some time spent in the maintenance mode of the UUT. Functions required for battery conditioning that happen only with some user-selected switch or other control shall not be included in this measurement. (The technician shall manually turn off any battery conditioning cycle or setting.) Regularly occurring battery conditioning or maintenance functions that are not controlled by the user will, by default, be incorporated into this measurement.
b. During the measurement period, input power values to the UUT shall be recorded at least once every minute.
c. The technician shall follow these steps:
(1) Ensure that the user-controllable device functionality not associated with battery charging and any battery conditioning cycle or setting are turned off, as instructed in section 4.4;
(2) Ensure that the test battery used in this test has been conditioned, prepared, discharged, and rested as described in sections 5.3 through 5.7;
(7) Record the input power for the duration of the “Charging and Maintenance Mode Test” period, as determined by section 5.2. The actual time that power is connected to the UUT shall be within ±5 minutes of the specified period; and
5.7. Resting the Battery
5.8. Battery Discharge Energy Test
a. If multiple batteries were charged simultaneously, the discharge energy is the sum of the discharge energies of all the batteries.
b. During discharge, the battery voltage and discharge current shall be sampled and recorded at least once per minute. The values recorded may be average or instantaneous values.
c. For this test, the technician shall follow these steps:
(2) Set the battery analyzer for a constant discharge current of 0.2 °C and the end-of-discharge voltage in Table 5.2 for the relevant battery chemistry.
d. If not available from the battery analyzer, the battery discharge energy (in watt-hours) is calculated by multiplying the voltage (in volts), current (in amperes), and sample period (in hours) for each sample, and then summing over all sample periods until the end-of-discharge voltage is reached.
5.9. Determining the Maintenance Mode Power
(1) If the maintenance mode power is cyclic or shows periodic pulses, compute the average power over a time period that spans a whole number of cycles and includes at least the last 4 hours.
(2) Otherwise, calculate the average power value over the last 4 hours.
5.10. Determining the 24-Hour Energy Consumption
Table 5.2—Required Battery Discharge Rates and End-of-Discharge Battery Voltages
Discharge rateC
End-of-dischargevoltagevolts per cell
5.11. Standby Mode Energy Consumption Measurement
a. Conduct a measurement of standby power consumption while the battery charger is connected to the power source. Disconnect the battery from the charger, allow the charger to operate for at least 30 minutes, and record the power (i.e., watts) consumed as the time series integral of the power consumed over a 10-minute test period, divided by the period of measurement. If the battery charger has manual on-off switches, all must be turned on for the duration of the standby mode test.
b. Standby mode may also apply to products with integral batteries. If the product uses a cradle and/or adapter for power conversion and charging, then “disconnecting the battery from the charger” will require disconnection of the end-use product, which contains the batteries. The other enclosures of the battery charging system will remain connected to the main electricity supply, and standby mode power consumption will equal that of the cradle and/or adapter alone.
c. If the product is powered through a detachable AC power cord and contains integrated power conversion and charging circuitry, then only the cord will remain connected to mains, and standby mode power consumption will equal that of the AC power cord (i.e., zero watts).
d. Finally, if the product contains integrated power conversion and charging circuitry but is powered through a non-detachable AC power cord or plug blades, then no part of the system will remain connected to mains, and standby mode measurement is not applicable.
5.12. Off Mode Energy Consumption Measurement
a. If the battery charger has manual on-off switches, record a measurement of off mode energy consumption while the battery charger is connected to the power source. Remove the battery from the charger, allow the charger to operate for at least 30 minutes, and record the power (i.e., watts) consumed as the time series integral of the power consumed over a 10-minute test period, divided by the period of measurement, with all manual on-off switches turned off. If the battery charger does not have manual on-off switches, record that the off mode measurement is not applicable to this product.
b. Off mode may also apply to products with integral batteries. If the product uses a cradle and/or adapter for power conversion and charging, then “disconnecting the battery from the charger” will require disconnection of the end-use product, which contains the batteries. The other enclosures of the battery charging system will remain connected to the main electricity supply, and off mode power consumption will equal that of the cradle and/or adapter alone.
c. If the product is powered through a detachable AC power cord and contains integrated power conversion and charging circuitry, then only the cord will remain connected to mains, and off mode power consumption will equal that of the AC power cord (i.e., zero watts).
d. Finally, if the product contains integrated power conversion and charging circuitry but is powered through a non-detachable AC power cord or plug blades, then no part of the system will remain connected to mains, and off mode measurement is not applicable.
[76 FR 31776, June 1, 2011]