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Materials Handling
 
NG/N3G Chargers

Technical Description

This series of Forklift Battery Chargers have been designed to recharge forklift Batteries. They are also suitable for other charging operations.

NG indicates 1 phase charger.

N3G indicates 3-phase charger.

Switch mode technology is used.

Design Aims

To provide a charger which is insensitive to variations in mains voltage.

To provide a charger which has a greatly improved power factor.

To provide a charger with greatly reduced harmonic distortion.

To provide a charger with reduced weight.

To provide a charger with DV/DT battery sensing and control.

Power Factor

1 phase chargers- approximately 0.94

3 phase chargers - approximately 0.96

Mains voltage range giving stable output

1 phase charger 216V to 264V

3 phase charger 374V to 456V

Battery Voltages

24V, 36V, 48V, 72V, 80V

Operation

Input

NG chargers are available in single and three phase. Single-phase chargers operate up to 2.5 kW and three phase to 10kW. Beyond 10 kW the power modules are set up in parallel to produce higher ranges.

We can also set up a 5kW single-phase charger by building a two-tier unit with 2 x 2.5kW modules fitted. Power input requirements would be doubled of course.

Power factor ratings mean that these chargers are more efficient than the equivalent transformer style taper charger.

Output

New Generation chargers have a controlled output which is related at any point to the battery voltage. For example if the charger is set to deliver 100 amps at 2.1 volts per cell then it will deliver that current provided the mains voltage is in the wide range specified.

The output is a controlled taper that reduces the output current as the voltage rises. All chargers have a 3:1 taper designed into them. For example a charger with 105Amps at 2.1 volts per cell (VPC) will deliver 35 Amps at 2.6 VPC.

DV/DT Control System

The control system incorporates a LCD display that delivers information on charging status to the operator. (This detail is shown on an attached sheet.)

The control operates on the rate of change of the battery voltage in relation to time. When the battery voltage ceases to rise then the charger will shut down some 45 minutes later.

Identification

NG/N3G chargers are always identified by the number of battery cells they are designed to charge and the maximum rated output at 2.1 volts per cell.

For example: -

NG12/100 - Single phase, 24 volt (12 cells), 100 Amp charger

N3G24/100 - Three phase, 48 volt (24 cells), 100 Amp charger.

Compliance

Stanbury Chargers comply with the following standards:

AS/NZS 1044 Limits and methods of measurement of radio disturbance characteristics of electrical motor-operated and thermal appliances for household and similar purposes, electric tools and similar electrical apparatus.

CISPR14-1: 2000 Electromagnetic compatibility Requirements for household appliances, electric tools and similar apparatus Part: Emission.

AS 2548.1 1998 Battery Chargers for lead acid traction batteries Part 1: Battery chargers for vented cells.

AS/NZS 3100 Approval and test specification General requirements for electrical equipment

AS/NZS 3760:2001 In-service safety inspection and testing of electrical equipment.

Our C-Tick mark is N1339 Compliance and labelling - Incidental emissions.

Chargers for Materials handling are specifically designed to charge a battery within a specific time frame, traditionally 12 or 8 hours.

Any New Generation chargers will charge a range of battery capacities in a varying time scale depending on the battery capacity. For example our N3G24/100 (48 volt 100 amps) will charge any 48 volt battery in the range of 500 700 ampere hours correctly.

Taking 8 hours at 500ah and 12 hours at 700ah.

In practice the charge time is somewhat less than these figures as batteries are not always discharged 100%.



 
Fast Chargers

SEEL Battery Charger Product Lines 

The materials handling industry is diverse, and the SEEL product has the diversity to meet all battery charging needs. Our high frequency technology leads to:

  • High efficiency (91-93%)
  • High power factor
  • Much less current from the utility
  • Much less battery heating as a result of charging
  • Much lighter weight
  • Much quieter operation

The basic battery charging products are:

1. The Stanbury Charger

[Charger Models NG/N3G-xx/yyyy/zz]

This basic charger is designed as a ferro replacement. It has the same taper characteristic as the ferro, but implements it electronically, is more efficient than the ferro and causes less heating to the battery than the ferro. [Ferro= ferro resonant charger mostly used in the USA but has been introduced to Australia in Scissor lifts and more recently for forklifts.]

This model is for applications where initial purchase price is the primary concern and recharge times are not critical to the operation. Most models operate from a 415 Volt, 3 phase supply, the models for smaller batteries operate off 240 Volt single phase.

2. The Infinity Line

This species all clad in blue cases with the infinity logo, all operate some variant of the PEI profile. The PEI profile charges in three stages:

  • P = constant power, up to 80% charged
  • E = constant voltage, until finish current is reached
  • I = constant current, until charge completed

You can find more information on charge profiles under the Charger Operation tab. The Infinity line includes sub-species as follows:

3. The Utility Charger [Models PEI-xx/yyyy]

This model operates with the standard PEI profile, and accepts a nominal 415V 3 phase supply. This model is for use in any situation where opportunity charging is not contemplated, and where a 415 three phase supply is available.

4. The SE Zip Charger [Models PEI-xx/yyyy-Rrr]

This model operates a PEI profile, modified for high-rate opportunity charging. It accepts a nominal 415V, 3 phase supply. It is configured with start rates of 25 and 30 Amps/100AH of battery capacity. Designed for high rate opportunity charging, the 30 A/100AH will charge a battery from 20% to 80% in a little over 2 hours and the 25 A/100AH profile will charge a battery from 20% to 80% in about 2½ hours.

5. The FC Super Charger

[Models PFC-xx/yyyy & DPFC-xx/yyyy]

A small-footprint, fan-cooled, charger, this model includes very high power output chargers in its range. Configured with a standard PEI profile they are also available as dual chargers in a single case, for applications where the customer wants fewer boxes. Designed for use on a wide range of battery sizes, and where space is at a premium.

6. The FC Super Zip Charger

[Models PFC-xx/yyyy-Rrr & DPFC-xx/yyyy-Rrr]

The FC Super Charger configured with the PEI profile modified for high rate opportunity charging. Also available as dual chargers in a single case, for applications where the customer wants fewer boxes.

The small size, light weight, and quietness in operation make this an unobtrusive charger. It is easy to locate it close to where the trucks rest for efficiency in an opportunity charging application.

SEEL Charger Selector Summary

Infinity Lineup

Convection Cooled

Fan Cooled

Stanbury

Super Charger

Zip Super Charger

NG/N3G

Utility

SE Zip

PFCxx/yyyy

PFCxx/yyyy-Rrr

xx/yyyy

PEIxx/yyyy

PEIxx/yyyyRrr

DPFCxx/yyyy

DPFCxx/yyyy-Rrr

Energy Efficient

x

x

x

x

x

High Power

x

x

x

x

x

Factor

Minimum Utility

x

x

x

x

x

Current

Light Weight

x

x

x

xx

xx

Low Battery

x

x

x

x

x

Heating

Quiet

x

x

x

x

x

415 V 3 phase

x

x

x

x

x

240 V 1 phase

x

x

Taper profile

x

PEI profile

x



 


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