1、 Printed copies are uncontrolled Page 1 of 21 BATTERY AND COMPARTMENT BATTERY CONNECTORS BATTERY CHARGERS 1.0 PURPOSE The purpose of this Standard is to promote safety and flexibility through design, construction and application of batteries, battery compartments, battery connectors and battery char
2、gers. In this standard, Sections 2.0 5.0 reference the requirements in North America and Sections 6.0 7.0 reference the requirements in Europe. NORTH AMERICAN STANDARD SCOPE: This standard covers minimum requirements for the battery, battery compartment, battery connections and battery charger for i
3、ndustrial trucks within Ford Motor Company. It is intended to be complimentary to existing regulations, National Standards, Trade Association Standards, and other Ford Motor Company Standards governing the supply and operation of applicable components or systems. 2.0 REFERENCES: Other standards whic
4、h are considered part of this specification include: National Electric Manufacturers Association Standard (NEMA): 1B2 Determination of Capacity of Lead-acid Industrial Storage Batteries for Motive Power Service 1B3 Life Testing of Lead-acid Industrial Storage Batteries for Motive Power Service Ameri
5、can National Standards Institute (ANSI): B56 Material Handling Trucks B15.1 For Mechanical Power Transmission Apparatus 1984 UL 583 Standard for Safety for Electric Powered Industrial Trucks UL-1564 Industrial Battery Charges Industrial Truck Association Standards (ITA) Underwriters Laboratories (UL
6、) UL 1564 Ford Motor Co. Electrical Standards EX-3 EL3X ES-20 Standard Number w-ZA2 Issue Date: 20000405 Global Manufacturing Standards Rev: Printed copies are uncontrolled Page 2 of 21 3.0 BATTERY TYPES, DIMENSIONS AND SIZES: 3.1 BATTERY TYPE: Shall be lead-acid in a steel tray. Capacity rated at a
7、 6 hour discharge rate. BATTERY VOLTAGE NUMBER OF CELLS CELL ARRANGEMENT A.H. PER POSITIVE PLATE 18 9 3 X 3 24 12 4 X 3 160 36 18 3 X 6 85 36 18 3 X 6 125 48 24 4 X 6 85 3.2 BATTERY CAPACITY DIMENSIONS AND CABLE SIZE: BATTERY ID NUMBER BATTERY VOLTAGE NUMBER OF PLATES AMPERE HOUR CAPACITY CABLE SIZE
8、 MINIMUM WEIGHT(LBS) ZA2-A 18 13 540 1/0 900 ZA2-B 18 13 660 1/0 950 ZA2-C 24 9 640 1/0 1360 ZA2-D 24 11 800 1/0 1650 ZA2-E 24 13 960 3/0 1850 ZA2-F 24 15 1120 4/0 2300 ZA2-G 36 17 660 1/0 1880 ZA2-H 36 19 750 2/0 2090 ZA2-I 36 21 850 2/0 2320 ZA2-J 36 23 935 3/0 2535 ZA2-K 36 25 1020 3/0 2765 ZA2-L
9、 36 17 1000 3/0 2825 ZA2-M 48 19 765 2/0 2900 ZA2-N 48 21 850 2/0 3200 ZA2-0 48 23 925 3/0 3600 ZA2-P 48 25 1020 3/0 4000 ZA2-Q 48 29 1190 4/0 4700 3.3 LEADS: Lead termination location and length shall be specified by the requisitioning activity in accordance with UL 583 and the equipment manufactur
10、ers requirement. Standard Number w-ZA2 Issue Date: 20000405 Global Manufacturing Standards Rev: Printed copies are uncontrolled Page 3 of 21 3.4 BATTERY HANDLING: 3.4.1 LIFTING EYES: There shall be one at the top center of both “Y“ ends in accordance with ITA. 3.4.2 AUTOMATED HANDLING: For requisiti
11、oning activities with “Vacuum or magnetic handling systems“, end plates for the battery cases must be reinforced. 3.5 BATTERY PAINT AND COATING: The standard color “acid resistant“ paint or coating supplied by the manufacturer will be acceptable unless otherwise specified by the requisitioning activ
12、ity. All surfaces of the battery case and lid shall be painted. 3.6 BATTERY CONSTRUCTION: Shall be in accordance with UL 583. 3.7 MARKING: All batteries shall be legibly stamped on the battery tray near the lifting means in accordance with ANSI B56 and UL 583. In addition a serial number, date of ma
13、nufacture, manufacturer and weight shall be shown. 3.8 BATTERY AND COMPARTMENT SIZE: Shall conform to the specifications as shown: Standard Number w-ZA2 Issue Date: 20000405 Global Manufacturing Standards Rev: X-DIM. IN INCHES Y-DIM. IN INCHES Z-DIM. IN INCHES BATTERY ID NUMBER VOLT. AMPERE HOUR CAP
14、ACITY BATTERY SIZE (MAX) COMPARTMENT SIZE (MIN) BATTERY SIZE (MAX) COMPARTMENT SIZE (MIN) BATTERY SIZE (MAX) COMPARTMENT SIZE (MIN) ZA2-A 18 540 27.50 28 11.75 12 31.5 32 ZA2-B 18 660 27.50 28 11.75 12 31.5 32 ZA2-C 24 640 36.25 36.5 11.75 12.25 31 32 ZA2-D 24 800 36.25 36.5 14.25 14.75 31 32 ZA2-E
15、24 960 36.25 36.5 16.25 16.75 31 32 ZA2-F 24 1120 35.50 36.5 18.13 18.68 30.38 32 ZA2-G 36 660 37.75 38.125 15.625 16.125 30.375 30.625 ZA2-H 36 750 37.75 38.125 15.625 16.125 30.375 30.625 ZA2-I 36 850 38.25 38.75 20.125 20.75 30.5 30.75 ZA2-J 36 935 38.75 38.75 20.125 20.75 30.5 30.75 ZA2-K 36 102
16、0 38.25 38.75 20.125 20.75 30.5 30.75 ZA2-L 36 1000 38.25 38.75 20.125 20.75 30.5 30.75 ZA2-M 48 765 38.75 39.25 30.5 31.0 22.63 23.5 ZA2-N 48 850 38.75 39.25 33.0 33.5 22.63 23.5 ZA2-0 48 925 38.75 39.25 38.5 39.0 22.63 23.5 ZA2-P 48 1020 39.00 39.5 38.5 39.0 22.63 23.5 ZA2-Q 48 1190 45.25 45.75 38
17、.75 39.25 22.63 23.5 Printed copies are uncontrolled Page 4 of 21 4.0 BATTERY CONNECTOR COLORS FOR ALL INDUSTRIAL TRUCKS: Specific colors are used for connectors on industrial truck batteries and chargers to eliminate confusion, safety hazards, fire hazards and damage to trucks, batteries or charger
18、s. The following colors are to be used with industrial trucks, batteries and chargers: * Color to be determined by the requisitioning activity. 4.1 OPTIONS: The following options are available for Anderson SB and SBX connectors: Cable clamp - Anderson Model 911G2 Handle and clamp - Anderson Model 99
19、5G2 5.0 BATTERY CHARGERS 5.1 EQUIPMENT REQUIREMENTS: 5.1.1 DEFINITION: This standard outlines the requirements for single and multi circuit 12-18-24-36 and 48 volt automatically controlled battery chargers designed to re-charge electric Industrial truck batteries. Standard Number w-ZA2 Issue Date: 2
20、0000405 Global Manufacturing Standards Rev: COLOR VOLTAGE AMPERE HOUR RATING CABLE SIZE REFERENCE ANDERSON PART NUMBER YELLOW 18 V 510 - 580 1/0 SB 6328G1 YELLOW 18 V 660 - 935 2/0 SB 6323G1 GRAY 24 V 640 - 800 1/0 SB 6325G1 GRAY 24 V 960 - 1020 3/0 SBX 6345G2 * 24 V 1120 4/0 * RED 36 V 660 - 750 2/
21、0 SBX 6347G1 RED 36 V 850 2/0 SB 6322G1 BLUE 36 V 935 - 1020 3/0 SBX 6346G2 GRAY 48 V 765 2/0 SB 6320G1 BLUE 48 V 850 2/0 SB 6321G1 YELLOW 48 V 925 3/0 SB 6323G5 RED 48 V 1020 3/0 SB 6322G5 GREEN 48 V 1190 4/0 SB 6324G2 Printed copies are uncontrolled Page 5 of 21 5.1.2 TYPE: The charger shall be au
22、tomatically operated, charge rate controlled, designed to recharge in eight hours a battery that is 80% discharged, in conformance with the Battery Manufacturers published data. An “equalize“ function shall be provided to extend the charge a maximum of four (4) hours beyond normal charge termination
23、. The charger shall conform with NEMA 1B6, U.L. 1564, Ford Motor Co. Electrical Standard EX3, OSHA and other applicable standards. For supply to Canadian plants, it shall additionally meet the requirements and approval of CSA, Canadian Electrical Code Ontario Hydro Electric Power Commission or other
24、 governing/regulating authorities. Should conflict materialize between this and other Ford Motor Company Standards, the provision of this Standard shall take precedence. 5.1.3 CAPACITY: The data shown on the following page details the Ford Standard Number for each capacity charger. The requisitionin
25、g activity shall ascertain that the capacity of charger specified conforms to the requirements of the industrial truck batteries to be charged. 5.1.4 VOLTAGE: The primary AC input voltage is 460 volts, single or three phase, 60 cycle. Phase requirement shall be specified by the requesting activity a
26、ccording to data shown on page two. Means shall be provided on the battery charger transformer to accommodate line voltages from 420 to 500 volts. NOTE: Purchase orders for plants outside the United States shall indicate their specific voltage, frequency and phase required. Standard Number w-ZA2 Iss
27、ue Date: 20000405 Global Manufacturing Standards Rev: Printed copies are uncontrolled Page 6 of 21 BATTERY CHARGERS - FOR LEAD - ACID TYPE, INDUSTRIAL TRUCK BATTERIES CHARGER CAPACITY DATA CHARGER ID NUMBER NO. OF CIRCUITS NO. BATTERY CELLS VOLTS AMP. HR. RANGE ONE OR 3 PHASE ZA2-1 1 6 12 500-625 Ei
28、ther ZA2-2 2 12 500-625 Either ZA2-3 4 6 12 500-625 3 ZA2-4 1 12 620-770 ZA2-5 1 9 18 400-500 Either ZA2-6 2 18 400-500 Either ZA2-7 4 9 18 400-500 3 ZA2-8 1 18 500-625 ZA2-9 2 9 18 500-625 3 ZA2-10 4 9 18 500-625 3 ZA2-11 1 9 18 620-770 3 ZA2-12 2 9 18 620-770 3 ZA2-13 4 9 18 620-770 3 ZA2-14 1 9 1
29、8 770-960 3 ZA2-15 1 12 24 500-625 3 ZA2-16 1 12 24 625-770 3 ZA2-17 4 12 24 625-770 3 ZA2-18 1 12 24 770-960 3 ZA2-19 1 12 24 960-1200 3 ZA2-20 1 18 36 400-500 3 ZA2-21 2 18 36 400-500 3 ZA2-22 1 18 36 500-625 3 ZA2-23 2 18 36 500-625 3 ZA2-25 1 18 36 625-770 3 ZA2-26 4 18 36 625-700 3 ZA2-27 1 18
30、36 770-960 3 ZA2-28 2 18 36 770-960 3 ZA2-30 4 18 36 770-960 3 ZA2-31 1 18 36 960-1200 3 ZA2-32 1 24 48 625-770 3 ZA2-33 1 24 48 770-960 3 ZA2-34 1 24 48 1020-1190 3 Charger Capacity Power Control voltage shall be normal 115 volts, single phase, obtained from a transformer with an isolated secondary
31、 winding. The charger shall be equipped with a Ford approved fused AC safety main line disconnect switch conforming with Ford Manufacturing Standard ES-20. The door shall be equipped with vault type hardware and handle. Standard Number w-ZA2 Issue Date: 20000405 Global Manufacturing Standards Rev: P
32、rinted copies are uncontrolled Page 7 of 21 The A.C. line (as part of the disconnect switch), and the secondary sides of both the power and control transformers shall be fuse protected such that a failure in an output component shall not damage the transformers, and associated rectifier components.
33、All voltages above normal control voltage levels should be shorted to ground via an approved safety interlock device when the electrical panel is opened, to discharge capacitors. 5.1.5 CONTROLS: (1) Charging Circuits: The charging circuit shall be of such design as to sense the back E.M.F. of the ba
34、ttery and to supply the battery with the current necessary to charge it to a minimum required voltage per cell. Provision shall be made to manually adjust the finish voltage to better meet the requirement of new battery designs as they evolve. The basic charger circuitry shall be inherently fail saf
35、e requiring no additional protective circuitry to the degree that any shorting or failure of any component will not result in damage to the battery being charged. (2) Heat Sinking: The heat sinking of all solid state components shall meet the latest ANSI Standard, and for chargers manufactured for u
36、se in Canada, the CSA Standard. (3) Temperature Rise: A battery charger shall not cause the electrolyte temperature of a battery, which is matched to its rating, to exceed limits established in NEMA 1B6. (4) Control Components: All control and power components shall be rated for continuous duty cycl
37、e at maximum charger demand. All transformers shall be insulated to a minimum of class H with class F thermal characteristics. The manufacturer shall provide necessary design information to support this specification. Provision shall be made to easily adjust charger output voltage to properly charge
38、 lead acid or absolite batteries. All control devices shall be protected from: All self-generated transients. Normally externally applied transients. Damage when the charger is turned ON or OFF at any charging rate or with the battery disconnected. Damage when disconnecting the battery at any chargi
39、ng rate. Damage should the output terminals be shorted. Damage should the battery polarity be reversed. Standard Number w-ZA2 Issue Date: 20000405 Global Manufacturing Standards Rev: Printed copies are uncontrolled Page 8 of 21 5.1.6 ENCLOSURE: (1) Construction: The enclosure shall be made of 14GA s
40、teel and equipped with sufficient openings to provide cooling of the heat generating components without the use of cooling fans. Ventilation openings, if required, should be on the bottom and sides of the enclosure. If the enclosure has top surface openings, they shall be protected with an approved
41、gable type, gage sheet steel drip cover. The charger enclosure shall be a free standing cabinet provided with either 4 inch legs for shelf mounting or 19 inch legs for floor mounting. Each of these legs shall be provided with anchor bolt holes to attach to the bottom of the unit and to the mounting
42、surface. The required type of mounting shall be specified by the requesting activity. Component layout and cabinet design shall be such that all normally serviced components can be easily serviced and removed through the front of the cabinet for maintenance. (2) Receptacle: The charging receptacle s
43、hall conform to Ford Manufacturing Standard w-ZA2, Section 4.0 and shall be equipped with approved ten foot charging cable leads unless other length is specified by the requisitioning activity. Output cables shall be color coded with positive (red) - negative (black). 5.1.7 CONTROL OPERATION: (1) Vo
44、ltage And Current: The D.C. voltage level shall be controlled and the D.C. current limited to assure: 1a). The starting current is within the range of a maximum 0.22 or a minimum of 0.16 times the ampere hour rating of the battery (6 hour rating). 1b). The finishing current does not exceed 0.05 time
45、s the ampere hour rating of the battery (6 hour rating). Room ambient temperature changes in the range of 40 F to 122 F shall not affect voltage settings by more than 1%. Line compensation shall be such that current output limits during the initial charge period are maintained within +/- 10% of the
46、nominal value, and current output limits, during the final charge period, are maintained within +/- 1% for a +/- change in input line voltages. Should loss of power occur during the charging cycle, the charger shall resume charging at the same point in the charging cycle when the power is restored.
47、Standard Number w-ZA2 Issue Date: 20000405 Global Manufacturing Standards Rev: Printed copies are uncontrolled Page 9 of 21 (2) Operation: The charger shall have automatic start capability. Charging start shall commence 3-5 seconds after connecting the battery and will automatically stop upon comple
48、tion of the charging cycle. To minimize the effect of over-charging, a fully automatic non-adjustable timer shall be provided. It shall be connected so that when the charger is activated, it shall terminate charging after a 12 hour charging period has elapsed. In the event the charging cycle should
49、stop due to loss of power, the timer shall stop and continue at the same point when power is restored. A back-up circuit should be provided to automatically turn off the charger in the event a defective battery is connected to the charger or the control experiences a component failure which could prevent the charge termination circuitry from performing properly. A manual stop function should be provided to allow turning off the charger before a normal charge termination takes place to allow disconnecting t
