Testing and Commissioning of AEG 125VDC Battery Charger

Testing and Commissioning Procedure for AEG DC Charger

1. Pre-Commissioning Checks

Before applying power to the system, perform the following checks:

1.1 Documentation Review

Verify all technical manuals, drawings, and datasheets are available and correct.

Confirm that the DC charger model matches project specifications (e.g., voltage, current rating).

1.2 Visual Inspection

Check for physical damages, loose wires, or missing parts.

Ensure all terminals are tight and properly labeled.

Inspect cabinet for proper grounding and cleanliness.

1.3 Mechanical Checks

Ensure ventilation fans (if any) are free from obstructions.

Check all panel doors close securely and have proper gaskets for IP rating.

1.4 Electrical Inspection

Confirm input AC supply rating (voltage, frequency, phase) is as per the charger specification.

Verify correct polarity of DC output terminals.

Measure insulation resistance using a Megger:

Between AC input and ground

Between DC output and ground

Acceptable value: 1 MΩ

2. Power-On Testing

2.1 Initial Energization

Ensure DC output is disconnected from the load.

Switch ON the main AC supply breaker.

Observe charger startup behavior (LEDs, HMI, display initialization).

2.2 Input Voltage and Current Check

Measure and verify AC input voltage at terminals.

Check input current and ensure it is within expected range.

2.3 Self-Test and Diagnostics

Allow the charger to complete self-check routines.

Review display or indicators for error/fault messages.

Acknowledge and clear any non-critical alarms.

3. Functional Tests

3.1 Output Voltage Test

Connect a dummy or resistive load.

Measure DC output voltage and verify it matches charger settings.

3.2 Output Current Test

Adjust load to draw current gradually.

Monitor current through the display or external meter.

Verify charger limits output as per nameplate rating.

3.3 Protection Function Test

Simulate:

Overvoltage condition

Overcurrent condition

Input failure

Output short circuit (if safe to test)

Verify system trips, alarms activate, and charger shuts down as designed.

3.4 Communication and Monitoring

Test any communication interfaces (Modbus, Ethernet, etc.).

Verify monitoring system receives real-time data (voltage, current, status).

Test remote shutdown/startup commands if applicable.

4. Battery Integration

4.1 Battery Connection

Confirm correct polarity and connection.

Monitor battery voltage and ensure the charger recognizes it.

4.2 Charging Profile Verification

Check the configured charging profile (Float/Boost/Equalize).

Verify voltage and current settings are appropriate for the battery type.

Monitor for any abnormal battery behavior (heating, swelling, etc.).

5. Final Checks and Documentation

5.1 System Stability Test

Run the charger under normal load for a minimum of 2–4 hours.

Monitor temperature, voltage, current, and alarms.

5.2 Parameter Logging

Record key commissioning parameters:

Input voltage/current

Output voltage/current

Charger temperature

Faults/alarm history

5.3 Handover and Reporting

Prepare a Test and Commissioning Report.

Get sign-off from client/QA/QC engineer.

Provide training or demonstration if required.

6. Safety and Compliance

Ensure all tests are performed with proper PPE.

Follow local electrical codes and standards (e.g., IEC 61851, NEC, etc.).

Confirm proper signage and labeling is in place before handover.