Third Party Inspection for Battery Charger

The Third Party Inspection for Battery Charger article provides you information about battery charger test and battery charger inspection and testing in manufacturing shop.

You may need to review this article in conjunctions of following article:

Inspection and Test Plan (ITP) for Battery Charger

This content guides you about all necessary stages in the production of the Battery Charger from the examination of the raw material, final inspection, preservation and packing to despatch to site.

This content is written for typical Battery Charger and might not be detail for special cases.

This content would be useful for second and third party inspectors, Battery Charger manufacture quality control personnel, engineering companies, purchasers and any interested individuals.

Battery Charger inspection and test is done against the approved drawings, purchase order specifications, purchasers or company standards, and within the practices and rules of the country, state or province and any government decrees, laws, ordinance or regulation as may apply.

The applicable codes and specifications for Battery Chargers which are under construction or supply process are:

Design code and Standard
Purchase order specification
Purchaser's standards
Approved drawings

Your applicable codes and standards may be based any international standards. This content is general and can be useful for all recognized standards.

Required Documents for Third Party Inspector Review

The list of documents normally is agreed in the Pre-Inspection meeting which is hold several weeks before actual commencement of inspection work. (In great purchases)

The parties which are participated in this meeting are manufacture, purchaser and third party inspection agency representatives.

This already explained in the Inspection and Test Plan for Battery Charger article.

These are the list of documents which are normally agreed to be provided to the inspector:

Battery Charger Purchase Order or Contract
Battery Charger Manufacture proforma Invoice
Battery Charger Manufacture Quality Control Plan
Battery Charger Inspection and Test plan
Battery Charger Data Sheet
Battery Charger Approved Drawings, (arrangements, schematics, wiring, single line)
Battery Charger Raw Material Test Reports
Battery Charger Weld procedures and procedure qualification records (if applicable)
Battery Charger Calibration Certificates for Test Equipment
Battery Charger Special Procedures
Battery Charger Special Qualifications
Battery Charger Preservation, Packing and Shipping Procedure
Battery Charger Packing List

Third Party Inspection for Battery Charger-Material Inspection

The first actual inspection work is raw materials inspection. The original or authenticated copy of mill certificates normally is available at manufacturer's premises.

The third party inspector examines these certificates for compliance with specifications and where appropriate with drawings.

The review includes checks on:

Maker’s name and location
Certificate number, grade
Batch number
Chemical composition
Mechanical properties
Cast or Heat number (for metal parts)
Heat treatment condition
Surface finish
Structural observations, notable defects

Ancillary items may be supported by test certification, or by certificates of conformity. It is necessary the content of certification to be appropriate to the required scope of the items.

Inspector witnesses the materials identification on the certificates against materials marking. It is also necessary to check with Battery Charger drawing datasheet, material list and other specification as appropriate.

When third party inspector carried out the material inspection, then provides inspection visit report (IVR), the report contains following items:

Confirmation of satisfactory document review
Record of the endorsement of certification reviewed/witnessed
Record of all non-conformities
Record of any tests witnessed and the result

Third Party Inspection for Battery Charger Construction

When Battery Charger raw material inspection carried out and results was satisfactory or non-conformities closed by remedial action, then Battery Charger manufacture will start fabrication.

The third party Inspector checks following points on Battery Charger based on the inspection and test plan (ITP) which is already agreed between purchaser and Battery Charger manufacture.

The inspection scope is determined in the ITP, some purchasers prefer to have stringent control and assign the TPI inspector in more “hold or witness points” for inspection and test activities and some others prefer lesser “hold or witness points” and assign TPI much more in the “review document”.

This depend to the inspection budget which purchasers assign for inspection, much more inspection will have much more costs and less risks and conversely less more inspection will have less costs but more risks.

For more detail review Inspection and Test Plan for Battery Charger article. There is draft ITP in this article which I believe it is the best practice for Battery Charger inspection.

The third party inspector (TPI) checks following in accordance of approved drawings and applicable standards:

Paint using specified colour swatch, measure thickness, if specified
Name plate
Outline dimensions, interface dimensions, bus bar dimensions and clearances and other specified dimensions
Tightness / torque of terminals
Degree of protection

If third party inspector (TPI) is not in the “hold” or “witness” point in the ITP for this inspection stage, will review the Battery Charger manufacture quality control report in coming visit or in the final inspection day.

Third Party Inspection for Battery Charger General Arrangement Check

The third party inspector checks that all instruments, compartments, control switches etc. are correctly rated and are correctly located, with specified labelling.

The inspection is carried out in accordance of approved drawings.

Similarly If third party inspector is not in the “hold” or “witness” point in the ITP for this inspection stage, will review the Battery Charger manufacture quality control report in the coming visit or in the final inspection day.

Third Party Inspection for Battery Charger Insulation Resistance Test

Battery Charger Insulation resistance is measured between control circuits and earth (with sensitive devises excluded) with a 500V Megger.

In the second step Insulation resistance is measured in all applicable permutations for mains single phase/three phase circuits with a 1000V Megger.

The acceptable limit depends to the circuit but normally more than 2 Megohms would not be acceptable.

Depending to the ITP the third party inspector either witnesses the test or will review the Battery Charger manufacture quality control test report in the coming visit or in the final inspection day.

Third Party Inspection for Battery Charger Withstand Voltage Test (Dialectric Test)

Power frequency voltage of 1.5 kV is applied between control circuits and earth for 1 minute. Then power frequency voltage of 2 KV is applied to all applicable permutations for power circuits for 1 minute.

The test would be acceptable if no flashover and puncture occurs during the test.

Similarly depending to the ITP the third party inspector either witnesses the test or will review the Battery Charger manufacture quality control test report in coming visit or in the final inspection day.

Third Party Inspection for Battery Charger Sequence Test

Circuitry is functionally tested and circuits proven by appropriate tests. The acceptance criteria for sequence test are approved schematic diagrams (including appropriate, recorded, “as built” alterations) and project philosophy.

Third Party Inspection for Battery Charger Characteristics Protection Relays Test

Relay functions and operating curves is observed through primary and /or secondary injection methods etc. The performance normally is in accordance of manufacturer’s data.

Third Party Inspection for Battery Charger Temperature Rise Test

The Battery Charger is operated at full load until major components reach temperature stability.

The test would be acceptable if the temperature rise is not exceeding specified value.

Third Party Inspection for Battery Charger Mechanical Operation Test

The test is done to ensure that all control mechanisms operate correctly, with correct responses.

The test would be acceptable if operate correctly based reference document and schematics.

Battery Charger Performance and Functional Test

The detail of these tests is varying with design and specification. The following are normally applied.

Starting and stopping
Mode changeover in normal operation
Fault mode
Voltage accuracy: output voltage is measured with the following permutations applied: input voltage at rated, lower limit and upper limit values; output current at rated, 50%, minimum and maximum values; frequency at rated, lower limit and upper limit values
Dropping characteristic: At rated input voltage, gradually increment output current and measure the output current when output voltage equals the nominal voltage of the battery.
Efficiency. (Calculated: output voltage x output current/input power)
Power factor. (it is measured with a P.F. meter)
Load compensation circuit test. voltage difference is measured when changing load current from the lower to upper limits
Voltage adjustable range. output voltages is measured where the voltage regulator is set to the lower extreme and then the higher extreme and the output current is reduced to the lower limit and then increased to the rated value, while changing the input from the lower limit to the rated value and then the upper limit.
Ripple voltage is measured at 20% and full load (peak to peak with the battery, RMS. with a resistive load.

If third party inspector is not in the “hold” or “witness” point in the ITP for this inspection stage, will review the Battery Charger manufacture quality control report in coming visit or in the final inspection day.

Third Party Inspection for Battery Charger -Battery Charger Reporting:

Third party inspector provides Inspection Visit Report (IVR) after each visit as well as a final report summarising the activities carried out during the Battery Charger production in accordance with the contract requirements and circulated within the time limits specified in the contract.

The report is in the format required by the client and clearly indicates final acceptance or rejection of the Battery Charger.

Third Party Inspection for Battery Charger - Release Note:

When required by the contract or purchase order a release note is issued by third party agency and given to the manufacturer when the Battery Charger have been finally accepted.

Battery Charger Packing, Marking and Shipping:

The following points are checked by third party inspector:

Verify that the packing materials conform to specifications and accepted practice for the mode of transport.
Verify protection against humidity, abrasion, distortion and other damage.
Verify shipping marks to marking instructions and record.
Verify handling marks.

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